EWM drive 4X IC HP D200 User manual

Operating instructions
EN
Wire feed unit
drive 4X IC HP D200
099-005508-EW501 Observe additional system documents! 04.04.2016

General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•
Read the operating instructions for all system components!
•
Observe accident prevention regulations!
•
Observe all local regulations!
• Confirm with a signature where appropriate.
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-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, 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
2Safety instructions.................................................................................................................................6
2.1 Notes on the use of these operating instructions .......................................................................... 6
2.2 Explanation of icons ....................................................................................................................... 7
2.3 General .......................................................................................................................................... 8
2.4 Transport and installation ............................................................................................................ 12
2.4.1 Ambient conditions ....................................................................................................... 13
2.4.1.1 In operation ................................................................................................... 13
2.4.1.2 Transport and storage ................................................................................... 13
3Intended use.........................................................................................................................................14
3.1 Use and operation solely with the following machines ................................................................ 14
3.2 Applications .................................................................................................................................. 14
3.3 Documents which also apply ....................................................................................................... 15
3.3.1 Warranty ....................................................................................................................... 15
3.3.2 Declaration of Conformity ............................................................................................. 15
3.3.3 Welding in environments with increased electrical hazards ......................................... 15
3.3.4 Service documents (spare parts and circuit diagrams) ................................................ 15
3.3.5 Calibration/Validation ................................................................................................... 15
4Machine description – quick overview ..............................................................................................16
4.1 Front view .................................................................................................................................... 16
4.2 Rear view ..................................................................................................................................... 17
4.3 Inside view ................................................................................................................................... 18
4.4 Machine control – Operating elements ........................................................................................ 19
4.4.1 Functional sequence .................................................................................................... 21
5Design and function.............................................................................................................................22
5.1 General ........................................................................................................................................ 22
5.2 Installation .................................................................................................................................... 23
5.3 Welding torch cooling system ...................................................................................................... 24
5.3.1 List of coolants .............................................................................................................. 24
5.3.2 Maximal hose package length ...................................................................................... 24
5.4 Notes on the installation of welding current leads ....................................................................... 25
5.5 Connecting the intermediate hose package to the power source ............................................... 27
5.5.1 Strain relief ................................................................................................................... 27
5.5.2 Snap hook strain relief .................................................................................................. 28
5.6 Shielding gas supply (shielding gas cylinder for welding machine) ............................................. 29
5.6.1 Gas test ........................................................................................................................ 29
5.6.1.1 Setting the shielding gas quantity ................................................................. 29
5.7 Welding data display .................................................................................................................... 30
5.8 MIG/MAG welding ........................................................................................................................ 31
5.8.1 Welding torch connection ............................................................................................. 31
5.8.2 Wire feed ...................................................................................................................... 34
5.8.2.1 Open the protective flap of the wire feeder ................................................... 34
5.8.2.2 Inserting the wire spool ................................................................................. 34
5.8.2.3 Changing the wire feed rollers ...................................................................... 35
5.8.2.4 Inching the wire electrode ............................................................................. 37
5.8.2.5 Spool brake setting ....................................................................................... 39
5.8.3 Standard MIG/MAG torch ............................................................................................. 39
5.8.4 MIG/MAG special-torches ............................................................................................ 39
5.8.5 Definition of MIG/MAG welding tasks ........................................................................... 40
5.8.6 Welding task selection .................................................................................................. 40
5.8.6.1 Basic welding parameters ............................................................................. 40
5.8.6.2 Operating mode ............................................................................................ 40
5.8.6.3 Choke effect / dynamics ................................................................................ 41
5.8.6.4 superPuls ...................................................................................................... 41
5.8.6.5 Burn-back ...................................................................................................... 42
5.8.7 MIG/MAG operating point ............................................................................................. 43

