EWM T 4.00 - AC/DC Comfort 2.0 User manual

Operating instructions
EN
Control
T 4.00 - AC/DC Comfort 2.0
099-00T400-EW501
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21.10.2016
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the location where the machine is operated.
•Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
•Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of
liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Straße 8
56271 Mündersbach
Germany
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2For your safety .......................................................................................................................................5
2.1 Notes on the use of these operating instructions ..........................................................................5
2.1.1 Explanation of icons .......................................................................................................6
2.2 Part of the complete documentation..............................................................................................7
3Machine control –Operating elements................................................................................................8
3.1 Overview of control sections..........................................................................................................8
3.1.1 Control section A ............................................................................................................9
3.1.2 Control section B ..........................................................................................................11
3.1.3 Control section C..........................................................................................................12
3.2 Machine display...........................................................................................................................13
3.2.1 Setting the welding current (absolute/percentage).......................................................13
3.3 Operating the machine control.....................................................................................................14
3.3.1 Main screen..................................................................................................................14
3.3.2 Welding power setting..................................................................................................14
3.3.3 Welding parameter setting in the operation sequence.................................................14
3.3.4 Setting advanced welding parameters (Expert menu) .................................................14
3.3.5 Changing basic settings (machine configuration menu) ..............................................14
4Welding procedure...............................................................................................................................15
4.1 TIG welding..................................................................................................................................15
4.1.1 Setting the shielding gas volume (gas test)/rinse hose package.................................15
4.1.2 Welding task selection..................................................................................................16
4.1.2.1 Recurring welding tasks (JOB 1–7) ..............................................................17
4.1.3 Tungsten balling function .............................................................................................18
4.1.4 AC balance (optimise cleaning effect and penetration characteristics) .......................19
4.1.5 AC amplitude balance ..................................................................................................20
4.1.6 Arc ignition....................................................................................................................21
4.1.6.1 HF ignition.....................................................................................................21
4.1.6.2 Liftarc ............................................................................................................21
4.1.6.3 Automatic cut-out ..........................................................................................21
4.1.7 Function sequences/operating modes .........................................................................22
4.1.7.1 Explanation of symbols.................................................................................22
4.1.7.2 Non-latched mode.........................................................................................23
4.1.7.3 Latched mode ...............................................................................................24
4.1.7.4 spotArc..........................................................................................................25
4.1.7.5 spotmatic.......................................................................................................27
4.1.7.6 Non-latched operation, version C .................................................................29
4.1.8 TIG activArc welding.....................................................................................................30
4.1.9 TIG antistick..................................................................................................................30
4.1.10 Pulse welding ...............................................................................................................31
4.1.10.1 Automated pulses .........................................................................................31
4.1.10.2 Thermal pulsing.............................................................................................32
4.1.10.3 Average value pulsing...................................................................................34
4.1.10.4 Metallurgical pulsing (kHz pulsing) ...............................................................35
4.1.10.5 AC special.....................................................................................................37
4.1.11 Welding torch (operating variants) ...............................................................................38
4.1.11.1 Tap torch trigger (tapping function)...............................................................38
4.1.12 Torch mode and up/down speed setting......................................................................38
4.1.12.1 Standard TIG torch (5-pole)..........................................................................39
4.1.12.2 TIG up/down torch (8-pole)...........................................................................41
4.1.12.3 Potentiometer torch (8-pole).........................................................................43
4.1.12.4 Configuring the TIG potentiometer torch connection....................................44
4.1.12.5 RETOX TIG torch (12-pole) ..........................................................................45
4.1.13 Up/down operation in modes 4 and 14.........................................................................46
4.1.14 Alternating current waveforms......................................................................................47
4.1.15 Ramp function ..............................................................................................................48

