Ewm PDF

Operating instructions
Power sources for automated applications
alpha Q 352, 552 RC Puls

GB
alpha Q RC2
099-005079-EW501 Observe additional system documents! 07.09.2012
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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.
NOTE
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 +49 2680 181-0.
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 HIGHTEC WELDING GmbH · 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.
Subject to technical amendments.
Contents
Notes on the use of these operating instructions
1 Contents
1 Contents.................................................................................................................................................. 3
2 Safety instructions................................................................................................................................. 7
2.1 Notes on the use of these operating instructions .......................................................................... 7
2.2 Explanation of icons....................................................................................................................... 8
2.3 General .......................................................................................................................................... 9
2.4 Transport and installation ............................................................................................................ 13
2.4.1 Lifting by crane .............................................................................................................14
2.5 Ambient conditions....................................................................................................................... 15
2.5.1 In operation................................................................................................................... 15
2.5.2 Transport and storage ..................................................................................................15
3 Intended use ......................................................................................................................................... 16
3.1 Applications.................................................................................................................................. 16
3.1.1 MIG/MAG standard welding ......................................................................................... 16
3.1.2 coldArc.......................................................................................................................... 16
3.1.3 forceArc ........................................................................................................................ 16
3.1.4 pipeSolution.................................................................................................................. 16
3.1.5 MIG/MAG pulse welding...............................................................................................16
3.2 Documents which also apply ....................................................................................................... 17
3.2.1 Warranty ....................................................................................................................... 17
3.2.2 Declaration of Conformity.............................................................................................17
3.2.3 Welding in environments with increased electrical hazards......................................... 17
3.2.4 Service documents (spare parts and circuit diagrams) ................................................ 17
4 Machine description – quick overview .............................................................................................. 18
4.1 alpha Q 352, 552 Puls ................................................................................................................. 18
4.1.1 Front view ..................................................................................................................... 18
4.1.2 Rear view...................................................................................................................... 20
4.2 alpha Q RC2 ................................................................................................................................ 22
4.2.1 Front and rear views..................................................................................................... 22
4.3 Machine control – Operating elements ........................................................................................ 24
4.3.1 alpha Q RC2.................................................................................................................24
5 Design and function............................................................................................................................. 26
5.1 General ........................................................................................................................................ 26
5.2 Installation.................................................................................................................................... 27
5.3 Machine cooling ........................................................................................................................... 27
5.4 Workpiece lead, general .............................................................................................................. 27
5.5 Notes on the installation of welding current leads ....................................................................... 28
5.6 Welding torch cooling system ...................................................................................................... 29
5.6.1 General......................................................................................................................... 29
5.6.2 List of coolants.............................................................................................................. 29
5.7 Mains connection ......................................................................................................................... 30
5.7.1 Mains configuration ...................................................................................................... 30
5.8 Intermediate hose package connection ....................................................................................... 31
5.9 Connection for workpiece lead .................................................................................................... 32
5.10 Connect the cooling module to the power source ....................................................................... 33
5.11 Connect the alpha Q RC 2 to the power source.......................................................................... 34
5.12 Shielding gas supply .................................................................................................................... 35
5.12.1 Connecting the shielding gas supply............................................................................35
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Contents
5.13 Interfaces .....................................................................................................................................37

5.13.1 Connecting the RINT X11 robot interface/BUSINT X11 industrial bus interface..........37
5.13.1.1 RINT X11 robot interface...............................................................................37
5.13.1.2 BUSINT X11 industrial bus interface.............................................................37
5.13.2 Connecting the PC 300.net welding parameterisation software...................................39
5.13.3 Connecting the Q-DOC 9000 welding data documentation software...........................40
5.13.4 Connecting the WELDQAS welding data monitoring and documentation system .......41
5.13.5 Automation interface.....................................................................................................42
5.13.6 Sensor Voltage .............................................................................................................44
5.14 Protecting welding parameters from unauthorised access ..........................................................44
5.15 Welding data display ....................................................................................................................45
5.16 Definition of MIG/MAG welding tasks ..........................................................................................46
5.17 Welding task selection .................................................................................................................47
5.17.1 Selecting or defining a new job.....................................................................................47
5.17.2 coldArc ..........................................................................................................................48
5.17.3 forceArc.........................................................................................................................49
5.17.4 Operating mode ............................................................................................................50
5.17.5 Welding type .................................................................................................................50
5.17.6 Program or control voltage mode .................................................................................51
5.17.7 Program sequence .......................................................................................................52
5.17.8 Superpulses..................................................................................................................53
5.18 MIG/MAG functional sequences / operating modes ....................................................................54
5.18.1 Explanation of signs and functions ...............................................................................54
5.19 MIG/MAG program sequence ("Program steps" mode) ..............................................................59
5.19.1 Selection .......................................................................................................................59
5.19.2 MIG/MAG overview of parameters for M3.1x ...............................................................59
5.20 Main program A mode..................................................................................................................60
5.20.1 Selection .......................................................................................................................60
5.20.2 MIG/MAG overview of parameters for M3.1x ...............................................................61
5.21 "Special Mode" mode...................................................................................................................62
5.21.1 Selection .......................................................................................................................62
5.21.2 Switching the Hold function on and off .........................................................................63
5.21.3 WF speed switching (absolute / relative)......................................................................63
5.21.4 Resetting JOBs to status on delivery (Reset ALL) .......................................................63
5.21.5 Exiting "Special Mode" after making changes ..............................................................63
5.22 "Job Info" mode............................................................................................................................64
5.23 Operating time counter.................................................................................................................64
5.24 Organising welding tasks (Mode "JOB Manager").......................................................................65
5.24.1 Creating a new JOB in the memory or copying a JOB.................................................65
5.24.2 Loading an existing job .................................................................................................66
5.24.3 Resetting an existing JOB to the factory setting (Reset JOB)......................................66
5.25 Expert parameters........................................................................................................................67
5.25.1 Selecting expert model parameters..............................................................................67
5.25.2 Selecting variables (5 model points).............................................................................67
5.25.3 Setting parameters .......................................................................................................67
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Contents
6 Maintenance, care and disposal......................................................................................................... 68

6.1 General ........................................................................................................................................ 68
6.2 Maintenance work, intervals ........................................................................................................ 69
6.2.1 Daily maintenance tasks .............................................................................................. 69
6.2.1.1 Visual inspection ...........................................................................................69
6.2.1.2 Functional test............................................................................................... 69
6.2.2 Monthly maintenance tasks.......................................................................................... 69
6.2.2.1 Visual inspection ...........................................................................................69
6.2.2.2 Functional test............................................................................................... 69
6.2.3 Annual test (inspection and testing during operation) .................................................. 70
6.3 Maintenance work........................................................................................................................ 70
6.4 Disposing of equipment ............................................................................................................... 71
6.4.1 Manufacturer's declaration to the end user ..................................................................71
6.5 Meeting the requirements of RoHS ............................................................................................. 71
7 Rectifying faults ................................................................................................................................... 72
7.1 Checklist for rectifying faults ........................................................................................................ 72
7.2 Error messages............................................................................................................................ 74
7.3 Error messages (RC-Panel) ........................................................................................................ 76
7.3.1 Interface for automated welding ................................................................................... 77
7.4 Display machine control software version ................................................................................... 78
7.4.1 Resetting JOBs to status on delivery (Reset ALL) ....................................................... 78
7.5 Vent coolant circuit....................................................................................................................... 79
8 Technical data ...................................................................................................................................... 80
8.1 alpha Q 352, 552 Puls ................................................................................................................. 80
8.2 alpha Q RC2 ................................................................................................................................ 80
9 Accessories .......................................................................................................................................... 81
9.1 Connection cables, connection sockets....................................................................................... 81
9.2 General accessories .................................................................................................................... 81
9.3 Options......................................................................................................................................... 81
9.4 Transportsysteme ........................................................................................................................ 81
9.5 Interfaces ..................................................................................................................................... 81
9.6 Computer communication............................................................................................................ 81
9.7 Cooling units ................................................................................................................................ 82
9.8 alpha Q RC2 ................................................................................................................................ 82
10 Circuit diagrams................................................................................................................................... 83
11 Appendix A ........................................................................................................................................... 85
11.1 JOB-List ....................................................................................................................................... 85
12 Appendix B ........................................................................................................................................... 86
12.1 Overview of EWM branches ........................................................................................................ 86
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Contents
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Safety instructions
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.
NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
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.
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Safety instructions
Explanation of icons
2.2 Explanation of icons

Symbol Description
Press
Do not press
Turn
Switch
0
Switch off machine
l
0
Switch on machine
l
ENTER (enter the menu)
NAVIGATION (Navigating in the menu)
EXIT (Exit the menu)
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)

Tool not required/do not use
Tool required/use
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Safety instructions
General
2.3 General
DANGER
Electric shock!
Welding machines use high voltages which can result in 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!
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 Maintenance and Testing 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)!
WARNING
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
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!
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Safety instructions
General
WARNING
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!
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)!
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!
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Safety instructions
General
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.
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Safety instructions
General
CAUTION
EMC Machine Classification
In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic
compatibility classes (see technical data):
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 not 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 equipment
• 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
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Safety instructions
Transport and installation
2.4 Transport and installation

WARNING
Incorrect handling of shielding gas cylinders!
Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.
• Observe the instructions from the gas manufacturer and in any relevant regulations
concerning the use of compressed air!
• Place shielding gas cylinders in the holders provided for them and secure with fixing
devices.
• Avoid heating the shielding gas cylinder!
CAUTION
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 EN 60974-A2).
• Set up and transport the machine on level, solid ground!
• Secure add-on parts using suitable equipment!
• Replace damaged wheels and their fixing elements!
• Fix external wire feed units during transport (avoid uncontrolled rotation)!
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
• Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
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!
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Safety instructions
Transport and installation
2.4.1 Lifting by crane
DANGER
Risk of injury during lifting by crane!
When lifting the equipment by crane, serious injuries can be inflicted by falling
equipment or add-on units.
• Transport on all lifting lugs at the same time
(see Fig. Lifting principle)!
m
.1
• Ensure that there is an even load distribution! Only
min
use ring chains or suspension ropes of the same °
length! 75
• Observe the lifting principle (see Fig.)!
• Remove all accessory components before lifting
(e.g. shielding gas cylinders, tool boxes, wire feed
units, etc.)! Fig. Lifting principle
• Avoid jerky movements when raising or lowering!
• Use shackles and load hooks of the appropriate size!
Risk of injury due to unsuitable lifting eye!
In case of improper use of lifting eyes or the use of unsuitable lifting eyes, persons can
be seriously damaged by falling equipment or add-on components!
• The lifting eye must be completely screwed in!
• The lifting eye must be positioned flat onto and in full contact with the supporting surfaces!
• Check that the lifting eyes are securely fastened before use and check for any damage
(corrosion, deformation)!
• Do not use or screw in damaged lifting eyes!
• Avoid lateral loading of the lifting eyes!
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Safety instructions
Ambient conditions
2.5 Ambient conditions

CAUTION
Installation site!
The 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
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!
2.5.1 In operation
Temperature range of the ambient air:
• -20 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.5.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -25 °C to +55 °C
Relative air humidity
• Up to 90% at 20 °C
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Intended use
Applications
3 Intended use
This machine has been manufactured according to the latest developments in technology and current
regulations and standards. It must only be operated in line with the instructions on correct usage.
WARNING
Hazards due to improper usage!
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 proper usage and by trained or expert staff!
• Do not modify or convert the equipment improperly!
3.1 Applications
3.1.1 MIG/MAG standard welding
Metal arc welding using a wire electrode whereby gas from an external source surrounds the arc and the
molten pool to protect them from the atmosphere.
3.1.2 coldArc
Welding process for joining thin panels and root layers, steel, chrome/nickel and aluminium as well as for
mixed joints. Also suitable for welding large air gaps in all layers.
3.1.3 forceArc
Welding with a powerful forced arc, deep fusion penetration and virtually spatter-free weld seams of the
highest quality.
3.1.4 pipeSolution
Reduced-energy MAG welding. X-ray-proof welding of pipelines and pipework without lack of fusion. Root
pass and fill and final pass with or without air gap. Low- and high-alloy steels with solid and cored wires.
3.1.5 MIG/MAG pulse welding
Welding process for optimum welding results when joining stainless steel and aluminium thanks to
controlled drop transfer and targeted, adapted heat input.
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Intended use
Documents which also apply
3.2 Documents which also apply

