EWM drive 4X IC D EX User manual

Operating instructions
EN
Wire feed unit
drive 4X IC D EX
099-005598-EW501 Observe additional system documents! 26.01.2018

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/en/specialist-dealers.
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
Tel.: [phone], Fax: -244
Email: [e-mail]
www.ewm-group.com
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
2.2 Explanation of icons.......................................................................................................................6
2.3 Part of the complete documentation..............................................................................................7
2.4 Safety instructions..........................................................................................................................7
2.5 Transport and installation ............................................................................................................10
3Intended use.........................................................................................................................................12
3.1 Applications..................................................................................................................................12
3.2 Use and operation solely with the following machines................................................................12
3.3 Documents which also apply.......................................................................................................12
3.3.1 Warranty.......................................................................................................................12
3.3.2 Declaration of Conformity.............................................................................................13
3.3.3 Service documents (spare parts and circuit diagrams)................................................13
3.3.4 Calibration/Validation ...................................................................................................13
4Machine description – quick overview ..............................................................................................14
4.1 Front view / side view from the right............................................................................................14
4.2 Inside view from the right.............................................................................................................15
4.3 Inside view from the left...............................................................................................................16
5Design and function.............................................................................................................................18
5.1 Transport and installation ............................................................................................................18
5.1.1 Ambient conditions.......................................................................................................18
5.1.1.1 In operation...................................................................................................18
5.1.1.2 Transport and storage...................................................................................18
5.1.2 Welding torch cooling system.......................................................................................20
5.1.2.1 Approved coolants overview.........................................................................20
5.1.2.2 Maximal hose package length ......................................................................20
5.1.3 Notes on the installation of welding current leads........................................................21
5.1.4 Stray welding currents..................................................................................................22
5.1.5 Intermediate hose package connection .......................................................................23
5.1.6 Shielding gas supply (shielding gas cylinder for welding machine).............................24
5.1.6.1 Shielding gas volume settings ......................................................................24
5.1.6.2 Gas test.........................................................................................................25
5.1.6.3 Purge hose package.....................................................................................25
5.2 MIG/MAG welding........................................................................................................................26
5.2.1 Welding torch connection.............................................................................................26
5.2.2 Wire feed......................................................................................................................28
5.2.2.1 Open the protective flap of the wire feeder...................................................28
5.2.2.2 Inserting the wire spool.................................................................................28
5.2.2.3 Changing the wire feed rollers......................................................................29
5.2.2.4 Inching the wire electrode.............................................................................31
5.2.2.5 Spool brake setting .......................................................................................32
5.2.2.6 Basic settings for operation with two wire feeders (P10)..............................33
5.2.2.7 Switching between wire feed units................................................................33
5.2.2.8 Special points when operating with two wire feed units................................33
5.2.3 Welding task selection..................................................................................................34
5.3 TIG welding..................................................................................................................................34
5.3.1 Welding torch connection.............................................................................................34
5.3.2 Welding task selection..................................................................................................35
5.4 MMA welding ...............................................................................................................................35
5.4.1 Welding task selection..................................................................................................35
5.4.2 Air arc gouging .............................................................................................................35
5.5 Remote control.............................................................................................................................35
5.6 Interfaces for automation.............................................................................................................36
5.6.1 Remote control connection socket, 19-pole.................................................................36
5.7 Access control..............................................................................................................................37

Contents
Notes on the use of these operating instructions
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6Maintenance, care and disposal.........................................................................................................38
6.1 General.........................................................................................................................................38
6.1.1 Cleaning........................................................................................................................38
6.2 Maintenance work, intervals ........................................................................................................38
6.2.1 Daily maintenance tasks...............................................................................................38
6.2.2 Monthly maintenance tasks..........................................................................................39
6.2.3 Annual test (inspection and testing during operation)..................................................39
6.3 Disposing of equipment................................................................................................................39
7Rectifying faults....................................................................................................................................40
7.1 Checklist for rectifying faults ........................................................................................................40
7.2 Error messages (power source)...................................................................................................41
7.3 Vent coolant circuit.......................................................................................................................42
8Technical data.......................................................................................................................................43
8.1 drive 4X IC D EX..........................................................................................................................43
9Accessories ..........................................................................................................................................44
9.1 General accessories ....................................................................................................................44
9.2 Remote control/connecting and extension cable.........................................................................44
9.2.1 7-pole connection .........................................................................................................44
9.2.2 19-pole connection .......................................................................................................44
10 Replaceable parts.................................................................................................................................45
10.1 Wire feed rollers...........................................................................................................................45
10.1.1 Wire feed rollers for steel wire......................................................................................45
10.1.2 Wire feed rollers for aluminium wire.............................................................................45
10.1.3 Wire feed rollers for cored wire.....................................................................................46
10.1.4 Wire guide.....................................................................................................................46
11 Appendix A............................................................................................................................................47
11.1 Searching for a dealer..................................................................................................................47

