
EWELCON
Welding Machine
CAW04
Operating instructions
BA/0499
BRUGG Rohrsysteme GmbH ·- Adolf-Oesterheld-Str. 31 - D-31515 Wunstorf
Tel.: +49 (0) 5031 170-0
Fax: +49 (0) 5031 170-170
e-mail: info@brugg.de
page 1 of 11
This operating manual serves as a reference for trained technicians.
It does not substitute proper training.
Contents
1
2
Technical data, performance data, weight, power requirement
Safety, important safety information - compulsory reading for all
operators
3
3
3
Functions, welding machine description and functions
5
4
Operation, operator controls, using welding outfit and analyzer
software, trouble shooting
5
5
Catalog of spare parts, connecting cable and fuses
11
6
Maintenance, connecting cable check, trouble shooting
11
7
Transport and storage: what to observe when transporting and storing
welding outfit
11
8
Decommissioning: regulations and information on the
decommissioning of this welding machine
11
- Specifications subject to change -
BRUGG Rohrsysteme GmbH ·- Adolf-Oesterheld-Str. 31 - D-31515 Wunstorf
Tel.: +49 (0) 5031 170-0
Fax: +49 (0) 5031 170-170
e-mail: info@brugg.de
page 2 of 11
1
Technical data
Power supply:
230V 50Hz max. 3kVA
Initial fuse
16A
Equipment grounding conductor must be connected properly!
Clear sinusoidal voltage is essential whenever the welding machine is
powered by a generator!
General specifications:
Initial value:
2
weight: approximately 16 kg:
dimensions: 350 x 250 x 250 mm (H x W x L)
max. 52V 50Hz 50A
Important safety information
Only use manufacturer-approved joints when operating this equipment. Operators
must observe equipment technical data and this operating manual as well as use
genuine spare-parts and accessories. Do not use this equipment for purposes not
designated in this instruction manual. Improper use or handling releases the
manufacturer of any and all liability.
To ensure that the internal safety features are fully enabled, ensure that the
equipment is adequately grounded. The operator is responsible for ensuring that the
joint connections do not fall off. Contact with the output terminal during welding
procedures can lead to serious injury.
Any form of manipulation or removal of protective features is prohibited.
In addition to the operating and safety rules in this manual, the operator must
observe all statutory and otherwise binding safety and environmental regulations.
These regulations can, for example, pertain to the handling of hazardous substances
or the availability of/the wearing of protective gear.
Always check the operative features of all safety fixtures after servicing or
maintenance.
The operator must ensure that mains supply is conform with the specifications listed
under chapter 1. All supply lines must match outlet terminal.
Only use the genuine spare parts listed in this manual.
BRUGG Rohrsysteme GmbH ·- Adolf-Oesterheld-Str. 31 - D-31515 Wunstorf
Tel.: +49 (0) 5031 170-0
Fax: +49 (0) 5031 170-170
e-mail: info@brugg.de
page 3 of 11
Equipment modifications, i.e. extensions and refitting, that could in any way affect
the safety features are subject to prior understanding with BRUGG and require the
manufacturer’s expressed written approval.
The manufacturer is responsible for product safety; with the acceptance of this unit
particular responsibilities devolve upon the person or company in charge of
operation.
The manufacturer monitors his product beyond delivery to the person or company in
charge of operation. He can request information, in particular on safety aspects,
from the latter.
The person or company in charge of operation must ensure that only authorized
personnel operate the welding machine. He is responsible for the thorough and
comprehensive training of all machine operators. This liability also pertains to
general and occasional workers.
The spheres of responsibility pertaining to all operational procedures, in particular
commissioning, operation, cleaning and maintenance must be distinctly defined and
observed so that competencies are always understandably regulated.
The person or company in charge of operation must ensure that his personnel
always operates the welding unit in accordance with this operating manual. He will
provide the operators with all safety relevant resources stated in this manual.
Danger signs are to be kept in a legible condition at all times.
The welding machine must be kept and operated in perfect condition. Maintenance
intervals must be observed. The shop must be equipped with the tools required to
carry out maintenance, service and repair procedures.
Should operational hazards or risks arise that have not been described in this
manual, the person or company in charge of the operation of the welding machine
undertakes to inform BRUGG of such hazards or risks.
The obligations of the person or company in charge of operation extend to operating
personnel, to the extent that the latter is responsible to immediately inform superiors
of defects that impair safety.
This operating manual must be available at the workplace at all times and in the
respective national language(s).
Individual trade and indemnity associations also require the person or company in
charge of operation to train those workers with a poor command of the national language in their native language. In this case the safety regulations and information
contained in this manual must be translated into the respective language.
BRUGG Rohrsysteme GmbH ·- Adolf-Oesterheld-Str. 31 - D-31515 Wunstorf
Tel.: +49 (0) 5031 170-0
Fax: +49 (0) 5031 170-170
e-mail: info@brugg.de
page 4 of 11
3
Functions
This welding machine is a computer-controlled high-performance power unit. The
power released is calculated by a variety of measuring procedures and set
automatically.
