EWM Titan XQ 350 puls C Operating Instructions Manual
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Summary of Contents for EWM Titan XQ 350 puls C
- Page 1 Operating instructions Power source Titan XQ 350 puls C Titan XQ 400 puls C 099-005609-EW501 Observe additional system documents! 07.08.2019...
- 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. No other form of liability, regardless of type, shall be accepted.
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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 ............................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 Part of the complete documentation ....................7 Safety instructions .......................... - Page 4 Contents Notes on the use of these operating instructions 5.4.5 Welding task selection ....................40 TIG welding ..........................41 5.5.1 Welding torch connection ..................... 41 5.5.2 Connection for workpiece lead ..................42 5.5.3 Welding task selection ....................42 MMA welding ..........................43 5.6.1 Connecting the electrode holder and workpiece lead ..........
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Page 5: 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 6: 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 Correct / Valid Numerical value –... -
Page 7: 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 8: Safety Instructions
For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 9 For your safety Safety instructions WARNING 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 temperatures, sparks, glowing parts and hot slag that occur during welding, there is a risk of flames.
- Page 10 For your safety Safety instructions CAUTION According to IEC 60974-10, welding machines are divided into two classes of electromagnetic compatibility (the EMC class can be found in the Technical da- ta) > see 8 chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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Page 11: Transport And Installation
For your safety Transport and installation The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode hold- ers, remote controls, spare parts and replacement parts, etc.) from our range of products! •... - Page 12 For your safety Transport and installation The units are designed for operation in an upright position! Operation in non-permissible positions can cause equipment damage. • Only transport and operate in an upright position! Accessory components and the power source itself can be damaged by incorrect connection! •...
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Page 13: Intended Use
3.2.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.2.2 Declaration of Conformity The labelled product 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 3.2.4 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 (expansion stages) of the device series Titan XQ: Type Figure Transport properties Torch cooling Figure 4-1 099-005609-EW501 07.08.2019... -
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 4-2 099-005609-EW501 07.08.2019... - Page 17 Machine description – quick overview Front view / side view from the right Item Symbol Description Main switch, machine on/off LED status bar - display of operating status The operating status is indicated by a light guide > see 5.2.1 chapter. 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.)
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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 4-3 099-005609-EW501 07.08.2019... - 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 optional > see 6.3.1 chapter Securing elements for shielding gas cylinder (strap/chain) Bracket for shielding gas cylinder Aluminium continuous casting profile flexFit Individual mounting option for accessories and options Gas cylinder holder...
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Page 20: Inside View
Machine description – quick overview Inside view Inside view Figure 4-4 Item Symbol Description Key switch for protection against unauthorised use > see 5.8 chapter --------- changes possible,G front drive-4x-EX --------- changes not possible. Welding torch function changeover switch (special welding torch required) --- Changing over programs or JOBs --- Infinite adjustment of welding performance. -
Page 21: 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 22: 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 23: Welding Torch Cooling System
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 24: Adding Coolant
Design and function Transport and installation 5.1.6.4 Adding coolant After switching on the machine, the coolant pump runs for a maximum of 2 min. (Filling hose package). If the machine does not detect a sufficient coolant flow during this time, the coolant pump is switched off (protection against damage in dry run). -
Page 25: 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 26: 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 27: Pressure Regulator Connection
Design and function Transport and installation 5.1.9.1 Pressure regulator connection Figure 5-7 Item Symbol Description Pressure regulator Output side of the pressure regulator Shielding gas cylinder Cylinder valve • Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out any dirt. -
Page 28: Setting The Shielding Gas Volume (Gas Test)/Rinse Hose Package
Design and function Transport and installation 5.1.9.3 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 29: 5.1.10 Mains Connection
Design and function Transport and installation 5.1.10 Mains connection DANGER Hazards caused by improper 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 qualified electrician in accordance with the respective local laws or nati- onal regulations! •... -
Page 30: 5.1.10.2 Adjusting The Power Source To The Mains Voltage
Design and function Transport and installation 5.1.10.2 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 31: 5.1.10.4 Mains Configuration