3.2.1 Warranty
NOTE
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
3.2.2 Declaration of Conformity

The designated machine conforms to EC Directives and standards in terms of its design
and construction:
• EC Low Voltage Directive (2006/95/EC),
• EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly
conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted
conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
3.2.3 Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
3.2.4 Service documents (spare parts and circuit diagrams)
DANGER
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
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Machine description – quick overview
alpha Q 352, 552 Puls
4 Machine description – quick overview

4.1 alpha Q 352, 552 Puls
4.1.1 Front view
1
2 8
3
9
4
5 10
7
Figure 4-1
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Item Symbol Description 0

1 Lifting lug
2 Operating state signal lamp
Lights up when the machine is ready for use.
3 "Fault" display
"Collective interference" signal light
If the signal light is on, the power unit is automatically switched off. Because some
interference is short-term and one-off (e.g. excess temperature), the signal light will go
off again and the welding machine will be ready for welding. If the signal light is still on
after a reasonable amount of time, see the chapter on “Operating errors, causes and
remedies”.
4 Welding process signal lamp
Lights up when the welding process runs.
5 PC interface, serial (D-Sub connection socket, 9-pole)

COM
6 Cooling air inlet

7 Machine feet
8 7-pole connection socket (digital)
For connecting digital accessory components
Operating panel connection lead connection
0
10 Main switch, machine on/off
l
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4.1.2 Rear view
1
10
11
9 12
2
3
4 13
5
6
8 14
Figure 4-2
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Connection of the connection lead to the power source
digital
2 19-pole mechanised welding interface (analogue)

(See chapter entitled "Design and function > interfaces".)
analog
3 8-pole connection socket
Cooling unit control lead
Wire feed unit connection
6 12-pole connection socket (analogue)
Connection socket for analogue control signals (collision protection, etc. ) between the
welding torch and the power source
7 Connector plug, welding current "+"
Welding current connection on wire feed unit
8 Connection socket, “-” welding current
Workpiece connection
9 Key button, Automatic cutout
Wire feed motor supply voltage fuse
(press to reset a triggered fuse)
10 Mains connection cable
11 Connection socket, 5-pole
Cooling unit voltage supply
12 Intermediate hose package strain relief
13 Cooling air outlet
14 Machine feet
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alpha Q RC2
4.2 alpha Q RC2

4.2.1 Front and rear views
2
3
Figure 4-3
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alpha Q RC2

1 Operating panel
2 Machine control
See Machine control – operating elements chapter
0 Key switch for protection against unauthorised use
3
1 Position “1” > changes possible,
Position “0” > changes not possible.
Please take note of chapter “Protecting welding parameters from unauthorised access”
4 "Welding parameter" rotary dial
Select and change the welding parameters

COM

digital
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Machine control – Operating elements
4.3 Machine control – Operating elements

4.3.1 alpha Q RC2
NOTE
The machine control can be built in the front of the machine or in an external panel!
2
A V
500A 49.9V
MA
1
Job Nr 3
Hold
Status
4 Mode
PROG 0 PROG 8
m/min 5
P start
12
PROG 1 PROG 9
PROG 2 PROG 10 t start Puls
V PROG 3 PROG 11 P0...15 Standard 6

DYN
PROG 4 PROG 12 P end Job info
0
SP PROG 5 PROG 13 t end new
11 Enter
PROG 6 PROG 14 copy 1
PROG 7 PROG 15 list
S
10 9 8 7
Figure 4-4
1 Buttons switching digital display, left
A Welding current (nominal, actual and hold values)
Material thickness (nominal value)
Wire speed (nominal, actual and hold values)
Operating hour counter
Selection of further welding parameters in lower programming levels.
2 500A 49,9V Display, 16-digit
Display of all welding parameters and their values
3 Switching of the digital display Buttons, right
V Welding voltage (nominal / actual values)
MA
Motor current (actual value)
Job Nr JOB number
Hold After each completed welding process, the last parameter values used for the
welding process are shown on the display in the main program; the signal
light is on.
4 Status
Display of the current parameters specified by the robot control.
Non-latched
Special, non-latched
Puls Pulse welding
Standard Standard welding
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Machine control – Operating elements

5 Button, Mode
Select further programming levels
(program steps mode, main program A mode, JOB Manager, JOB Info)
0 Key switch for protection against unauthorised use
6
1 Position “1” > changes possible,
Position “0” > changes not possible.
Please take note of chapter “Protecting welding parameters from unauthorised access”
7 "JOB Manager" button (organise welding tasks)
Job info Display information on the current welding task selected
new Define new welding task
copy Copy welding task
list Display information on any welding task (job)
8 Button, "Program sequence"
During operation, the current position in the program sequence is shown.
Outside, the values can be selected and welding parameters changed by means of the
rotary dial.
Gas pre-flows (0.0 to 20.0 sec)
P start Start program (WFstart 0% to 200% / Ustart)
t start Start time (0.0 to 20.0 sec)
P0...15 Current program display
P end End program (0% to 200%)
t end End time (0.0 to 20.0 sec)
Wire burn-back (2 to 500)
Gas post-flow time (0.0 s to 20.0 s)
9 Button, "Program selection 8 to 15"
Display the selected program during the welding process and select program outside
the welding process.
10 Button, "Program selection 0 to 7"
Display the selected program during the welding process and select program outside
11 "ENTER" button
Enter
Confirmation, e.g.: of JOB parameters
SP Superpuls
12 Button, "Program A" (operating point)
m/min Wire speed
V Voltage correction
DYN Dynamics (signal light flashing)
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Design and function
General
5 Design and function

5.1 General
WARNING
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
• Follow safety instructions on the opening pages of the operating instructions.
• Commissioning may only be carried out by persons who have the relevant expertise of
working with arc welding machines!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
CAUTION
Insulate the arc welder from welding voltage!
Not all active parts of the welding current circuit can be shielded from direct contact. To
avoid any associated risks it is vital for the welder to adhere to the relevant safety
regulations. Even low voltages can cause a shock and lead to accidents.
• Wear dry and undamaged protective clothing (shoes with rubber soles/welder's gloves
made from leather without any studs or braces)!
• Avoid direct contact with non-insulated connection sockets or connectors!
• Always place torches and electrode holders on an insulated surface!
Risk of burns on the welding current connection!
If the welding current connections are not locked, connections and leads heat up and
can cause burns, if touched!
• Check the welding current connections every day and lock by turning in clockwise direction,
if necessary.
Risk of injury due to moving parts!
The wire feed units are equipped with moving parts, which can trap hands, hair,
clothing or tools and thus injure persons!
• Do not reach into rotating or moving parts or drive components!
• Keep casing covers closed during operation!
Risk of injury due to welding wire escaping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may
escape in an uncontrolled manner and injure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the
welding torch!
• Remove the pressure rollers from the wire feed unit if no welding torch is fitted!
• Check wire guide at regular intervals!
• Keep all casing covers closed during operation!
Risk from electrical current!
If welding is carried out alternately using different methods and if a welding torch and
an electrode holder remain connected to the machine, the open-circuit/welding voltage
is applied simultaneously on all cables.
• The torch and the electrode holder should therefore always be placed on an insulated
surface before starting work and during breaks.
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Design and function
Installation
CAUTION
Damage due to incorrect connection!
Accessory components and the power source itself can be damaged by incorrect
connection!
• 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.
Using protective dust caps!
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!
NOTE
Observe documentation of other system components when connecting!
5.2 Installation
CAUTION
Installation site!
The 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.
5.3 Machine cooling

To obtain an optimal duty cycle from the power components, the following precautions should be
observed:
• Ensure that the working area is adequately ventilated.
• Do not obstruct the air inlets and outlets of the machine.
• Do not allow metal parts, dust or other objects to get into the machine.
5.4 Workpiece lead, general

CAUTION
Risk of burns due to incorrect connection of the workpiece lead!
Paint, rust and dirt on the connection restrict the power flow and may lead to stray
welding currents.
Stray welding currents may cause fires and injuries!
• Clean the connections!
• Fix the workpiece lead securely!
• Do not use structural parts of the workpiece as a return lead for the welding current!
• Take care to ensure faultless power connections!
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Design and function
Notes on the installation of welding current leads
5.5 Notes on the installation of welding current leads

NOTE
Incorrectly installed welding current leads can cause faults in the arc (flickering).
A Install welding lead and hose package in parallel and as close together as possible.
B Keep the welding lead and hose packages of each welding machine separate, with an
installation distance of at least 15 cm!
C Fully unroll welding current leads, torch hose packages and intermediate hose
packages. Avoid loops!
D Use an individual welding lead to the workpiece for each welding machine!
Connect the work clamp close to the welding point.
E Always keep leads as short as possible! For optimum welding results max. 30 m
(welding lead + intermediate hose package + torch lead).
1 1 1
A
E
C
B
2 2 2
Figure 5-1

1 Welding machine
2 Wire feed unit
3 Workpiece
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Design and function
Welding torch cooling system
5.6 Welding torch cooling system

5.6.1 General
CAUTION
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.
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch (see overview of coolants).
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 (see accessories).
• Replace coolant as necessary if frost protection is inadequate!
NOTE
The disposal of coolant must be carried out according to official regulations and
observing the relevant safety data sheets (German waste code number: 70104)!
• Coolant must not be disposed of together with household waste.
• Coolant must not be discharged into the sewerage system.
• Recommended cleaning agent: water, if necessary with cleaning agent added.
5.6.2 List of coolants

The following coolants may be used (for item nos., please see the Accessories chapter):
Coolant Temperature range
KF 23E (Standard) -10 °C to +40 °C
KF 37E -20 °C to +10 °C
DKF 23E (for plasma machines) 0 °C to +40 °C
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Design and function
Mains connection
5.7 Mains connection

DANGER
Hazard caused by improper mains connection!
An improper mains connection can cause injuries or damage property!
• Only use machine with a plug socket that has a correctly fitted protective conductor.
• If a mains plug must be fitted, this may only be carried out by an electrician in accordance
with the relevant national provisions or regulations!
• Mains plug, socket and lead must be checked regularly by an electrician!
• When operating the generator always ensure it is earthed as stated in the operating
instructions. The resulting network has to be suitable for operating devices according to
protection class 1.
5.7.1 Mains configuration
NOTE
The machine may be connected to:
• a three-phase system with four conductors and an earthed neutral conductor
• a three-phase system with three conductors of which any one can be earthed,
e.g. the outer conductor
Figure 5-2
Legend
Item Designation Colour code
L1 Outer conductor 1 brown
L2 Outer conductor 2 black
L3 Outer conductor 3 grey
N Neutral conductor blue
PE Protective conductor green-yellow
CAUTION
Operating voltage - mains voltage!
The operating voltage shown on the rating plate must be consistent with the mains
voltage, in order to avoid damage to the machine!
• For mains fuse protection, please refer to the “Technical data” chapter!
• Insert mains plug of the switched-off machine into the appropriate socket.
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Design and function
Intermediate hose package connection
5.8 Intermediate hose package connection

NOTE
Note the polarity of the welding current!
Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity.
In this case, the welding current lead should be connected to the "-" welding current
socket, and the workpiece lead should be connected to the "+" welding current socket.
• Observe the information from the electrode manufacturer!
Figure 5-3
1 Intermediate hose package strain relief
Wire feed unit connection
3 12-pole connection socket (analogue)
Connection socket for analogue control signals (collision protection, etc. ) between the
welding torch and the power source
4 Connection socket, “+” welding current
• MIG/MAG welding: Welding current to wire feed/torch
5 Connection socket, “-” welding current
• MIG/MAG cored wire welding: Welding current to wire feed/torch
• Insert the end of the tube package through the intermediate tube package strain relief and lock by
turning to the right. If applicable, follow the instructions from the third party manufacturer of the strain
relief.
• Insert the welding current plug of the WF unit in the "+" welding current connection socket and lock by
turning to the right.
• Insert the wire feed control lead plug into the 7-pole connection socket (digital) and lock.
• Insert the analogue control signal cable plug into the 12-pole (analogue) connection socket and lock
by turning to the right.
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Design and function
Connection for workpiece lead
5.9 Connection for workpiece lead

NOTE
Note the polarity of the welding current!
Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity.
In this case, the welding current lead should be connected to the "-" welding current
socket, and the workpiece lead should be connected to the "+" welding current socket.
• Observe the information from the electrode manufacturer!
Figure 5-4
1 Connection socket, "+" welding current
• MIG/MAG cored wire welding: Workpiece connection
2 "-" welding current connection socket
• MIG/MAG welding: Workpiece connection
• Insert the plug on the workpiece lead into the "-" welding current connection socket and lock.
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Design and function
Connect the cooling module to the power source
5.10 Connect the cooling module to the power source

