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Design and function

Transport and installation

26

099-005674-EW501

28.06.2022

5.1.8 Stray welding currents

WARNING

Risk of injury due to stray welding currents!

Stray welding currents can destroy protective earth conductors, damage machines and

electronic devices and cause overheating of components, leading to fire.

• 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 insulated.

• Always put welding torches and electrode holders on an insulated surface when they are

not in use.

Figure 5-6

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Содержание Tetrix XQ 350 AC/DC puls

Страница 1: ...Operating instructions EN Power source Tetrix XQ 350 AC DC puls Tetrix XQ 400 AC DC puls Tetrix XQ 500 AC DC puls 099 005674 EW501 Observe additional system documents 28 06 2022 ...

Страница 2: ... 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 not these instructions or the conditions and methods are observed during installation operation usag...

Страница 3: ... 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 23 5 1 6 4 Adding coolant 24 5 1 7 Notes on the installation of welding current leads 25 5 1 8 Stray welding currents 26 5 1 9 Mains connection 27 5 1 9 1 Mains configuration 27 5 1 10 Switching on and system diagnosis 27 5 1 10 1 LED status bar display of o...

Страница 4: ...ent coolant circuit 55 7 5 Fixing the pump shaft coolant circuit 56 8 Technical data 57 8 1 Dimensions and weighte 57 8 1 1 Welding torch cooling system 57 8 2 Performance data 58 8 2 1 Tetrix XQ 350 puls AC DC 58 8 2 2 Tetrix XQ 400 puls AC DC 59 8 2 3 Tetrix XQ 500 puls AC DC 60 9 Accessories 61 9 1 Welding torch cooling system 61 9 1 1 Coolant type blueCool 61 9 1 2 Coolant type KF 61 9 2 Remot...

Страница 5: ...Contents Notes on using these operating instructions 099 005674 EW501 28 06 2022 5 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 13: ... of Conformity This product corresponds in its design and construction to the EU directives listed in the decla ration The product comes with a relevant declaration of conformity in the original The manufacturer recommends carrying out the safety inspection according to national and in ternational standards and guidelines every 12 months 3 2 3 Welding in environments with increased electrical haza...

Страница 14: ...on and valid 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 general example of a welding system Figure 3 1 Item Documentation A 1 Power source A 2 Remote control A 3 Control A 4 Welding torch A Complete documentation ...

Страница 15: ...nsion 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 cket Wheel kit double cylinder bra cket Gas Water coolant Water coolant reinforced pump F06 R1 G F06 R1 W F06 R1 WRF F06 R2 G F06 R2 W F06 R2 WRF F06 RS G F06 RS W F06 RS WRF F06 P G F06 P W F06 P W...

Страница 16: ...Machine description quick overview Front view side view from the right 16 099 005674 EW501 28 06 2022 4 2 Front view side view from the right Figure 4 2 ...

Страница 17: ...Dirt filter can be retrofitted 13 Wheels fixed castors 14 Lifting lug see 5 1 1 chapter 15 Intermediate hose package strain relief 16 Aluminium extrusion profile flexFit Individual mounting option for accessories and options 17 Quick connect coupling red coolant return 18 Quick connect coupling blue coolant supply 19 Connection socket welding current How to connect the accessories depends on the w...

Страница 18: ...Machine description quick overview Rear view side view from left 18 099 005674 EW501 28 06 2022 4 3 Rear view side view from left Figure 4 3 ...

Страница 19: ...0 Service opening for coolant pump see 7 5 chapter 11 Lifting lug see 5 1 1 chapter 12 Wheels fixed castors 13 Wheels guide castors 14 Lifting lug see 5 1 1 chapter 15 Carrying handle 16 Connection socket 9 pole D Sub PC interface see 5 6 chapter 17 Connection socket 19 pole analogue optional Interface for automated welding see 5 5 1 chapter 18 Automatic circuit breaker key button fuse protection ...

Страница 20: ... severely injured by falling machines or mount on components Simultaneous lifting of system components such as power source wire feeder or cooling unit without suitable crane components is not allowed Each system 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...

