EWM Drive XQ IC D200 Operating Instructions Manual Download Page 1

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Operating instructions

Wire feed unit

Drive XQ IC D200

099-005637-EW501 Observe additional system documents!

27.04.2021

Summary of Contents for Drive XQ IC D200

Page 1: ...Operating instructions EN Wire feed unit Drive XQ IC D200 099 005637 EW501 Observe additional system documents 27 04 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 f...

Page 3: ...d torch coolant 19 5 1 3 2 Maximal hose package length 20 5 2 Intermediate hose package connection 21 5 2 1 Intermediate hose package strain relief 22 5 2 1 1 Locking the strain relief 22 5 2 2 Shield...

Page 4: ...ying faults 46 7 4 Vent coolant circuit 47 8 Technical data 48 8 1 Drive XQ IC 200 48 9 Accessories 49 9 1 General accessories 49 9 1 1 Welding torch cooling system 49 9 1 1 1 Coolant type blueCool 49...

Page 5: ...s 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 ope...

Page 6: ...tch 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 gr...

Page 7: ...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 Befo...

Page 8: ...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 excessi...

Page 9: ...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...

Page 10: ...placement 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...

Page 11: ...on 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 powe...

Page 12: ...y 3 3 1 Warranty For more information refer to the Warranty registration brochure supplied and our information regarding warranty maintenance and testing at www ewm group com 3 3 2 Declaration of Conf...

Page 13: ...id only in 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 gene...

Page 14: ...4 099 005637 EW501 27 04 2021 4 Machine description quick overview 4 1 Front view rear view The maximum possible machine configuration is given in the text description If necessary the optional connec...

Page 15: ...grated 4 Connection depending on the device version 5 19 pole connection socket optional For connecting analogue accessory components remote control control cable welding torch etc 6 Analogue gas volu...

Page 16: ...om left and right 16 099 005637 EW501 27 04 2021 4 2 Side view from left and right The maximum possible machine configuration is given in the text description If necessary the optional connection may...

Page 17: ...6 Power source welding current connector plug Welding current connection between power source and wire feeder 7 14 pole connection socket Wire feeder control cable 8 Connection thread G Shielding gas...

Page 18: ...ot 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 only The machine must not be suspended or lift...

Page 19: ...for suffi cient frost protection Replace coolant with insufficient frost protection if necessary Material damage due to unsuitable coolants Unsuitable coolant coolants mixed with other types liquids o...

Page 20: ...on is to be ensured taking into account the max delivery height Pump Pmax 3 5 bar 0 35 MPa Power source Hose package Wire feeder miniDrive Welding torch Max Compact 25 m 82 ft 5 m 16 ft 30 m 98 ft 20...

Page 21: ...der 8 Quick connect coupling blue coolant supply Secure hose package end with the strain relief see 5 2 1 chapter Push the welding current cable socket onto the welding current connecting plug and loc...

Page 22: ...hielding gas cylinder for welding machine WARNING Risk of injury due to improper handling of shielding gas cylinders Improper handling and insufficient securing of shielding gas cylinders can cause se...

Page 23: ...ure regulator Switch on the power source at the main switch Trigger gas test see 5 2 4 chapter function welding voltage and wire feed motor remain switched off no accidental arc ignition Set the relev...

Page 24: ...ces with HF igniter TIG for as long as pos sible in parallel with a distance of 20 cm to avoid HF sparkover Always keep a distance of at least 20 cm to leads of other power sources to avoid interferen...

Page 25: ...ire 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 tra...

Page 26: ...age and the torch hose package Observe maximal hose package length see 5 1 3 2 chapter When using a gas cooled welding torch use a hose bridge to establish the coolant cir cuit see 9 chapter Figure 5...

Page 27: ...h a guide tube for welding torches with steel liner Conver sion is necessary if a welding torch with a steel liner is used Operate welding torches with a liner with a guide tube Operate welding torche...

Page 28: ...ch 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 or protective caps closed during operation Risk of in...

Page 29: ...For fixing the wire spool 2 Knurled nut For fixing the wire spool Unlock and open protective flap Loosen knurled nut from spool holder Fix welding wire reel onto the spool holder so that the carrier p...

Page 30: ...r Fixing the clamping unit and setting the pressure 4 Clamping unit 5 Wire feed roller see the Wire feed roller overview table Rotate the tommy by 90 clockwise or anti clockwise tommy locks into place...