NOTE
Observe the fitting and connection instructions given in the relevant operating
instructions for the cooling unit.
Figure 5-5
1 8-pole connection socket
Cooling unit control lead
2 Connection socket, 5-pole
Cooling unit voltage supply
• Insert and lock the 8-pole control lead plug on the cooling unit into the 8-pole connection socket on the
welding machine.
• Insert and lock the 5-pole supply plug on the cooling unit into the 5-pole connection socket on the
welding machine.
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Design and function
Connect the alpha Q RC 2 to the power source
5.11 Connect the alpha Q RC 2 to the power source
A 4 B
1
Figure 5-6
1 Phoenix RC1 / alpha Q RC2
digital
3 Connection cable
Operating panel connection lead connection
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Design and function
Shielding gas supply
5.12 Shielding gas supply

5.12.1 Connecting the shielding gas supply
WARNING
Incorrect handling of shielding gas cylinders!
Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.
• Observe the instructions from the gas manufacturer and in any relevant regulations
concerning the use of compressed air!
• Place shielding gas cylinders in the holders provided for them and secure with fixing
devices.
• Avoid heating the shielding gas cylinder!
CAUTION
Faults in the shielding gas supply.
An unhindered shielding 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 being destroyed.
• Always re-fit the yellow protective cap when not using the shielding gas connection.
• All shielding gas connections must be gas tight.
NOTE
Before connecting the pressure regulator to the gas cylinder, open the cylinder valve
briefly to expel any dirt.
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Design and function
Shielding gas supply
2
Figure 5-7

1 Pressure regulator
2 Shielding gas cylinder
3 Output side of the pressure regulator
4 Cylinder valve
• Place the shielding gas cylinder in the cylinder holder and secure it from tipping over using the
securing chain!
• Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out
any dirt.
• Mount the pressure regulator on the gas cylinder valve.
• Screw gas hose connection crown nut onto the output side of the pressure regulator.
• Screw the gas hose connection nipple onto the G¼" connection nipple.
• Tighten gas hose on pressure regulator to be gas tight.
• Fit the gas hose and G1/4" crown nut onto the relevant connection on the welding machine, and fit the
wire feed unit (if present on this version).
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Design and function
Interfaces
5.13 Interfaces
5.13.1 Connecting the RINT X11 robot interface/BUSINT X11 industrial bus interface
CAUTION
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!
Damage due to incorrect connection!
Accessory components and the power source itself can be damaged by incorrect
connection!
• 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.
The interfaces can be operated directly on the power source in a separate interface casing or externally,
e.g. in a robot control cabinet or via a data cable.
5.13.1.1 RINT X11 robot interface
The standard digital interface for mechanised applications•
(optional, retrofitting on the machine or external fitting by the customer)
Functions and signals:
• Digital inputs: start/stop, operating modes, JOB and program selection, inching, gas test
• Analogue inputs: control voltages, e.g. for welding performance, welding current, etc.
• Relay outputs: process signal, ready for welding, system composite fault, etc.
5.13.1.2 BUSINT X11 industrial bus interface
The solution for integration into mechanised production lines, with for example
• Profibus
• CAN-Open, CAN DeviceNet
• Interbus systems with copper and optical fibre connection (FSMA/Rugged Line)
NOTE
Only one variant can ever be operated at any one time.
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Design and function
Interfaces
A B
2
2
5 4 3
7
1
6
Figure 5-8
2 Switching cabinet
3 Robot interface, Tetrix / Phoenix / alpha Q, RINT X12
4 Industrial bus interface, Tetrix / Phoenix / alpha Q, BUSINT X11
5 Interface casing
6 Connection cable, 7-pole
Connection between switching cabinet and power source
7 Connection lead
Connection between interface casing and switching cabinet
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Design and function
Interfaces
5.13.2 Connecting the PC 300.net welding parameterisation software

Create all welding parameters quickly on the PC and easily transfer them to one or more welding
machines (accessories, set consisting of software, interface, connection leads)
3 4
6 1
Figure 5-9
COM
2 Connection cable, 9-pole, serial

3 Windows PC
4 RC300 tablet PC
5 USB connection
6 SECINT X10 USB
CAUTION
Equipment damage or faults may occur if the PC is connected incorrectly!
Not using the SECINT X10USB interface results in equipment damage or faults in signal
transmission. The PC may be destroyed due to high frequency ignition pulses.
• Interface SECINT X10USB must be connected between the PC and the welding machine!
• The connection must only be made using the cables supplied (do not use any additional
extension cables)!
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Design and function
Interfaces
5.13.3 Connecting the Q-DOC 9000 welding data documentation software

(Accessories: Set consisting of software, interface, connection leads)
The ideal tool for welding data documentation of, for example:
welding voltage and current, wire speed and motor current.
1 2
3
7
5
6
Figure 5-10
2 Windows PC
3 RC300 tablet PC
4 SECINT X10 USB
5 Connection cable, 9-pole, serial
6 PCINT X10
CAUTION
Equipment damage or faults may occur if the PC is connected incorrectly!
Not using the SECINT X10USB interface results in equipment damage or faults in signal
transmission. The PC may be destroyed due to high frequency ignition pulses.
• Interface SECINT X10USB must be connected between the PC and the welding machine!
• The connection must only be made using the cables supplied (do not use any additional
extension cables)!
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Design and function
Interfaces
5.13.4 Connecting the WELDQAS welding data monitoring and documentation system
Network-compatible welding data monitoring and documentation system for digital power sources.
2
5
6
1
Figure 5-11
2 Windows PC
3 WELDQAS welding data monitoring and documentation system
5 Integration option of WELDQAS into existing network systems via network
cables
6 Connection cable included as standard with WELDQAS
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Design and function
Interfaces
5.13.5 Automation interface

The welding power sources feature a very high safety standard.
This safety standard is also maintained when peripheral equipment is connected for mechanised welding,
if this peripheral equipment meets the same criteria, particularly with regard to isolation from the mains
supply.
This is guaranteed by the use of transformers conforming to VDE 0551.
The welding machines are equipped for mechanised operation as standard.
For the simplest possible mechanised applications, control inputs and galvanically isolated relay contacts
are available on the interface for mechanised welding.
CAUTION
Equipment damage due to unshielded control leads!
Unshielded control leads can cause damage to the power source and accessory
components.
• Use shielded control leads only.
ROBOT
X4-
PE A
REGaus B
Gasdüsensensor 1 C
S 2 14
IGR0 D
Not/Aus E
A
B M 0V F
IGR0 G
C N L
P Uist H
U DVist J
D V K
R SYN_A1 K
T STA/STP L
E S J
+15V M
F H -15V N
G IGR0 P
Not/Aus R
0V S
Iist T
Not-Aus1 U
V 2 14
Not-Aus2 V
W 2 14
X2-
NC A
NC B
Not-Aus2 C
W 1 16
NC D
A Gasdüsensensor 1 E
S 1 16
B J NC F
L NC G
C H
M NC H
K J
D G NC
NC K
E F
Not-Aus1 L
V 1 16
NC M
drive 4 Rob
Figure 5-12
WARNING
No function of the external interrupt equipment (emergency stop switch)!
If the emergency stop circuit has been realised using an external interrupt equipment
via the interface for automated welding, the machine must be configured for this setup.
If this is not observed, the power source will ignore the external interrupt equipment
and will not shut down!
• Disconnect jumper 1 on PCB T320/1 (Tetrix) or M320/1 (Phoenix / alpha Q)!
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Design and function
Interfaces
19-pole connection assignment for mechanised welding interface (X4):

Pin Input/output Designation Note
A Output PE
Cable screen connection
B Output REGaus
C Input Gasdüsensensor 1
D Output IGR0 Maximum load 100 mA

Current flowing signal (I>0) Not isolated!
0 V = welding current
15 V = no welding current
E/R Input Not/Aus Make sure that jumper 1 on PCB
Open = welding current switched off M320/1 of the welding machine is
open!
Connection with potential-free
contact!
F Output 0V
G/P Output IGR0 Potential-free, +-15 V/100 mA
Power relay contact,
I>0 to the user
H Output Uist 10 V = 100 V welding voltage
+Uact
J Output DVist
K Output SYN_A1 Seam tracking synchronising signal
L Input STA/STP Contact at M

Start/stop Switch to potential-free
M Output +15V +15 V, max. 75 mA
Power supply
N Output -15V -15 V, max. 25 mA
Power supply
S Output 0V
T Output Iist 10 V = 1000 A welding current
+Iact
U Output Not-Aus 1
e.g. emergency stop for shutdown
box, collision switch
V Output Not-Aus 2
e.g. emergency stop for shutdown
box, collision switch
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Design and function
Protecting welding parameters from unauthorised access
12-pole connection assignments for mechanised welding interface (X2):
Pin Signalshape Circuit diagram signal Function

name
A NC
B NC
C/L Input NOT-AUS Emergency stop for higher level shut-down of the
power source.
To use this function, jumper 1 must be unplugged
on PCB M320/1 in the welding machine.
Contact open = welding current switched off
D NC
E Gasdüsensensor 1
F NC
G NC
H NC
J NC
K NC
M NC
5.13.6 Sensor Voltage
The sensor voltage is transmitted via PIN F of the mechanised welding torch connection socket (X22).
Outside the welding process, there is a voltage of approx. 12 V on the welding torch electrode. If the
electrode comes into contact with the workpiece or the molten pool, the short-circuit produced means that
when using the relevant interface (BUSINT X11/RINT X12), the resultant signal can be used for various
functions (e.g. workpiece search). The output signal can be used to connect the cold wire component in
order to enable fusing detection at the end of the process.
5.14 Protecting welding parameters from unauthorised access
To protect against unauthorised or unintentional adjustment of the welding parameters on the machine,
the control input can be locked with the aid of a key switch.
In key switch position 1 all functions and parameters can be set without restriction.
In key switch position 0 the following functions and parameters cannot be changed:
• JOB switching function, welding task selection
(block JOB mode possible with Power-control torch)
• JOB Manager mode
• Program Steps mode
• Program A mode
• JOB Info mode
• Super pulse function
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Design and function
Welding data display
5.15 Welding data display

To the left and right of the LCD display on the control there are 2 “arrow keys” on each side for selecting
the welding parameter to be displayed. The button is used to scroll through the parameters from the
bottom upwards and the button is used to scroll downwards from the top.
As soon as changes have been made to the settings after welding (display on hold values), the display
switches back to the nominal values.
A V
500A 49.9V
MA
Job Nr
Hold
Figure 5-13
Parameter Before welding During welding After welding
Nominal value Actual value Nominal Hold Nominal
value value value
Welding current ; ; ;
Material thickness ; ; ;
Wire speed ; ; ;
Welding voltage ; ; ;
Motor current ; ;
JOB no. ; ; ;
Operating time ; ;
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Design and function
Definition of MIG/MAG welding tasks
5.16 Definition of MIG/MAG welding tasks

The user defines the welding tasks using job numbers.
Each job number stores all the parameters relating to the welding task.
For the most commonly used applications, 128 pre-programmed JOBs (welding tasks) are stored in the
machine control with the relevant parameters.
On the control panel, the user can either load an existing job, load an existing job and change it, or define
a completely new job.
The welding task or job is defined using the following parameters:
Basic parameters
The job number is defined using four basic welding parameters:
Welding process, material type, wire diameter and gas type.
According to the pre-programmed jobs, the typical or frequently used gas types and wire diameters for
the material are suggested automatically depending on the material type selected. It is impossible to
select inappropriate combinations for welding.
Program sequence
Other welding parameters, such as parameters for the start program, secondary program or end program
and the gas pre-flow time, wire creep, slope times, wire burn-back (and many more) are preset for a
variety of applications, but can be modified where required. On the control panel, the most important
welding parameters are displayed directly and can be modified where required.
Program or control voltage (operating point)
The operating point can either be set using up to 15 (PROG 1 to PROG 15) freely definable programs or
using control voltages (PROG 0) via the robot interface (RINTX12 / BUSINTX11).
• The wire speed, voltage correction and dynamics are stored in each program. These program
parameters can be specified on the control panel. The program number is selected by the robot
control.
• In control voltage mode, there is a control voltage (0 V to 10 V) available on the robot interface for
each parameter (wire speed, voltage correction and dynamics).
The digital system calculates the required process parameters, such as the welding current, welding
voltage and pulse current according to the operating point specified.
NOTE
The parameters and functions described here can also be programmed using a PC or
laptop and the PHOENIX PCM 300 welding parameter software.
Operating mode
Non-latched or non-latched special (start current, main current and end program)
Welding type
Pulse or standard welding
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Design and function
Welding task selection
5.17 Welding task selection

