Service Manual: Ewm RC

EWM
HIGHTEC WELDING GmbH

Dr. Günter - Henle - Straße 8 • D-56271 Mündersbach
Phone: +49 2680 181 0 • Fax: +49 2680 181 244
www.ewm.de • info@ewm.de
GB Service manual
EWM RC
© 2007 Subject to alteration. Item No.:099-S000RC-EWM01 Revised: 08.01.2008

FR30 14pol 10M 090-008005-00010 FR21 14pol 5M 094-000051-00000
FR30PWS 14pol 10M 090-008039-00010 FR30 14pol 5M 090-008005-00000
FR35 14pol 10M 090-008044-00010 FR30PWS 14pol 5M 090-008039-00000
FRA40 14pol 0,3M 090-008032-00000 FR35 14pol 5M 090-008044-00000
FRF30 14pol 5M 090-008057-00000 FRF30 14pol 10M 090-008057-00010
FRF30 PWS 14pol 5M 090-008061-00000 FRF30 PWS 14pol 10M 090-008061-00010
FRP10 14pol 5M 090-008002-00000 FRP10 14pol 10M 090-008002-00010
FRP15 14pol 5M 090-008045-00000 FRP15 14pol 10M 090-008045-00010
INTEGRAL C10 5M 090-008031-00000 FRT50 090-008043-00000
INTEGRAL C20 5M 090-008065-00000 INTEGRAL C10 HIGHSPEED 090-008056-00000
INTEGRAL C30 5M 090-008066-00000 INTEGRAL C20 HIGHSPEED 5M 090-008071-00000
INTEGRAL C40 5M 090-008082-00000 INTEGRAL C30 HIGHSPEED 5M 090-008072-00000
INTEGRAL C40 040-000548-00000 INTEGRAL C40 HIGHSPEED 5M 090-008083-00000
INTEGRAL C40HS 040-000548-00001 INTEGRAL C40 040-000548-LR000
INTEGRAL SP11 5M 090-008055-00000 INTEGRAL SP10 5M 090-008042-00000
PHOENIX R20 090-008263-00000 PHOENIX R10 090-008087-00000
RT PWS1 090-008199-00000 PHOENIX R40 090-008088-00000
RTAC1 090-008197-00000 RT1 090-008097-00000
RTP1 090-008098-00000 RTF1 19POL 5M 094-006680-00000
RTP3 090-008211-00000 RTP2 090-008099-00000
WELDON R40 090-008102-00000 WELDON R10 090-008101-00000
Content
1 Content
1 Content.................................................................................................................................................... 3
2 Remote control....................................................................................................................................... 4
2.1 Digital remote control (7-pole) ....................................................................................................... 4
2.1.1 R40 manual remote control ............................................................................................ 4
2.1.2 WELDON R40 ................................................................................................................ 4
2.1.3 Integral C10 / Integral C10 HS ....................................................................................... 4
2.1.4 Integral C20 .................................................................................................................... 5
2.1.5 Integral C30 / C30 HS .................................................................................................... 5
2.1.6 Integral C40 / C40 HS .................................................................................................... 5
2.1.7 Integral SP 10................................................................................................................. 5
2.1.8 Integral SP11.................................................................................................................. 6
2.2 Analogue remote control (14/19-pole) ........................................................................................... 6
2.2.1 R10 manual remote control ............................................................................................ 6
2.2.2 Manual remote control R20 ............................................................................................ 7
2.2.3 WELDON R10 ................................................................................................................ 7
2.2.4 Manual remote control RT 1........................................................................................... 8
2.2.5 Manual remote control RT AC 1..................................................................................... 8
2.2.6 Manual remote control RT PWS 1.................................................................................. 8
2.2.7 Manual remote control RTP 1 ........................................................................................ 8
2.2.8 Manual remote control RTP 2 ........................................................................................ 8
2.2.9 RTP 3 manual remote control ........................................................................................ 9
2.2.10 Foot-operated remote control RTF 1.............................................................................. 9
2.2.11 FR21............................................................................................................................... 9