Contents
Notes on the use of these operating instructions
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4.1.15.1 Foot-operated remote control responsiveness..............................................48
4.1.15.2 RTF 1 foot-operated remote control..............................................................49
4.1.16 Automatic AC frequency...............................................................................................50
4.1.17 AC commutation optimisation.......................................................................................51
4.1.18 Simultaneous welding on both sides, synchronisation types .......................................51
4.1.19 Synchronisation via mains voltage (50Hz / 60Hz)........................................................51
4.1.20 Expert menu (TIG)........................................................................................................52
4.1.21 Aligning the cable resistance........................................................................................54
4.2 MMA welding................................................................................................................................56
4.2.1 Welding task selection..................................................................................................56
4.2.2 Hotstart .........................................................................................................................57
4.2.2.1 Hotstart current..............................................................................................57
4.2.2.2 Hotstart time..................................................................................................57
4.2.3 Arcforce.........................................................................................................................58
4.2.4 Antistick.........................................................................................................................58
4.2.5 Welding current polarity reversal (polarity reversal) .....................................................58
4.2.6 Pulse welding................................................................................................................59
4.2.7 Average value pulse welding........................................................................................60
4.3 Filler wire welding.........................................................................................................................61
4.3.1 Configuring the welding machine for mechanical arc fusion welding...........................61
4.3.1.1 Selecting a welding task by means of the JOB list .......................................61
4.3.1.2 Select wire speed operating mode (KORREKTUR / MANUELL)..................61
4.3.1.3 Setting the welding current and wire speed..................................................61
4.3.2 Function sequences/operating modes..........................................................................62
4.3.2.1 Explanation of symbols .................................................................................62
4.3.2.2 Non-latched mode.........................................................................................63
4.3.2.3 3-cycle operation...........................................................................................64
4.3.2.4 Latched mode................................................................................................64
4.4 Power-saving mode (Standby).....................................................................................................65
4.5 Access control..............................................................................................................................65
4.6 Voltage reducing device...............................................................................................................65
4.7 Machine configuration menu........................................................................................................65
4.7.1 Selecting, changing and saving parameters.................................................................65
5Rectifying faults....................................................................................................................................71
5.1 Warnings (power source).............................................................................................................71
5.2 Error messages (power source)...................................................................................................72
5.3 Resetting welding parameters to the factory settings..................................................................74
5.4 Display machine control software version....................................................................................74
6Appendix A............................................................................................................................................75
6.1 Parameter overview –setting information....................................................................................75
6.1.1 TIG welding...................................................................................................................75
6.1.2 MMA welding ................................................................................................................76
7Appendix B............................................................................................................................................77
7.1 Overview of EWM branches.........................................................................................................77

For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
•The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
•Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
•The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
•The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
•The risk is explained using a symbol on the edge of the page.
Special technical points which users must observe.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
•Insert the welding current lead socket into the relevant socket and lock.

For your safety
Notes on the use of these operating instructions
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2.1.1 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/tip
Switch off machine
Release
Switch on machine
Press and keep pressed
Switch
Wrong
Turn
Correct
Numerical value –adjustable
Menu entry
Signal light lights up in green
Navigating the menu
Signal light flashes green
Exit menu
Signal light lights up in red
Time representation (e.g.: wait
4 s/activate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use

For your safety
Part of the complete documentation
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2.2 Part of the complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with all other parts of these instructions! Read and observe the operating
instructions for all system components, especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 2-1
Item
Documentation
A.1
Options conversion instructions
A.2
Power source
A.3
Cooling unit, voltage converter, tool box etc.
A.4
Transport cart
A.5
Welding torch
A.6
Remote control
A.7
Control
A
Complete documentation

Machine control –Operating elements
Overview of control sections
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3 Machine control – Operating elements
3.1 Overview of control sections
For description purposes, the machine control has been divided into three sections (A, B, C) to
ensure maximum clarity. The setting range for the parameter values are summarised in the
parameter overview section > see 6.1 chapter.
Figure 3-1
Item
Symbol
Description 0
1
Control section A
> see 3.1.1 chapter
2
Control section B
> see 3.1.2 chapter
3
Control section C
> see 3.1.3 chapter

Machine control –Operating elements
Overview of control sections
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3.1.1 Control section A
Figure 3-2
Item
Symbol
Description 0
1
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 3.2 chapter
2
Push-button gas test / rinse hose package > see 4.1.1 chapter
3
Operating mode/power-saving mode push-button
---------Latched > see 4.1.7.2 chapter
-------Non-latched > see 4.1.7.3 chapter
------spotArc spot welding procedure –signal light turns
green > see 4.1.7.4 chapter
------spotmatic spot welding procedure –signal light turns red > see 4.1.7.5 chapter
--------Press button for long interval to put machine into power-saving
mode > see 4.4 chapter.
Activate one of the operating elements to reactivate.
4
Pulsing push-button > see 4.1.10 chapter
------Automated pulsing (frequency and balance)
-------Signal light turns green: Thermal pulsed TIG welding/MMA pulse welding
-------Signal light turns red: Metallurgical pulsed TIG welding (kHz pulsing)/average
value pulsing
---Special TIG AC
5
Welding current polarity/tungsten balling push-button
----Signal light turns green: DC welding with negative polarity on the electrode
holder or welding torch.
----Signal light turns red: MMA DC welding with positive polarity on the electrode
holder > see 4.2.5 chapter.
----Alternating current welding/alternating current forms > see 4.1.14 chapter
-Tungsten balling current > see 4.1.3 chapter

