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Design and function

TIG welding

099-005670-EW501

7.03.2022

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.
TIG welding machines are equipped ex works with a dedicated connection socket for the welding torch

control cable (5- or 8-pole). As mobile machines offer more free space, they may even feature two control

cable connection sockets. The functionality increases with the number of poles.

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 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 belts provided on the device as stan-

dard! Belts must be tight.

• Do not attach any element to the shielding gas cylinder valve!

• Prevent the shielding gas cylinder from heating up.

An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a

fundamental requirement for optimum welding results. In addition, a blocked shielding gas

supply may result in the welding torch being destroyed.

• All shielding gas connections must be gas tight.

5.2.2.1 Pressure regulator connection

Figure 5-13

Item Symbol Description

Pressure regulator

Output side of the pressure regulator

Shielding gas cylinder

Cylinder valve

Содержание Tetrix XQ 350 puls DC

Страница 1: ...Operating instructions EN Power source Tetrix XQ 350 puls DC Tetrix XQ 400 puls DC Tetrix XQ 500 puls DC Tetrix XQ 600 puls DC 099 005670 EW501 Observe additional system documents 7 03 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...

Страница 3: ...onal 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 weld...

Страница 4: ...ults 53 7 4 Vent coolant circuit 55 7 5 Fixing the pump shaft coolant circuit 56 8 Technical data 57 8 1 Dimensions and weighte 57 8 2 Welding torch cooling system 57 8 3 Performance data 58 8 3 1 Tet...

Страница 5: ...Contents Notes on using these operating instructions 099 005670 EW501 7 03 2022 5...

Страница 6: ...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 oper...

Страница 7: ...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 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 Befo...

Страница 9: ...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 excessiv...

Страница 10: ...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 11: ...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 12: ...n 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...

Страница 13: ...onformity 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 manufa...

Страница 14: ...n 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 sho...

Страница 15: ...ion 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: ...Machine description quick overview Front view side view from the right 16 099 005670 EW501 7 03 2022 4 2 Front view side view from the right Figure 4 2...

Страница 17: ...irt 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...

Страница 18: ...Machine description quick overview Rear view side view from left 18 099 005670 EW501 7 03 2022 4 3 Rear view side view from left Figure 4 3...

Страница 19: ...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 soc...

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...

Страница 21: ...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...

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...

Страница 23: ...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...

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 s...

Страница 25: ...th 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 Al...

Страница 26: ...oper mains connection An improper mains connection can cause injuries or damage property The connection mains plug or cable the repair or voltage adjustment of the device must be carried out by a qual...

Страница 27: ...marked on the rating plate and the label on the mains connection cable by a marking If the marked mains voltage range coincides with the supply voltage further commissioning may take place If the spe...

Страница 28: ...p Reconnect operating voltage plug printed circuit board VB xx0 to the corresponding voltage range of the supply voltage 380V 400V ex works Hook housing cover from above into the aluminium continuous...

Страница 29: ...ces This time can take from several seconds to several minutes e g for the system components interconnected for the first time During this start phase the system components will display the controller...

Страница 30: ...ion 30 099 005670 EW501 7 03 2022 5 1 11 Protective flap welding machine control Figure 5 10 Open the protective cap Apply slight pressure on the left connecting bridge figure until the flap s fasteni...

Страница 31: ...urrent 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 loc...

Страница 32: ...d 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...

Страница 33: ...ght 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 q...

Страница 34: ...ion 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 plicat...

Страница 35: ...l 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...

Страница 36: ...max 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 volta...

Страница 37: ...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 usi...

Страница 38: ...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 Wh...

Страница 39: ...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 ca...

Страница 40: ...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 41: ...ne 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 42: ...7 03 2022 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 f...

Страница 43: ...nel 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 co...

Страница 44: ...o 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...

Страница 45: ...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...

Страница 46: ...fault 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...

Страница 47: ...ss 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 shi...

Страница 48: ...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 19 Shielding gas error Category B No shielding gas C...

Страница 49: ...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 26 Excess temperature of the pilot arc module Cate...

Страница 50: ...ssion Error 48 Ignition error Category B No ignition at process start automated machines Check the wire feeding Check the load cable connections in the welding circuit Clean corroded surfaces on the w...

Страница 51: ...wire feeder slave drive Check the connections connectors lines Permanent overload of the wire drive slave drive Do not lay the liner in tight radii Check the liner for smooth movement Error 58 Short...

Страница 52: ...gas supply 5 Coolant flow Check min flow rate 2 6 Wire reserve Only a small amount of wire is left on the spool 7 CAN bus failure Wire feeder not connected automatic circuit breaker of wire feed motor...

Страница 53: ...otor slave Excess current detected on wire feed motor slave push push system or intermediate drive 36 Slave tacho error Fault of wire feeder permanent overload of the wire drive push push system or in...

Страница 54: ...type Select HF start Depending on the machine the setting is defined by the change over switch for ignition types or the parameter in one of the machine menus see the Con trol operating instructions...

Страница 55: ...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 Posi...

Страница 56: ...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 57: ...9 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 l...

Страница 58: ...assification 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...

Страница 59: ...cation 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...

Страница 60: ...cation 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...

Страница 61: ...ssification 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...

Страница 62: ...20 C 200 l 094 006256 00001 TYP1 Frost protection tester 094 014499 00000 9 2 Remote controls and accessories Type Designation Item no RT1 19POL Remote control current 090 008097 00000 RTG1 19POL 5m R...

Страница 63: ...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 Design...

Страница 64: ...ndix Searching for a dealer 64 099 005670 EW501 7 03 2022 10 Appendix 10 1 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldw...

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