2.2.12 FR 30.............................................................................................................................. 9
2.2.13 FR35............................................................................................................................... 9
2.2.14 FRA40 .......................................................................................................................... 10
2.2.15 FRP10 .......................................................................................................................... 10
2.2.16 FRP15 .......................................................................................................................... 10
2.3 Interfaces ..................................................................................................................................... 11
2.3.1 7-pole digital interface .................................................................................................. 11
2.3.2 14-pole analogue interface (EB3).................................................................................12
2.3.3 19-pole analogue interface........................................................................................... 13
2.4 Circuit diagrams ........................................................................................................................... 15
2.4.1 FR 30............................................................................................................................ 15
2.4.2 FR35............................................................................................................................. 17
2.4.3 FRA40 .......................................................................................................................... 17
2.4.4 FRP10 .......................................................................................................................... 18
2.4.5 FRP15 .......................................................................................................................... 18
2.4.6 WELDON R10 .............................................................................................................. 19
2.4.7 WELDON R40 .............................................................................................................. 20
2.4.8 Manual remote control RT 1.........................................................................................21
2.4.9 Manual remote control RT AC 1...................................................................................22
2.4.10 Manual remote control RT PWS 1................................................................................ 23
2.4.11 Manual remote control RTP 1 ......................................................................................26
2.4.12 Manual remote control RTP 2 ......................................................................................27
2.4.13 RTP 3 manual remote control ...................................................................................... 28
2.5 Error ............................................................................................................................................. 29
2.5.1 Fault detection/FAQ...................................................................................................... 29
2.5.2 Returns note ................................................................................................................. 30
3
Remote control
2 Remote control
2.1 Digital remote control (7-pole)
The remote controls PHOENIX R10, PHOENIX R40, WEDLON R10 and WELDON R40 may only be
operated on the welding machines intended for their use!
Serious damage may be caused to the machines if this is not observed.
2.1.1 R40 manual remote control
Functions
• Create and retrieve up to 16 operating points/main programs
• Set program sequence
• Superpulse function "ON/OFF"
• MIG standard/MIG pulse arc welding switching
(EXPERT PULSE only)
• Preset number of main programs (PA1 to PA16)
• LCD display (16-digit ) for displaying the welding parameters
• LED for displaying the Hold function
• The remote control is connected to the digital remote control connection socket
on the welding machine (7-pole) via an extension cable
2.1.2 WELDON R40
• WELDON R40 090-008102-00000
• Create and save MIG welding programs
• Retrieval of 10 programs via the MIG program torch or via remote
control, e.g. frequently used applications, 32 programs externally,
e.g. with mechanised applications
• Display of setpoints and actual values via integrated display
• Robust metal casing with holding magnet
• 7-pole connection socket
2.1.3 Integral C10 / Integral C10 HS