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5.8.7.1 Selecting the display unit............................................................................... 43
5.8.7.2 Operating point setting using material thickness .......................................... 43
5.8.7.3 Arc length correction setting .......................................................................... 44
5.8.7.4 Accessory components for operating point setting ....................................... 44
5.8.7.5 coldArc / coldArc puls .................................................................................... 45
5.8.7.6 forceArc / forceArc puls ................................................................................. 46
5.8.7.7 rootArc/rootArc puls ....................................................................................... 47
5.8.7.8 pipeSolution ................................................................................................... 47
5.8.8 MIG/MAG functional sequences / operating modes ..................................................... 48
5.8.8.1 Explanation of signs and functions ................................................................ 48
5.8.9 MIG/MAG program sequence ("Program steps" mode) ............................................... 61
5.8.9.1 Selection of the program sequence parameter ............................................. 61
5.8.9.2 MIG/MAG overview of parameters ................................................................ 62
5.8.9.3 Example, tack welding (non-latched) ............................................................ 63
5.8.9.4 Example, aluminium tack welding (non-latched special) .............................. 63
5.8.9.5 Example, aluminium welding (latched special) ............................................. 64
5.8.9.6 Example, visible seams (latched super pulse) .............................................. 65
5.8.10 Main program A mode .................................................................................................. 66
5.8.10.1 Selecting parameters (program A) ................................................................ 68
5.8.11 MIG/MAG automatic cut-out ......................................................................................... 68
5.8.12 Standard MIG/MAG torch ............................................................................................. 69
5.8.13 MIG/MAG special-torches............................................................................................. 69
5.8.13.1 Program- and Up- / down operation .............................................................. 69
5.8.13.2 Switching between Push/Pull and intermediate drive ................................... 70
5.8.14 Expert menu (MIG/MAG) .............................................................................................. 71
5.8.14.1 Selection ........................................................................................................ 71
5.9 TIG welding .................................................................................................................................. 73
5.9.1 Welding torch connection ............................................................................................. 73
5.9.2 Welding task selection .................................................................................................. 74
5.9.3 Welding current setting ................................................................................................. 74
5.9.4 TIG arc ignition ............................................................................................................. 74
5.9.4.1 Liftarc ignition ................................................................................................ 74
5.9.5 Function sequences/operating modes .......................................................................... 75
5.9.5.1 Explanation of signs and functions ................................................................ 75
5.9.6 TIG automatic cut-out ................................................................................................... 78
5.9.7 TIG program sequence ("Program steps" mode) ......................................................... 79
5.10 MMA welding ................................................................................................................................ 80
5.10.1 Welding task selection .................................................................................................. 80
5.10.2 Welding current setting ................................................................................................. 80
5.10.3 Arcforce......................................................................................................................... 80
5.10.4 Hotstart ......................................................................................................................... 81
5.10.5 Antistick......................................................................................................................... 81
5.10.6 Parameter overview ...................................................................................................... 81
5.11 Remote control ............................................................................................................................. 82
5.12 Interfaces for automation ............................................................................................................. 82
5.12.1 Remote control connection socket, 19-pole ................................................................. 83
5.13 Access control .............................................................................................................................. 84
5.14 Special parameters (advanced settings) ...................................................................................... 84
5.14.1 Selecting, changing and saving parameters................................................................. 85
5.14.1.1 Reset to factory settings ................................................................................ 87
5.14.1.2 Special parameters in detail .......................................................................... 88
5.15 Machine configuration menu ........................................................................................................ 98
5.15.1 Selecting, changing and saving parameters................................................................. 98
5.15.2 Aligning the cable resistance ...................................................................................... 100
5.15.3 Power-saving mode (Standby) ................................................................................... 101
6Maintenance, care and disposal.......................................................................................................102
6.1 General....................................................................................................................................... 102
6.2 Maintenance work, intervals ...................................................................................................... 102
6.2.1 Daily maintenance tasks ............................................................................................. 102
6.2.1.1 Visual inspection ......................................................................................... 102

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6.2.1.2 Functional test ............................................................................................. 102
6.2.2 Monthly maintenance tasks ........................................................................................ 103
6.2.2.1 Visual inspection ......................................................................................... 103
6.2.2.2 Functional test ............................................................................................. 103
6.2.3 Annual test (inspection and testing during operation) ................................................ 103
6.3 Disposing of equipment ............................................................................................................. 103
6.3.1 Manufacturer's declaration to the end user ................................................................ 103
6.4 Meeting the requirements of RoHS ........................................................................................... 103
7Rectifying faults.................................................................................................................................104
7.1 Checklist for rectifying faults ...................................................................................................... 104
7.2 Error messages .......................................................................................................................... 105
7.3 Resetting JOBs (welding tasks) to the factory settings ............................................................. 107
7.3.1 Resetting a single JOB ............................................................................................... 107
7.3.2 Resetting all JOBs ...................................................................................................... 108
7.4 Vent coolant circuit ..................................................................................................................... 109
8Technical data ....................................................................................................................................110
8.1 drive 4X IC HP D200.................................................................................................................. 110
9Accessories........................................................................................................................................111
9.1 General accessories .................................................................................................................. 111
9.2 Remote control/connecting and extension cable ....................................................................... 111
9.2.1 19-pole connection ..................................................................................................... 111
10 Replaceable parts ..............................................................................................................................112
10.1 Wire feed rollers ......................................................................................................................... 112
10.1.1 Wire feed rollers for steel wire .................................................................................... 112
10.1.2 Wire feed rollers for aluminium wire ........................................................................... 113
10.1.3 Wire feed rollers for cored wire .................................................................................. 113
10.1.4 Wire guide .................................................................................................................. 113
11 Appendix A .........................................................................................................................................114
11.1 JOB-List ..................................................................................................................................... 114
12 Appendix B .........................................................................................................................................115
12.1 Overview of EWM branches ...................................................................................................... 115

