EWM Titan XQ 400 puls D Operating Instructions Manual
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Summary of Contents for EWM Titan XQ 400 puls D
- Page 1 Operating instructions 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! 09.03.2018...
- Page 2 +49 2680 181-0. A list of 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.
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Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 Part of the complete documentation ....................8 Safety instructions .......................... - Page 4 Welding torch cooling system ...................... 54 Performance data ......................... 55 8.3.1 Titan XQ 350 puls D ..................... 55 8.3.2 Titan XQ 400 puls D ..................... 56 8.3.3 Titan XQ 500 puls D ..................... 57 8.3.4 Titan XQ 600 puls D ..................... 58 8.3.5...
- Page 5 Contents Notes on the use of these operating instructions 099-005560-EW501 09.03.2018...
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Page 6: For Your Safety
For your safety Notes on the use of these operating instructions For your safety Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. •... -
Page 7: Explanation Of Icons
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Numerical value –... -
Page 8: Part Of The Complete Documentation
For your safety Part of the complete documentation Part of the complete documentation These operating instructions are part of the complete documentation 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. - Page 9 For your safety Safety instructions WARNING Hazard when interconnecting multiple power sources! If a number of power sources are to be connected in parallel or in series, only a technical specialist may interconnect the sources as per standard IEC 60974-9:2010: Installation and use and German Accident Prevention Regulation BVG D1 (formerly VBG 15) or country-specific regulations.
- Page 10 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
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Page 11: Transport And Installation
For your safety Transport and installation Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the introduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines. - Page 12 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.
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Page 13: Intended Use
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 Conformity The labelled machine complies with the following EC directives in terms of its design and construction: •... -
Page 14: Service Documents (Spare Parts And Circuit Diagrams)
Intended use Documents which also apply 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 and void in the event of unauthorised interference. -
Page 15: Machine Description - Quick Overview
Machine description – quick overview Machine configuration Machine description – quick overview Machine configuration The following table shows the different design variants (development stages) of the device series Titan XQ: Type Figure Transport properties Torch cooling Figure 4-1 099-005560-EW501 09.03.2018... -
Page 16: Front View / Side View From The Right
Machine description – quick overview Front view / side view from the right Front view / side view from the right Figure 4-2 099-005560-EW501 09.03.2018... - Page 17 Machine description – quick overview Front view / side view from the right Item Symbol Description WiFi antenna Factory-fit option, (version OW Expert XQ 2.0 WLG) Main switch, machine on/off Infoline - display of operating status The operating status is indicated by fibre optics > see 5.3 chapter. 7-pole connection socket (digital) For connecting digital accessory components Cooling air outlet...
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Page 18: Rear View / Side View From Left
Machine description – quick overview Rear view / side view from left Rear view / side view from left Figure 4-3 099-005560-EW501 09.03.2018... - Page 19 Machine description – quick overview Rear view / side view from left Item Symbol Description Securing elements for shielding gas cylinder (strap/chain) Cooling air inlet Dirt filter can be retrofitted Connection socket, “+” welding current How to connect the accessories depends on the welding procedure. Please observe the connection description for the corresponding welding procedure >...
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Page 20: Design And Function
Design and function Transport and installation Design and function WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •... -
Page 21: Ambient Conditions
Design and function Transport and installation 5.1.3 Ambient conditions T he machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 22: Approved Coolants Overview
All information relates to the total hose package length of the complete welding system and presents exemplary configurations (of components of the EWM product portfolio with standard lengths). A straight kink-free installation is to be ensured, taking into account the max. delivery height. -
Page 23: Adding Coolant
Design and function Transport and installation 5.1.6.4 Adding coolant The unit is supplied ex works with a minimum level of coolant. Figure 5-2 Item Symbol Description Coolant tank cap Coolant filter sieve Coolant tank > see 5.1.6 chapter Filling level display MIN ------ minimum coolant level MAX ----- maximum coolant level •... -
Page 24: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.7 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. -
Page 25: Stray Welding Currents
Design and function Transport and installation 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. •... -
Page 26: Connecting The Intermediate Hose Package To The Power Source
Design and function Transport and installation 5.1.9 Connecting the intermediate hose package to the power source Figure 5-7 Item Symbol Description Wire feed unit Intermediate hose package 14-pole connection socket Wire feeder control cable connection Intermediate hose package strain relief > see 5.6.1 chapter Connection socket, “+”... -