5.17.1 Selecting or defining a new job
Option 1: Select job from existing job reference list
To do this, the job overview (see Appendix 2) is used as a reference for determining the welding task.
It is also possible to use the "Job list" menu option on the M3.40 power source control to determine the
relevant job number according to the basic parameters (see Appendix 1: "Job organisation function
sequence").
Defining a new job
Operating Action Result Display (example)
element
Job info Select "Job new" Verf. : MIG
new
Xx The signal light displays the selection.
copy
list
Select "Welding process" Verf. : MIG

Enter
1x
Select "Welding process" Verf. : MIG
Select "Material type" Material: xxxxx

Enter
1x
Select "Material type" Material: xxxxx
Select "Wire diameter" Draht : xxxxxx

Enter
1x
Select "Wire diameter" Draht : xxxxxx
Select "Gas type" Gas-Art : xxxxxx

Enter
1x
Select "Gas type" Gas-Art : xxxxxx
Select "Job number" Job-Nr. : xxx

Enter
1x
Select "Job number" Job-Nr. : xxx
Search for job number for selected welding task:
Jobs 129 to 256 (free memory space)
Save job number Wait
Enter
1x Save selected job number in the free memory
NOTE
The job number is selected and changed by the robot control via robot interface
RINTX11 or BUSINTX12.
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5.17.2 coldArc
Heat-reduced, low-spatter short arc for welding and brazing of thin metal sheets with low distortion and
for root welding with excellent gap bridging properties.
Figure 5-14
After selecting the coldArc process (see chapter “Selecting a MIG/MAG welding task”) the following
properties are available:
• Less distortion and reduced discolouration thanks to minimised heat input
• Considerably reduced spatter thanks to virtually power-free material transfer
• Easy welding of root passes in all panel thicknesses and in all positions
• Perfect gap bridging even with inconsistent gap widths
• Unalloyed, low-alloy and high-alloy steels and also dissimilar joints of even the thinnest metal sheets
• Brazing of CrNi sheets with CuAl8/AlBz8
• Brazing and welding of coated metal sheets, e.g. with CuSi, AlSi and Zn
• Manual and automated applications
coldArc welding to: Wire Ø (mm)

0.6 0.8 0.9 1 1.2 1.6
Material Gas JOB JOB JOB JOB JOB JOB
CrNi Ar 91–99% x x 50 8.0 x x 51 7.6 52 6.0 53 8.0
AlMg Ar 100% x x 54 8.0 x x 55 8.0 56 8.0 57 8.0
ALSi Ar 100% x x 58 8.0 x x 59 8.0 60 6.0 61 8.0
AL99 Ar 100% x x 62 8.0 x x 63 8.0 64 8.0 65 8.0
Ar 91–99% 176 7.0 x x x x x x x x x x
Steel Ar 80–90% 175 8.0 191 7.0 192 6.0 193 6.0 194 5.0 195 5.0
CO2 x x 182 7.0 183 6.0 184 6.0 185 5.0 186 5.0
coldArc brazing to: Wire Ø (mm)

0.6 0.8 0.9 1 1.2 1.6
Material Gas JOB JOB JOB JOB JOB JOB
CuSi Ar 100% x x 66 10.0 x x 67 8.0 68 6.0 69 6.0
CuAl Ar 100% x x 70 7.0 x x 71 6.0 72 6.0 73 7.0
AlSi Ar 100% x x 196 8.0 x x 197 8.0 198 8.0 199 8.0
Zn Ar 100% x x 200 6.0 x x 201 6.0 202 6.0 203 6.0
You can make use of these properties after selecting the coldArc process (see the "Selecting a MIG/MAG
welding task" chapter).
With coldArc welding, it is important to ensure good quality wire feeding because of the welding
filler materials being used!
• Equip the welding torch and torch hose package to suit the task! (See the "Connecting the welding
torch" chapter and the operating instructions for the welding torch.)
NOTE
This function can only be enabled with the PC300.NET software.
• (See operating instructions for the software)
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5.17.3 forceArc
Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range.
Figure 5-15
• Smaller included angle due to deep penetration and directionally stable arc
• Excellent root and sidewall fusion
• Secure welding also with very long stick-outs
• Reduced undercuts
• Un-, low- and high-alloyed steels as well as high-tensile fine-grained building steels
• Manual and automated applications
forceArc welding from: Wire Ø (mm)

0.8 1 1.2 1.6
Material Gas JOB JOB JOB JOB
Steel Ar 91–99% 190 17.0 254 12.0 255 9.5 256 7.0
Ar 80–90% 189 17.0 179 12.0 180 9.5 181 6.0
CrNi Ar 91–99% x x 251 12.0 252 12.0 253 6.0
You can make use of these properties after selecting the forceArc process (see the "Selecting a
MIG/MAG welding task" chapter).
As with pulse arc welding, it is important to make sure of a good welding current connection.
• Keep welding current cables as short as possible and ensure that cable cross-sections are adequate!
• Fully unroll welding current cables, torche tube packages and, if applicable, intermediate tube
packages. Avoid loops!
• Use welding torches, preferably water-cooled, that are suitable for the higher power range.
• Use welding wire with adequate copper coating when welding steel. The wire spool should have layer
spooling.
NOTE
Unstable arc!
Welding current cables that are not fully unrolled can cause faults in the arc (flickering).
• Fully unroll welding current cables, torch tube packages and, if applicable, intermediate
tube packages. Avoid loops!
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Design and function
5.17.4 Operating mode

This parameter setting is specified by the robot control via the RINTX12 or BUSINTX11 robot interface
(see documentation in the relevant interface description).
The selected parameter is displayed on the status displays on the control panel.
5.17.5 Welding type
The selected parameter is displayed on the status displays on the control panel.
NOTE
This parameter can be changed over during the welding process.
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Design and function
5.17.6 Program or control voltage mode
NOTE
The operating point can either be specified using up to 15 freely definable programs
(PROG 1 to PROG 15) or an operating point can be set using control voltages (PROG 0)
via the robot interface (RINTX11 / BUSINTX10).
Program operation
Different welding tasks or positions on a workpiece demand various welding outputs (operating points) or
welding programs.
For each program, the
• Wire speed
• Correction of the arc length and the
• Dynamics / choke effect
can be set separately.
15 different programs (PROG 1 to PROG 15) can be defined. It is possible to switch between these
programs during the welding process.
The parameters for the relevant program are selected on the control panel.
Operating Action Result Display
element
PROG 0
PROG 1
PROG 8
PROG 9
Select "Program number" P1 DV2 : 2.0m/m
PROG 2 Xx
PROG 10 The signal light displays the selection.
PROG 3 PROG 11
PROG 4 PROG 12
PROG 1 to PROG 15 are available.
PROG 5 PROG 13
PROG 6 PROG 14
PROG 7 PROG 15
m/min
Select "Wire speed" P1 DV2 : x.x m/m
1x The signal light displays the selection (m/min).
DYN V
Select "Wire speed" P1 DV2 : x.x m/m
Setting from 0.1 to 40.0 m/min.
m/min
Select "Voltage correction" P1 U2 : + x.x V
1x The signal light displays the selection (V).
DYN V
Select "Voltage correction" P1 U2 : + x.x V
Setting from -9.9 V to +9.9 V.
m/min
Press "Dynamics"
1x The signal light (DYN) flashes.
DYN V
Select "Dynamics"
Setting from -40 to +40.
Control voltage operation
Signal light "PROG 0" lights up on control panel.
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Design and function
5.17.7 Program sequence

Certain materials, such as aluminium, require special functions in order to be able to weld them safely
and at high quality. The non-latched special operating mode is used here with the following programs:
I PSTART PA PEND
DVstart
Ustart
DVend
Uend
tstart tS1 t2 tSe tend
t
Figure 5-16
The following parameters can be selected and changed on the control panel:
Graphic Symbol Parameter Value
Gas pre-flows 0.0 to 20.0 sec
P start Ignition program WFstart 0 % to 200 % or
• Wire speed Ustart -9.9 V to +9.9 V
m/min
• Voltage correction
Change with button
DYN V
t start Start time 0.0 to 20.0 sec
P0...15 Program number P0 to P15
P end End program WFend 0 % to 200 % or
• Wire speed Uend -9.9 V to +9.9 V
m/min
• Voltage correction
Change with button
DYN V
t end End time 0.0 to 20.0 sec
Wire burn-back 2 to 500
Gas post-flow time 0.0 to 20.0 sec
V
MA
Parameter changes are made either using the "Welding parameter " rotary dial or the Job Nr
Hold
buttons.
The program PA corresponds to one of the up to 15 freely definable programs. The times for parameters
tS1 and tSe (soft wire transfer) are factory-set.
The complete list of parameters can be found in chapter:
MIG/MAG program sequence ("Program steps" mode).
The signal lights display the current progress in the function sequence throughout the welding process.
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Design and function
5.17.8 Superpulses
I PSTART
PA PA
PB
PEND
t
Figure 5-17
With superpulses, there is a changeover between the main program (PA) and reduced main program (PB).
This function is used in the very thin metal sheet range, for example, to reduce the heat input in a
targeted way.
Selection on the operating panel:
element
2s Switch superpulses on or off No change
Enter
The "SP" signal light displays the selection.
For setting the program parameters, see "MIG/MAG program sequence" ("Program steps" mode) chapter.
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Design and function
MIG/MAG functional sequences / operating modes
5.18 MIG/MAG functional sequences / operating modes

NOTE
There are optimum pre-sets for welding parameters such as gas pre-flow and burn
back, etc. for numerous applications (although these can also be changed if required).
5.18.1 Explanation of signs and functions

Symbol Meaning
Start of welding
End of welding
Shielding gas flowing
I Welding output
Wire electrode is being conveyed
Wire creep
Wire burn-back
Gas pre-flows
Gas post-flows
Non-latched
Non-latched special
t Time
PSTART Start program
Flat Main program
PEND End program
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Design and function
Non-latched mode
1. 2.
t
I PA
t
Figure 5-18
Step 1
• Robot issues the start signal to the power source.
• Shielding gas is expelled (gas pre-flows).
• Wire feed motor runs at “creep speed”.
• Arc ignites after the wire electrode makes contact with the workpiece; welding current flows.
• Changeover to pre-selected wire speed (main program PA).
Step 2
• Robot issues the stop signal to the power source.
• WF motor stops.
• Arc is extinguished after the pre-selected wire burn-back time elapses.
• Gas post-flow time elapses.
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Design and function
Non-latched operation with superpulse
NOTE
Pulse arc welding machines only.
1. 2.
PB t
I PA
t
Figure 5-19
Step 1
• Shielding gas is expelled (gas pre-flows).
• Arc ignites after the wire electrode makes contact with the workpiece; welding current flows.
• Start the super pulse function beginning with main program PA:
The welding parameters switch between main program PA and the reduced main program PB at the
specified times.
Step 2
• Super pulse function is ended.
• WF motor stops.
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Design and function
Special, non-latched
1. 2.
PSTART t
PEND
I PA
t
Figure 5-20
Step 1
• Shielding gas is expelled (gas pre-flows)
• Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start
program PSTART for the time tstart).
• Slope to main program PA.
Step 2
• Slope to end program PEND for the time tend.
• WF motor stops.
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Design and function
Special, non-latched with superpulse
NOTE
Pulse arc welding machines only.
1. 2.
PSTART t
PB PEND
I PA
t
Figure 5-21
Step 1
• Shielding gas is expelled (gas pre-flows)
• Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start
program PSTART for the time tstart).
• Slope on main program PA.
• Start the super pulse function beginning with main program PA:
The welding parameters switch between main program PA and the reduced main program PB at the
specified times.
Step 2
• Super pulse function is ended.
• Slope to end program PEND for the time tend.
• WF motor stops.
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Design and function
MIG/MAG program sequence ("Program steps" mode)
5.19 MIG/MAG program sequence ("Program steps" mode)

