EWM Cool XQ 40 Operating Instructions Manual Download

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Operating instructions

Power source

Tetrix XQ 230 puls DC Comfort 3.0

Tetrix XQ 230 puls AC/DC Comfort 3.0

Tetrix XQ 230 puls DC Expert 3.0

Tetrix XQ 230 puls AC/DC Expert 3.0

099-005630-EW501 Observe additional system documents!

02.03.2021

Summary of Contents for Cool XQ 40

Page 1: ...ns EN Power source Tetrix XQ 230 puls DC Comfort 3 0 Tetrix XQ 230 puls AC DC Comfort 3 0 Tetrix XQ 230 puls DC Expert 3 0 Tetrix XQ 230 puls AC DC Expert 3 0 099 005630 EW501 Observe additional system documents 02 03 2021 ...

Page 2: ... authorised sales partners can be found at www ewm group com en specialist dealers 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 ac cepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or...

Page 3: ...general 19 5 1 4 Transport belt 20 5 1 4 1 Adjusting the length of the carrying strap 20 5 1 5 Dirt filter 20 5 1 6 Welding torch cooling system 20 5 1 7 Notes on the installation of welding current leads 22 5 1 8 Stray welding currents 24 5 1 9 Mains connection 25 5 1 9 1 Mains configuration 25 5 1 10 LED status bar display of operating status 25 5 1 11 Protective flap welding machine control 26 ...

Page 4: ...g faults 41 7 2 Warnings 42 7 3 Error messages power source 44 7 4 Vent coolant circuit 48 8 Technical data 49 8 1 Dimensions and weighte 49 8 2 Tetrix XQ 230 puls DC 50 8 3 Tetrix XQ 230 puls AC DC 51 9 Accessories 52 9 1 General accessories 52 9 2 Remote controls and accessories 52 9 2 1 19 pole connection 52 9 2 2 Welding torch cooling system 52 9 2 2 1 Coolant type blueCool 52 9 2 2 2 Coolant ...

Page 5: ...Contents Notes on using these operating instructions 099 005630 EW501 02 03 2021 5 ...

Page 6: ...us and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning sym bol 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 warn ing symbol The risk i...

Page 7: ...itch off machine Release Switch on machine Press and hold Switch Incorrect Invalid Turn Correct Valid Numerical value adjustable Input Signal light lights up in green Navigation Signal light flashes green Output Signal light lights up in red Time representation e g wait 4 s ac tuate Signal light flashes red Interruption in the menu display other setting options possible Tool not required do not us...

Page 8: ... cal specialist may interconnect the sources as per standard IEC 60974 9 2010 Installa tion and use and German Accident Prevention Regulation BVG D1 formerly VBG 15 or country specific regulations Before commencing arc welding a test must verify that the equipment cannot exceed the maximum permitted open circuit voltage Only qualified personnel may connect the machine When taking individual power ...

Page 9: ...t temperatures of 100 C or higher and arcing and work on live components Hearing protection against harming noise 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 Fire hazard Due to the high ...

Page 10: ...ts 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 o...

Page 11: ...eplacement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the ma chine is switched off 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 ma...

Page 12: ...ion or connection points can heat up significantly during operation water cooled version When opening the coolant circuit escaping coolant may cause scalding Open the coolant circuit only when the power source or cooling unit is switched off Wear proper protective equipment protective gloves Seal open connections of the hose leads with suitable plugs The units are designed for operation in an upri...

Page 13: ...ent must only be used in line with its designated purpose and by trained or expert personnel Do not improperly modify or convert the equipment 3 1 Applications Arc welding machine for TIG DC and AC welding with lift arc touch starting or HF ignition contactless and MMA welding as secondary process It may be possible to expand the functionality by using acces sories see the documentation in the rel...

Page 14: ...th this marking can be used for welding in an environment with increased electrical hazard e g boilers For this purpose appropriate national or international regulations must be followed The power source must not be placed in the danger zone 3 3 4 Service documents spare parts and circuit diagrams WARNING Do not carry out any unauthorised repairs or modifications To avoid injury and equipment dama...

Page 15: ...n combination with all other parts of these instructions Read and observe the operating instructions for all system components especially the safety instructions The illustration shows a general example of a welding system Figure 3 1 Item Documentation A 1 Transport vehicle A 2 Power source A 3 Cooling unit A 4 Welding torch A 5 Remote control A 6 Control A Complete documentation ...

