EWM Drive 4X D200 Basic S, Operating Instructions Manual

Page 1: ...Operating instructions EN Wire feed unit Drive 4 Basic S Drive 4X Steel Synergic S Drive 4X Steel puls S 099 005593 EW501 Observe additional system documents 10 01 2022...

Page 2: ...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 ac...

Page 3: ...ng current leads 21 5 1 4 Stray welding currents 22 5 2 Intermediate hose package connection 22 5 2 1 Shielding gas supply shielding gas cylinder for welding machine 24 5 2 2 Pressure regulator connec...

Page 4: ...47 9 Accessories 48 9 1 General accessories 48 9 1 1 Welding torch cooling system 48 9 1 1 1 Coolant type blueCool 48 9 1 1 2 Coolant type KF 48 9 2 19 pole remote control 48 9 2 1 Connection cables...

Page 5: ...s and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning sym bol The hazard is also highlighted using a symbol in the page margin CAUTION Working or ope...

Page 6: ...tch 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 gr...

Page 7: ...cal specialist may interconnect the sources as per standard IEC 60974 9 2010 Installa tion and use and German Accident Prevention Regulation BVG D1 formerly VBG 15 or country specific regulations Befo...

Page 8: ...temperatures of 100 C or higher and arcing and work on live components Hearing protection against harming noise Explosion risk Apparently harmless substances in closed containers may generate excessi...

Page 9: ...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...

Page 10: ...placement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the ma chine is switched off Requirements for connection to the public...

Page 11: ...on or connection points can heat up significantly during operation water cooled version When opening the coolant circuit escaping coolant may cause scalding Open the coolant circuit only when the powe...

Page 12: ...ly 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 MMA welding system for GMAW pulse and standard weld...

Page 13: ...cording to national and in ternational standards and guidelines every 12 months 3 3 3 Service documents spare parts and circuit diagrams WARNING Do not carry out any unauthorised repairs or modificati...

Page 14: ...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 3 1...

Page 15: ...Machine description quick overview Front view side view from the right 099 005593 EW501 10 01 2022 15 4 Machine description quick overview 4 1 Front view side view from the right Figure 4 1...

Page 16: ...ndrel using this support to enable horizontal pivoting of the machine 5 Sliding rails 6 Intermediate hose package strain relief see 5 2 chapter 7 Slide latch lock for the protective cap 8 Welding curr...

Page 17: ...Machine description quick overview Rear view side view from left 099 005593 EW501 10 01 2022 17 4 2 Rear view side view from left Figure 4 2...

Page 18: ...wire feed unit 4 Quick connect coupling red coolant return 5 Quick connect coupling blue coolant supply 6 Wire spool protective cap 7 Wire spool holder 8 Wire feed unit 9 Lighting inside 10 Push butto...

Page 19: ...e 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 Depending on machine type equipment for l...

Page 20: ...nd the material safety data sheets 5 1 2 1 Permitted torch coolant Coolant Temperature range blueCool 10 10 C to 40 C 14 F to 104 F KF 23E Standard 10 C to 40 C 14 F to 104 F KF 37E 20 C to 30 C 4 F t...

Page 21: ...ith HF igniter TIG for as long as pos sible in parallel with a distance of 20 cm to avoid HF sparkover Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences A...

Page 22: ...Set up attach or suspend all conductive power source components such as casing trans port vehicles and crane frames so they are insulated Do not place any other electronic devices such as drills or a...

Page 23: ...belt Intermediate hose package strain relief Secure hose package end with the strain relief Push the welding current cable socket onto the welding current connecting plug and lock by turning to the r...

Page 24: ...g gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch be...

Page 25: ...tective cap of wire feed mechanism 25s 0 Figure 5 7 5 2 2 2 Purge hose package The operating elements are installed under the protective cap of wire feed mechanism 5s 0 300s Figure 5 8 5 2 3 Protectiv...

Page 26: ...Ni Use a plastic or teflon liner when welding or brazing soft wire electrodes high alloy wire electrodes or aluminium materials Preparation for connecting welding torches with a spiral guide Check tha...

Page 27: ...2 Welding torch hose package 3 Welding torch connection Euro torch connector Welding current shielding gas and torch trigger integrated 4 Quick connect coupling blue coolant supply 5 Quick connect co...

Page 28: ...rvals Keep all casing covers or protective caps closed during operation 5 3 3 1 Inserting the wire spool CAUTION Risk of injury due to incorrectly secured wire spool If the wire spool is not secured p...

Page 29: ...ed rollers Figure 5 15 Item Symbol Description 0 1 Tommy The tommy is used to secure the closure brackets of the wire feed rollers 2 Closure bracket The closure brackets are used to secure the wire fe...