Before welding procedures begins the computer requests joint- and work-specific
data that will be save for later documentation. This data has no influence on program
execution or on the heating of the welding rod. All necessary sizes are measured or
calculated during welding procedures. The power is then adjusted to the values
read.
Under consideration of the maximum permissible current the heat conductor
temperature is raised to the setpoint. The heat conductor then kept at maximum
temperature until the unit reaches the weld pool temperature. As soon as the weld
pool temperature reaches the setpoint the power transfer is cut off.
In the course of welding the heat conductor and weld pool temperatures as well as
welding time are stored for later analysis. The integrated memory chip can archive
up to 200 welding operations. When the chip reaches its memory capacity it issues
a warning that the processor will begin to overwrite the oldest data to accommodate
new incoming data (FIFO overwrite memory).
The welding machine comes with DOS software for the analysis of the collected
data. Welding data can be transferred from the CAW04 via a serial interface to an
IBM-compatible PC for further processing. Upon successful data transmission the
allocated memory space can be re-enabled.
4
Operation and controls
Controls, operation of the machine and the evaluation software, troubleshooting list.
The connections for the power supply, joint and temperature sensor are accessed
by opening the machine. In this state steps must be taken to protect the connections
against water in wet weather.
The control panel and LCD display are then also visible.
Switching on/off
The machine is switched on with the ON key and off with the OFF key. Immediately
after switching off the machine it is only possible to switch it back on again after one
to three seconds to protect the electronics.
Switching the machine off during a welding process leads to the loss of the welding
data.
BRUGG Rohrsysteme GmbH ·- Adolf-Oesterheld-Str. 31 - D-31515 Wunstorf
Tel.: +49 (0) 5031 170-0
Fax: +49 (0) 5031 170-170
e-mail: info@brugg.de
page 5 of 11
Before welding
At the beginning of a day all joint and building-site-specific data has to be entered
into the machine. For all welding processes on the same day it is then only still
necessary to specify the joint number and, if necessary, the welding section. All the
other data only has to be confirmed with OK and can be changed, if necessary, after
pressing the C key.
Control panel of the CAW 04
BRUGG Rohrsysteme GmbH ·- Adolf-Oesterheld-Str. 31 - D-31515 Wunstorf
Tel.: +49 (0) 5031 170-0
Fax: +49 (0) 5031 170-170
e-mail: info@brugg.de
page 6 of 11
Key functions:
ON/OFF
0..9
A
E
C
OK
R
Used to switch the machine on and off
Numeric keys to enter joint and building-site-specific data
Display of measured values
Enter – confirmation of inputs
Clear – changing of defined values and deletion of error messages
Confirmation of defined values
Return – switches within the queries one query back or within the input
of joint-specific values one point back
Starts the welding process
START
Sequence
Action
Display
No./Remarks
ON key
CAW04 V1.0
1. The machine carries out a RESET and
checks the power supply and internal
temperature.
CAW04 V1.0
<Date> <Time>
2. The machine is ready. If a weld pool sensor
is connected, the temperature can be
queried by pressing the A key.
PIN old:000
PIN new:___
3. Query of the operator's PIN number. The
inputs can only be confirmed with E when
all the digits required have been entered
completely, e.g. the PIN no. 1 must be
entered as 001.
OK
PIN old:000
PIN new:001
Proj. no. old:0000
Proj. no. new:____
Joint no.:
DN old: 0000
DN new:____
4. Confirm input with E.
5. Input of the project number (four-digit).
Confirm with E after input of the last digit,
e.g.: 1234.
6. Input of the joint number (four-digit),
e.g.: 5678.
7. Input of the nominal diameter (four-digit),
e.g.: 0315.
BRUGG Rohrsysteme GmbH ·- Adolf-Oesterheld-Str. 31 - D-31515 Wunstorf
Tel.: +49 (0) 5031 170-0
Fax: +49 (0) 5031 170-170
e-mail: info@brugg.de
page 7 of 11
Width old: 0000
Width new:____
OK
A
Welding section:_
9. Input of the welding section (one-digit).
This question is only asked in the case of
a correspondingly large joint, e.g.: 1.
Data: 1 001/1234
5678/0315/0700/1
10. Summary of the data entered.
The order: data record no./PIN/project
no./joint no./DN/width/welding section.
Should a value be incorrect, it is possible to
move to the point with the R key and
change the value with the C key.
Machine ready
Press the START key
START
8. Input of the width (four-digit), e.g.: 0700.
11. The machine is ready for welding.
Welding running
12. The machine begins to check the
connected joint.
Welding running
13. As soon as the welding time 00:01 is
shown, the power transfer begins. The
heating wire is heated.
Welding running
047 00:01
14. The weld pool temperature can be
queried during welding with the key A. The
key A must be pressed until the value is
shown. The value shown is the last weld
pool temperature saved. It is, therefore,
possible that the same value is shown
twice one after the other if there has been
no significant change.
Welding
finished
150/04:50
15. The end of the welding process is
indicated by this display and an acoustic
signal.
Shows the weld pool temperature and
welding time.
The inputs 3 to 8 described above are then proposed for the following welding
processes of the day with the exception of the joint number. The proposed values
can be changed by pressing the key C. If the values are to be taken over for the next
welding process, it is only necessary to press OK.