Page 27: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Transport and installation • Insert the hose package end of the intermediate hose package from the outside through the strain relief of intermediate hose package and then lock by turning to the right. • Insert the control cable through the recess in the gas cylinder bracket, insert the cable plug into the into the connection socket (14-pole) and secure with crown nut (the plug can only be inserted into the connection socket in one position). -
Page 28: 5.1.11 Mains Connection
Design and function Transport and installation • Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out any dirt. • Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight. •... -
Page 29: 5.1.11.2 Adjusting The Power Source To The Mains Voltage
Design and function Transport and installation 5.1.11.2 Adjusting the power source to the mains voltage The mains voltage is adapted by replugging the operating voltage plug on the printed circuit board VB xx0 into the power source. The machine can be reconnected between three possible voltage ranges: 1.... -
Page 30: 5.1.11.4 Mains Configuration
Design and function Switching on and system diagnosis 5.1.11.4 Mains configuration The machine may be connected to: • a three-phase system with four conductors and an earthed neutral conductor • a three-phase system with three conductors of which any one can be earthed, e.g. -
Page 31: Protective Flap, Welding Machine Control
Design and function Protective flap, welding machine control Protective flap, welding machine control Figure 5-12 • 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. 099-005560-EW501 09.03.2018... -
Page 32: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.5.1 Connection for workpiece lead Figure 5-13 Item Symbol Description Connection socket, “–” welding current Workpiece lead connection Workpiece • Insert the plug on the workpiece lead into the "-" welding current connection socket and lock. Some wire electrodes (e.g. -
Page 33: Setting The Shielding Gas Volume (Gas Test)/Rinse Hose Package
Design and function TIG welding 5.5.3 Setting the shielding gas volume (gas test)/rinse hose package • Shielding gas supply as described in chapter Transport and positioning > see 5.1 chapter. • Slowly open the gas cylinder valve. • Open the pressure regulator. •... -
Page 34: Tig Welding
Design and function TIG welding TIG welding 5.6.1 Connecting the intermediate hose package to the power source TIG combi welding torches are connected to wire feed unit and power source. The welding current for the intermediate hose package must be connected to the welding current connection (-) at the rear of the unit! Figure 5-14 099-005560-EW501... -
Page 35: Connection For Workpiece Lead
Design and function TIG welding Item Symbol Description Welding torch Wire feed unit Intermediate hose package 14-pole connection socket Wire feeder control cable connection Intermediate hose package strain relief > see 5.1.9 chapter Connection socket, “-” welding current Connection for welding current plug from intermediate hose package •... -
Page 36: Welding Task Selection
Design and function MMA welding Item Symbol Description Workpiece Connection socket, "+" welding current • TIG welding: Workpiece connection • Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by turning to the right. 5.6.3 Welding task selection For selection of the welding task and for general operation see the relevant Control operating... -
Page 37: Welding Task Selection
Design and function Remote control Item Symbol Description Connection socket, “-” welding current Connection socket, “+” welding current Workpiece Electrode holder • Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right. -
Page 38: Rint X12 Robot Interface
Design and function Interfaces for automation Input / Designation Figure Output Output PE -------- Connection for cable screen Output IGRO ---- Current flows signal I>0 (maximum load 20 mA / (open 15 V) 0 V = welding current flows collector) E +R Input Not-Aus - Emergency stop for higher level shut-down of the... -
Page 39: Pc Interface
Design and function PC interface 5.10 PC interface PC 300 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 •... -
Page 40: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General WARNING Incorrect maintenance, testing and repair! Maintenance, testing and repair of the machine may only be carried out by skilled and qualified personnel. A qualified person is one who, because of his or her training, knowledge and experience, is able to recognise the dangers that can occur while testing welding power sources as well as possible subsequent damage, and who is able to implement the required safety procedures. -
Page 41: Explanation Of Icons
Maintenance, care and disposal Explanation of icons 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 099-005560-EW501 09.03.2018... -
Page 42: Maintenance Schedule
Maintenance, care and disposal Maintenance schedule Maintenance schedule Maintenance step Only the person who has been certified as an examiner or repairer may carry out the relevant work step on the basis of their training! Non-applicable checkpoints are omitted. • Check and clean the welding torch. -
Page 43: Dirt Filter
Maintenance, care and disposal Maintenance schedule 6.3.1 Dirt filter The duty cycle of the welding machine decreases as an effect of the reduced cooling air volume. The dirt filter must be remove at regular intervals and cleaned by blowing out with compressed air (depending on the level of soiling). -
Page 44: Coolant Error
Maintenance, care and disposal Maintenance schedule 6.3.2 Coolant error Observe all instructions for handling, use and disposal of torch coolant > see 5.1.6 chapter. Figure 6-2 099-005560-EW501 09.03.2018... - Page 45 4. Screw the drain plug with seal back into the tank from bottom (tightly), insert the cleaned filter screen into the filler neck. Fill tank with original -EWM- coolant. (For type and item no.: see sticker near filler). After filling, close the tank screw plug and vent the coolant circuit > see 7.4 chapter.