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.
Technical aspects which the user must observe to avoid material or equipment damage.
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
Explanation of icons
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2.2 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
Input Signal light lights up in green
Navigation Signal light flashes green
Output
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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2.3 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
The illustration shows a general example of a welding system.
Item
Documentation
A.1
Wire feeder
A.2
Controller
A.3
Remote adjuster
A.4
Options conversion instructions
A.5
Welding torch
A.6
Power source
A
Complete documentation
2.4 Safety instructions
WARNING
Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
• Carefully read the safety instructions in this manual!
• Observe the accident prevention regulations and any regional regulations!
• Inform persons in the working area that they must comply with the regulations!
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low
voltages can cause a shock and lead to accidents.
• Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
• Always place torches and electrode holders on an insulated surface!
• Wear the full personal protective equipment (depending on the application)!
• The machine may only be opened by qualified personnel!
• The device must not be used to defrost pipes!

For your safety
Safety instructions
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WARNING
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a
technical specialist may interconnect the sources as per standard IEC 60974-9:2010:
Installation and use
and German Accident Prevention Regulation BVG D1 (formerly VBG
15) or country-specific regulations.
Before commencing arc welding, a test must verify that the equipment cannot exceed
the maximum permitted open circuit voltage.
• Only qualified personnel may connect the machine.
• When taking individual power sources out of operation, all mains and welding current leads
must be safely disconnected from the welding system as a whole. (Hazard due to reverse
polarity voltage!)
• Do not interconnect welding machines with pole reversing switch (PWS series) or machines
for AC welding since a minor error in operation can cause the welding voltages to be
combined, which is not permitted.
Risk of injury due to improper clothing!
During arc welding, radiation, heat and voltage are sources of risk that cannot be
avoided. The user has to be equipped with the complete personal protective equipment
at all times. The protective equipment has to include:
• Respiratory protection against hazardous substances and mixtures (fumes and vapours);
otherwise implement suitable measures such as extraction facilities.
• Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and
heat.
• Dry welding clothing (shoes, gloves and body protection) to protect against warm
environments with conditions comparable to ambient temperatures of 100 °C or higher and
arcing and work on live components.
• Hearing protection against harming noise.
Risk of injury due to radiation or heat!
Arc radiation can lead to skin and eye injuries.
Contact with hot workpieces and sparks can lead to burns.
• Use hand shield or welding helmet with the appropriate safety level (depends on the
application).
• Wear dry protective clothing (e.g. hand shield, gloves, etc.) in accordance with
the applicable regulations of your country.
•
Persons who are not directly involved should be protected with a welding curtain or suitable
safety screen against radiation and the risk of blinding!
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during
welding, there is a risk of flames.
• Be watchful of potential sources of fire in the working area!
• Do not carry any easily inflammable objects, e.g. matches or lighters.
• Ensure suitable fire extinguishers are available in the working area!
• Thoroughly remove any residue of flammable materials from the workpiece prior to starting
to weld.
• Only further process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!

For your safety
Safety instructions
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CAUTION
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent
vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to
the ultraviolet radiation of the arc!
• Ensure that there is sufficient fresh air!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
According to IEC 60974-10, welding machines are divided into two classes of
electromagnetic compatibility (the EMC class can be found in the Technical
data) > see 8 chapter:
Class A
machines are not intended for use in residential areas where the power supply comes
from the low-
voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference n
ot only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas,
including residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the
surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding system
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
• Observe the maintenance instructions > see 6.2 chapter!
• Unwind welding leads completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if
necessary).

For your safety
Transport and installation
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Obligations of the operator!
The respective national directives and laws must be complied with when operating the machine!
• Implementation of national legislation relating to framework directive 89/391/EEC on the
introduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
•
In particular, directive 89/655/EEC concerning the minimum safety and health requirements for
the use of work equipment by workers at work.
• The regulations applicable to occupational safety and accident prevention in the country
concerned.
• Setting up and operating the machine as per IEC 60974.-9.
• Brief the user on safety-conscious work practices on a regular basis.
• Regularly inspect the machine as per IEC 60974.-4.
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of the
operator, where necessary in consultation with the mains network operator, to ensure that the
machine can be connected.
2.5 Transport and installation
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause
serious injuries!
• Observe the instructions from the gas manufacturer and any relevant regulations
concerning the use of compressed air!
• Do not attach any element to the shielding gas cylinder valve!
• Prevent the shielding gas cylinder from heating up.