• Integrated C10 H remote control WF, 5m 090-008031-00000
• Integrated C10 Highspeed WF, 5m 090-008056-00000
• Wire feed speed (1-20m/min or 1-30m/min) and correction of the
arc length (-10V – +10V) can be infinitely adjusted.
4
Remote control
2.1.4 Integral C20

• Integrated C20 H remote control WF, 5m 090-008065-00000
• Integrated C20 HighSpeed H remote control, 5m 090-008071-
00000
• Wire feed speed (welding operating point) and correction of the
arc length
• Start value:
− Time duration (0-5 sec.) and height (0-200%)
− Slope (0-5 sec.) from start value to welding value
− Slope (0-5 sec.) from welding value to end crater value
− End crater value: Time duration (0-5 sec.) and height (0-
100%)
Not for MIG/TIG 450, 500

2.1.5 Integral C30 / C30 HS
• Integrated C30 H remote control, 5m 090-008066-00000
00000
• 10 program positions (operating points)
• Wire-feed speed
• Arc length correction
• Welding data display before, during and after welding (Hold
function)
• Welding data setting function can be locked
2.1.6 Integral C40 / C40 HS
• Integrated C40 H remote control, 5m 090-008082-00000
00000
• 10 programs each with 4 welding operating points
• Programmable operating points:
− Welding operating point, start operating point,
− End crater operating point, reduced welding operating point
• Changeover switch for non-latched and latched mode
• Changeover switch for superpulse function
• LCD display
2.1.7 Integral SP 10
• Integrated SP10 H remote control, 5m 090-008042-00000
• 2 welding programs A, B (operating points)
• Wire feed speed (welding performance) and correction of the arc
length can be infinitely adjusted for each program
• Superpulse function:
− Change between A and B
− Time duration for A and B can be infinitely adjusted
5
Remote control
2.1.8 Integral SP11

• Integrated SP11 H remote control, 5m 090-008055-00000
• 3 welding programs A, B and (Hot)start program (operating
points)
• Wire feed speed (welding performance) and correction of the arc
length can be infinitely adjusted for each program
• Superpulse function:
− Change between A and B
− Time duration for A and B can be infinitely adjusted
• (Hot) start program with functions:
− Time duration for (Hot) start program can be infinitely
adjusted
• Remote control can be switched on and off
• Changeover between MIG/MAG pulse and standard welding
2.2 Analogue remote control (14/19-pole)
2.2.1 R10 manual remote control
Figure 2-1
Item Symbol Description 0
6 7 8 9 10
1 3,5
3
4
5
11
12
13
“Wire speed” rotary dial
14
2,5
2
1,5
15
16
Infinitely adjustable setting of the wire speed from min. to max.
1 18
0,5
m/min
20
(welding output, one-dial operation)
1 0 1
2 2 2 “Arc length correction” rotary dial
3 3
5
7 7
5 Arc length correction from -10 V to + 10 V
10 10
- V +
3 19-pole connection socket (analogue)

For connecting the control lead.
6
Remote control
2.2.2 Manual remote control R20

Manual remote controls R20 can only be used together with controls M3.70 or M3.71!
Figure 2-2
6 7 8 9 10
1 3,5
3
4
5
11
12
13
"Wire speed" rotary dial
14
2,5
2
1,5
15
16
• Infinitely adjustable setting of the wire speed from min. to max.
1 18
0,5
m/min
20
(welding output, one-dial operation).
• The wire correction value is set in the correction operation with welding programs
(key switch set to "0").
1 0 1
2 2 2 "Arc length correction" rotary dial
3 3
5
7 7
5 • Arc length correction from -10V to +10V
10 10
- V + • The arc correction value is set in the correction operation with welding programs
(key switch set to "0").
3 Display for showing the current program number
4 Program switching "Up" button
Select program number up
5 Program switching "Down" button
Select program number down
6 Holder for suspending the remote control
7 19-pole connection socket (analogue)
For connecting the control lead.
2.2.3 WELDON R10
• WELDON R10 090-008101-00000
• Infinite adjustment of the operating point via wire-feed speed and
welding voltage
• Robust metal casing with holding magnet
• 19-pole connection socket
7
Remote control
2.2.4 Manual remote control RT 1

Functions
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• The remote control is connected to the 19-pole remote control connection socket
on the welding machine via a 19-pole extension cable.
2.2.5 Manual remote control RT AC 1

Functions
• AC frequency of welding current infinitely adjustable.
• AC balance (positive/negative half-wave ratio) can be set from +15% to -15%.
Please note
2.2.6 Manual remote control RT PWS 1
Functions
• Changeover switch for pole reversal, suitable for welding machines with PWS-
function.
• The remote control is connected to the 19-pole remote control connection socketon
the welding machine via a 19-pole extension cable.
2.2.7 Manual remote control RTP 1
Functions
• TIG / MMA
• Pulse / spot / normal
• Pulse, spot and break times are infinitely adjustable.
Please note
• TIG AC pulses special is not possible.
Functions
• TIG / MMA
• Pulse / spot / normal
• Frequency and spot times infinitely adjustable.
• Coarse adjustment of the cycle frequency.
• Pulse/pause ratio (balance) adjustable from 10% to 90%.
Please note
8
Remote control
2.2.9 RTP 3 manual remote control