Certain materials, such as aluminium, require special functions in order to be able to weld them safely
and at high quality. The non-latched special operating mode is used here with the following programs:
• Start program PSTART (reduction of cool points at the start of the seam)
• Main program PA (continuous welding)
• Reduced main program PB (targeted heat reduction)
• End program PEND (minimisation of end craters via targeted heat reduction)
5.19.1 Selection
element
Select program sequence mode Program steps
1x
A Select the parameters using the buttons "Up"

nx
and "Down" (left)
V Adjust the selected parameter using the buttons

MA
Job Nr
nx "Up" and "Down" (right)
Hold
Machine returns to display mode

3x
5.19.2 MIG/MAG overview of parameters for M3.1x
I PSTART PA PB PA PEND
DVstart
Ustart
DV3
DVend
U3
Uend
tstart tS1 t2 tS2 t3 tS3 tSe tend
t
Figure 5-22
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Design and function
Main program A mode
Basic parameters
Display Meaning / explanation Setting range
GASstr Gas pre-flow time 0.0s to 0.9s
RUECK Wire burn-back length 2 to 500
GASend: Gas post-flow time 0.0s to 20s
Proc.Sp. Process speed to determine the a-measurement 10cm to 200cm
"PSTART" start program
DVstart Wire speed 1% to 200%
Ustart Arc length correction -9.9V to +9.9V
tstart Duration 0.0s to 20.0s
"PA" main program
tS1 Slope duration from PSTART to PA 0.0s to 20.0s
t2 Duration (spot time and superpulse) 0.01s to 20.0s
tS2 Slope duration from PA to PB 0.00s to 20.0s
"PB" reduced main program
DV3 Wire speed 1% to 200%
U3 Arc length correction -9.9V to +9.9V
t3 Duration 0.01s to 20.0s
tS3 Slope duration from PB to PA 0.00s to 20.0s
"PEND" end program
tSe Slope duration from PA to PEND 0.0s to 20s
DVend Wire speed 1% to 200%
Uend Arc length correction -9.9V to +9.9V
tend Duration (superpulse) 0.0s to 20s
PSTART, PB, and PEND are "relative programs", i.e. they relate to percentages of the WF value from main
program PA . The wire feed values of the relative programs can also be set as absolute values if required,
regardless of the main program (see chapter "Special Mode" mode).
Various functional sequences can be set up according to the operating mode. Selecting and setting other
parameters, functions and modes.
5.20 Main program A mode
5.20.1 Selection
element
Select main program A mode Program A
2x
A Select the welding parameters using the buttons

nx "Up" and "Down" (left)
V Change values for the selected welding

MA
Job Nr
nx parameter using the buttons "Up" and
Hold
"Down" (right)
Machine returns to Display mode
2x
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Main program A mode
5.20.2 MIG/MAG overview of parameters for M3.1x

Different welding tasks or positions on a workpiece demand various welding outputs (operating points) or
welding programs.
For each program, the
• Wire speed
• Correction of the arc length and the
• Dynamics / choke effect
can be set separately.
Up to 15 programs (P1 to P15) can be defined, and the user can switch between these programs during
Display Meaning/explanation Setting range
curr.prg.: X Active main program A 0 to 15
P0 U2 :+0.0V Arc length correction (offset WF unit) -9.9V to +9.9V
P1 15 UK :+2.0V Limitation of the setting range for the voltage 0.0V to +9.9V
correction in program mode
P1 15 DK : 20% Restriction of the wire correction range 0% to 30%
(for more details, see operating instructions for the
wire feed unit)
P1 DV2 :+2.0m/m Wire speed 0.1m/min. to 20.0m/min.
P1 U2 :+0.0V Arc length correction -9.9V to +9.9V
P1 DYN2: + 0 Dynamics/choke effect -40% to +40%
P2 to P14 P2 to P14 P2 to P14
P15 DV2 :+2.0m/m Wire speed 0.1m/min. to 20.0m/min.

P15 U2 :+0.0 V Arc length correction -9.9V to +9.9V
P15 DYN2: + 0 Dynamics/choke effect -40% to +40%
PA1
I
PA2
PA3 PA3
PA4 PA4
PA0
PA5
t
Figure 5-23
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Design and function
"Special Mode" mode
5.21 "Special Mode" mode

5.21.1 Selection
NOTE
Combination of buttons shown must be selected without pauses!

element
Select Special Mode Program Steps
1x
Job info
new
copy 1x
list
PROG 0
PROG 1
PROG 2 2x
PROG 3
PROG 4
PROG 5
PROG 6
PROG 7
PROG 8
PROG 9
Special Mode
PROG 10 1x
PROG 11
PROG 12
PROG 13
PROG 14
PROG 15
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"Special Mode" mode
5.21.2 Switching the Hold function on and off
NOTE
There is the option of switching the Hold function on and off for welding parameters.

element
A Select the Hold function using the buttons Hold-Fct 1
"Up" and "Down" (left)
V Use the buttons "Up" and "Down" (right) Hold-Fct 1

M A
Job Nr to switch the Hold function on or off. Hold-Fct 0

Hold
1 = Hold function on
0= Hold function off
5.21.3 WF speed switching (absolute / relative)
The following wire feed speeds are "relative programs" in the factory settings: DVStart (start program);
DV3 (reduced main program); DVEnd (end program). This means that they represent a percentage of the
wire feed speed DV2 (main program A) that has been set.
All wire feed speeds can also be specified as absolute values (independent of other values).
To do this, the absolute function (Abs-Fct = 1) must be configured as follows:
element
A Select function using the buttons "Up" und Abs-Fct 0
"Down" (left)
V Switch the function on and off using the "Up" Abs-Fct 0

MA
Abs-Fct 1
Job Nr und "Down" (right) buttons
Hold
1= Absolute wire feed speeds activated
0= Relative wire feed speeds activated
5.21.4 Resetting JOBs to status on delivery (Reset ALL)
element
A Select Res. All using the buttons "Up" and Res. All 1
"Down" (left).
5.21.5 Exiting "Special Mode" after making changes

element
Saves the change No change
Enter
1x
Exits Special Mode Last selected
1x parameters are
displayed
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Design and function
"Job Info" mode
5.22 "Job Info" mode

NOTE
Information on the current JOB is displayed in this mode.
• In JOBs 127 and 128 (TIG & MMA), it is not possible to select the mode as it would not be
relevant.
Selection:
element
Select “JOB Info mode” JOB Info
nx
A Parameter selection See “JOB Info” parameter list

table
JOB Info parameter list:

Parameter (display) Explanation
Uist Voltage
System System status
Job-Typ Pre-defined or user-defined Job
Job-Nr. JOB number
akt. Prg. Program number
Mode Operating mode
Schweiss Welding type
Job-Text Text information relating to the JOB (can be edited using PC 300.Net
software)
Wire Wire diameter
Material Material type
Gas-Typ Gas type
Verf. Welding process
5.23 Operating time counter
The operating time is displayed in the format hhhh:mm:'h'. Four digits for the hours, two digits for the
minute, and a final 'h' symbol.
On the welding machine control
Operating element Action Result Display
A Press until signal light comes on Operating time
nx display
The operating time is counted when current is flowing, and is written to non-volatile memory once per
minute.
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Organising welding tasks (Mode "JOB Manager")
5.24 Organising welding tasks (Mode "JOB Manager")

NOTE
The Job Manager can be used to load, copy or save JOBs.
The JOB is the welding task defined by the 4 main welding parameters; welding process,
material type, wire diameter and gas type.
One program sequence can be defined in each JOB.
Up to 15 operating points (P1 to P15) can be set in each program sequence.
The user has a total of 256 jobs available. 128 of these JOBs are pre-programmed. A
further 128 JOBs can be freely defined.
To ensure that all the changes are active, the welding machine should be switched off
after at least 5 seconds have elapsed.
A distinction is made between two memory sectors:

• 128 factory-set, pre-programmed, fixed jobs (jobs 1 to 128).
Each welding task is assigned a JOB number (1 to 128).
• 128 freely definable JOBs (JOBs 129 to 256).
Each job can also be loaded directly (see chapter Loading an existing job).
5.24.1 Creating a new JOB in the memory or copying a JOB
NOTE
It is normally possible to adjust all 256 JOBs individually. However, it is useful to assign
a separate JOB number to special welding tasks.
Define the welding task which most closely matches the required application.
Copy the preset welding task (JOB 1-128) to the free memory sector (JOB 129-256):
element
Select JOB Manager mode JOB Manager
3x
A Select the JOB copy function using the buttons Copy to: xxx
xx "Up" and "Down" (left)
V Select the target JOB number (JOB 129-256) Copy to: xxx
MA
Job Nr
xx using the buttons "Up" and "Down" (right)
Hold
JOB has been copied Copy to: xxx

Enter
1x
1x
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Design and function
Organising welding tasks (Mode "JOB Manager")
5.24.2 Loading an existing job
NOTE
This function is used, for example, if the welding task (JOB) has been selected from the
JOB reference list (see Appendix).

element
3x
A Select JOB load function using the buttons Load JOB: xxx
xx
"Up" and "Down" (left)
V Select the JOB to be loaded using the buttons Load JOB: xxx
MA
Job Nr
xx "Up" and "Down" (right)
Hold
JOB has been loaded Load JOB: xxx

Enter
1x
3x
5.24.3 Resetting an existing JOB to the factory setting (Reset JOB)
NOTE
If a pre-programmed JOB (JOB 1 to 128) has been changed accidentally, it can be reset
to the factory settings.

element
3x
A Select the JOB reset function using the buttons Res. JOB: xxx
xx "Up" and "Down" (left)
V Select the JOB (JOB 1-128) to be reset to the Res. JOB: xxx
MA
Job Nr
xx factory settings using the buttons "Up" and
Hold
"Down" (right)
JOB has been reset Res. JOB: xxx
Enter
1x
1x
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Design and function
Expert parameters
5.25 Expert parameters

5.25.1 Selecting expert model parameters
Operating Action Result
element
1x
Job info
new 1x
copy
list
1x
Select expert model parameters
Job info
new 2x
copy
list
5.25.2 Selecting variables (5 model points)

element
1x Select model points 1 to 5
5.25.3 Setting parameters

element
V Select parameter
M A
Job Nr
Hold
A Adjust parameter
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Maintenance, care and disposal
General
6 Maintenance, care and disposal

DANGER
Risk of injury from electric shock!
Cleaning machines that are not disconnected from the mains can lead to serious
injuries!
• Disconnect the machine completely from the mains.
• Remove the mains plug!
• Wait for 4 minutes until the capacitors have discharged!
6.1 General
When used in the specified environmental conditions and under normal operating conditions, this
machine is largely maintenance-free and requires a minimum of care.
There are some points, which should be observed, to guarantee fault-free operation of your welding
machine. Among these are regular cleaning and checking as described below, depending on the pollution
level of the environment and the length of time the unit is in use.
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Maintenance work, intervals
6.2 Maintenance work, intervals

CAUTION
Electric current!
Repairs may only be carried out by authorised specialist staff!
• Do not remove the torch from the tube package!
• Never clamp the torch body in a vice or similar, as this can cause the torch to be irreparably
destroyed!
• If damage occurs to the torch or to the tube package which cannot be corrected as part of
the maintenance work, the entire torch must be returned to the manufacturer
6.2.1 Daily maintenance tasks

• Check that all connections and wearing parts are hand-tight and tighten if necessary.
• Check that all screw and plug connections and replaceable parts are secured correctly, tighten if
necessary.
• Remove any spatter.
• Clean the wire feed rollers on a regular basis (depending on the degree of soiling).
6.2.1.1 Visual inspection
• Check hose package and power connections for exterior damage and replace or have repaired by
specialist staff as necessary!
• Mains supply lead and its strain relief
• Gas tubes and their switching equipment (solenoid valve)
• Other, general condition
6.2.1.2 Functional test
• Check correct mounting of the wire spool.
• Welding current cables (check that they are fitted correctly and secured)
• Gas cylinder securing elements
• Operating, message, safety and adjustment devices (Functional test)
6.2.2 Monthly maintenance tasks
6.2.2.1 Visual inspection
• Casing damage (front, rear and side walls)
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
• Check coolant tubes and their connections for impurities
6.2.2.2 Functional test
• Selector switches, command devices, emergency stop devices, voltage reducing devices, message
and control lamps
• Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
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Maintenance work
6.2.3 Annual test (inspection and testing during operation)
NOTE
The welding machine may only be tested by competent, capable personsl.
A capable person is one who, because of his training, knowledge and experience, is
able to recognise the dangers that can occur while testing welding power sources as
well as possible subsequent damage and who is able to implement the required safety
procedures.
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition
to the regulations on testing given here, the relevant local laws and regulations must also be observed.
6.3 Maintenance work
DANGER
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service 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 spare parts. When ordering spare parts, please quote the
machine type, serial number and item number of the machine, as well as the type designation and item
number of the spare part.
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Disposing of equipment
6.4 Disposing of equipment

NOTE
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and
electronic components, which must be disposed of.
• Do not dispose of in household waste!
• Observe the local regulations regarding disposal!
6.4.1 Manufacturer's declaration to the end user