For your safety
Transport and installation
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CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
• Disconnect all supply lines before transport!
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10°
(according to IEC 60974-1).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Risk of accidents due to incorrectly installed leads!
Incorrectly installed leads (mains, control and welding leads or intermediate hose
packages ) can present a tripping hazard.
• Lay the supply lines flat on the floor (avoid loops).
• Avoid laying the leads on passage ways.
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant
accessory components.
• Accessory components are detected automatically after the power source is switched on.
Protective dust caps protect the connection sockets and therefore the machine against dirt and
damage.
• The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
• The cap must be replaced if faulty or if lost!

Intended use
Applications
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
• The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
3.1 Applications
Wire feeder to feed wire electrodes for gas-shielded metal-arc welding.
Machine series
Main process
Secondary
process
Standard MIG/MAG
welding
Pulsed MIG/MAG welding
TIG welding (lift arc)
MMA welding
Gouging
forceArc
rootArc
coldArc
pipeSolution
forceArc puls
rootArc puls
coldArc puls
alpha Q puls MM
         
Phoenix puls MM
         
Taurus Synergic S MM
         
possible
not possible
3.2 Use and operation solely with the following machines
A suitable power source (system component) is required in order to operate the wire feed unit!
For machine variants with wheel spacers only!
The following system components can be combined with this machine:
• alpha Q Expert 2.0 puls MM
• alpha Q Progress puls MM
• Phoenix Expert 2.0 puls MM
• Phoenix Progress puls MM
• Taurus Synergic S MM
Power sources must have the MM identifier for MULTIMATRIX technology in their model
designation.
3.3 Documents which also apply
3.3.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!

Intended use
Documents which also apply
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3.3.2 Declaration of Conformity
The labelled machine complies with the following EC directives in terms of its design and
construction:
•
Low Voltage Directive (LVD)
•
Electromagnetic Compatibility Directive (EMC)
• Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment
– Inspection and Testing during Operation," and/or prohibited modifications which
have not been explicitly authorised by the manufacture
r, this declaration shall be voided. An original
document of the specific declaration of conformity is included with every product.
3.3.3 Service documents (spare parts and circuit diagrams)
WARNING
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.3.4 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months

Ma
chine description – quick overview
Front view / side view from the right
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4 Machine description – quick overview
4.1 Front view / side view from the right
Figure 4-1

Machine description – quick overview
Inside view from the right
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Item
Symbol
Description 0
1
Carrying handle
2
Machine control, see the relevant control operating instructions
3
Connection socket, 7-pole
Connection for peripheral devices with digital interface
4
19-pole connection socket (analogue)
For connecting analogue accessory components (remote control, welding torch control
lead, etc.)
5
Quick connect coupling (red)
Coolant return
6
Quick connect coupling (blue)
Coolant feed
7 Welding torch connection (Euro or Dinse torch connector)
Welding current, shielding gas and torch trigger integrated
8
Protective cap
Cover for the wire feed mechanismand other operating elements.
Depending on the machine series, additional stickers with information on the
replacement parts and JOB lists will be located on the inside.
9
Recessed grip for opening the cap
10
Slide latch, lock for the protective cap
11 Machine feet
4.2 Inside view from the right
Figure 4-2

Machine description
– quick overview
Inside view from the left
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Item
Symbol
Description 0
1
Push-button gas test / rinse hose package > see 5.1.6 chapter
2
Wire inching push-button
For potential- and gas-free inching of the wire electrode through the hose package to
the welding torch.
3 Lighting, inside
In power-saving mode and with MMA or TIG welding, the lighting is switched off.
4
Welding torch function changeover switch (special welding torch required)
---- Welding power infinitely adjustable
--- Change over programs or JOBs
5
Wire feed unit
6
Quick connect coupling (red)
coolant return
7
Intermediate hose package strain relief > see 5.1.5 chapter
8
Quick connect coupling (blue)
coolant supply
9
Connector plug, welding current "+"
Welding current connection on wire feed unit
10
7-pole connection socket (digital)
• Control lead for wire feed unit
11
Connecting nipple G¼, shielding gas connection
12 Wire spool holder
4.3 Inside view from the left
Figure 4-3

Machine description – quick overview
Inside view from the left
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Item
Symbol
Description 0
1
Push-button gas test / rinse hose package > see 5.1.6 chapter
2
Welding torch function changeover switch (special welding torch required)
-----Welding power infinitely adjustable
----Change over programs or JOBs
3
Connecting nipple G¼, shielding gas connection
4 Wire spool holder
5
Wire feed unit
6
Lighting, inside
In power-saving mode and with MMA or TIG welding, the lighting is switched off.
7
Key switch for protection against unauthorised use > see 5.7 chapter
---------changes possible,G front drive-4x-EX
----------changes not possible.
8
Wire inching push-button
For potential- and gas-free inching of the wire electrode through the hose package to
the welding torch.