Functions
• TIG / MMA.
• Pulse / SpotArc spots / normal
• Frequency and spot time infinitely adjustable.
• Coarse adjustment of the pulse frequency.
• Pulse/pause ratio (balance) adjustable from 10% to 90%.
Please note
• The remote control is connected to a 19-pole remote control connection socket on
the welding machine via a 19-pole extension cable.
2.2.10 Foot-operated remote control RTF 1
Functions
• Start/stop welding operation
• It is connected to the 19-pole remote control connection socket
2.2.11 FR21
• FR 21 F remote control current, 5m 094-000051-00000
• Welding current infinitely adjustable
• Welding current on/off
2.2.12 FR 30
• FR 30 H remote control current, 5m 090-008005-00000
• FR 30 H remote control current, 10m 090-008005-00010
2.2.13 FR35
• FR35 H remote control, hotstart, 5m 090-008044-00000
• FR35 H remote control, hotstart, 10m 090-008044-00010
• Hotstart current, hotstart time and welding current infinitely
adjustable.
• Connection socket for additional remote control FR21, FR30

• Welding current setting with additional remote control (lower
toggle switch position)
9
Remote control
2.2.14 FRA40
• FRA40 H remote control current display, 0.3m 090-008032-
00000
• Manual remote control with digital ampere meter, welding current
I1 infinitely adjustable
2.2.15 FRP10
• FRP10 H remote control pulse/spot, 5m 090-008002-00000
• FRP10 H remote control pulse/spot, 10m 090-008002-00010
• Changeover switch spots/pulses
− Spots: Spot time infinitely adjustable
− Pulses: Infinitely adjustable pulse and pause times
2.2.16 FRP15
• FRP15 H remote control, pulses, 5m 090-008045-00000
• FRP15 H remote control, pulses, 10m 090-008045-00010
• Pulses ON/OFF changeover switch
• Infinitely adjustable pulse and pause times
10
Remote control
2.3 Interfaces
2.3.1 7-pole digital interface
Figure 2-3
1 42V AC (power supply)
2 RSGND (digital 0V)
3 RXD (digital signal line)
4 TXD (digital signal line)
5 REF (reference +12V, data line power supply)
6 0V AC
7 Shield (data lines shielding)
11
Remote control
2.3.2 14-pole analogue interface (EB3)

1
15
2
3
4
16
5
18
6
7 17
8 19
9
10
11
12
13
14
Figure 2-4
1 A Overhead
2 NC (unassigned)
3 J,U 0V
4 B I > 0 (Current flows signal)
5 B I > 0 (Current flows signal)
6 V -15V (output, max. 25mA)
7 K + 15V (output, max. 75mA)
8 H Pulser I2
9 ISIN (setpoint value input)
10 TSPOT (spot time)
11 R TT (Start/Stop torch trigger)
12 ISUM ( = 0V,remote control is connected)
13 SPOTON (spots)
14 F + 10V (output, max. 10mA)
15 A Overhead
16 IGRO (power relay, galvanically isolated)
17 R TT (Start/Stop torch trigger)
18 Bridge (remote control detection)
19 Potentiometer
10-100kΩ
0V = IMIN
10V = IMAX
12
Remote control
2.3.3 19-pole analogue interface

