Contents
Notes on the use of these operating instructions
099-000236-EW501
25.04.2019
1 Contents
1 Contents .................................................................................................................................................. 3
2 For your safety ....................................................................................................................................... 6
2.1 Notes on the use of these operating instructions .......................................................................... 6
2.2 Explanation of icons ....................................................................................................................... 7
2.3 Part of the complete documentation .............................................................................................. 8
2.4 Safety instructions .......................................................................................................................... 9
2.5 Transport and installation ............................................................................................................ 13
3 Intended 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
4 Machine description – quick overview .............................................................................................. 16
4.1 Front view .................................................................................................................................... 16
4.2 Rear view ..................................................................................................................................... 18
4.3 Machine control – Operating elements ........................................................................................ 20
4.3.1 Machine control – Concealed operating elements ....................................................... 22
4.3.2 Operating elements in the machine .............................................................................. 23
4.4 Connection plan ........................................................................................................................... 24
4.4.1 Legend .......................................................................................................................... 25
5 Design and function ............................................................................................................................. 26
5.1 Transport and installation ............................................................................................................ 26
5.1.1 Protective flap, welding machine control ...................................................................... 26
5.1.2 Ambient conditions ....................................................................................................... 27
5.1.2.1 In operation ................................................................................................... 27
5.1.2.2 Transport and storage ................................................................................... 27
5.1.3 Machine cooling ............................................................................................................ 27
5.1.4 Workpiece lead, general ............................................................................................... 27
5.1.5 Notes on the installation of welding current leads ........................................................ 28
5.1.6 Stray welding currents .................................................................................................. 29
5.1.7 Mains connection .......................................................................................................... 30
5.1.7.1 Mains configuration ....................................................................................... 30
5.1.8 Welding torch cooling system ....................................................................................... 30
5.1.8.1 Permitted torch coolant ................................................................................. 31
5.1.8.2 Maximal hose package length ...................................................................... 31
5.1.9 Intermediate hose package connection ....................................................................... 32
5.1.9.1 Intermediate hose package strain relief ........................................................ 33
5.1.9.2 Locking the strain relief ................................................................................. 34
5.1.9.3 Control cable pin configuration ..................................................................... 34
5.1.10 Connection for workpiece lead ..................................................................................... 35
5.1.11 Welding torch connection ............................................................................................. 36
5.1.11.1 Control cable pin configuration ..................................................................... 37
5.1.12 Wire feed ...................................................................................................................... 38
5.1.12.1 Inserting the wire spool ................................................................................. 38
5.1.12.2 Changing the wire feed rollers ...................................................................... 39
5.1.12.3 Inching the wire electrode ............................................................................. 39
5.1.12.4 Spool brake setting ....................................................................................... 41
5.1.13 Shielding gas supply (shielding gas cylinder for welding machine) ............................. 41
5.1.13.1 Connecting the shielding gas supply ............................................................ 41
5.1.13.2 Shielding gas volume settings ...................................................................... 42
5.1.13.3 Gas test ......................................................................................................... 43
5.1.13.4 Purge hose package ..................................................................................... 43
5.1.14 Configuring the welding machine for mechanical arc fusion welding ........................... 43
5.1.14.1 Selection and adjustment .............................................................................. 44