Machine control –Operating elements
Overview of control sections
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Item
Symbol
Description 0
6
Welding procedure push-button
--------- TIG welding
---- MMA welding (signal light turns green)
---- Arcforce setting (signal light turns red)
7
Display switching push-button
kW------- Welding power display
V --------- Welding voltage display
JOB ----- Display and setting of the JOB number with the control button
8
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 3.2 chapter
9
Filler wire welding signal light
For machines with filler wire only (AW) > see 4.3 chapter
10
TIG ignition type signal light
Signal light on: Lift arc ignition active/HF start off. You can switch the ignition type in the
Expert menu (TIG) > see 4.1.20 chapter.
11
Character function signal light
Indicates that it is possible to weld in an environment with major electric hazards, such
as in boilers. Service must be informed if this signal light is not on.
12
Coolant fault signal light
Comes on when pressure is lost in the coolant circuit. Check coolant level and ensure
that coolant circuit is leak-tight.
13
VRD
Voltage reduction device (VRD) signal light
The VRD signal light is illuminated when the voltage reduction device is operating
without fault and the output voltage is reduced to a value specified in the relevant
standard (see technical data) > see 4.6 chapter. The voltage reduction device is only
active on VRD machine versions.
14
Hold
Signal light Status display
After each completed welding task, the last values used in the welding process for the
welding current and welding voltage are shown on the displays, and the signal light will
be on
15
Excess temperature signal light
In case of excess temperature, temperature monitors de-activate the power unit, and
the excess temperature control lamp comes on. Once the machine has cooled down,
welding can continue without any further measures.
16
Access control active signal light
Signal light is on when access control is active on the machine
control > see 4.5 chapter.
17
Simultaneous AC welding on both sides, signal light
This signal light indicates that the function is active > see 4.1.18 chapter.
18
Automatic AC frequency > see 4.1.16 chapter

Machine control –Operating elements
Overview of control sections
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3.1.2 Control section B
Figure 3-3
Item
Symbol
Description 0
1
Parameter selection push-button, left
The welding sequence parameters are selected one after another in an anti-clockwise
direction.
2
Control button
Central control button to be pressed or turned > see 3.2 chapter.
3
Parameter selection push-button, right
The welding sequence parameters are selected one after another in a clockwise
direction.
4
Balance signal light
DC balance (JOBs 0–7)
AC balance (JOBs 1–7), pulse balance, AC amplitude balance (JOBs 0–7)
5
Electrode diameter signal light
Ignition optimisation (TIG)/tungsten balling basic setting
6
Gas post-flow time
7
AMP%
Signal light, two colour
Red: End current
Green: End current time > see 4.1.20 chapter
8
sec
Down-slope time signal light
9
AMP%
sec
Signal light, two colour
Red: Secondary or pulse pause current (% of AMP)
Green: Pulse pause time /slope time (Expert menu)
10
AMP
sec
Signal light, two colour
Red: Main or pulse current
Green: Pulse time /slope time (AMP to AMP%, Expert menu)
11
sec
Signal light
Up-slope time (TIG)/hot start time (MMA)
12
AMP%
Signal light, two colour
Red: Ignition current (TIG)/hot start current (MMA)
Green: Ignition current time (TIG, Expert menu)

Machine control –Operating elements
Overview of control sections
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Item
Symbol
Description 0
13
Gas pre-flow time signal light
14
activArc TIG welding process
•Switch activArc <>
•Correct the activArc characteristic > see 4.1.20 chapter
15
Signal light, two colour
Green: AC frequency (TIG)/pulse frequency (MMA)
Red: Pulse frequency (TIG, kHz pulsing)
3.1.3 Control section C
Figure 3-4
Item
Symbol
Description 0
1
AC frequency rotary knob (JOB 0)
2
Balance
AC balance rotary knob (JOB 0)
3
Tungsten electrode diameter rotary knob (JOB 0)