2.3.3.1 19-pole TIG
If the machine is operated using control voltages, the connection should be made via isolating
amplifiers!
To control the main or secondary current via control voltages, the relevant inputs must be
enabled (activation of control voltage specification).
Figure 2-5
Pos. Pin Signal shape Designation
1 A Output Connection for cable screen (PE)
2 B/L Output Current flows signal I>0, galvanically isolated (max. +- 15V/100mA)
3 F Output Reference voltage for potentiometer 10V (max. 10mA)
4 C Input Control value specification for main current, 0-10V (0V = Imin, 10V = Imax)
5 D Input Control value specification for secondary current, 0-10V (0V = Imin, 10V
= Imax)
6 J/U Output Reference 0V
7 K Output Power supply +15V, max. 75mA
8 V Output Power supply -15V, max. 25mA
9 R Input Start/Stop welding current
10 S Input Switching between MMA and TIG welding
11 H Input Switching between main and secondary welding currents (pulses)
12 M/N/P Input Activation of control voltage specification
Set all 3 signals to reference potential 0V to activate external control
voltage specification for main and secondary currents
13 G Output Measured value ISETPOINT (1V = 100A)
13
Remote control
2.3.3.2 19-pole MIG/MAG

If the machine is operated using control voltages, the connection should be made via isolating
amplifiers!
To control the main or secondary current via control voltages, the relevant inputs must be
enabled (activation of control voltage specification).
A
1
B LED-A
2
C 3
+10V
D 0-10V
4
10K 10K
E 0V
5
F 6
BRT
A G 0-10V
M B 7
L N C H 8
LED-G
P
U
J 9
LED-D
K V D
R K 10
LED-E
T L CODE UP
J S E 11
H F
M 12
LED-B
G
N 13
LED-C
P 14
CODE DV
R 15
CODE US
S 16
BRT
T 17
LED-F
U 18
PP-Motor -
V 19
PP-Motor + M
Figure 2-6
Pos. Pin Signal shape Designation
1 A Connection for cable screen (PE)
2 B Output LED-A
3 C Input Reference voltage for potentiometer 10V (max. 10mA)
4 D Input DV-UP wire feed
5 E Output 0V
6 F Input TT
7 G Input Correction voltage (US-Down)
8 H Output LED-G
9 J Output LED-D
10 K Output LED-E
11 L Input Upslope coding (CODE UP)
12 M Output LED-B
13 N Output LED-C
14 P Input Wire feed setpoint value coding (CODE DV)
15 R Input Correction voltage coding (CODE US)
16 S Input TT
17 T Output LED-F
18 U Output PP motor -
19 V Output PP motor +
14
Remote control
2.4 Circuit diagrams

2.4.1 FR 30
15
Remote control
16
Remote control
2.4.2 FR35
2.4.3 FRA40
17
Remote control
2.4.4 FRP10
2.4.5 FRP15
18
Remote control
2.4.6 WELDON R10
19
Remote control
2.4.7 WELDON R40
20
Remote control
2.4.8 Manual remote control RT 1
21
Remote control
2.4.9 Manual remote control RT AC 1
1
?T
2
C1-
1 2
2n2F
X2-
A PE X1-
B T? T1.1? 1 T1?
C Poti IH T2.1? 2 T2?
D Poti Freq./Bal. T3.1? 3 T3?
E Freq./Bal. T4.1? 4 T4?
F Uref. 10V T5.1? 5 T5?
G T? T6.1? 6 T6?
H T? T7.1? 7 T7?
J 0V T8.1? 8 T8?
K +15V T9.1? 9 T9?
L T? T10.1? 10 T10?
M FR Typ1 T11.1? 11 T11?
N T? T12.1? 12 T12?
P FR Typ3 T13.1? 13 T13?
R T? T14.1? 14 T14?
S T? T15.1? 15 T15?
T T? T16.1? 16 T16?
U 0V T17.1? 17 T17?
V -15V T18.1? 18 T18?
22
Remote control
2.4.10 Manual remote control RT PWS 1
PE
RT PWS1
X1-
A PE
-
B ISAUS
P1- A
+
C IH S
D 0V
10k
E PWS E
F +10V
G ISUM
H AC-Frequenz
J 0V
K T?
L T?
M T?
N FR-Typ2
P T?
R T?
S T?
T T?
U T?
V T?
23
Remote control
X1-
A PE
B NC
C IH
1
D NC R2-
2
1k5
E PWS 2
S1-
F +10V
G NC A
- +
S
4
H
P1-
NC
S1
10k
J 0V 3
PWS
E
K NC 350A 150A
L
1
NC 4
R1-
12k
M NC S2-
N
2
FR-Typ2
P NC
R NC
S NC
T NC
U NC
V NC
RT PWS2
24
Remote control
25
Remote control
26
Remote control
27
Remote control
2.4.13 RTP 3 manual remote control
A PE X1-
B IGR0 X1/1
C Poti IH X1/2
D Poti I2 X1/3
E NC X1/4
F Uref. 10V X1/5
G Isoll X1/6
H Puls Freq. X1/7
J 0V X1/8
K +15V X1/9
L IGR0 X1/10
M FR Typ1 X1/11
N FR Typ2 X1/12
P FR Typ3 X1/13
R Str/Stp. X1/14
S WIG/Elek. X1/15
T NC X1/16
U 0V X1/17
V -15V X1/18
X5 X6
Elektrode-ein
WIG-aus
S2-
Elektrode/WIG
28
Remote control
2.5 Error
2.5.1 Fault detection/FAQ
Fault: Cause: Remedy:
29
Remote control
2.5.2 Returns note

