EWM drive 4X IC D EX User manual

Operating instructions
EN
Wire feed unit
drive 4X IC D HP
099-005507-EW501
Observe additional system documents!
13.09.2018

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: [email protected]
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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3
1 Contents
1Contents..................................................................................................................................................3
2For your safety.......................................................................................................................................7
2.1 Notes on the use of these operating instructions ..........................................................................7
2.2 Explanation of icons.......................................................................................................................8
2.3 Part of the complete documentation..............................................................................................9
3Intended use.........................................................................................................................................10
3.1 Applications..................................................................................................................................10
3.2 Use and operation solely with the following machines................................................................10
3.3 Documents which also apply.......................................................................................................10
3.3.1 Warranty.......................................................................................................................10
3.3.2 Declaration of Conformity.............................................................................................11
3.3.3 Service documents (spare parts and circuit diagrams)................................................11
3.3.4 Calibration/Validation ...................................................................................................11
4Machine description –quick overview ..............................................................................................12
4.1 Front view / side view from the right............................................................................................12
4.2 Inside view from the right.............................................................................................................14
4.3 Inside view from the left...............................................................................................................15
4.4 Machine control –Operating elements........................................................................................16
4.4.1 Functional sequence ....................................................................................................17
5Design and function.............................................................................................................................19
5.1 Transport and installation ............................................................................................................19
5.1.1 Lifting by crane.............................................................................................................19
5.1.2 Ambient conditions.......................................................................................................19
5.1.2.1 In operation...................................................................................................19
5.1.2.2 Transport and storage...................................................................................19
5.1.3 Welding torch cooling system.......................................................................................21
5.1.3.1 Approved coolants overview.........................................................................21
5.1.3.2 Maximal hose package length ......................................................................21
5.1.4 Notes on the installation of welding current leads........................................................22
5.1.5 Stray welding currents..................................................................................................23
5.1.6 Intermediate hose package connection .......................................................................24
5.1.7 Shielding gas supply (shielding gas cylinder for welding machine).............................25
5.1.7.1 Shielding gas volume settings ......................................................................25
5.1.7.2 Gas test.........................................................................................................25
5.1.7.3 Purge hose package.....................................................................................26
5.2 Welding data display....................................................................................................................26
5.3 Basic settings for operation with two wire feeders (P10).............................................................27
5.3.1 Switching between wire feed units...............................................................................27
5.3.2 Special points when operating with two wire feed units...............................................27
5.4 MIG/MAG welding........................................................................................................................28
5.4.1 Welding torch connection.............................................................................................28
5.4.2 Wire feed......................................................................................................................29
5.4.2.1 Open the protective flap of the wire feeder...................................................29
5.4.2.2 Inserting the wire spool.................................................................................29
5.4.2.3 Changing the wire feed rollers......................................................................31
5.4.2.4 Inching the wire electrode.............................................................................32
5.4.2.5 Spool brake setting .......................................................................................34
5.4.3 Definition of MIG/MAG welding tasks...........................................................................35
5.4.4 Welding task selection..................................................................................................35
5.4.4.1 Basic welding parameters.............................................................................35
5.4.4.2 Operating mode ............................................................................................35
5.4.4.3 Welding type .................................................................................................36
5.4.4.4 Welding power (operating point)...................................................................36
5.4.4.5 Accessory components for operating point setting.......................................36
5.4.4.6 Arc length......................................................................................................36
5.4.4.7 Arc dynamics (choke effect)..........................................................................37
5.4.4.8 superPuls......................................................................................................37
5.4.5 Conventional MIG/MAG Welding (GMAW non synergic).............................................38

Contents
Notes on the use of these operating instructions
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5.4.5.1 Setting the operating point (welding output)..................................................38
5.4.5.2 Welding power (operating point)...................................................................39
5.4.5.3 Operating point setting via welding current, material thickness or wire
feed speed.....................................................................................................39
5.4.5.4 Arc length......................................................................................................39
5.4.5.5 Accessory components for operating point setting.......................................39
5.4.6 coldArc / coldArc puls...................................................................................................40
5.4.7 forceArc / forceArc puls................................................................................................40
5.4.8 rootArc/rootArc puls......................................................................................................41
5.4.9 pipeSolution..................................................................................................................41
5.4.10 Operating modes (functional sequences).....................................................................42
5.4.10.1 Explanation of signs and functions................................................................42
5.4.10.2 Automatic cut-out ..........................................................................................42
5.4.11 MIG/MAG program sequence ("Program steps" mode)...............................................55
5.4.11.1 Selection of the program sequence parameter.............................................55
5.4.11.2 MIG/MAG overview of parameters................................................................56
5.4.11.3 Example, tack welding (non-latched)............................................................56
5.4.11.4 Example, aluminium tack welding (non-latched special) ..............................57
5.4.11.5 Example, aluminium welding (latched special).............................................58
5.4.11.6 Example, visible seams (latched super pulse)..............................................59
5.4.12 Main program A mode..................................................................................................60
5.4.12.1 Selecting parameters (program A)................................................................61
5.4.13 Standard MIG/MAG torch.............................................................................................62
5.4.14 MIG/MAG special-torches.............................................................................................62
5.4.14.1 Program and up/down operation...................................................................62
5.4.14.2 Switching between Push/Pull and intermediate drive...................................62
5.4.15 Expert menu (MIG/MAG)..............................................................................................63
5.4.15.1 Selection........................................................................................................63
5.4.15.2 Burn-back......................................................................................................64
5.4.15.3 Programme limit............................................................................................65
5.5 TIG welding..................................................................................................................................65
5.5.1 Welding torch connection .............................................................................................65
5.5.2 Welding task selection..................................................................................................66
5.5.2.1 Welding current setting..................................................................................66
5.5.3 TIG arc ignition .............................................................................................................67
5.5.3.1 Liftarc.............................................................................................................67
5.5.4 Operating modes (functional sequences).....................................................................68
5.5.4.1 Explanation of signs and functions................................................................68
5.5.4.2 Automatic cut-out ..........................................................................................68
5.5.5 TIG program sequence ("Program steps" mode).........................................................72
5.6 MMA welding................................................................................................................................72
5.6.1 Welding task selection..................................................................................................72
5.6.1.1 Welding current setting..................................................................................73
5.6.2 Arcforce.........................................................................................................................73
5.6.3 Hotstart .........................................................................................................................73
5.6.4 Antistick.........................................................................................................................73
5.6.5 Parameter overview......................................................................................................74
5.7 Remote control.............................................................................................................................74
5.8 Interfaces for automation .............................................................................................................74
5.8.1 Remote control connection socket, 19-pole .................................................................75
5.9 Access control..............................................................................................................................75
5.10 Special parameters (advanced settings)......................................................................................75
5.10.1 Selecting, changing and saving parameters.................................................................76
5.10.2 Reset to factory settings...............................................................................................78
5.10.3 Special parameters in detail .........................................................................................78
5.10.3.1 Ramp time for wire inching (P1)....................................................................78
5.10.3.2 Program "0", releasing the program block (P2).............................................78
5.10.3.3 Display mode for Up/Down welding torch with one-digit 7-segment
display (P3) ...................................................................................................79
5.10.3.4 Program limit (P4) .........................................................................................79