Machine control –Operating elements
Machine display
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3.2 Machine display
The following welding parameters can be displayed before (nominal values), during (actual values) or
after welding (hold values):
"left display"
Parameter
Before welding
(nominal values)
During welding
(actual values)
After welding
(hold values)
Welding current



Parameter times



Parameter currents



Frequency, balance



JOB number



"right display"
Welding power



Welding voltage



When the hold values are displayed after welding and the settings are then changed (e.g. welding
current), the display will switch to the relevant nominal values.
possible
not possible
The parameters that can be set in the function sequence of the machine control depend on the selected
welding task. This means that if for example you have not selected a pulse variant, then you cannot set
any pulse times in the function sequence.
3.2.1 Setting the welding current (absolute/percentage)
The welding current for the ignition, secondary, end and hot start current can be set as a percentage of
the main current AMP or as an absolute value. To select, use the parameter <dg in the configuration
menu_ref_source_inline>Gerätekonfigurationsmenü</dg_ref_source_inline>.
> see 4.7 chapter

Machine control –Operating elements
Operating the machine control
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3.3 Operating the machine control
3.3.1 Main screen
The machine control switches to the main screen after it has been turned on or a setting has been
completed. This means that the previously selected settings (indicated by signal lights where applicable)
and the nominal value for the current (A) are displayed in the left-hand welding data display. Depending
on the selection, the right-hand display shows the welding voltage (V) nominal value or the welding power
(kW) actual value. The control always switches back to the main screen after 4 sec. of inactivity.
3.3.2 Welding power setting
The welding power is set using the control button. You can also adjust the parameters in the operation
sequence or settings in the different machine menus.
3.3.3 Welding parameter setting in the operation sequence
A welding parameter can be set in two ways in the operation sequence.
1. Push the "left" or "right" arrow keys (flashing signal light will indicate your selection). Turn the control
button to set the parameter value.
2. Press briefly on the control button (operation sequence selection) and then turn the button (navigate to
the required parameter). Press again to apply the selected parameter as the setting (corresponding
signal light flashes). Turn the button to set the parameter value.
The welding parameter setting is shown on the left-hand display while it is being set. A parameter
abbreviation or a deviation in the specified parameter value upwards or downwards is shown on the right-
hand display:
Display
Meaning
Increase the parameter value
To return to the factory settings.
Factory setting (example value = 20)
Parameter is set to optimum value
Decrease the parameter value
To return to the factory settings.
3.3.4 Setting advanced welding parameters (Expert menu)
The Expert menu contains functions and parameters which cannot be set directly in the machine control
or which do not need to be et on a regular basis. The number and display of these parameters depends
on the previously selected welding procedure or the functions.
To select them hold the control button for more than 2 sec. Select the required parameter/menu item by
turning (navigate) and pressing (confirm) the control button.
You can also or alternatively use the push-buttons to the left and right of the control button to navigate.
3.3.5 Changing basic settings (machine configuration menu)
The basic welding system functions can be adjusted in the machine configuration menu. Only
experienced users should change the settings > see 4.7 chapter.

Welding procedure
TIG welding
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4 Welding procedure
4.1 TIG welding
4.1.1 Setting the shielding gas volume (gas test)/rinse hose package
•Slowly open the gas cylinder valve.
•Open the pressure regulator.
•Switch on the power source at the main switch.
•Set the relevant gas quantity for the application on the pressure regulator.
•The gas test can be activated at the machine control by pressing the "Gas test/purge " push-
button > see 3.1.1 chapter.
Setting the shielding gas quantity (gas test)
•Shielding gas flows for approx. 20 seconds or until the push-button is pressed again.
Purging long hose packages (purging)
•Press push-button for about 5 sec. Shielding gas flows continuously until the push-button is pressed
again.
If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause
pores to form. Adjust the shielding gas quantity to suit the welding task!
Setting instructions
Welding process
Recommended shielding gas quantity
MAG welding
Wire diameter x 11.5 = l/min
MIG brazing
Wire diameter x 11.5 = l/min
MIG welding (aluminium)
Wire diameter x 13.5 = l/min (100 % argon)
TIG
Gas nozzle diameter in mm corresponds to l/min gas throughput
Helium-rich gas mixtures require a higher gas volume!
The table below can be used to correct the gas volume calculated where necessary:
Shielding gas
Factor
75% Ar/25% He
1.14
50% Ar/50% He
1.35
25% Ar/75% He
1.75
100% He
3.16
For connecting the shielding gas supply and handling the shielding gas cylinder refer to the
power source operating instructions.