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Page 46: Heat Exchanger (Torch Cooling)
Maintenance, care and disposal Maintenance schedule 6.3.3 Heat exchanger (torch cooling) WARNING Risk of injury due to insufficient training! An appropriate training is necessary for the following maintenance steps to avoid injuries. • This maintenance step may only be carried out by trained and authorized specialist staff. •... -
Page 47: Power Source (Inverter)
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-005560-EW501 09.03.2018... -
Page 48: Disposing Of Equipment
• Information about returning used equipment or about collections can be obtained from the respective municipal administration office. • In addition to this, returns are also possible throughout Europe via EWM sales partners. 099-005560-EW501 09.03.2018... -
Page 49: Rectifying Faults
Rectifying faults Error messages (power source) Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer. - Page 50 Rectifying faults Error messages (power source) Category Error Possible cause Remedy Pre-pressure too low Remove kinks in the hose package; nominal value: 4- 6 bar pre-pressure Sec. Overvoltage at output: Inverter Inform the service overvoltage error Earth fault Electrical connection between Check wire space, eliminate welding wire and housing connection...
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Page 51: Warnings
Rectifying faults Warnings Category Error Possible cause Remedy Permanent overload of the wire Do not place liner in tight radii; drive (slave drive) check wire core for smooth movement Short circuit Check welding circuit for short Check welding circuit; isolate circuit welding torch before depositing... -
Page 52: Checklist For Rectifying Faults
Rectifying faults Checklist for rectifying faults 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 Collective interference signal light illuminates ... -
Page 53: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit 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 7-1 Fixing the pump shaft (coolant circuit) Continuing non-use and impurities in the coolant may result in the the coolant pump not being in proper working order. -
Page 54: Technical Data
Technical data Dimensions and weighte Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Dimensions and weighte Housing version F06R1/R2 F06RS F06P Figure inch inch inch Dimensions 38.4 38.4 31.9 27.0 23.2 15.7 1152 45.3 33.6 33.6... -
Page 55: Performance Data
Technical data Performance data Performance data 8.3.1 Titan XQ 350 puls D MIG/MAG Welding current setting range (I 5 A - 350 A Welding voltage according to standard 14.3 V - 31.5 V 20.2 V - 34.0 V 10.2 V - 24.0 V Duty cycle DC at 40°... -
Page 56: Titan Xq 400 Puls D
Technical data Performance data 8.3.2 Titan XQ 400 puls D MIG/MAG Welding current setting range (I 5 A - 400 A 14.3 V - 34 V 20.2 V - 36.0 V 10.2 V - 26.0 V Welding voltage according to standard Duty cycle DC at 40°... -
Page 57: Titan Xq 500 Puls D
Technical data Performance data 8.3.3 Titan XQ 500 puls D MIG/MAG Welding current setting range (I 5 A - 500 A 14.3 V - 39 V 20.2 V - 40.0 V 10.2 V - 30.0 V Welding voltage according to standard Duty cycle DC at 40°... -
Page 58: Titan Xq 600 Puls D
Technical data Performance data 8.3.4 Titan XQ 600 puls D MIG/MAG Welding current setting range (I 5 A - 600 A 14.3 V - 44 V 20.2 V - 44.0 V 10.2 V - 34.0 V Welding voltage according to standard Duty cycle DC at 40°... -
Page 59: Footnotes
Technical data Performance data 8.3.5 Footnotes Load cycle: 10 min. (60 % DC ≙ 6 min. welding, 4 min. pause) Multi-voltage device - Adjusting the power source to the mains voltage > see 5.1.11.2 chapter Safety fuses are recommended DIAZED xxA gG. When using automatic cutouts, the "C" trigger characteristic must be used. -
Page 60: Accessories
Accessories General accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. KLF-L1-L2-L3-PE Label of mains cable 094-023697-00000 TYP 1 Frost protection tester 094-014499-00000 KF 23E-10 Coolant (-10 °C), 9.3 l 094-000530-00000... -
Page 61: Computer Communication
Accessories Computer communication Computer communication Type Designation Item no. PC300.Net PC300.Net welding parameter software kit incl. 090-008777-00000 cable and SECINT X10 USB interface ON WLG-EX Wi-Fi gateway in external casing 090-008790-00502 ON LG-EX LAN gateway in external casing 090-008789-00502 FRV 7POL 5 m Extension/connecting cable 092-000201-00003 FRV 7POL 10 m... -
Page 62: Searching For A Dealer
Appendix A Searching for a dealer Appendix A 10.1 Searching for a dealer Sales & service parteners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005560-EW501 09.03.2018...
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