Contents
Notes on the use of these operating instructions
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5.10.3.5 Special cycle in the operating modes special latched and non-latched
(P5) ...............................................................................................................79
5.10.3.6 Correction operation, threshold value setting (P7) .......................................80
5.10.3.7 Switching programs with the standard torch trigger (P8)..............................81
5.10.3.8 Latched/special-latched tap start (P9) ..........................................................82
5.10.3.9 "Single or dual operation" (P10) setting........................................................82
5.10.3.10Latched special tapping time setting (P11)...................................................82
5.10.3.11JOB list switching (P12)................................................................................83
5.10.3.12Lower and upper limits of the remote JOB changeover process (P13,
P14)...............................................................................................................84
5.10.3.13Hold function (P15) .......................................................................................84
5.10.3.14Block JOB mode (P16) .................................................................................84
5.10.3.15Selecting programs with the standard torch trigger (P17) ............................85
5.10.3.16Mean value display for superPuls (P19).......................................................85
5.10.3.17Predefined execution of the pulsed arc welding process in the PA
program (P20)...............................................................................................85
5.10.3.18Predefined absolute value for relative programs (P21)................................85
5.10.3.19Electronic gas flow control, type (P22)..........................................................85
5.10.3.20Program settings for relative programs (P23)...............................................85
5.10.3.21Correction or nominal voltage display (P24).................................................86
5.10.3.22JOB selection in Expert mode (P25).............................................................86
5.10.3.23Nominal value wire heater (P26)...................................................................86
5.10.3.24Mode switching at welding start (P27)..........................................................86
5.10.3.25Error threshold electronic gas flow control (P28)..........................................86
5.10.3.26Units system (P29)........................................................................................86
5.10.3.27Selection option –Program sequence with welding power rotary knob
(P30) .............................................................................................................86
5.11 Machine configuration menu........................................................................................................87
5.11.1 Aligning the cable resistance........................................................................................88
5.11.2 Power-saving mode (Standby).....................................................................................89
6Maintenance, care and disposal.........................................................................................................90
6.1 General........................................................................................................................................90
6.2 Cleaning.......................................................................................................................................90
6.2.1 Dirt filter........................................................................................................................90
6.3 Maintenance work, intervals........................................................................................................91
6.3.1 Daily maintenance tasks ..............................................................................................91
6.3.2 Monthly maintenance tasks..........................................................................................91
6.3.3 Annual test (inspection and testing during operation)..................................................91
6.4 Disposing of equipment ...............................................................................................................92
7Rectifying faults ...................................................................................................................................93
7.1 Checklist for rectifying faults........................................................................................................93
7.2 Error messages (power source) ..................................................................................................94
8Technical data ......................................................................................................................................96
8.1 drive 4X IC D HP..........................................................................................................................96
9Accessories..........................................................................................................................................97
9.1 General accessories....................................................................................................................97
9.2 Remote control/connecting and extension cable.........................................................................97
9.2.1 7-pole connection.........................................................................................................97
9.2.2 19-pole connection.......................................................................................................97
10 Replaceable parts ................................................................................................................................98
10.1 Wire feed rollers...........................................................................................................................98
10.1.1 Wire feed rollers for steel wire......................................................................................98
10.1.2 Wire feed rollers for aluminium wire.............................................................................98
10.1.3 Wire feed rollers for cored wire ....................................................................................99
10.1.4 Wire guide ....................................................................................................................99
11 Appendix A .........................................................................................................................................100
11.1 JOB-List.....................................................................................................................................100
12 Appendix B .........................................................................................................................................107
12.1 Searching for a dealer ...............................................................................................................107

Contents
Notes on the use of these operating instructions
6
099-005507-EW501
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For your safety
Notes on the use of these operating instructions
099-005507-EW501
13.09.2018
7
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
8
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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 hold
Switch
Incorrect / Invalid
Turn
Correct / Valid
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 /
actuate)
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
099-005507-EW501
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9
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

Intended use
Applications
10
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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!