Страница 21: ...ne observe maintenance intervals see 6 3 chapter Avoid large amounts of smoke steam oily fumes grinding dust and corrosive ambient air In operation Temperature range of the ambient air 25 C to 40 C 13 F to 104 F 1 Relative humidity up to 50 at 40 C 104 F up to 90 at 20 C 68 F 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 h...

Страница 22: ...as the coolant pump welding torch and hose packages Only use the coolants described in these instructions for the specified ambient conditions temperature range see 5 1 6 2 chapter Do not mix coolants of different types including those described in these instructions When changing the coolant all liquid must be replaced and the cooling system flushed Dispose of the coolant in accordance with local...

Страница 23: ...ion 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 m 65 ft 5 m 16 ft Decompact 25 m 82 ft 5 m 16 ft 15 m 49 ft 10 m 32 ft 5 m 16 ft Pump Pmax 4 5 bar 0 45 MPa Power source Hose package Wire feeder miniDrive Welding torch Max Compact 25 m 82 ft 5 m 16...

Страница 24: ... less coolant 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 chapter The unit is supplied ex works with a minimum level of coolant The level of coolant must never fall below the MIN mark Figure 5 2 Item Symbol Description 0 1 Coolant tank cap 2 Coolant ...

Страница 25: ...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 interferences Always keep leads as short as possible For optimum welding results max 30 m welding lead inter mediate hose package torch lead Figure 5 3 Use an individual welding lead to the workpiece for each weldi...

Страница 26: ...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...

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 switched off machine into the appropriate socket 5 1 10 Switching on and system diagnosis Each time the system is switched on the entire welding system runs data synchronization and the system diagnostics...

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 Warning see 7 2 chapter red Error see 7 1 chapter 5 1 11 Protective flap welding machine control Figure 5 8 Open the protective cap Apply slight pressure on the left connecting bridge figure until the ...

Страница 29: ...current Workpiece lead connection 9 Workpiece Remove yellow protective cap on G connecting nipple Insert the welding current plug on the welding torch into the welding current connection socket and lock by turning to the right Screw welding torch shielding gas connection tightly onto the G connection nipple Plug the welding torch control cable plug into the welding torch control cable connection s...

Страница 30: ...ING Risk of injury due to improper handling of shielding gas cylinders Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries Observe the instructions from the gas manufacturer and any relevant re gulations concerning the use of compressed air Lift the shielding gas cylinder onto the receptacle of the shielding gas cy linder and secure with both safety be...

Страница 31: ...t Screw the gas hose connection to the shielding gas connection inlet on the machine gas tight 5 2 2 3 Gas test setting the shielding gas volume If the shielding gas setting is too low or too high this can introduce air to the weld pool and may cause pores to form Adjust the shielding gas quantity to suit the welding task Rule of thumb for the gas flow rate Diameter of gas nozzle in mm corresponds...

Страница 32: ...tion socket welding current 2 Workpiece 3 Connection socket welding current 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 polarity will be based on the infor mation of the electrode manufacturer on the electrode packaging 5 4 Remote control The remote contr...

Страница 33: ...ll ignore the external interrupt equipment and will not shut down Remove jumper 1 on the corresponding control board to be done only by qualified service personnel Pin Signal form Designation Drawing A Output Connection for the cable screen B Input Digital signal controls a configurable function 1 C J Output Switching output in case of device error relay contact 1 D G Output Current flows signal I...

Страница 34: ... Imax J U Output Reference potential 0 V K Output Power supply 15 V max 75 mA R Input Welding current start stop M N Input Control voltage specification activation To activate the external control voltage specification for the main and se condary current the signals M and N must be set to reference potential 0 V 5 6 PC interface Welding parameter software Set all welding parameters on the PC and s...

Страница 35: ...PC 5 7 Network connection This accessory component is only available as a factory fit option The network connection allows the integration of the product into an existing network and exchanging data using the quality management software Xnet Some features of the software Real time display of the welding parameters Recording documentation Monitoring of welding parameters Maintenance Calculations WP...

Страница 36: ... back into opera tion until it has been repaired and tested again 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 type serial number and artic...

