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Design and function

Transport and installation

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099-005560-EW501

20.11.2020

5.1.6 Notes on the installation of welding current leads

• Incorrectly installed welding current leads can cause faults in the arc (flickering).
• Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long

and as close as possible in parallel.

• Lay the workpiece lead and hose package of power sources 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 p torch lead).

Figure 5-3

• Use an individual welding lead to the workpiece for each welding machine!

Figure 5-4

• 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 5-5

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Содержание Titan XQ 350 puls D

Страница 1: ...Operating instructions EN Power source Titan XQ 350 puls D Titan XQ 400 puls D Titan XQ 500 puls D Titan XQ 600 puls D 099 005560 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 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...

Страница 3: ...4 Workpiece lead general 21 5 1 5 Welding torch cooling system 22 5 1 5 1 Functional characteristics 22 5 1 5 2 Permitted torch coolant 22 5 1 5 3 Maximal hose package length 22 5 1 5 4 Adding coolant 23 5 1 6 Notes on the installation of welding current leads 24 5 1 7 Stray welding currents 25 5 1 8 Connecting the intermediate hose package to the power source 26 5 1 8 1 Intermediate hose package ...

Страница 4: ...5 Annual test inspection and testing during operation 47 6 4 Disposing of equipment 47 7 Rectifying faults 48 7 1 Error messages power source 48 7 2 Warnings 51 7 3 Checklist for rectifying faults 52 7 4 Vent coolant circuit 53 7 5 Fixing the pump shaft coolant circuit 54 8 Technical data 55 8 1 Dimensions and weighte 55 8 2 Welding torch cooling system 56 8 3 Performance data 57 8 3 1 Titan XQ 35...

Страница 5: ...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 6: ...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 7: ...t 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 sources out of operation all mains and welding current leads must be safely disconnected from the welding system as a ...

Страница 8: ...osion 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 temperatures sparks glowing parts and hot slag that occur during welding there is a risk of flames Be watchful of pote...

Страница 9: ...s 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 of...

Страница 10: ...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 11: ...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 12: ...A suitable wire feed unit system component is required in order to operate the welding machine The following system components can be combined Titan XQ 350 600 puls D Phoenix XQ 350 600 puls D Taurus XQ 350 600 Syner gic D Drive XQ 3 2 Applications Device control of multi process welding machines for arc welding covering the following welding proce dures Machine se ries Main procedure for MIG MAG ...

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 WARNING Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repaired or modified by specialist skilled persons The warranty becomes null ...

Страница 14: ...l 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 The illustration shows a general example of a welding system Item Documentation A 1 Wire feeder A 2 Remote adjuster A 3 Controller A 4 Power source A 5 Welding torch A Complete documentat...

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: ...quick overview Front view side view from the right 16 099 005560 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 OW Expert XQ 2 0 WLG ...

Страница 17: ...ith 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 1 8 chapter 16 Aluminium extrusion profile flexFit Individual mounting option for accessories and options 17 Connection socket welding current How to connect the accessories depends on the welding pro...

Страница 18: ...iew side view from left 18 099 005560 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 inlet Dirt filter optional see 6 3 1 chapter ...

Страница 19: ... Individual mounting option for accessories and options 10 Intermediate hose package strain relief see 5 1 8 chapter 11 Mains connection cable see 5 1 10 chapter 12 Outlet opening cooling air torch cooling 13 Service opening for coolant pump see 7 5 chapter 14 Lifting lug see 5 1 1 chapter 15 Wheels fixed castors 16 Wheels guide castors 17 Lifting lug see 5 1 1 chapter 18 Carrying handle 19 Connec...

Страница 20: ...m 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 Properly close and lock all casing covers and protective caps before lifting by crane Use the correct number of hoisting equipment of the right size in the correct position Ob serve craning principle see 5 ...

Страница 21: ... 2 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 3 Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Ke...

Страница 22: ...s 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 welding process is switched off in a controlled manner 5 1 5 2 Permitted torch coolant Coolant Temperature range blueCool 10 10 C to 40 C 14 F to 104 F KF 23E Standard 10 C to 40 C 14 F to 104 F KF 37E 20 ...

Страница 23: ...olant 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 filter s...

Страница 24: ...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 25: ...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 26: ...le connection socket Wire feeder control cable connection 4 Intermediate hose package strain relief see 5 1 8 chapter 5 Connection socket welding current Standard MIG MAG welding intermediate hose package 6 Connection socket welding current Connection for welding current plug from intermediate hose package MIG MAG flux cored wire welding TIG welding 7 Quick connect coupling blue coolant supply 8 Q...

Страница 27: ... coolant 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 lead should be connected to the welding current socket Observe the information from the electrode manufacturer 5 1 8 1 Intermediate hose package strain relief Property damage due to strain rel...

Страница 28: ...ng 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 w...

Страница 29: ... as stipulated in the operating in structions The network created must be suitable for operating machines according to pro tection class I The welding power source is equipped with an internal clamp device for multiple mains volta ges The currently set mains voltage of the power source must match the supply voltage The following steps have to be carried out Visual inspection comparison between the...