Design and function
Transport and installati
on
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5 Design and function
WARNING
Risk of injury from electrical voltage!
Contact with live parts, e.g. power connections, can be fatal!
• Observe the safety information on the first pages of the operating instructions!
• Commissioning must be carried out by persons who are specifically trained in handling
power sources!
• Connect connection or power cables while the machine is switched off!
Read and observe the documentation to all system and accessory components!
5.1 Transport and installation
WARNING
Risk of accident due to improper transport of machines that must not be lifted!
Do not lift or suspend the machine! The machine can drop and cause injuries! The
handles, straps or brackets are suitable for transport by hand only!
• The machine must not be suspended or lifted using a crane.
5.1.1 Ambient conditions
T he machine must not be operated in the open air and must only be set up and operated on a
suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient lighting
for the place of work.
• Safe operation of the machine must be guaranteed at all times.
Equipment damage due to contamination!
Unusually high amounts of dust, acids, corrosive gases or substances can damage the machine
(observe maintenance intervals > see 6.2 chapter).
• Avoid large amounts of smoke, steam, oily fumes, grinding dust and corrosive ambient air!
5.1.1.1 In operation
Temperature range of the ambient air:
• -25 °C to +40 °C (-13 F to 104 F)
Relative humidity:
• up to 50 % at 40 °C (104 F)
• up to 90 % at 20 °C (68 F)
5.1.1.2 Transport and storage
Storage in a closed room, temperature range of the ambient air:
• -30 °C to +70 °C (-22 F to 158 F)
Relative humidity
• up to 90 % at 20 °C (68 F)

Design and function
Transport and installation
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WARNING
Risk of accident due to improper transport of machines that must not be lifted!
Do not lift or suspend the machine! The machine can drop and cause injuries! The
handles, straps or brackets are suitable for transport by hand only!
• The machine must not be suspended or lifted using a crane.
CAUTION
Risk of accident due to unsuitable power source!
If this wire feeder is operated with an unsuitable power source, it may topple and injure
persons. In addition, the performance of the overall system would be
restricted.
• For suitable power sources, see the "Intended use" chapter > see 3 chapter.
T he machine must not be operated in the open air and must only be set up and operated on a
suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient lighting
for the place of work.
• Safe operation of the machine must be guaranteed at all times.
CAUTION
Risk of falling!
If the double wire feed unit is not
positioned correctly on the holder, it may fall, become
damaged and cause injury to persons as a result.
•
Always position the inner feet of the wire feed unit in the provided recesses!
•
Outer housing frames of the wire feed must lay flat on the holder!
(See figure, part "b")
•
Check that the wire feed is properly secured before any transport and every start-up
operation!
•
Observe the safety instructions on transport and positioning, as well as on lifting by crane,
in the operating instructions for the power source!
•
Do not apply tractive force to the torch tube package! If there is any possibility that tractive
force may be unavoidable, the wire feed must be removed from the support!
• The press arbor bracket must not be used (even with a single wire feed)!

Design and function
Transport and installation
20 099-005598-EW501
26.01.2018
Figure 5-1
Item
Symbol
Description 0
1 Internal unit feet
2 Holder for wire feed unit
3
Press arbor bracket
4
Recesses for unit feet
5 External casing frame
• Set the double wire feed on the holder in such a way that the unit's inner feet are held securely in the
recesses provided for them.
5.1.2 Welding torch cooling system
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch > see 5.1.2.1 chapter.
Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the
frost protection is adequate to prevent damage to the machine or the accessory components.
• The coolant must be checked for adequate frost protection with the TYP 1 frost protection
tester .
• Replace coolant as necessary if frost protection is inadequate!
Coolant mixtures!
Mixtures with other liquids or the use of unsuitable coolants result in material damage and
renders the manufacturer's warranty void!
• Only use the coolant described in this manual (overview of coolants).
• Do not mix different coolants.
• When changing the coolant, the entire volume of liquid must be changed.
Dispose of the coolant in accordance with local regulations and the material safety data sheets.
5.1.2.1 Approved coolants overview
Coolant
Temperature range
KF 23E (Standard)
-10 °C to +40 °C
KF 37E
-20 °C to +30 °C
5.1.2.2 Maximal hose package length
Pump 3.5 bar
Pump 4.5 bar
Machines with or without separate wire feeder
30 m
60 m
Compact machines with additional intermediate
drive (example. miniDrive)
20 m 30 m
Machines with separate wire feeder and additional
intermediate drive (example: miniDrive)
20 m 60 m
Data as a rule refer to the entire hose package length
including welding torch. The pump output is shown on the type plate (parameter: Pmax).
Pump 3.5 bar: Pmax = 0.35 MPa (3.5 bar)
Pump 4.5 bar: Pmax = 0.45 MPa (4.5 bar)