Страница 37: ...ection points are omitted Repairer Check and clean the welding torch Deposits in the welding torch may cause short circuits impair the welding result and lead to welding torch damage Check wire drive welding torches and liner elements for application related equipment and setting Clean the wire feed rolls on a regular basis depending on the degree of soiling Replace worn wire feed rolls Connection...

Страница 38: ...hat the solenoid valve opens and closes properly Checking operating signalling and indicator lights protective devices and actuators Check wire feed roll holder wire feed rolls must be firmly seated on their holders and must not have any play Cleaning dirt filter if applicable see 6 3 1 chapter Checking correct mounting of the wire spool Clean external surfaces with a damp cloth do not use aggress...

Страница 39: ...mpressed 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 inlet of the heat exchanger torch cooling Loosen the locking screws of the filters pull the filter of the power unit downwards and then back wards and the filter of the heat exchanger downwards and then...

Страница 40: ...hine 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 4 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 ...

Страница 41: ... 06 2022 41 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 filling refit the tank cap and vent the coolant circuit see 7 4 chapter ...

Страница 42: ...anel 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 due to the compressed air and thus become damaged Therefore use a screwdriver to block the machine fan mechanically Please note The strips of the heat exchanger be hind the machine fans must not be damaged by the...

Страница 43: ...Do not blow on electronic components directly The ma chine fans may over rev due to the compressed air and thus become damaged Therefore use a screwdriver to block the machine fan mechanically Figure 6 9 Blow out the areas in front of the inverter from the side Follow official regulations on disposal After cleaning remove any mechanical blockages from the fans close the machine in reverse order an...

Страница 44: ...s tem separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private households can be disposed of free of charge The deletion of personal data is the responsibility of the end user Lamps batteries or accumulators must be removed and disposed of separately before disposing of the device The type of batter...

Страница 45: ...t number see table In the case of an error the power unit shuts down Document machine errors and inform service staff as necessary If multiple errors occur these are displayed in succession 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 mac...

Страница 46: ...cess Operation with a gas cooled welding torch Deactivate the torch cooling Connect the coolant feed and return with a hose bridge Error 8 Shielding gas error Category A B No shielding gas Check the shielding gas supply The pre pressure is too low Remove kinks in the hose package nominal value 4 6 bar pre pressure Error 9 Overvoltage on secondary Overvoltage at the output Inverter error Request se...

Страница 47: ... replace Air inlet or outlet is blocked Check the air inlet and outlet Short circuit on welding torch Check the welding torch Request service Error 17 Cold wire error Category B Fault in the wire feeder Check the electrical connections connectors lines Permanent overload of the wire drive Do not lay the liner in tight radii Check the liner for smooth movement Error 18 Plasma gas error Category B N...

Страница 48: ... the switched on machine to cool Fan is blocked dirty or defective Check clean or replace the fan Air inlet or outlet is blocked Check the air inlet and outlet Error 23 Excess temperature of the HF choke Category A External XF ignition unit is overheating Allow the switched on machine to cool Error 24 Pilot arc ignition error Category B The pilot arc cannot ignite Check the welding torch equipment...

Страница 49: ... Request service Error 37 Electronics error The power source is overheating Allow the switched on machine to cool Fan is blocked dirty or defective Check fan and clean or replace Air inlet or outlet is blocked Check the air inlet and outlet Error 38 Error IIST Short circuit in the welding circuit before welding Eliminate the short circuit in the welding circuit Request service Error 39 Electronics...

Страница 50: ...een activated internally configurable Deactivate the emergency stop circuit Error 52 No wire feeder After switching on the automated system no wire feeder DV was detected Check or connect the control cables of the wire feeders Correct the identification number of the automated wire feeder for 1DV make sure it is num ber 1 for 2DV a wire feeder with number 1 and a wire feeder with number 2 Error 53...

Страница 51: ...ding monitoring The actual value of a welding parameter is outside the specified tolerance range Maintain the tolerance ranges Adjust the welding parameters Error 62 System component The system component was not found Request service Error 63 Mains voltage error Operating and mains voltage are incompatible Check or adjust the operating and mains voltage 1 See technical data for values and other sw...