Page 16: ...Machine description quick overview Front view rear view 16 099 005630 EW501 02 03 2021 4 Machine description quick overview 4 1 Front view rear view Figure 4 1 ...

Page 17: ... chapter Transport belt see 5 1 4 chapter 8 Cable holder Option see 9 4 chapter 9 Connection socket 9 pole D Sub PC interface 10 Connection socket RJ45 Option Network connection see 5 6 chapter 11 Main Switch Switching the machine on or off 12 Mains connection cable see 5 1 9 chapter 13 Machine feet 14 Cooling air inlet 15 Connection thread G Shielding gas connection inlet 16 Connection socket 19 ...

Page 18: ...ct connection or power cables while the machine is switched off Read and observe the documentation to all system and accessory components 5 1 Transport and installation WARNING Risk of accident due to improper transport of machines that must not be lifted Do not lift or suspend the machine The machine can drop and cause injuries The handles straps or brackets are suitable for transport by hand onl...

Page 19: ... 1 2 Transport and storage Storage in a closed room temperature range of the ambient air 30 C to 70 C 22 F to 158 F 1 Relative humidity up to 90 at 20 C 68 F 1 Ambient temperature dependent on coolant Observe the coolant temperature range of the torch coo ling 5 1 2 Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Ke...

Page 20: ...is reduced as a result The duty cycle decreases with the increasing contamination of the filter The dirt filter must be remove at regular intervals and cleaned by blowing out with compressed air depending on the level of soiling see 6 3 2 chapter 5 1 6 Welding torch cooling system WARNING Risk of accidents due to improperly connected modules Improperly installed modules may come loose and cause se...

Page 21: ...esign allows the power source to be retrofitted with a cooling unit for liquid torch cooling For information about connection and installation see the documentation for the cooling unit Figure 5 3 1 Switch off the power source and disconnect the mains plug 2 Place the power source to the side ...

Page 22: ... the cooling unit Secure the cooling unit and power source with all four Torx screws M5 x 14 mm 8 Fill in the coolant see 5 1 6 chapter For further information on installing the machine video scan the QR code on the information sticker if necessary 5 1 7 Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc flickering Lay the wor...

Page 23: ... 23 Use an individual welding lead to the workpiece for each welding machine Figure 5 5 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Always keep leads as short as possible Lay any excess cable lengths in meanders Figure 5 6 ...

Page 24: ...Check that all welding current connections are firmly secured and electrical connections are in perfect condition Set up attach or suspend all conductive power source components such as casing trans port vehicles and crane frames so they are insulated Do not place any other electronic devices such as drills or angle grinders on the power source transport vehicle or crane frames unless they are ins...

Page 25: ... earthed as stipulated in the operating in structions The network created must be suitable for operating machines according to pro tection class I 5 1 9 1 Mains configuration The machine may only be connected to a one phase system with two conductors and an earthed neutral conductor Figure 5 8 Legend Item Designation Colour code L Outer conductor brown N Neutral conductor blue PE Protective conduc...

Page 26: ... from top 5 1 12 Wear part compartment The transport handles in this machine series have a wear part compartment for stowing typical wear parts such as gas nozzles and electrodes The compartment closes with a transparent plastic flap Figure 5 10 5 2 TIG welding 5 2 1 Welding torch and workpiece line connection Prepare welding torch according to the welding task in hand see operating instructions f...

Page 27: ...le or reverse cooling unit 5 2 1 1 Control lead connection All standard 5 and 8 pin TIG welding torches can be connected to this machine and operated except for 8 pin potentiometer torches 5 pin EWM function torches with X TECHNOLOGIE are also supposed Figure 5 12 5 2 2 Shielding gas supply shielding gas cylinder for welding machine WARNING Risk of injury due to improper handling of shielding gas ...

Page 28: ... cylinder 4 Cylinder valve Before connecting the pressure regulator to the gas cylinder open the cylinder valve briefly to blow out any dirt Tighten the pressure regulator screw connection on the gas bottle valve to be gas tight Screw the gas hose connection to the outlet side of the pressure regulator gas tight 5 2 2 2 Shielding gas hose connection Figure 5 14 Item Symbol Description 0 1 Connecti...