Page 30: ...ace Fold the closure brackets outwards by 90 Unfasten pressure units and fold out clamping units and pressure rollers will automatically flip up wards Remove the wire feed rollers from the roller supp...

Page 31: ...Wire feed roll overview table Material Diameter Colour code Groove form mm inch Steel Stainless steel Brazing 0 6 024 monochrome light pink V groove 0 8 031 white 0 8 0 9 1 0 031 035 039 bicolour whit...

Page 32: ...he inching speed is infinitely adjustable by simultaneously pressing the wire inching push button and turning the wire speed rotary knob The left display shows the wire feed speed selected the right d...

Page 33: ...workpiece during inching Inching of the welding wire will stop as soon it touches the workpiece 5 3 3 4 Spool brake setting Figure 5 18 Item Symbol Description 0 1 Allen screw Securing the wire spool...

Page 34: ...ting during Operation according to IEC BS EN 60974 4 Arc welding systems Inspection and Testing during Operation has to be performed Perform test to IEC DIN EN 60974 4 The plugs are located directly o...

Page 35: ...peration see the relevant Control operating instructions 5 5 Remote control The manufacturer s warranty becomes void if non genuine parts are used Only use system components and options power sources...

Page 36: ...ce matters always consult the dealer who supplied the machine Return deliveries of defective equipment subject to warranty may only be made through your dealer When replacing parts use only original s...

Page 37: ...rollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks Visual inspection Casing damage front rear and side walls Wheels and their securing elements Transport ele...

Page 38: ...tem separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private households can be disposed of free of...

Page 39: ...ed in succession Document machine warning and inform service personnel if required If there are several errors in a control system the error with the lowest error number Err is displayed If this error...

Page 40: ...oving the logical signal ro bot ready during the process Eliminate errors on the higher level control 16 A General pilot arc Emergency stop circuit error Check emergency stop circuit Temperature error...

Page 41: ...art au tomated machines Check wire feeding Check load cable connections in welding current circuit clean corroded surfaces on work piece before welding if necessary 49 B Arc interruption An arc interr...

Page 42: ...63 Mains voltage error Operating and mains voltage are incompatible Check or adjust operating and mains voltage 1 only for XQ machine series 2 not for XQ machine series 3 See technical data for values...

Page 43: ...gas supply 19 Gas warning 4 reserved 20 Coolant temperature warning Check coolant level and top up if necessary 21 Excess temperature 2 reserved 22 Excess temperature 3 reserved 23 Excess temperature...

Page 44: ...ntrol signal lights are illuminated after switching on No machine control signal light is illuminated after switching on No welding power Phase failure check mains connection fuses Machine restarts co...

Page 45: ...92 002960 E0000 see 10 1 4 chapter Contact tip blocked Clean and if necessary replace Setting the spool brake see 5 3 3 4 chapter Check settings and correct if necessary Setting pressure units see 5 3...

Page 46: ...with a suitable tool connection open To vent the cooling system always use the blue coolant connection which is located as deep as possible inside the system close to the coolant tank Figure 7 2 Posi...

Page 47: ...in Factory installed roll equipment 1 0 1 2 mm for steel wire Drive 4 rollers 37 mm Wire spool diameter Standardised wire spools up to 300 mm Welding torch connection Euro torch connector Contaminatio...

Page 48: ...024142 00025 FSP blueCool Frost protection tester 094 026477 00000 9 1 1 2 Coolant type KF Type Designation Item no KF 23E 5 Coolant up to 10 C 14 F 5 l 094 000530 00005 KF 23E 200 Coolant 10 C 200 l...

Page 49: ...h wheel kit ON WAK D01 092 002871 00000 ON RFAK D01 Rubber feet 092 002845 00000 ON CC D01 Transparent cover cap for protection of device con trol 092 002834 00000 ON TS D01 D02 Torch holder 092 00283...

Page 50: ...tainless steel and brazing 092 002770 00020 FE 4R 2 4 MM 0 095 INCH BROWN Drive roll set 37 mm 4 rolls V groove for steel stainless steel and brazing 092 002770 00024 FE 4R 2 8 MM 0 11 INCH LIGHT GREE...

Page 51: ...4 FUEL 4R 1 6 MM 0 06 INCH BLACK ORANGE Drive roll set 37 mm 4 rolls V groove knurled for flux cored wire 092 002848 00016 FUEL 4R 2 0 MM 0 08 INCH GREY ORANGE Drive roll set 37 mm 4 rolls V groove kn...

Page 52: ...ndix Searching for a dealer 52 099 005593 EW501 10 01 2022 11 Appendix 11 1 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners world...