Страница 52: ... tolerance field 13 Contact error The resistance in the welding circuit is too high Check earth connection 14 Alignment error Switch the machine off and on If the error persists notify Ser vice 15 Mains fuse The power limit of the mains fuse is reached and the welding power is reduced Check the fuse setting 16 Shielding gas warning Check the gas supply 17 Plasma gas warning Check the gas supply 18...

Страница 53: ... only for the XQ machine series 2 See technical data for values and other switching thresholds see 8 2 chapter 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 Mains fuse triggers Mains fuse triggers unsuitable mains fuse Set up recommended mains ...

Страница 54: ...iece Regrind or replace the tungsten electrode Bad current transfer on ignition Check the setting on the Tungsten electrode diameter Ignition optimisation rotary dial and in crease if necessary higher ignition energy Unstable arc Material inclusions in the tungsten electrode due to contact with filler material or workpiece Regrind or replace the tungsten electrode Incompatible parameter settings C...

Страница 55: ...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...

Страница 56: ...ng 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 centre of the pump shaft Turn the screwdriver clockwise until the pump shaft can be easily rotated again Remove screwdriver Insert mains plug of the switched off machine into the appropriate socket Switch...

Страница 57: ... 3 1 All weights refer to 5 m 16 4 ft machine versions Mains connection cable For versions with longer mains connection cables the weights increase 10 m 32 8 ft 2 5 kg 5 5 lb 15 m 49 2 ft 5 0 kg 11 0 lb 8 1 1 Welding torch cooling system Torch cooling F06W F06WRF Cooling capacity at 1 l min 25 C 77 F 1 5 kW max Flow rate 5 l min 1 3 gal min 20 l min 5 2 gal min max Delivery height 35 m 115 ft 45 m...

Страница 58: ...n Residual current circuit breaker IP 23 Type B recommended Noise level 6 70 dB A Ambient temperature 7 25 C to 40 C Machine cooling Torch cooling Fan AF gas or water Mains connection cable H07RN F4G6 Workpiece lead min EMC class 70 mm2 A Test mark Standards used See declaration of conformity appliance documents 1 Factory set mains voltage cannot be configured later 2 Load cycle 10 min 60 DC 6 min...

Страница 59: ...dual current circuit breaker IP 23 Type B recommended Noise level 6 70 dB A Ambient temperature 7 25 C to 40 C Machine cooling Torch cooling Fan AF gas or water Mains connection cable H07RN F4G6 Workpiece lead min EMC class 70 mm2 A Test mark Standards used See declaration of conformity appliance documents 1 Factory set mains voltage cannot be configured later 2 Load cycle 10 min 60 DC 6 min weldi...

Страница 60: ...Residual current circuit breaker IP 23 Type B recommended Noise level 6 70 dB A Ambient temperature 7 25 C to 40 C Machine cooling Torch cooling Fan AF gas or water Mains connection cable H07RN F4G6 Workpiece lead min EMC class 95 mm2 A Test mark Standards used See declaration of conformity appliance documents 1 Factory set mains voltage cannot be configured later 2 Load cycle 10 min 60 DC 6 min w...

Страница 61: ...tection tester 094 014499 00000 9 2 Remote controls and accessories Type Designation Item no RT1 19POL Remote control current 090 008097 00000 RT PWS1 19POL Remote control vertical down weld current pole re versal 090 008199 00000 RTG1 19POL 5m Remote control current 090 008106 00000 RTG1 19POL 10m Remote control current 090 008106 00010 RTF1 19POL 5 M Foot operated remote control current with con...

Страница 62: ... 00000 ON Water Filter K 06 Optional water filter 092 004051 00000 ON RPH TIG F 06 Holder for TIG welding rods for mounting on flexFit casing system 092 004388 00000 9 4 General accessories Type Designation Item no 32A 5POLE CEE Machine plug 094 000207 00000 KLF L1 L2 L3 PE Label of mains cable 094 023697 00000 ON AL D13 27 Cap for load sockets 092 003282 00000 9 5 Shielding gas supply shielding g...

Страница 63: ...endix Searching for a dealer 099 005674 EW501 28 06 2022 63 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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