Page 29: ... lock in place by turning to the right The corresponding polarity will be based on the infor mation of the electrode manufacturer on the electrode packaging 5 4 Remote control The remote controls are operated on the 19 pole remote control connection socket analogue 5 4 1 RT1 19POL Functions Infinitely adjustable welding current 0 to 100 depending on the preselected main current on the welding mach...

Page 30: ...be enabled see specification for activation of control voltage 5 5 1 Remote control connection socket 19 pole Figure 5 16 Pin Signal form Name A Output Connection for cable screen PE B L Output Current flowing signal I 0 potential free max 15 V 100 mA F Output Reference voltage for potentiometer 10 V max 10 mA C Input Control voltage specification for main current 0 10 V 0V Imin 10 V Imax J U Outp...

Page 31: ... welding parameters Recording documentation Monitoring of welding parameters Maintenance Calculations WPS management Welder management xButton management Component management The functionality of the software is in constant development see the documentation for Xnet The welding machines are delivered with a fixed factory set IP address printed on a sticker attached to the control unit or for machi...

Page 32: ...ine must not be operated again until it has been repaired and a new test has been carried out As a rule contact your specialised dealer i e the supplier of the machine with respect to all servicing matters Any return deliveries in the case of warranty claims can be made via your specialised dealer only Only use original spare parts to replace any part When ordering a spare part always specify the ...

Page 33: ... EW501 02 03 2021 33 6 2 Explanation of icons Person Welder operator Service staff expert qualified person Test Visual inspection Functional check Period interval One shift operation Multi shift operation every 8 hours Daily Weekly Monthly Every 6 months Annually ...

Page 34: ...nd their connections pipes hoses hose packages for damage or leaks Checking the welding system for damage to the housing Transport elements strap lifting eyes handle wheels parking brake corresponding safety elements if necessary fuse caps are present and flawless Cleaning connections of coolant pipes quick connect coupling connections from impurities and install protective caps when not in use Ga...

Page 35: ... suitable collecting container under the drain plug of the coolant tank Unscrew the drain plug of the coolant tank remove the tank cap to ventilate Figure 6 2 Wait until the coolant has run out of the tank into the collection container Remove the filter screen from the filler neck and clean Then rinse the dirt out of the tank with water Follow official regulations on disposal ...

Page 36: ...eal back into the tank Fill the tank with original EWM coolant up to the maximum level After filling refit the tank cap and vent the coolant circuit see 7 4 chapter 6 3 2 Dirt filter Figure 6 4 Remove the dirt filter and blow out with compressed air free of oil and water After cleaning reassemble in reverse order Follow the official regulations for the disposal of dirt residues ...

Page 37: ...alist staff Observe warnings and maintenance instructions at the beginning of this chapter Figure 6 5 Switch off the machine and disconnect the mains plug Remove the screws of the side panels Re move side panels fold out sideways at the bottom and pull out downwards Disconnect all four mains leads 6 3 mm flat pin terminals from the main switch Figure 6 6 Disconnect the plugs of the supply lines to...

Page 38: ... rotate due to the compressed air and be damaged as a result Blow out the inverter through both fan openings from the back to the front with compressed air free of oil and water Do not blow directly towards external electronic components Follow the official regulations for the disposal of dirt residues Figure 6 8 Push the machine fan back in note the installation direction Reconnect the plugs of t...

Page 39: ...r the following maintenance steps to avoid inju ries This maintenance step may only be carried out by trained and authorized specialist staff Observe warnings and maintenance instructions at the beginning of this chapter Figure 6 10 Switch off the machine and disconnect the mains plug Remove the screws of the side panels Re move side panels fold out sideways at the bottom and pull out downwards Cl...

Page 40: ...serve the local regulations regarding disposal According to European provisions Directive 2012 19 EU on Waste of Electrical and Electronic Equipment 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 has to b...

Page 41: ...ers cannot be set machines with access block Entry level is blocked disable access lock All machine control signal lights are illuminated after switching on No machine control signal light is illuminated after switching on No welding power Phase failure check mains connection fuses Connection problems Make control lead connections and check that they are fitted correctly Welding torch overheated L...