Страница 30: ... up 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 casting profile flexFit and secure with fastening screws Install a mains plug which is permissible for the selected mains voltage to the mains cable Identify the selected mains voltage on the rating...

Страница 31: ...vices 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 type and if applicable software information in the welding data display if available This start phase is terminated by display of the nominal valuesfor current voltage or wire feed speed Operation ...

Страница 32: ...tion 32 099 005560 EW501 20 11 2020 5 1 12 Protective flap welding machine control Figure 5 14 Open the protective cap Apply slight pressure on the left connecting bridge figure until the flap s fastening pin can be removed to the left from top ...

Страница 33: ... welding current connection socket and lock 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 lead should be connected to the welding current socket Observe the information from the electrode manufacturer 5 2 2 Welding task selection For selection of the wel...

Страница 34: ... 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 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 Welding process Recommended shielding gas quantity MAG welding Wire d...

Страница 35: ...ed work pieces Figure 5 17 Item Symbol Description 0 1 Connection socket welding current 2 Connection socket welding current 3 Workpiece 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 o...

Страница 36: ... 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 Output Name Figure A Output PE Connection for cable screen D Output open collec tor IGRO Current flows signal I 0 maximum load 20 mA 15 V 0 V welding current flows E R Input Not Aus Emergency stop fo...

Страница 37: ...onnected 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 parameters on the PC and simply transfer to one or more welding machines accessory set consisting of software interface connection leads Manage up to 510 JOBs Exchange JOBs with the welding machin...

Страница 38: ... 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...

Страница 39: ...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 ...

Страница 40: ...560 EW501 20 11 2020 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 ...

Страница 41: ...e 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 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 connectio...

Страница 42: ...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 43: ...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 44: ... 20 11 2020 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 45: ... 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 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 dam...

Страница 46: ...onnect 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 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 fa...

Страница 47: ... 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 be disposed of or recycled in accordance with the waste separation systems in use According to Ger...

Страница 48: ... 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 legend resetting the error a The error message will disappear once the error has been rectified b The error message can be reset by pressing a push button c The error message can only be reset by swit...

Страница 49: ... 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 short circuit in welding circuit remove exter nal sensor voltage 38 Error IIST 3 Short circuit in welding circuit before welding Eliminate short circuit in welding circuit 48 Ignition error No ignitio...

Страница 50: ...t 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 welding torch before deposi ting 59 Incompatible machine A machine connected to the system is not compatible Please disconnect the incom patible machine from the sys tem 60 Incompatible software A m...

Страница 51: ...t 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 65 C 149 F 1 12 Welding monitor The actual value of a welding parameter is outside the spe cified tolerance field 13 Contact error The resistance in the welding circuit is too high Check earth conne...

Страница 52: ...heck 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 flowi...

Страница 53: ...ding 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 spiral replace kinked or worn cores 7 4 Vent coolant circuit Figure 7 1 Switch off the machine and fill the coolant tank to the maximum level Unlock the quick connect coupling with a suitable tool conne...

Страница 54: ...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 55: ... 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 F06G 113 9 251 1 103 7 228 6 88 7 195 5 F06W 128 5 283 2 118 3 260 8 103 3 227 7 F06WRF 132 5 292 1 122 3 269 6 107 3 236 5 1 All weights refer to 5 m 16 4 ft machine versions Mains connection cable For versions with longer mains connection cables the weights inc...

Страница 56: ... 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 monitoring Error limit 0 7 l min 0 18 gal min Warning limit Error limit 0 3 l min Error limit 0 08 gal min Temperature monitoring Error limit 70 C 158 F Warning limit Error limit 5 C Error limit 23 F ...

Страница 57: ...class 3 H protection classification 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 Safety marking Standards used See declaration of conformity appliance documents 1 Load cycle 10 min 60 DC 6 min welding 4 min p...

Страница 58: ... H protection classification 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 Safety marking Standards used See declaration of conformity appliance documents 1 Load cycle 10 min 60 DC 6 min welding 4 min pause 2 ...

Страница 59: ... H protection classification 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 Safety marking Standards used See declaration of conformity appliance documents 1 Load cycle 10 min 60 DC 6 min welding 4 min pause 2 ...

Страница 60: ...ass 3 H protection classification 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 Safety marking Standards used See declaration of conformity appliance documents 1 Load cycle 10 min 60 DC 6 min welding 4 min pau...

Страница 61: ...OL 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 cable 092 000201 00005 FRV 7POL 20 m Extension connecting cable 092 000201 00001 FRV 7POL 25M Extension connecting cable 092 000201 00007 9 3 19 pole remote control Type Designation Item no R10 19POL ...

Страница 62: ...xpert 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 automated welding 092 003498 00000 9 5 Computer communication Type Designation Item no PC300 XQ Set PC300 Net welding parameter software kit incl cable and SECINT X10 USB interface 090 008777 00000 ...

Страница 63: ...endix Searching for a dealer 099 005560 EW501 20 11 2020 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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