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Rectifying faults

Checklist for rectifying faults

099-005607-EW501

20.11.2020

7.3 Checklist for rectifying faults

The correct machine equipment for the material and process gas in use is a fundamental

requirement for perfect operation!

Legend

Symbol

Description



Fault/Cause



Remedy

Functional errors



Mains fuse triggers - unsuitable mains fuse



Set up recommended mains fuse

> see 8 chapter



Machine does not start up after switching on (device fan and possibly coolant pump have no function).



Connect the control cable of the wire feeder.



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)



Machine restarts continuously



Wire feeder without function



System does 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 the contact tip and contact tip holder.

Collective interference signal light illuminates



Excess temperature, welding machine



Allow the machine to cool down whilst still switched on



Welding current monitoring device triggered (stray welding currents flowing across the protective e-

arth). The error must be reset by switching the machine off and on again.



Welding wire is touching electrically conductive casing parts (check wire guide, has the welding

wire sprung off the wire spool?).



Check for a correct mounting of the welding lead. Fit the feeder clamp of the welding lead as

close as possible to the arc.

Excess temperature signal light illuminates



Excess temperature, welding machine



Allow the machine to cool down whilst still switched on

Coolant error/no coolant flowing



Insufficient coolant flow





Check coolant level and refill if necessary





Air in the coolant circuit



Vent coolant circuit

> see 7.4 chapter

Содержание Poenix XQ 350 Plus D

Страница 1: ...Operating instructions EN Power source Titan XQ 400 AC puls D 099 005607 EW501 Observe additional system documents 20 11 2020...

Страница 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...

Страница 3: ...eneral 21 5 1 6 Welding torch cooling system 22 5 1 6 1 Functional characteristics 22 5 1 6 2 Permitted torch coolant 22 5 1 6 3 Maximal hose package length 22 5 1 6 4 Adding coolant 23 5 1 7 Notes on...

Страница 4: ...orch cooling 46 6 3 4 Power source inverter 47 6 3 5 Annual test inspection and testing during operation 48 6 4 Disposing of equipment 48 7 Rectifying faults 49 7 1 Error messages power source 49 7 2...

Страница 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...

Страница 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...

Страница 7: ...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 volta...

Страница 8: ...sion 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 ex...

Страница 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...

Страница 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...

Страница 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...

Страница 12: ...n solely with the following machines A suitable wire feed unit system component is required in order to operate the welding machine The following system components can be combined with this machine Dr...

Страница 13: ...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 WARN...

Страница 14: ...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...

Страница 15: ...sion stages of the device series XQ Type Figure Transport properties Torch cooling Wheel kit narrow track wit hout cylinder bracket Pallet bottom without cylinder bracket Wheel kit single cylinder bra...

Страница 16: ...uick overview Front view side view from the right 16 099 005607 EW501 20 11 2020 4 2 Front view side view from the right Figure 4 2 Item Symbol Description 0 1 WiFi antenna Factory fit option version...

Страница 17: ...h a foot lock 12 Inlet opening for cooling air torch cooling Dirt filter can be retrofitted 13 Wheels fixed castors 14 Lifting lug see 5 1 1 chapter 15 Intermediate hose package strain relief see 5 2...

Страница 18: ...ew side view from left 18 099 005607 EW501 20 11 2020 4 3 Rear view side view from left Figure 4 3 Item Symbol Description 0 1 Securing elements for shielding gas cylinder strap chain 2 Cooling air in...

Страница 19: ...ndividual mounting option for accessories and options 10 Intermediate hose package strain relief see 5 2 1 1 chapter 11 Mains connection cable see 5 1 10 chapter 12 Outlet opening cooling air torch co...

Страница 20: ...em component has to be lifted separately Remove any supply leads and accessories before lifting by crane e g hose package wire spool shielding gas cylinder toolbox wire feeder remote control etc Prope...

Страница 21: ...3 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...

Страница 22: ...in the machine adjustable depending on control system are stored for monitoring and control of the cooling system If the cooling system is faulty or overloaded an error message appears and the weldin...

Страница 23: ...lant in the coolant tank than the minimum required you may need to vent the coolant circuit In this case the welding machine will automatically shut down the coolant pump and signal an error see 7 4 c...

Страница 24: ...ith 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 interferences A...

Страница 25: ...lated surface when they are not in use Figure 5 6 5 1 9 Shielding gas supply shielding gas cylinder for welding machine WARNING Risk of injury due to improper handling of shielding gas cylinders Impro...

Страница 26: ...or 2 Output side of the pressure regulator 3 Shielding gas cylinder 4 Cylinder valve Before connecting the pressure regulator to the gas cylinder open the cylinder valve briefly to blow out any dirt T...

Страница 27: ...Item Designation Colour code L1 Outer conductor 1 brown L2 Outer conductor 2 black L3 Outer conductor 3 grey N Neutral conductor blue PE Protective conductor green yellow Insert mains plug of the swit...

Страница 28: ...the LED status bar Operating status white change light dark Booting switching on up to welding readiness blue Ready for welding blue change light dark Power saving mode Standby green Welding yellow Wa...

Страница 29: ...pole connection socket Wire feeder control cable connection 4 Intermediate hose package strain relief see 5 2 1 1 chapter 5 Connection socket welding current Standard MIG MAG welding intermediate hos...

Страница 30: ...t supply Some wire electrodes e g self shielding cored wire are welded using negative polarity In this case the welding current lead should be connected to the welding current socket and the workpiece...