Safety instructions
Notes on the use of these operating instru
ctions
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2 Safety instructions
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.
CAUTION
Working and operating procedures which must be followed
precisely to avoid damaging
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at 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.

Safety instructions
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Special technical points which users must observe.
Correct
Wrong
Press
Do not press
Press and keep pressed
Turn
Switch
Switch off machine
Switch on machine
ENTER
enter the menu
NAVIGATION
Navigating in the menu
EXIT
Exit the menu
4 s
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use

Safety instructions
General
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2.3 General
DANGER
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 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).
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)!
Electric shock!
Welding machines use high voltages which can result i
n potentially fatal electric shocks
and burns on contact. Even low voltages can cause you to get a shock and lead to
accidents.
• Do not touch any live parts in or on the machine!
• Connection cables and leads must be free of faults!
• Switching off alone is not sufficient!
• Place welding torch and stick electrode holder on an insulated surface!
• The unit should only be opened by specialist staff after the mains plug has been
unplugged!
• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!
WARNING
Validity of the document!
This document is valid only in combination with the operating instructions for the
product being used!
• Read and observe the operating instructions for all system components, especially the
safety instructions!
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!
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!

Safety instructions
General
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WARNING
Risk of injury due to radiation or heat!
Arc radiation results in injury to skin and eyes.
Contact with hot workpieces and sparks results in burns.
• Use welding shield or welding helmet with the appropriate safety level (depending on the
application)!
• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
• Protect persons not involved in the work against arc beams and the risk of glare using
safety curtains!
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!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
• Check for fire hazards in the working area!
• Do not carry any easily flammable objects such as matches or lighters.
• Keep appropriate fire extinguishing equipment to hand in the working area!
• Thoroughly remove any residue of flammable substances from the workpiece before
starting welding.
• Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
• Connect welding leads correctly!
Danger when coupling multiple power sources!
Coupling multiple power sources in parallel or in series has to be carried out by
qualified personnel and in accordance with the manufacturer's guidelines. Before
bringing the power sources into service for arc welding operations, a test has to verify
that they cannot exceed the maximum allowed open circuit voltage.
• Connection of the machine may be carried out by qualified personnel only!
• When decommissioning individual power sources, all mains and welding current leads
have
to be safely disconnected from the welding system as a whole. (Danger due to inverse
voltages!)
• Do not couple welding machines with pole reversing switch (PWS series) or machines for
AC welding, as a minor error in operation can cause the welding voltages to be combined.
CAUTION
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!

Safety instructions
General
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CAUTION
Obligations of the operator!
The respective national directives and laws must be observed for operation of the
machine!
• National implementation of the framework directive (89/391/EWG), as well as the
associated individual directives.
• In particular, directive (89/655/EWG), on the minimum regulations for safety and health
protection when staff members use equipment during work.
• The regulations regarding work safety and accident prevention for the respective country.
• Setting up and operating the machine according to IEC 60974-9.
• Check at regular intervals that users are working in a safety-conscious way.
• Regular checks of the machine according to IEC 60974-4.
Damage due to the use of non-genuine parts!
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.
Damage to the machine due to stray welding currents!
Stray welding currents can destroy protective earth conductors,
damage equipment and
electronic devices and cause overheating of components leading to fire.
• Make sure all welding leads are securely connected and check regularly.
• Always ensure a proper and secure electrical connection to the workpiece!
• Set up, attach or suspend all conductive power source components like casing, transport
vehicle and crane frames so they are insulated!
• Do not place any other electronic devices such as drillers or angle grinders, etc., on the
power source, transport vehicle or crane frames unless they are insulated!
• Always put welding torches and electrode holders on an insulated surface when they are
not in use!
Mains connection
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.