• According to European provisions (guideline 2002/96/EG of the European Parliament and the Council
of January, 27th 2003), used electric and electronic equipment may no longer be placed in unsorted
municipal waste. It must be collected separately. The symbol depicting a waste container on wheels
indicates that the equipment must be collected separately.
This machine is to be placed for disposal or recycling in the waste separation systems provided for this
purpose.
• According to German law (law governing the distribution, taking back and environmentally correct
disposal of electric and electronic equipment (ElektroG) from 16.03.2005), used machines are to be
placed in a collection system 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 charge.
• Information about giving back used equipment or about collections can be obtained from the
respective municipal administration office.
• EWM participates in an approved waste disposal and recycling system and is registered in the Used
Electrical Equipment Register (EAR) under number WEEE DE 57686922.
• In addition to this, returns are also possible throughout Europe via EWM sales partners.
6.5 Meeting the requirements of RoHS
We, EWM HIGHTEC Welding GmbH Mündersbach, hereby confirm that all products supplied by us which
are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).
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Rectifying faults
Checklist for rectifying faults
7 Rectifying faults
7.1 Checklist for rectifying faults
NOTE
The correct machine equipment for the material and process gas in use is a
fundamental requirement for perfect operation!
Legend Symbol Description

a Fault/Cause
# Remedy
Coolant error/no coolant flowing

a Insufficient coolant flow
# Check coolant level and refill if necessary
a Air in the coolant circuit
# see chapter "Vent coolant circuit"
Functional errors
a Machine control without displaying the signal lights after switching on
# Phase failure > check mains connection (fuses)
a No welding performance
# Phase failure > check mains connection (fuses)
a Various parameters cannot be set
# Entry level is blocked, disable access lock (see chapter entitled "Lock welding parameters
against unauthorised access")
a Connection problems
# Make control lead connections and check that they are fitted correctly.
Wire feed problems

a Unsuitable or worn welding torch equipment
# Adjust contact tip to wire diameter and -material and replace if necessary
# Adjust wire guide to material in use, blow through and replace if necessary
a Contact tip blocked
# Clean, spray with anti-spatter spray and replace if necessary
a Setting the spool brake (see "Setting the spool brake" chapter)
# Check settings and correct if necessary
a Setting pressure units (see "Inching wire electrodes" chapter)
a Worn wire rolls
# Check and replace if necessary
a Wire feed motor without supply voltage (automatic cutout triggered by overloading)
# Reset triggered fuse (rear of the power source) by pressing the key button
a Kinked hose packages
# Extend and lay out the torch hose package
a Incompatible parameter settings
a Arc between gas nozzle and workpiece (metal vapour on the gas nozzle)
# Replace gas nozzle
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Rectifying faults
Checklist for rectifying faults
Welding torch overheated

# Eliminate kinks in conduit system (hose packages)
a Loose welding current connections
# Tighten power connections on the torch and/or on the workpiece
# Tighten contact tip correctly
a Overload
# Check and correct welding current setting
# Use a more powerful welding torch
Unstable arc
# Adjust contact tip to wire diameter and -material and replace if necessary
# Adjust wire guide to material in use, blow through and replace if necessary
a Material inclusions in the tungsten electrode due to contact with filler material or workpiece
# Regrind or replace the tungsten electrode
a Incompatible parameter settings
Pore formation
a Inadequate or missing gas shielding
# Check shielding gas setting and replace shielding gas cylinder if necessary
# Shield welding site with protective screens (draughts affect the welding result)
# Use gas lens for aluminium applications and high-alloy steels
# Check size of gas nozzle and replace if necessary
a Condensation (hydrogen) in the gas tube
# Purge hose package with gas or replace
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Rectifying faults
Error messages
7.2 Error messages

All products are subject to rigorous production checks and final checks. If, despite this, something fails to
work at any time, please check the product using the following flowchart. If none of the fault rectification
procedures described leads to the correct functioning of the product, please inform your authorised
dealer.
NOTE
The error code is signalled via the robot interface!
• If multiple errors occur, these are displayed in succession.

• Document machine errors and inform service staff as necessary.
General system errors
1 The change of application signal of the power Phoenix/alpha Q/Te Yes
source has not been updated. trix
4 Wire feed error Phoenix/alpha Q/Te Yes
trix
5 Inverter/inverter emergency stop circuit Phoenix/alpha Q/Te No, automatic reset
temperature error trix
6 Excess mains voltage Phoenix/alpha Q/Te No, switch off
trix machine
7 Insufficient mains voltage Phoenix/alpha Q/Te No, switch off
trix machine
8 Low water level Phoenix/alpha Q/Te No, switch off
trix machine
9 Gas error Phoenix/alpha Q/Te Yes
trix
10 Excess secondary circuit voltage Phoenix/alpha Q/Te No, switch off
trix machine
11 Protective conductor error Phoenix/alpha Q/Te No, switch off
trix machine
12 System quick stop Phoenix/alpha Q/Te Yes
trix
13 Internal error, please contact EWM Phoenix/alpha Q/Te No, switch off
trix machine
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Rectifying faults
Error messages
Error Meaning Relevance Error can be reset

number to system
(value)
Process error
49 Process ignition error Phoenix/alpha Q/Te Yes
trix
50 Arc break error Phoenix/alpha Q/Te Yes
trix
51 Emergency shutdown/excess temperature Phoenix/alpha Q/Te No, automatic reset
trix
52 Wire feeder missing in the MIG/MAG system Phoenix/alpha Q Yes
or not configured correctly
53 In a system configured for wire feeder Phoenix/alpha Q Yes
switching an attempt has been made to switch
to a non-existent wire feeder
54 In power sources equipped with voltage Phoenix/alpha Q No
reduction devices the open circuit voltage
could not be reduced to the defined value.
99 No connection to welding power source (e.g. Phoenix/alpha Q/Te No, automatic reset
system switched off) trix
255 Unknown error(1) Phoenix/alpha Q/Te Yes

trix
NOTE
The error numbers displayed on operating units are different from those transmitted via
the field bus.
(1)
An error has been assigned by the system which cannot be assigned. This situation can occur
with differences in the software versions between the power source and interface.
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Rectifying faults
Error messages (RC-Panel)
7.3 Error messages (RC-Panel)

All products are subject to rigorous production checks and final checks. If, despite this, something fails to
work at any time, please check the product using the following flowchart. If none of the fault rectification
procedures described leads to the correct functioning of the product, please inform your authorised
dealer.
NOTE
A welding machine error is indicated by an error code being displayed (see table) on the
display on the machine control.
In the event of a machine error, the power unit is shut down.
• If multiple errors occur, these are displayed in succession.

• Document machine errors and inform service staff as necessary.
Error Category Possible cause Remedy
a) b) c)
Error 1 - - x Mains overvoltage Check the mains voltages and compare with
(Ov.Vol) the connection voltages of the welding
Error 2 - - x Mains undervoltage machine
(Un.Vol)
Error 3 x - - Welding machine excess Allow the machine to cool down (mains
(Temp) temperature switch to "1")
Error 4 - - x Low coolant level Top off the coolant
(Water) Leak in the coolant circuit >
rectify the leak and top off the coolant
Coolant pump is not working > check excess
current trigger on air cooling unit
Error 5 x - - Wire feeder, speedometer Check the wire feeder
(Wi.Spe) error speedometer is not issuing a signal,
M3.00 defective > inform Service
Error 6 x - - Shielding gas error Check shielding gas supply (for machines
(gas) with shielding gas monitoring)
Error 7 - - x Secondary excess voltage Inverter error > inform Service
(Se.Vol)
Error 8 - - x Earth fault between welding Separate the connection between the
(no PE) wire and earth line welding wire and casing or an earthed object
•(Phoenix 330 only)
Error 9 x - - Fast cut-out Rectify error on robot
(fast stop) triggered by BUSINT X11 or
RINT X12
Error 10 - x - Arc break Check wire feeding
(no arc) triggered by BUSINT X11 or
RINT X12
Error 11 - x - Ignition fault after 5 s Check wire feeding
(no ign) triggered by BUSINT X11 or
RINT X12
Error 14 - x - Wire feeder not detected. Check cable connections
(no DV) Control cable not connected.
Incorrect ID numbers Check assignment of ID numbers (see the
assigned during operation "Changing ID number of wire feeder"
with multiple wire feeders. chapter)
Error 15 - x - Wire feeder 2 not detected. Check cable connections
(DV2?) Control cable not connected.
Error 16 - - x VRD (open circuit voltage Inform Service
(VRD) reduction error)
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Rectifying faults
Error messages (RC-Panel)
Legend for categories (error reset)

a) The error message will disappear once the error has been rectified.
b) The error message can be reset by pressing a key button:
Welding machine control Key button
RC1 / RC2
Expert
CarExpert / Progress (M3.11)
alpha Q / Concept / Basic / Basic S / Synergic / not possible

Synergic S / Progress (M3.71)
c) The error message can only be reset by switching the machine off and on again.
7.3.1 Interface for automated welding
WARNING
No function of the external interrupt equipment (emergency stop switch)!
If the emergency stop circuit has been realised using an external interrupt equipment
via the interface for automated welding, the machine must be configured for this setup.
If this is not observed, the power source will ignore the external interrupt equipment
and will not shut down!
• Disconnect jumper 1 on PCB T320/1 (Tetrix) or M320/1 (Phoenix / alpha Q)!
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Rectifying faults
Display machine control software version
7.4 Display machine control software version

NOTE
The query of the software versions only serves to inform the authorised service staff!
0 A 0
l l
Figure 7-1
Display Setting/selection
List of the software
Start of the automated process
Software versions display
------- = System bus ID/printed circuit board
0.0.0.0.= Version number
System bus ID/printed circuit board and version number are separated by a colon.
List of the software
End of the list of software versions
NOTE
The printed circuit boards and software versions shown are displayed in an automated
process and vary according to the components that are connected and the versions.
7.4.1 Resetting JOBs to status on delivery (Reset ALL)

element
A Select Res. All using the buttons "Up" and Res. All 1
"Down" (left).
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Rectifying faults
Vent coolant circuit
7.5 Vent coolant circuit

NOTE
Coolant tank and quick connect coupling of coolant supply and return are only fitted in
machines with water cooling.
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)!
4
max
blau / blue 5 0
2 0
ca. 5s
6 0
3
l
KLICK
CLICK
7 KLICK
CLICK
092-007861-00000
Figure 7-2
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Technical data
8 Technical data
NOTE
Performance specifications and guarantee only in connection with original spare and
replacement parts!
8.1 alpha Q 352, 552 Puls

352 552
Welding current setting range 5A to 350A 5A to 550A
Welding voltage setting range 14.3V to 31.5V 14.3V to 41.5V
Duty cycle 40°C ambient temperature
60%DC - 550 A
80%DC - 520A
100%DC 350 A 420A
Duty cycle 25°C ambient temperature
60%DC - 550 A
100%DC 350 A 420 A
Load alternation 10 min (60% DC ∧ 6 min welding, 4 min break)
Open circuit voltage 93 V
Mains voltage (tolerance) 3 x 400V (-25% to +20%)
Frequency 50/60 Hz
Mains fuse 3 x 25 A 3 x 35 A
(slow-blow safety fuse)
Mains connection lead H07RN-F4G6
Max. connected power 13.9kVA 28.8kVA
Recommended generator rating 18.8kVA 38.8kVA
Cosϕ 0.99
Insulation class H
Protection classification IP 23
Ambient temperature -20°C to +40°C
Machine cooling Fan
Workpiece lead 70mm2 95mm2
Dimensions L/W/H in mm 780 x 375 x 625
Weight 85 kg
EMC class A
Constructed to standards IEC 60974 -1, -10
/
8.2 alpha Q RC2
Connection lead 2 m / 5 m / 10 m
Protection classification IP 23
Ambient temperature -20 °C to +40 °C
Dimensions L/W/D [mm] 285 x 315 x 115
Weight 2.5 Kg
EMC class A
Constructed to standards IEC 60974 / EN 60974 / VDE 0544
EN 50199 / VDE 0544 Part 206
/
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Accessories
Connection cables, connection sockets
9 Accessories
NOTE
Performance-dependent accessories like torches, workpiece leads, electrode holders or
intermediate hose packages are available from your authorised dealer.
9.1 Connection cables, connection sockets