Welding procedure
TIG welding
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4.1.2 Welding task selection
The setting of the tungsten electrode diameter has a direct influence on the machine functionality, TIG
ignition behaviour and minimum current limits. The ignition energy is controlled by the set electrode
diameter. Smaller electrode diameters requires less ignition current and less ignition current time than
greater electrode diameters. The set value should correspond to the tungsten electrode diameter. The
value can also be set to meet individual requirements, e.g. for thin panels a smaller diameter is
recommended to reduce the ignition energy.
The electrode diameter setting determines the minimum current limit, which in turn affects the ignition,
main and secondary current. The minimum current limits have a positive effect on the ignition behaviour
and ensure a very high arc stability for each electrode diameter selected. The minimum current limit
function is enabled ex works, but can be disabled with parameter in the machine configuration
menu > see 4.7 chapter.
For foot-operated remote control mode, minimum current limits are disabled by default.
The following welding task is an example of use:
EXIT
4s
mm
inch
?
Figure 4-1

Welding procedure
TIG welding
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4.1.2.1 Recurring welding tasks (JOB 1–7)
The user has 7 more memory locations at their disposal to save recurring or different welding tasks on a
permanent basis. To do so, simply select the required memory location (JOB 1–7) and the welding task is
set as described previously.
The three rotary knobs for AC frequency, AC balance and the tungsten electrode diameter are
exceptions. These settings are made in the operation sequence (signal lights with same name).
Switching a JOB is only possible if no welding current flows. Up-slope and down-slope times can be set
individually for latched and non-latched operation.
Selection
Figure 4-2
When one or more of the recurring welding tasks (JOB 1–7) has been selected the JOB signal light
comes on.

Welding procedure
TIG welding
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4.1.3 Tungsten balling function
The tungsten balling function provides optimum tungsten balling, ensuring that the best ignition and
welding results are achieved during AC welding.
Optimum tungsten balling requires a sharpened electrode (about 15–25°) and the set electrode diameter
on the machine control. The set electrode diameter affects the current for tungsten balling and,
consequently, also the ball size.
Press the tungsten balling push-button to activate the function. If required, this current can be adjusted on
an individual basis using the parameter (+/- 30 A). The user presses the torch trigger and the function
is started by non-contact ignition (HF start). The balled end is formed and the function then ends.
Tungsten balling should be performed on a test component as surplus tungsten may be melted and this
may lead to impurities on the weld seam.
Balling
mm
inch
Figure 4-3

Welding procedure
TIG welding
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4.1.4 AC balance (optimise cleaning effect and penetration characteristics)
To weld aluminium and aluminium alloys, AC welding is used in combination with a continuous change in
polarity of the tungsten electrode. The process encompasses two phases (half-waves): a positive and a
negative one. The positive phase cracks the aluminium oxide layer on the material surface (so called
cleaning effect).
At the same time, tungsten balling occurs at the tip of the tungsten electrode. The size of this balled end
depends on the length of the positive phase. Please note that an excessively big balled end will cause the
arc to become unstable and diffuse, with low penetration. In the negative phase, the tungsten electrode is
cooled and the required penetration is realised. Make sure to select the correct durations (balance) for
positive phase (cleaning effect, balled end size) and negative phase (penetration depth) by setting the AC
balance. The default (zero setting) balance setting is 65%, referring to the duration of the negative half-
wave.
Figure 4-4

Welding procedure
TIG welding
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4.1.5 AC amplitude balance
As with AC balance, durations (balance) for positive phase and negative phase are set for AC amplitude
balance. The balance changes in terms of the current amplitude.
Figure 4-5
Increasing the current amplitude in the positive half-wave facilitates the cleaning effect and the
cracking of the oxide layer.
Raising the negative current amplitude increases the penetration.