Design and function Switching on and system diagnosis 5.1.10.4 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 32: Protective Flap, Welding Machine Control
Design and function Polarity selection plug - changing the welding current polarity 5.2.2 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. -
Page 33: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.4.1 Assemble the wire guide The Euro torch connector is factory-fitted with a guide tube for welding torches with steel liner. Conversi- on is necessary if a welding torch with a steel liner is used! •... -
Page 34: Welding Torch Connection
Design and function MIG/MAG welding 5.4.2 Welding torch connection Figure 5-15 Item Symbol Description Welding torch Welding torch hose package Connection of coolant lines (welding torch) Quick connect couplings Polarity selection plug, welding current cable > see 5.3 chapter • Insert the polarity selection plug into the "+"... -
Page 35: Connection For Workpiece Lead
Design and function MIG/MAG welding 5.4.3 Connection for workpiece lead Figure 5-16 Item Symbol Description Workpiece Connection socket, “–” welding current Workpiece lead connection • Insert the plug on the workpiece lead into the "-" welding current connection socket and lock. Some wire electrodes (e.g. -
Page 36: Inserting The Wire Spool
Design and function MIG/MAG welding 5.4.4.1 Inserting the wire spool CAUTION Risk of injury due to incorrectly secured wire spool. If the wire spool is not secured properly, it may come loose from the wire spool support and fall to the ground, causing damage to the machine and injuries. •... -
Page 37: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.4.4.2 Changing the wire feed rollers Figure 5-19 Item Symbol Description Tommy The tommy is used to secure the closure brackets of the wire feed rollers. Closure bracket The closure brackets are used to secure the wire feed rollers. Feed roll tensioner Fixing the clamping unit and setting the pressure. - Page 38 Design and function MIG/MAG welding Unsatisfactory welding results due to faulty wire feeding! The wire feed rolls must be suitable for the diameter of the wire and the material. The wire feed rolls are colour-coded to facilitate distinction (see the Wire feed roll overview table). When working with a wire diameter of >...
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Page 39: Inching The Wire Electrode
Design and function MIG/MAG welding 5.4.4.3 Inching the wire electrode CAUTION Risk of injury due to welding wire escaping from the welding torch! The welding wire can escape from the welding torch at high speed and cause bodily injury including injuries to the face and eyes! •... -
Page 40: Spool Brake Setting
Design and function MIG/MAG welding A prerequisite for the automatic inching process is the correct preparation of the wire guide, especially in the capillary and wire guide tube area > see 5.4.2 chapter. • The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll ten- sioner setting nuts depending on the welding consumable used. -
Page 41: Tig Welding
Design and function TIG welding TIG welding 5.5.1 Welding torch connection Figure 5-23 Item Symbol Description Welding torch Welding torch hose package Connection of coolant lines (welding torch) Quick connect couplings Polarity selection plug, welding current cable > see 5.3 chapter •... -
Page 42: Connection For Workpiece Lead
Design and function TIG welding 5.5.2 Connection for workpiece lead Figure 5-24 Item Symbol Description Workpiece Connection socket, “+” welding current • Workpiece lead connection • Insert the plug on the workpiece lead into the "-" welding current connection socket and lock. Some wire electrodes (e.g. -
Page 43: Mma Welding
Design and function MMA welding MMA welding 5.6.1 Connecting the electrode holder and workpiece lead CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. •... -
Page 44: Interfaces For Automation
Design and function Interfaces for automation Interfaces for automation 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 45: Busint X11 Industrial Bus Interface
Windows PC 5.9.4.1 Component identification These accessory components can be retrofitted as an option > see 9 chapter. Bar codes predefined in ewm Xnet are recorded with a manual scanner. Component data are retrieved and displayed in the control. 099-005609-EW501 07.08.2019... -
Page 46: 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, know- ledge 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 im- plement the required safety procedures. -
Page 47: 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 099-005609-EW501 07.08.2019... -
Page 48: Maintenance Schedule
Maintenance, care and disposal Maintenance schedule Maintenance schedule Maintenance step Only people certified as inspectors or repairers may carry out the rele- vant work step due to their training! Non-applicable checkpoints are omitted. • Check and clean the welding torch. Deposits in the torch can cause short circuits and have a negative impact on the welding result, ulti- mately causing damage to the welding torch! •... -
Page 49: 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 50: 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 6-2 099-005609-EW501 07.08.2019... - Page 51 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 52: 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 inju- ries. • This maintenance step may only be carried out by trained and authorized specialist staff. •... -
Page 53: 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! 099-005609-EW501 07.08.2019... -
Page 54: 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. 099-005609-EW501 07.08.2019... -
Page 55: 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 dea- ler. - Page 56 Rectifying faults Error messages (power source) Category Error Possible cause Remedy Sec. overvolta- Overvoltage at output: Inverter Inform Service error Earth fault (PE Connection between welding Remove electrical connection error) wire and machine casing Quick shut- Removing the logical signal Eliminate errors on the higher- down “robot ready”...