Type Designation Item no.
5POLE/CEE/32A/M Machine plug 094-000207-00000
RA5 19POL 1x 5M Connection cable, 19-pole, 5 m 092-001569-00005
RA10 19POL 1x 10M Connection cable, 19-pole, 10 m 092-001569-00010
FRV5-L 7POL Extension/connecting cable 092-000201-00003
9.2 General accessories
DM1 35L/MIN Manometer pressure regulator 094-000009-00000
9.3 Options
BGA364X51X47 Panel for stacking machines 094-012294-00001
ON ZWIPA-CONNECTION Retrofit option for third party INTPA strain relief 094-007890-00000
9.4 Transportsysteme
PALETTE ROB XX2 Transport pallet for use with robots 090-008275-00000
9.5 Interfaces
RINT X12 STANDARD Robot interface 090-008291-00000
BUSINT X11 INTERBUS Interbus industrial bus interface in casing 090-008225-00000
ATCASE
ON PLUG SET RINT X12 Optional EWM plug set, retrofit kit for RINT X12 / 092-001822-00000
DVINT X11
9.6 Computer communication
RC 300 EWM tablet PC incl. software, adapter and interface 090-008238-00002
PC300.Net PC300.Net welding parameter software set incl. 090-008265-00000
cable and SECINT X10 USB interface
WELDQAS2 Station Stationary welding data monitoring and docu set for 090-008218-00000
two welding machines
QDOC9000 V2.0 Set consisting of interface, documentation software, 090-008713-00000
connection lead
ANALYSER Software for control and status signal analysis 090-008283-00000
PQS-ARC Quality assurance software 094-016609-00000
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Accessories
Cooling units
9.7 Cooling units

RK1 Reverse cooling unit 094-002283-00000
cool82 U44 Cooling module for robot welding machines 090-008268-00502
cool82 U45 Cooling module for robot welding machines 090-008280-00502
9.8 alpha Q RC2
Belt Strap 094-009375-00000
METAL SHEET FOR Metal sheet for holding robot panel 094-009374-00001
HOLDING ROBOT PANEL
CABLE, 12-POLE, 2 M Connection cable, 2 m 092-001967-00000
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10
07.09.2012
9x IGBT parallel + -UL +UL +
Ringkern Q1-
X1- Rückseite
Xx-
099-005079-EW501
L1
L1 T1 L1 A1-
L1
L1 L1
L2
L2 T2 L2 A1-
L2 X1/1 1
2 9
2 9
L2 L2 2
X1/2
D
E
L3 T3 L3
A5I-
L3 L3 A1-
L3 X1/3 3
C 2 12
L3 TRF-7M
4
PE 1
X7 X1/4
PE n=3Wdg. X7/1
PE
PE
PE X7/2
Ringkern
3
n=1Wdg. 400VAC X7/3
X7/4
WIG - -
X7/5
230VAC 6
X7/6 PE Rückseite
X7/7 4x2n2F
PE
X7/8
0VAC 9
X7/9
PE PE
X7/10
PE X7/11
X7/12
X3- X7/13
Circuit diagrams
PE X7/14
1 230VAC 12
X7/15
2 X7/16
A1-
3 X7/17 X5 X13
4 0VAC 18
X7/18 X3
DCx21 1
X3/1
X3/2
X13/1
X13/2
X5/1
X5/2
PE X2
T1- X2/1 1
+18V
1
2
1
2
8 16 A3- X2/2 2
+8V
Lüfter
Lüfter
0VAC
42VAC
400V/415V 6 6
15 42V X2/3 3
0V
A 2 7
14 0V X2/4 4
-18V F 1 10
B 2 8 LDC2
Temp
5
X1 X2/5 UD
105°C 11 25V X1/1
11 1
230V 4 4
25VAC
X2/6 6
0V
10 X1/2
0V 1
2 9 9
0V 0VAC 3
X1/3
X1/4
T2-
1/2 8/9
350V 1/2 8/9 42V
NC
NC
+5V2
MSO
SCK
MOSI
RESET
0V2
NC
NC
0V
0V
CAN_RXD
RESET
CAN_TXD
RXD1
EXT_INT
TXD1
+5V
+5V
5/6
0V 5/6 10/11 10/11
0V
X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8
X1/9
X3/1
X3/2
X3/3
X3/4
X3/5
X3/6
X3/7
X3/8
X11/1
X11/2
X11/3
X11/4
X11/5
X11/6
X11/7
X11/8
X11/9
X20/1
X20/2
X20/3
X20/4
X20/5
X20/6
X20/7
X20/8
X20/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X11/10
X20/10
X30-
1 NC X1 X3 X11 X20
Inverter sekundär Inverter primär Programmierstecker Programmierstecker
2
2 0V
G 2 3
3 NC X5/1 1
Iist
NOTE
4 NC X5/2 2
REGaus X7- 1
5 NC K 2 3
X7 X5/3 PE-
3
SYN_E SYN_E 1
Computer T?
Figure 10-1
6 NC X5/4 4
IGR0 0V 2 X4-
9polig
D-Sub.
7 NC X5/5 PE
5
0V A
8 NC X5/6 REGaus
6
0V B
9 NC X5/7 Gasdüsensensor 1
7
+15V C
S 2 14
10 NC X5/8 IGR0 D
11 NC X5/9 Not/Aus
9
X5 IGR0 E
12
12 IGR0
A2- Robo./Auto. X5/10
H 2 3 10
Uist 0V F
X5/11 11
DVist IGR0 G
X11- X5/12
M320/1 12
SYN_A Uist H
A Pumpe Pumpe 1
X9/1
X5/13 13
STA/STP DVist J
B Lüfter 2
Lüfter X9/2
X5/14 SYN_A1 K
C +15V +15V 3
X9/3
X9 X5/15 15
0V STA/STP L
D WMangel Wassermangel4
X9/4
Wasserkühler X5/16 16
-15V +15V M
E WKühler Wasserkühler5
X9/5
X5/17 -15V N
F 0V 6
0V X9/6
X5/18 18
IGR0 IGR0 P
G NC
Not/Aus R
H NC n=?Wdg.
Ringkern
0V S
X6/1 1
Not/Aus Iist T
X6
Not/Aus X6/2 2
Not/Aus Not-Aus1 U
V 2 14
Original format circuit diagrams are located inside the machine.
Not-Aus2 V
X19 X2 X4 X10 X-PE W 2 14
AC Inverter Lüfter X8 Versorgung Fühlerspannung Erdung
Systembus
X4/1
X4/2
X4/3
X4/4
X4/5
X4/6
X10/1
X10/2
D-Sub.
X19/1
X19/2
X19/3
X19/4
X19/5
X19/6
X19/7
X19/8
X19/9
X19/10
X19/11
X19/12
X2/1
X2/2
X2/3
X2/4
X-PE/1
X-PE/2
15polig
PE5-
1
2
4
5
6
8
1
2
3
4
1
2
3
4
5
6
1
2
1 0
1 1
1 2
0V
0V
0V
0V
Iist
UD
+8V
-18V
dIsoll
IGR0
+15V
+18V
Lüfter
Lüfter
X31-
Pulsen
PE
Kurz ein
Start vor
Invertertakt
1
1 dIsoll
I 2 10
Sammelfehler
2 NC
Fühlerspannung
Fühlerspannung
3 NC
4
2 3
1 17
2 10
2 10
4 Invertertakt
5
5 Pulsen
N
F
P
Q
Lüfter
NC
Lüfter
NC
NC
Sammelfehler
NC
+15V
6
6 Start vor
1 2 3 4 1 2 3 4
7 NC X32- X33-
J 2 12 8
8 0V
9 NC
Blatt: 01 / 2 Datum: Name: geprüft: This drawing is protected by copyright.
10
10 Kurz ein
gezeichnet: 25.03.2010 NIEDENTHAL It may not be reproduced or utilised in any way
11
11 Iist or communicated or forwarded to third parties
Änderung- 01 18.03.2011 NIEDENTHAL
12 NC without our express permission!
Änderung-
Zeichnungsnummer:
2 3
2 3
Änderung- ALPHA Q 352/552 RC PULS

L
M
Änderung- MIG-GERAET, 3X400V 6495-01

Freigabe:
83
Circuit diagrams
alpha Q RC2
84
alpha Q RC2
Frontseite Rückseite
1 4
1 4
1 11
1 11
A
B
P
Q
Betrieb
X6
gn X6/1 0V 1
G 1 2
X6/2
0VAC
A6- X1/1 42V
42VAC
ge X6/3 VP5/1D X1/2 RSGND
X6/4 4
S.Fehler X1/3 RXD
Fühlerspannung
Fühlerspannung
L 1 9
Sammelstörung X6/5 +15V5
X1/4 TXD
M 1 9
X6/6 X1/5 RS+12V
Circuit diagrams
1
2
15polig
D-SUB
Stecker X2
gn X6/7 IGR07
X1/6 0V
H 1 2
X6/8 X1/7 Schirm
IGR0
X8/1
X8/2
2n2F
X5 X2/1 T2
X5/1 TXD 1
X4 Pin-Belegung D-Sub 15polig
1
PE
X5/2 X2/2 PIN 1 TXD rt
42V X1/1 2
RS+12V
PIN 2 RS+12V bl
X5/3 X2/3
RSGND X1/2 0VAC3
PIN 3 42V vi
X2/4 PIN 4 42V ro/gr A7-
RXD X1/3 X5/4 4
PC-RTS PIN 5 0V42 bl/rt X1/1 42V
D-Sub.
15polig
X5/5 PIN 6 0V42 ge VP5/2D
5
TXD X1/4 PC-DTR
PIN 7 NC X1/2 RSGND
RS+12V X1/5 X5/6 6
PC-TXD PIN 8 PE
X3/1 X1/3 RXD
X5/7 PIN 9 RXD sw
7
0V X1/6 RSGND X5
PIN 10 RSGND ws X1/4 TXD
X5/8 X3/2
Schirm X1/7 RXD 8
PIN 11 42V br
X3/3
A4- PIN 12 NC
X1/5 RS+12V
X5/9 9
42VAC PIN 13 0V42 gn X1/6 0V
X5/10 X3/4 PIN 14 NC
WK-6 PIN 15 PE X1/7 Schirm
D-Sub.
15polig
42V X2/1 X5/11 11
PC-GND
F1
RSGND X2/2 X5/12 12
PC-RXD
X1/1 4AT 1 TXD
1
42VAC
RXD X2/3 X6 2 RS+15V
15polig
D-SUB
T1 X2/1 42V
Stecker X3
0VAC 2
X1/2
TXD X2/4 12V 4 42VAC
X1/3 X2/2 RSGND
RS+12V X2/5 6 0VAC
X1/4 9 RXD X2/3 RXD
PE4
0V X2/6
10 RSGND X2/4 TXD
D-SUB
X1/5
Stecker X3
15polig
D-Sub.
15polig
Schirm X2/7 15 PE
X1/6 X2/5 RS+12V
X1/7 X2/6 0V
X7
N 1 9 X1/8 X2/7 Schirm
A5- 2x2n2F
D-SUB
Stecker X4
15polig
VP-16 F1-
?T
1 1
Absicherung 1
X9/1
D-Sub.
15polig
1
PE
2
Absicherung X9/2
9polig
D-SUB
Stecker X7
?T
2
2 X2-
4A NC A
K 1 4 NC B
Not-Aus2 C
9polig
D-SUB
Stecker X8
W 1 16
NC D
Gasdüsensensor 1 E
S 1 16
NC F
1 14
1 13
NC G
X5-
Figure 10-2
NC
E
D
H
1 NC NC J
2 PC-RXD Ringkern NC K
3 PC-GND 1
n=2Wdg.
Ringkern Not-Aus1 L
V 1 16
4 NC PE NC M
PE 2
1
5
+UL
-UL 2
1
5 NC
6 PC-TXD
7 PC-DTR Ringkern
1Wdg. durchgezogen
X2/1
X2/2
X9/1
X9/2
X8/1
X8/2
X8/3
X8/4
X8/5
X8/6
X8/7
X8/8
X12/1
X12/2
8 PC-RTS n=2Wdg. X10-
9 NC X9 X8 X2 X12 X1 X1/1 TXD 1
1
0V
X1/2 RS+12V 2
2
Pulsen
X3 42VAC 3
X1/3 3
Inv.Takt
42VAC 4
X1/4 Iist4
J 1 2
X6- C1- 0V42 5
X1/5 5
Kurz ein
1
A PE_Dyn.
PE5-
1
X1/6 0V42 6
6
D-Sub.
Start vor
15polig
B 0VAC 2n2F PE A8- NC 7
C 42VAC
PE 8
D TXD X4 TRF-7 RXD 9
E PC-GND X10
X10/1 RSGND 10
1
42V
F PC-TXD
X10/2 42V 11
2
0V
G PC-RTS
X10/3 NC 12
C 1 13
D-Sub.
+3.3V
15polig
3
H PC-RXD
0V42 13
X10/4 4
J PC-DTR X11
Transistor NC 14
K RXD
PE 15
L RS+12V
X11/1
X11/2
X11/3
X11/4
Ringkern
M RSGND
n=2Wdg.
1
dIsoll
1 2
I
Blatt: 02 / 2 Datum: Name: geprüft: This drawing is protected by copyright.