Re. our delivery note no. ____________ of ____________
Please ensure that you use one returns note for each reason for return and for each item.
Returned by:
Customer number: Company:
Department/contact person:
Tel. no.: Address:
Fax. no.:
We are returning the following items:

Quanti Item number Type designation Serial number of the machine
ty
Reason for the return:

Incorrect delivery by EWM
(received with your com. no. ____________ or inv. no. ____________)
Correct delivery already ordered or received under com. no. ____________ or invoice no.
____________ of ____________.
Correct delivery still required no longer required
Incorrect delivery by sales partner
(received with your com. no. ____________ or inv. no. ____________)
Correct order will be/has been made
Yes No
Returned machines from demonstrations/trade fairs
Received under your com. no. ____________ or inv. no. ____________
Return discussed with your company with Ms/Mr ____________.
Repairs
with estimate without estimate warranty
Detailed description of fault:
____________________________________________________________________________________
____________________________________________________________________________________
Exchange processing
Replacement already ordered or received under com. no. ____________ or inv. no. ____________
of ____________.
Replacement still required
Other
____________________________________________________________________________________
____________________________________________________________________________________
30

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EWM

HIGHTEC WELDING GmbH

© 2007 Subject to alteration. Item No.:099-S000RC-EWM01 Revised: 08.01.2008

2.1.3 Integral C10 / Integral C10 HS

2.1.4 Integral C20

Not for MIG/TIG 450, 500

2.1.8 Integral SP11

3 19-pole connection socket (analogue)

2.2.2 Manual remote control R20

2.2.4 Manual remote control RT 1

2.2.5 Manual remote control RT AC 1

2.2.9 RTP 3 manual remote control

• Welding current infinitely adjustable

• Connection socket for additional remote control FR21, FR30

2.3.2 14-pole analogue interface (EB3)

2.3.3 19-pole analogue interface

2.3.3.2 19-pole MIG/MAG

2.4 Circuit diagrams

2.4.6 WELDON R10

2.4.7 WELDON R40

2.4.8 Manual remote control RT 1

2.4.9 Manual remote control RT AC 1

C Poti IH T2.1? 2 T2?

D Poti Freq./Bal. T3.1? 3 T3?

E Freq./Bal. T4.1? 4 T4?

F Uref. 10V T5.1? 5 T5?

K +15V T9.1? 9 T9?

M FR Typ1 T11.1? 11 T11?

P FR Typ3 T13.1? 13 T13?

V -15V T18.1? 18 T18?

2.4.10 Manual remote control RT PWS 1

2.4.11 Manual remote control RTP 1

2.4.12 Manual remote control RTP 2

2.4.13 RTP 3 manual remote control

2.5.2 Returns note

We are returning the following items:

Reason for the return:

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