Gas Management System EWR 3 Net
With the ABICOR BINZEL EWR 3 Net gas management system, you can reduce shielding gas consumption by up to 60 %. A precisely controlled gas flow consistently ensures optimum shielding gas coverage and a high-quality weld.
All information at a glance
Benefits of the EWR 3 Net gas management system
The EWR 3 Net is the next generation of the proven EWR 2 Net. It eliminates gas surges at the start of every process and supplies exactly the gas flow required for a high-quality weld. It also offers additional functions, easier process integration, and even better value for money.
The EWR 3 Net increases cost efficiency, ensures consistent weld quality, and reduces environmental impact.
Benefits at a glance:
- Up to 60 % lower shielding gas consumption thanks to an extremely fast solenoid valve
- MFC (Mass Flow Control) mode provides a precisely specified gas flow, independent of the characteristic curve, even with changing or fluctuating currents
- Only one shunt for all processes simplifies integration
- Consistent shielding gas coverage and reproducible weld quality
- Automatic compensation for fluctuations in gas inlet pressure or back pressure
- Process monitoring and documentation via the network connection
- No need to change the current measuring shunt when processes change
- No spare parts stock or accessories required
- Initial savings achievable with the basic configuration
- Easy integration into new and existing systems: ready to weld
Applications:
- Manual, mechanized, and automated GMAW processes
- Suitable for all types of shielding gases
- Gas inlet pressure range 1–6 bar
- Flow rate range 2–30 l/min
Avoid an unnecessarily high shielding gas supply, reduce your ongoing gas costs, and minimize the number of gas deliveries and the associated environmental impact. With the EWR gas management system, you create a solid foundation for safe and cost-effective welding processes.
Features of the EWR 3 Net
Precise gas control
The system controls gas flow much more precisely than conventional gas control systems and ensures a demand-based shielding gas supply.
Automatic compensation for interfering factors
Changing gas inlet pressures and back pressures in the cable assembly are automatically compensated.
Network-ready and designed for documentation
The EWR 3 Net can be integrated into the local network via Ethernet. This allows you to record, save, retrieve, and analyze process data.
MFC mode for maximum control
Mass Flow Control mode allows you to directly specify the gas flow required for the welding task. The EWR 3 Net keeps this value constant, independent of the stored characteristic curve.
One current measuring shunt for the entire current range
The EWR 3 Net is designed for welding currents from 50 A to 500 A. This means you only need one shunt type.
Service software as the ideal complement
Easily configure your EWR from a Windows PC. The software allows you to configure the system, activate MFC mode, monitor operating data, analyze errors, and select the gas type conveniently from your PC.
1. Button ON/OFF
2. Jack connector
3. Display
4. Gas input
5. Power supply
6. Shunt connection
7. Status LED
8. Cross button for device settings
9. Gas output
10. Ethernet interface
11. CANOpen interface
CANOpen interface:
The CANOpen interface allows the system to connect to any fieldbus system through an additional gateway and exchange data in real time.
Ethernet interface:
The Ethernet interface allows the EWR to be integrated into local networks for control and/or monitoring and connected to a higher-level control system. If required, the device can also be accessed using the optional ABICOR BINZEL service software.
All EWR devices feature a closed gas control loop, reducing deviations between the target and actual gas flow to a minimum. They are equipped with an integrated display and LED indicator, providing an easy overview of the current status and system parameters. Settings can be made directly on the device using the directional keypad. For easier and more convenient configuration, the EWR can be connected to a computer via a serial connection and used with the optional ABICOR BINZEL service software.
EWR calculator
Integrating another device into production process? Is it really worth it? An EWR gas management system can be integrated into your production process with little effort. The EWR calculator lets you check in advance whether it can save gas and reduce CO2 in your welding processes.
This calculator compares your current gas consumption with the potential gas savings achieved with the EWR. It also calculates your potential gas cost savings and monthly CO2 savings. You can then decide whether you would like to test this ABICOR BINZEL gas management system under your production conditions or order it directly from your welding technology distributor. Simply sign up and get started!