gezeichnet: 25.03.2010 NIEDENTHAL It may not be reproduced or utilised in any way
or communicated or forwarded to third parties
Änderung- 01 18.03.2011 NIEDENTHAL
without our express permission!
Änderung-
Zeichnungsnummer:
Änderung- ALPHA Q 352/552 RC PULS
Änderung- MIG-GERAET, 3X400V 6495-01
Freigabe:
099-005079-EW501
07.09.2012
Appendix A
JOB-List
11 Appendix A
11.1 JOB-List
094-015122-00501 094-015118-00501
Wire Wire
% 0,8 1,0 1,2 1,6 % 0,8 1,0 1,2 1,6
Material Gas Material Gas
Job-Nr. Job-Nr.
CO2 100 / C1 1 3 4 5 SG2/3 CO 2 100 / C1 182 184 185 186

SG2/3
Massivdraht / Solid Wire

G3/4 Si1 Ar80-90 / M2 6 8 9 10 G3/4 Si1 Ar80-90 / M2 191 193 194 195
Ar91-99 / M13
M12-
34 35 36 37 CrNi Ar91-99 / M12-
M13 50 51 52 53
CrNi
Ar/He / I3 42 43 44 45 AlMg Ar100 / I1 54 55 56 57
CuSi Ar100 / I1 98 99 100 101 AlSi Ar100 / I1 58 59 60 61
CuAl Ar100 / I1 106 107 108 109 Al99 Ar100 / I1 62 63 64 65
CuSi Ar100 / I1 114 115 116 117 CuSi Ar100 / I1 66 67 68 69

Löten / Löten /
Brazing Ar91-99 / M13
M12-
110 111 112 113 Brazing
CuAl Ar100 / I1 122 123 124 125 CuAl Ar100 / I1 70 71 72 73
Löten / Löten /
Brazing Ar91-99 / M13
M12-
118 119 120 121 Brazing
Ar100 / I1 74 75 76 77 AlSi Ar100 / I1 196 197 198 199

AlMg Löten /
Ar/He / I3 78 79 80 81 Brazing
Ar100 / I1 82 83 84 85 ZnAl Ar100 / I1 200 201 202 203

AlSi Löten /
Ar/He / I3 86 87 88 89 Brazing
Ar100 / I1 90 91 92 93 AlSi Ar100 / I1 223 224 225 226

Al99 St / Al
Ar/He / I3 94 95 96 97
Wire ZnAl Ar100 / I1 219 220 221 222

Fülldraht / Flux-Cored Wire
% 0,8 1,0 1,2 1,6 St / Al

Material Gas
Job-Nr. Pipe-Solution / Rohrleitungsbau
SG2/3 Ar80-90 / M2 235 237 238 239
G3/4 Si1 Wire
Metal % 0,8 1,0 1,2 1,6
SG2/3 Ar80-90 / M2 240 242 243 244 Material Gas
Job-Nr.
G3/4 Si1
Rutil / Basic CO 2 100 / C1 171 172
SG2/3
CrNi Ar91-99 / M13
M12- 227 228 229 230 G3/4 Si1 173 174
Ar80-90 / M2
Metal
CrNi Ar98/2 / M13 231 232 233 234

Rutil / Basic Ar92/8 / M22 210 211 212 213
CrNiMn Ar98/2 / M13 223 224 225 226

Rutil / Basic Ar92/8 / M22 206 207 208 209
Wire
% 0,8 1,0 1,2 1,6
Material Gas
Job-Nr.
SG2/3 Ar91-99 / M13

M12- 190 254 255 256
G3/4 Si1 Ar80-90 / M2 189 179 180 181
Ar91-99 / M13
M12- 251 252 253
CrNi
Ar100 / I1 247 248

AlMg
Ar100 / I1 249 250

AlSi
Ar100 / I1 245 246

Al99
SP1 129
SP2 130
SP3 131
GMAW non synergic <8m / min 188
GMAW non synergic >8m / min 187
WIG / TIG 127
MMA / E-Hand 128
099-005079-EW501
07.09.2012
85
Appendix B
Overview of EWM branches
12 Appendix B
12.1 Overview of EWM branches
Headquarters Technology centre
EWM HIGHTEC WELDING GmbH EWM HIGHTEC WELDING GmbH
Dr. Günter-Henle-Straße 8 Forststr. 7-13
56271 Mündersbach · Germany 56271 Mündersbach · Germany
Tel: +49 2680 181-0 · Fax: -244 Tel: +49 2680 181-0 · Fax: -144
www.ewm-group.com · info@ewm-group.com www.ewm-group.com · info@ewm-group.com
Production, Sales and Service

EWM HIGHTEC WELDING GmbH EWM HIGHTEC WELDING AUTOMATION GmbH
Dr. Günter-Henle-Straße 8 Boxbachweg 4
56271 Mündersbach · Germany 08606 Oelsnitz/V. · Germany
Tel: +49 2680 181-0 · Fax: -244 Tel: +49 37421 20-300 · Fax: -318
www.ewm-group.com · info@ewm-group.com www.ewm-automation.de · info@ewm-automation.de
EWM HIGHTEC WELDING (Kunshan) Ltd. EWM HIGHTEC WELDING s.r.o.

10 Yuanshan Road, Kunshan · New & High-tech Industry Development Zone Tr. 9. kvetna 718 / 31
Kunshan · Jiangsu · 215300 · People´s Republic of China 407 53 Jiříkov · Czech Republic
Tel: +86 512 57867-188 · Fax: -182 Tel: +420 412 358-551 · Fax: -504
www.ewm-kunshan.cn · info@ewm-kunshan.cn www.ewm-jirikov.cz · info@ewm-jirikov.cz
Sales and Service Germany

EWM HIGHTEC WELDING GmbH EWM HIGHTEC WELDING GmbH
Vertriebs- und Technologiezentrum Eiserfelder Straße 300
Grünauer Fenn 4 57080 Siegen · Tel: +49 271 3878103-0 · Fax: -9
14712 Rathenow · Tel: +49 3385 49402-0 · Fax: -20 www.ewm-siegen.de · info@ewm-siegen.de
www.ewm-rathenow.de · info@ewm-rathenow.de
EWM HIGHTEC WELDING GmbH
EWM HIGHTEC WELDING GmbH Vertriebs- und Technologiezentrum
Lindenstraße 1a Draisstraße 2a
38723 Seesen-Rhüden · Tel: +49 5384 90798-0 · Fax: -20 69469 Weinheim · Tel: +49 6201 84557-0 · Fax: -20
www.ewm-seesen.de · info@ewm-seesen.de www.ewm-weinheim.de · info@ewm-weinheim.de
EWM HIGHTEC WELDING GmbH EWM Schweißtechnik Handels GmbH

Sachsstraße 28 Rittergasse 1
50259 Pulheim · Tel: +49 2234 697-047 · Fax: -048 89143 Blaubeuren · Tel: +49 7344 9191-75 · Fax: -77
www.ewm-pulheim.de · info@ewm-pulheim.de www.ewm-blaubeuren.de · info@ewm-blaubeuren.de
EWM HIGHTEC WELDING GmbH EWM Schweißtechnik Handels GmbH

In der Florinskaul 14-16 Heinkelstraße 8
56218 Mülheim-Kärlich · Tel: +49 261 988898-0 · Fax: -20 89231 Neu-Ulm · Tel: +49 731 7047939-0 · Fax: -15
www.ewm-muelheim-kaerlich.de · info@ewm-muelheim-kaerlich.de www.ewm-neu-ulm.de · info@ewm-neu-ulm.de
EWM HIGHTEC WELDING GmbH EWM HIGHTEC WELDING AUTOMATION GmbH

Sälzerstr. 20 Steinfeldstrasse 15
56235 Ransbach-Baumbach · Tel: +49 261 2623 9276-0 · Fax: -244 90425 Nürnberg · Tel: +49 911 3841-727 · Fax: -728
www.ewm-ransbach-baumbach.de · info@ewm-ransbach-baumbach.de www.ewm-automation.de · info@ewm-automation.de
Sales and Service International

EWM HIGHTEC WELDING GmbH EWM HIGHTEC WELDING Sales s.r.o. / Prodejní a poradenské centrum
Fichtenweg 1 Tyršova 2106
4810 Gmunden · Austria · Tel: +43 7612 778 02-0 · Fax: -20 256 01 Benešov u Prahy · Czech Republic
www.ewm-gmunden.at · info@ewm-gmunden.at Tel: +420 317 729-517 · Fax: -712
www.ewm-benesov.cz · info@ewm-benesov.cz
EWM HIGHTEC WELDING UK Ltd.
Unit 2B Coopies Way · Coopies Lane Industrial Estate EWM HIGHTEC WELDING FZCO / Regional Office Middle East
Morpeth · Northumberland · NE61 6JN · Great Britain LOB 21 G 16 · P.O. Box 262851
Tel: +44 1670 505875 · Fax: -514305 Jebel Ali Free Zone · Dubai, UAE · United Arab Emirates
www.ewm-morpeth.co.uk · info@ewm-morpeth.co.uk Tel: +971 48870-322 · Fax: -323
www.ewm-dubai.ae · info@ewm-dubai.ae
EWM HIGHTEC WELDING (Kunshan) Ltd.
10 Yuanshan Road, Kunshan · New & High-tech Industry Development Zone
Kunshan · Jiangsu · 215300 · People´s Republic of China
Tel: +86 512 57867-188 · Fax: -182
www.ewm-kunshan.cn · info@ewm-kunshan.cn
Plants Branches More than 300 EWM sales partners worldwide
099-005079-EW501
86 07.09.2012

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Operating instructions

Power sources for automated applications

alpha Q 352, 552 RC Puls

099-005079-EW501 Observe additional system documents! 07.09.2012

For your benefit

© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany

5.13 Interfaces .....................................................................................................................................37

6 Maintenance, care and disposal......................................................................................................... 68

2.2 Explanation of icons

ENTER (enter the menu)

NAVIGATION (Navigating in the menu)

EXIT (Exit the menu)

Time display (example: wait 4s/press)

Interruption in the menu display (other setting options possible)

Setting up and operating

In order to evaluate any possible problems with electromagnetic compatibility in the

Recommendations for reducing interference emission

2.4 Transport and installation

2.4.1 Lifting by crane

2.5 Ambient conditions

3.2 Documents which also apply

3.2.2 Declaration of Conformity

3.2.4 Service documents (spare parts and circuit diagrams)

4 Machine description – quick overview

Item Symbol Description 0

5 PC interface, serial (D-Sub connection socket, 9-pole)

6 Cooling air inlet

4.1.2 Rear view

Item Symbol Description 0

2 19-pole mechanised welding interface (analogue)

4.2 alpha Q RC2

Item Symbol Description 0

5 PC interface, serial (D-Sub connection socket, 9-pole)

6 15-pole connection socket (digital)

4.3 Machine control – Operating elements

PROG 2 PROG 10 t start Puls

V PROG 3 PROG 11 P0...15 Standard 6

Item Symbol Description 0

5 Design and function

5.3 Machine cooling

5.4 Workpiece lead, general

5.5 Notes on the installation of welding current leads

Item Symbol Description 0

5.6 Welding torch cooling system

5.6.2 List of coolants

5.7 Mains connection

5.7.1 Mains configuration

5.8 Intermediate hose package connection

5.9 Connection for workpiece lead

5.10 Connect the cooling module to the power source

5.11 Connect the alpha Q RC 2 to the power source

5.12 Shielding gas supply

Item Symbol Description 0

5.13.2 Connecting the PC 300.net welding parameterisation software

2 Connection cable, 9-pole, serial

5.13.3 Connecting the Q-DOC 9000 welding data documentation software

5.13.5 Automation interface

19-pole connection assignment for mechanised welding interface (X4):

D Output IGR0 Maximum load 100 mA

K Output SYN_A1 Seam tracking synchronising signal

L Input STA/STP Contact at M

12-pole connection assignments for mechanised welding interface (X2):

Pin Signalshape Circuit diagram signal Function