Page 31: ...ter Wire feed roll overview table Material Diameter Colour code Groove form mm inch Steel Stainless steel Brazing 0 6 024 monochrome light pink V groove 0 8 031 white 0 8 0 9 1 0 031 035 039 bicolour...

Page 32: ...et the contact pressure of the front rollers in wire feed direction to a higher value The inching speed is infinitely adjustable by simultaneously pressing the wire inching push button and turning the...

Page 33: ...can be found on a sticker near the wire drive Version 1 left hand mounting Version 2 right hand mounting Figure 5 16 Automatic inching stop Touch the welding torch against the workpiece during inching...

Page 34: ...r source Insert the central plug for the welding torch into the central connector and screw together with crown nut Insert the welding current plug of the combi welding torch into the welding current...

Page 35: ...ks options or retrofitting options see 9 chapter Figure 5 19 Item Symbol Description 0 1 Electrode holder or gouging torch 2 Connection socket for welding current optional Welding current potential of...

Page 36: ...switching JOB block operation P16 possible No change of special parameters except P10 Restart required 5 9 Interfaces for automation WARNING Do not carry out any unauthorised repairs or modifications...

Page 37: ...ification 0 V 10 V wire feed speed E Output Reference potential 0 V F S Input Welding power start stop S1 G Input Control voltage specification 0 V 10 V arc length correction P Input Activation of con...

Page 38: ...ce 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 s...

Page 39: ...rollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks Visual inspection Casing damage front rear and side walls Wheels and their securing elements Transport ele...

Page 40: ...r on wheels indicates that the equipment must be collected separately This machine has to be disposed of or recycled in accordance with the waste separation systems in use According to German law law...

Page 41: ...ed in succession Document machine warning and inform service personnel if required If there are several errors in a control system the error with the lowest error number Err is displayed If this error...

Page 42: ...oving 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...

Page 43: ...art 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 interr...

Page 44: ...ains voltage error Operating and mains voltage are incompatible Check or adjust operating and mains voltage 1 only for XQ machine series 2 not for XQ machine series 3 See technical data for values and...

Page 45: ...mperature warning Check coolant level and top up if necessary 21 Excess temperature 2 reserved 22 Excess temperature 3 reserved 23 Excess temperature 4 reserved 24 Coolant flow warning Check coolant s...

Page 46: ...oes not start up Make control lead connections and check that they are fitted correctly Loose welding current connections Tighten power connections on the torch and or on the workpiece Properly fasten...

Page 47: ...ed by overloading Reset triggered fuse rear of the power source by pressing the key button Kinked hose packages Extend and lay out the torch hose package Wire guide core or spiral is dirty or worn Cle...

Page 48: ...d roll equipment 1 0 1 2 mm for steel wire Drive 4 rollers 37 mm Wire spool diameter Standardised wire spools up to 200 mm Welding torch connection Euro torch connector protection classification IP 23...

Page 49: ...ol Frost protection tester 094 026477 00000 9 1 1 2 Coolant type KF Type Designation Item no KF 23E 5 Coolant up to 10 C 14 F 5 l 094 000530 00005 KF 23E 200 Coolant 10 C 200 litres 094 000530 00001 K...

Page 50: ...W D12 Retrofitting option Water cooling for the wire feeder 092 004180 00000 ON FLOWMETER Option analogue gas flow control with gas flow me ter 092 003374 00000 ON Handle ON TG D12 Retrofitting option...

Page 51: ...tainless steel and brazing 092 002770 00020 FE 4R 2 4 MM 0 095 INCH BROWN Drive roll set 37 mm 4 rolls V groove for steel stainless steel and brazing 092 002770 00024 FE 4R 2 8 MM 0 11 INCH LIGHT GREE...

Page 52: ...4 FUEL 4R 1 6 MM 0 06 INCH BLACK ORANGE Drive roll set 37 mm 4 rolls V groove knurled for flux cored wire 092 002848 00016 FUEL 4R 2 0 MM 0 08 INCH GREY ORANGE Drive roll set 37 mm 4 rolls V groove kn...

Page 53: ...ndix Searching for a dealer 099 005637 EW501 27 04 2021 53 11 Appendix 11 1 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners world...

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EWM Drive XQ IC D200, Operating Instructions Manual

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