Important: These gas management systems are just as worthwhile for robotic welding as they are for manual welding. The results are equally impressive!
Technical data
| Operating voltage: | 24 V DC ± 20 % |
| Media temperature: | 10–40 °C |
| Ambient temperature: | -10 up to +50 °C |
| Relative humidity: | 20–90 % |
| Flow rate range: | 2–30 l/min* |
| Flow rate tolerance: | ± 1 l/min |
| For welding currents: | 50 A–500 A |
| Gas inlet pressure: | 1–6 bar |
Additional interfaces:
- Ethernet
- CANOpen
*Depending on the gas used and the inlet pressure, the device can also deliver gas flows exceeding 30 l/min. Whether the desired shielding gas flow can be achieved must be verified for the respective gas and setup at the applicable inlet pressure.
Like any company, we are always striving to reduce costs. [...] Then we found this [EWR 2] system. [...] And we were able to reduce gas consumption by 33 % right after the first run. [...] We are planning to continue with further testing, because we expect to achieve gas savings of up to 50 - 60 %. Furthermore, we also have an important effect for us, since our motto [...] is "For Earth, For Life", that we can thereby reduce CO2 emissions significantly.
Save gas and reduce costs
IGOR WELDER evaluates the gas-saving potential of manual welding using the EWR 2 from ABICOR BINZEL.
Service software
Easily configure your EWR using the ABICOR BINZEL service software. The optional tool runs on a standard Windows PC and supports the setup, configuration, monitoring, and analysis of your gas management system.
Your EWR 3 Net can be connected to a Windows PC directly via a serial connection or Ethernet.
Main functions at a glance:
- Configure and set up the EWR on a PC
- Select the characteristic curve and view settings
- Select and configure the gas type used
- Monitor operating status, error messages, and the error log
- Activate MFC mode and specify the required gas flow
- Determine gas savings using monitoring data
- Configure Ethernet settings for integration into a local network
Service software 2.10.0 (download)EWR calibration service
As with most lines that transport substances from one point to another, deposits can build up over time in gas supply lines and interfere with the gas flow. If dirt particles enter the EWR gas management system, they impair its function. To ensure a consistent gas flow, we recommend calibrating the EWR once a year. ABICOR BINZEL offers a calibration service for the EWR 3 Net gas management system.
Calibration helps ensure that all EWR 3 Net functions operate reliably. The calibration service also updates the device firmware, i.e., its software, to the latest version.
Request calibration service
You can easily request calibration for your EWR 3 Net gas management system, either through your welding technology distributor or directly through ABICOR BINZEL. Together with you, we can then determine whether the device should be sent in for calibration or whether on-site calibration service is preferred.
Good to know
On-site calibration takes an average of 15 minutes per gas management system. With regular, cost-effective calibration once a year, within three months before or three months after the previous calibration expires, the warranty is automatically extended to up to four years. You benefit twice: reliable function and a longer warranty.
Depending on the application and previous settings, the EWR gas management system can reduce shielding gas consumption by up to 60 %.
MFC stands for Mass Flow Control. In this mode, you specify the required gas flow directly. The EWR 3 Net regulates the gas flow to this target value, independent of welding current and characteristic curve.
The system can be integrated into virtually any standard GMAW process. It is suitable for manual, mechanized and automated applications.
Yes. After connecting the power supply and current measuring shunt, the basic parameters are configured. The system is designed for easy implementation.
The EWR 3 Net is designed for welding currents from 50 A to 500 A.
The service software can be used to view and analyze operating status, gas flow, inlet pressure, and stored error messages (error log), among other data.
An EWR can be connected directly via a serial connection. Access is also possible through an Ethernet network connection.
Depending on the operating conditions and potential savings, the EWR Net may pay for itself within the first year of use. The EWR calculator supports an initial assessment.