Page 42: ...orresponding warning number see table In case of multiple warnings these are displayed in sequence Document machine warning and inform service personnel if required Warning Possible cause remedy 1 Excess temperature A shutdown is imminent due to excess temperature 2 Half wave failures Check process parameters 3 Welding torch cooling warning Check coolant level and top up if necessary 4 Shielding g...

Page 43: ...wire 2 reserved 30 Low wire 3 reserved 31 Low wire 4 reserved 32 Tacho error Fault of wire feeder permanent overload of the wire drive 33 Wire feed motor excess current Excess current detected on wire feed motor 34 JOB unknown JOB selection was not performed because the JOB number is unknown 35 Wire feed motor slave excess current Excess current detected on wire feed motor slave push push system o...

Page 44: ...Err is displayed If this error is corrected the next higher error number appears This process is repeated until all errors have been resolved Reset error category legend A The error message disappears when the error is eliminated B The error message can be reset by pressing a push button All other error messages can only be reset by switching the machine off and on again Error category Possible ca...

Page 45: ...moving the logical signal ro bot ready during the process Eliminate errors on the higher level control 16 A General pilot arc Emergency stop circuit error Check emergency stop circuit Temperature error See description of error 4 Short circuit on welding torch Check welding torch Request service 17 B Cold wire error See description of error 3 See description of error 3 18 B Plasma gas error Low gas...

Page 46: ...tart au tomated machines Check wire feeding Check load cable connections in welding current circuit clean corroded surfaces on work piece before welding if necessary 49 B Arc interruption An arc interruption occurred during welding with an automa ted system Check wire feeding Adjust welding speed 50 B Program number Internal error Request service 51 A Emergency stop The emergency stop circuit of t...

Page 47: ...nt circuit Place welding torch on an insulated surface 59 Incompatible machine A machine connected to the system is not compatible Disconnect incompatible machine from system 60 Incompatible software A machine s software is not compatible Request service 61 Welding monitor The actual value of a welding parameter is outside the spe cified tolerance field Observe tolerance fields Adjust welding para...

Page 48: ...g with a suitable tool connection open 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 Figure 7 2 Position a suitable collection container for collecting the escaping coolant at the quick connect coup ling and switch on the machine for approx 5s Lock the quick connect coupling by pushing back the loc...

Page 49: ...Performance specifications and guarantee only in connection with original spare and replacement parts 8 1 Dimensions and weighte Tetrix XQ 230 puls DC Tetrix XQ 230 puls AC DC Dimensions l x b x h mm inch b1 257 10 1 b2 224 8 8 l 550 21 7 h 415 16 3 Weight kg lb kg lb 17 5 38 6 19 2 42 3 ...

Page 50: ...category Ⅰ Ⅲ Contamination level 3 Insulation class protection classification H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 4 25 C to 40 C Machine cooling Torch cooling Fan AF gas Mains connection cable H07RN F3G2 5 Workpiece lead min 35 mm2 EMC class A Safety marking Standards used See declaration of conformity appliance documents 1 Load cyc...

Page 51: ...ge category Ⅰ Ⅲ Contamination level 3 Insulation class protection classification H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 4 25 C to 40 C Machine cooling Torch cooling Fan AF gas Mains connection cable H07RN F3G2 5 Workpiece lead min 35 mm2 EMC class A Safety marking Standards used See declaration of conformity appliance documents 1 Load ...

Page 52: ...7 00000 9 2 2 Welding torch cooling system Type Designation Item no Cool XQ 40 Cooling unit 090 005632 00000 Cool XQ 40 MV Cooling unit 090 005633 00000 ON Water Filter K 0006 Optional water filter 092 004024 00000 HOSE BRIDGE UNI Tube bridge 092 007843 00000 9 2 2 1 Coolant type blueCool Type Designation Item no blueCool 10 5 l Coolant up to 10 C 14 F 5 l 094 024141 00005 blueCool 10 25 l Coolant...

Page 53: ...01 02 03 2021 53 9 4 Options Type Designation Item no ON TS TG 11 Torch holder 092 004054 00000 ON Filter TG 11 K 06 Dirt filter for air inlet 092 004056 00000 ON CC TG 11 Transparent cover cap for protection of control 092 004057 00000 ...

Page 54: ...endix Searching for a dealer 54 099 005630 EW501 02 03 2021 10 Appendix 10 1 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide ...

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