- Page 57 Rectifying faults Error messages (power source) Category Error Possible cause Remedy Short circuit Check welding circuit for short Check welding circuit; isolate circuit welding torch before deposi- ting Incompatible A machine connected to the Please disconnect the incom- machine system is not compatible patible machine from the sys- Incompatible A machine's software is not...
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Page 58: Warnings
Rectifying faults Warnings Warnings Depending on the display options of the machine display, a warning message is displayed as follows: Display type - machine control Display Graphic display two 7-segment displays one 7-segment display The cause of the warning is indicated by a corresponding warning number (see table). •... -
Page 59: 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 Functional errors Mains fuse triggers - unsuitable mains fuse Set up recommended mains fuse >... -
Page 60: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Wire feed problems Wire feed roll holder is worn (wire feed rolls must be firmly seated on their holders and must not have any play) Replace wire feed roll holder (092-002960-E0000) > see 10.1.4 chapter) ... -
Page 61: Fixing The Pump Shaft (Coolant Circuit)
Rectifying faults Fixing the pump shaft (coolant circuit) 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. Figure 7-2 • Switch off machine at the main switch. •... -
Page 62: 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 Dimensions inch inch inch 38.4 38.4 34.7 27.0 23.2 15.7 1152 45.3 33.6 33.6... -
Page 63: Welding Torch Cooling System
Technical data Dimensions and weighte 8.1.1 Welding torch cooling system Torch cooling F06W Cooling capacity at 1 l/min (+25°C/77°F) 1.5 KW Max. flow rate 5 l/min 1.3 gal./min max. delivery height 35 m 115 ft. Max. pump pressure 3.5 bar 0.35 MPa Pump Centrifugal pump... -
Page 64: Performance Data
Technical data Performance data Performance data 8.2.1 Titan XQ 350 C puls MIG/MAG Welding current (I 5 A to 350 A Welding voltage according to standard (U 14,3 V to 31,5 V 20,2 V to 34,0 V 10,2 V to 24,0 V Duty cycle DC at 40°... - Page 65 Technical data Titan XQ 400 C puls Ambient temperature dependent on coolant! Observe coolant temperature range! 099-005609-EW501 07.08.2019...
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Page 66: Titan Xq 400 C Puls
Technical data Titan XQ 400 C puls Titan XQ 400 C puls MIG/MAG Welding current (I 5 A to 400 A Welding voltage according to standard (U 14,3 V to 34 V 20,2 V to 36,0 V 10,2 V to 26,0 V Duty cycle DC at 40°... -
Page 67: 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 DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 32A 5POLE/CEE... -
Page 68: Extension Cable
Accessories Options 9.3.2 Extension cable Type Designation Item no. RV5M19 19POLE 5M Extension cable 092-000857-00000 RV5M19 19POL 10M Extension cable 092-000857-00010 RV5M19 19POL 15M Extension cable 092-000857-00015 RV5M19 19POL 20M Extension cable 092-000857-00020 Options Type Designation Item no. ON FILTER Dirt filter for air inlet 092-003337-00000 ON SHOCK PROTECT... -
Page 69: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts Performance specifications and guarantee only in connection with original spare and replacement parts! 10.1 Wire feed rollers 10.1.1 Wire feed rollers for steel wire Type Designation Item no. FE 4R 0.6 MM/0.023 INCH Drive roll set, 37 mm, 4 rolls, V-groove for steel, 092-002770-00006 LIGHT PINK... -
Page 70: 10.1.3 Wire Feed Rollers For Cored Wire
Replaceable parts Wire feed rollers 10.1.3 Wire feed rollers for cored wire Type Designation Item no. FUEL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00008 WHITE/ORANGE flux cored wire FUEL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00010 BLUE/ORANGE... -
Page 71: Appendix
Appendix Searching for a dealer Appendix 11.1 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005609-EW501 07.08.2019...
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