Страница 31: ...ng current Workpiece lead connection 2 Workpiece Insert the plug on the workpiece lead into the welding current connection socket and lock Some wire electrodes e g self shielding cored wire are welded...

Страница 32: ...ush buttons to set the shielding gas The push button is generally found near a wire feeder Shielding gas flows for around 25 seconds or until the button is pressed again If the shielding gas setting i...

Страница 33: ...current connection at the rear of the unit Figure 5 14 Item Symbol Description 0 1 Welding torch 2 Wire feed unit 3 Intermediate hose package 4 DV1 14 pole connection socket Wire feeder control cable...

Страница 34: ...red to quick connect coupling red coolant return and supply line blue to quick connect coupling blue coolant supply 5 3 1 1 Intermediate hose package strain relief Property damage due to strain relief...

Страница 35: ...Connection socket welding current TIG welding Workpiece connection 2 Workpiece Insert the cable plug on the work piece lead into the welding current connection socket and lock by turning to the right...

Страница 36: ...kpiece 4 Electrode holder Insert the electrode holder plug and workpiece lead into the welding current socket depending on ap plication and lock in place by turning to the right The corresponding pola...

Страница 37: ...will not shut down Remove jumper 1 on the corresponding control board to be done only by qualified service personnel These accessory components can be retrofitted as an option see 9 chapter Pin Input...

Страница 38: ...between the PC and the welding machine The connection must only be made using the cables supplied do not use any additional ex tension cables PC300 Net welding parameter software Set all welding param...

Страница 39: ...welding parameters Recording documentation Monitoring of welding parameters Maintenance Calculations WPS management Welder management xButton management Component management The functionality of the s...

Страница 40: ...ne 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 mat...

Страница 41: ...EW501 20 11 2020 41 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 operat...

Страница 42: ...packages secured with strain relief Checking all supply lines and their connections pipes hoses hose packages for damage or leaks Checking the welding system for damage to the housing Transport eleme...

Страница 43: ...pressed air depending on the level of soiling Figure 6 1 Two dirt filters option for retrofitting can be installed on the machine One at the air inlet of the power unit inverter and one at the air inl...

Страница 44: ...ine and disconnect the mains plug Position a 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...

Страница 45: ...11 2020 45 Figure 6 5 Insert the cleaned filter screen into the filler neck and screw the drain plug with seal back into the tank Fill the tank with original EWM coolant up to the maximum level After...

Страница 46: ...the side panel Remove the side panel from the system lift up and sidewards Use only compressed air free of water and oil Do not blow on electronic components directly The ma chine fans may over rev du...

Страница 47: ...nnect the mains plug Remove the screws of the side panels and the grille at the rear Remove side panels lift up and to the side Remove louvre remove downwards and to the back Use only compressed air f...

Страница 48: ...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 was...

Страница 49: ...system the error with the lowest error number Err is displayed If this error is corrected the next higher error number appears This process is repeated until all errors have been resolved Categories l...

Страница 50: ...or defective Check fan clean or replace Air inlet or outlet blocked Check air inlet and outlet 32 Error I 0 3 Inform Service 33 Error UIST 3 Short circuit in welding circuit before welding Eliminate s...

Страница 51: ...overload of the wire drive slave drive Do not place the liner in tight radii check wire core for smooth movement 58 Short circuit Check welding circuit for short circuit Check welding circuit isolate...

Страница 52: ...The welding circuit inductance is too high for the selected welding task 10 Partial inverter One of several partial inverters is not supplying welding cur rent 11 Excess temperature coolant 3 Coolant...

Страница 53: ...eck that they are fitted correctly Loose welding current connections Tighten power connections on the torch and or on the workpiece Properly fasten the contact tip and contact tip holder Collective in...

Страница 54: ...ing 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 Clean core or spi...

Страница 55: ...g order Figure 7 3 Switch off machine at the main switch Disconnect mains plug Insert a plain slot screwdriver with a maximum tip width of 6 5 mm through the maintenance opening and place in the centr...

Страница 56: ...nsions l x b x h mm inch mm inch mm inch l 1152 45 3 854 33 6 854 33 6 b 686 27 0 590 23 2 400 15 7 h 976 38 4 976 38 4 881 34 7 Weight 1 kg lb kg lb kg lb F06W 128 5 283 2 118 3 260 8 103 3 227 7 F06...

Страница 57: ...5 l min 1 3 gal min 20 l min 5 2 gal min max delivery height 35 m 115 ft 45 m 148 ft Max pump pressure 3 5 bar 0 35 MPa 4 5 bar 0 45 MPa Pump Centrifugal pump Max tank capacity 8 l 2 1 gal Flow monito...

Страница 58: ...ass protection classification H IP 23 Residual current circuit breaker Type B recommended Noise level 5 70 dB A Ambient temperature 6 25 C to 40 C Machine cooling Torch cooling Fan AF gas or water Wor...

Страница 59: ...L 1 m Extension connecting cable 092 000201 00002 FRV 7POL 5 m Extension connecting cable 092 000201 00003 FRV 7POL 10 m Extension connecting cable 092 000201 00000 FRV 7POL 15M Extension connecting c...

Страница 60: ...pert XQ 2 0 with LAN Wi Fi gate way including interface for barcode scanner 092 003496 00000 OU 2DV Conversion kit for two wire feeders 092 003497 00000 OU AIF F06 Conversion kit 19 pole interface for...

Страница 61: ...ndix Searching for a dealer 099 005607 EW501 20 11 2020 61 10 Appendix 10 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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