BRUGG Rohrsysteme GmbH ·- Adolf-Oesterheld-Str. 31 - D-31515 Wunstorf
Tel.: +49 (0) 5031 170-0
Fax: +49 (0) 5031 170-170
e-mail: info@brugg.de
page 8 of 11
Error messages
Should errors occur before or during the welding process, they are shown with an
error number and error text. A buzzer alarm is also sounded. The buzzer can be
switched off with the key C. Renewed pressing of the key C deletes the error
message. The error messages and their meaning are described in the following list.
01: Overtemperature
The machine is too hot. Place the machine without connection of a joint in the shade
and switch it on. The integrated fan sees to the dissipation of the heat via the
housing.
02: Undertemperature
The machine is too cold. Either heat the machine in a heated room or switch it on
with a connected joint. The machine will heat up slowly. Under no circumstances
may the machine be heated with a radiant heater or similar.
03: Low supply voltage
The voltage of the mains power supply is too low as a result of excessively long
cables.
04: Welding time exceeded
Occurs when attempting to weld excessively large joints or when the ambient
temperature is too low. It is also possible that the connections of the joint are dirty.
05: Data transfer fault
A fault has occurred during data transfer. This can occur when attempting to transfer
the data near a source of interference, e.g. a welding machine.
20: Short-circuit at joint
The cables to connect the joint have shorted.
21: Joint too large
The machine has attempted to weld the joint. However, it was already established at
the beginning of power transfer that the power available is inadequate. It is possible
that the welding section selected is too large or the connections are dirty.
22: Joint too large
The measurement before power transfer has shown that the joint is too large. Check
the size of the joint section selected and the connections. Then reattempt to weld.
The joint has not yet been heated.
23: Check joint connection
The resistance measured is much too high. Either a joint has not yet been
connected or the connection cables have come loose. Welding can be resumed
when the fault has been corrected. The joint has not yet been heated.
24: Joint too cold
The joint is colder than 0°C.
BRUGG Rohrsysteme GmbH ·- Adolf-Oesterheld-Str. 31 - D-31515 Wunstorf
Tel.: +49 (0) 5031 170-0
Fax: +49 (0) 5031 170-170
e-mail: info@brugg.de
page 9 of 11
25: Joint too warm
The joint is warmer than 35°C.
26: Check sensor connection
The weld pool sensor has not yet been connected.
27: Short-circuit at joint
A short-circuit occurred at the joint during welding. Correct the fault and allow the
joint to cool down. Then welding process can then be resumed.
28 to 32: Measurement TWP faulty
The weld pool temperature could not be measuring during welding. Either the
sensor cable has fallen off or the weld pool sensor is faulty. The joint must cool down
before welding is resumed.
28: Measurement TWP faulty
The weld pool temperature measured is outside the tolerance limits. A possible
source of interference is, for example, a welding machine in the vicinity.
29: Measurement TWP faulty
The sensor cable has fallen off or the sensor is broken.
30: Measurement TWP faulty
The weld pool temperature has dropped excessively. An excessively low ambient
temperature can be responsible for this.
31: Measurement TWP faulty
The weld pool temperature is much too low. A possible cause is a short-circuit in the
sensor cables.
32: Measurement TWP faulty
The weld pool temperature is lower than 0°C.
33: Measurement faulty
The resistance of the joint can no longer be measured during the welding process. It
is possible that the cables have fallen off.
34: Measurement faulty
An error occurred during the measurement. External sources of interference can be
responsible for this.
35: Measurement faulty
The joint resistance is lower than permitted. Moisture or similar can be responsible
for this.
39: Check sensor connection
BRUGG Rohrsysteme GmbH ·- Adolf-Oesterheld-Str. 31 - D-31515 Wunstorf
Tel.: +49 (0) 5031 170-0
Fax: +49 (0) 5031 170-170
e-mail: info@brugg.de
page 10 of 11
After a certain welding time the weld pool temperature has not risen to the extent
expected. It is possible that a temperature sensor not belonging to the welding
section has been connected.
5
Spare-parts catalog
Fine-wire fuse (6.3 x 32 mm, 16A/250V)
delayed-action
Thermal cable (TK01, 4 m long)
Connection cable (AK01, 2 m long)
Welding cable set (SK01, set of 2, each 4 m)
Data transmission line (2 m long)
6
Available in retail shops
Stock no. 83100191
Stock no. 83100192
Stock no. 83100193
Stock no. 83100194
Maintenance
The welding machine must be sent in annually for maintenance to BRUGG.
7
Transport and storage
The unit must be stored in a warm, dry area. Protect the unit against shock while in
transport, e.g. non-slip foam-rubber pad. The machine must be properly secured at
all times during transport (tension belts).
8
Decommissioning
The welding machine must be returned to BRUGG for proper decommissioning.
BRUGG Rohrsysteme GmbH ·- Adolf-Oesterheld-Str. 31 - D-31515 Wunstorf
Tel.: +49 (0) 5031 170-0
Fax: +49 (0) 5031 170-170
e-mail: info@brugg.de
page 11 of 11