EWM Drive XQ AC Operating Instructions Manual
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Summary of Contents for EWM Drive XQ AC
- Page 1 Operating instructions Wire feed unit Drive XQ AC 099-005613-EW501 Observe additional system documents! 23.04.2019...
- 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 3 Intended use ............................ - Page 4 Warnings ............................42 Vent coolant circuit ........................43 Checklist for rectifying faults ......................43 8 Technical data............................45 Drive XQ AC ..........................45 9 Accessories ............................46 Welding torch, electrode holder and workpiece lead ..............46 General accessories ........................46 7-pole remote control ........................
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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: 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 product complies with the following EC directives in terms of its design and construction: •... -
Page 9: Service Documents (Spare Parts And Circuit Diagrams)
Intended use Documents which also apply 3.3.3 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 10: Machine Description - Quick Overview
Machine description – quick overview Front view / side view from the right Machine description – quick overview Front view / side view from the right Figure 4-1 099-005613-EW501 23.04.2019... - Page 11 Machine description – quick overview Front view / side view from the right Item Symbol Description Carrying handle Protective cap, welding machine control > see 5.2.6 chapter Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Turning mandrel support The wire feeder is placed onto the power source turning mandrel using this support to enable horizontal pivoting of the machine.
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Page 12: Rear View / Side View From Left
Machine description – quick overview Rear view / side view from left Rear view / side view from left Figure 4-2 099-005613-EW501 23.04.2019... - Page 13 Machine description – quick overview Rear view / side view from left Item Symbol Description Connection socket 7-pole (digital) For connecting digital accessory components (remote control, etc.). Power source welding current connector plug Welding current connection between power source and wire feeder Shielding gas connection (inlet) Connecting nipple, G¼”...
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Page 14: 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 15: Transport And Storage
Design and function Transport and installation 5.1.1.2 Transport and storage Storage in a closed room, temperature range of the ambient air: • -30 °C to +70 °C (-22 °F to 158 °F) Relative humidity • up to 90 % at 20 °C (68 °F) Ambient temperature dependent on coolant! Observe the coolant temperature range of the torch coo- ling 5.1.2... -
Page 16: Maximal Hose Package Length
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 17: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.3 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 18: Stray Welding Currents
Design and function Transport and installation 5.1.4 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 19: Intermediate Hose Package Connection
Design and function Intermediate hose package connection Intermediate hose package connection Figure 5-5 Item Symbol Description Power source Intermediate hose package Power source welding current connector plug Welding current connection between power source and wire feeder Shielding gas connection (inlet) Connecting nipple, G¼”... -
Page 20: Intermediate Hose Package Strain Relief
The attachment must always take place on both sides of the intermediate hose package! • The connections of the hose package must be locked properly! 5.2.2 Locking the strain relief EWM intermediate hose package Figure 5-6 5.2.3 Shielding gas supply (shielding gas cylinder for welding machine) WARNING... -
Page 21: Pressure Regulator Connection
Design and function Intermediate hose package connection 5.2.4 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 22: Protective Flap, Welding Machine Control
• Power source of type Titan XQ 400 AC puls D • Wire feeder of type Drive XQ AC • Welding torch series of type PM 551 W AC Note the following equipment and setting features of the wire feed system: •... -
Page 23: Welding Torch Connection
Design and function MIG/MAG welding 5.3.2 Welding torch connection Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •... - Page 24 Design and function MIG/MAG welding Preparation for connecting welding torches with a liner: • Push forward the capillary tube on the wire feed side in the direction of the Euro torch connector and remove it there. • Insert the liner guide tube from the Euro torch connector side. •...
- Page 25 Design and function MIG/MAG welding Figure 5-11 Item Symbol Description Welding torch Welding torch hose package Welding torch connection (Euro torch connector) Welding current, shielding gas and torch trigger integrated Quick connect coupling (blue) coolant supply Quick connect coupling (red) coolant return 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control...
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Page 26: Wire Feed
Design and function MIG/MAG welding 5.3.3 Wire feed CAUTION Risk of injury due to moving parts! The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons! • Do not reach into rotating or moving parts or drive components! •... -
Page 27: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.3.3.2 Changing the wire feed rollers Figure 5-13 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 28 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 29: Inching The Wire Electrode
Design and function MIG/MAG welding 5.3.3.3 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 30: 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 5.3.2 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 31: Standard Mig/Mag Torch
Design and function MIG/MAG welding 5.3.4 Standard MIG/MAG torch The MIG welding torch trigger is essentially used to start and stop the welding process. Operating elements Functions Torch trigger • Start/stop welding 5.3.5 MIG/MAG special-torches 5.3.5.1 Switching between Push/Pull and intermediate drive 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... -
Page 32: Tig Welding
Design and function TIG welding TIG welding 5.4.1 Welding torch connection Figure 5-17 Item Symbol Description Welding torch Welding torch hose package Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Quick connect coupling (blue) coolant supply Quick connect coupling (red) coolant return... -
Page 33: Mma Welding
Design and function MMA welding MMA welding CAUTION Risk from electrical current! If welding is carried out alternately using different methods and if a welding torch and an electrode holder remain connected to the machine, the open-circuit/welding voltage is applied simultaneously on all cables. •... -
Page 34: Access Control
Design and function Access control Access control To protect against unauthorised or unintentional adjustment of the welding parameters on the machine, the control input can be locked with the aid of a key switch. In key switch position 1 all functions and parameters can be set without restriction. In key switch position 0 the following functions and parameters cannot be changed: •... -
Page 35: Remote Control Connection Socket, 19-Pole
Design and function Interfaces for automation 5.8.1 Remote control connection socket, 19-pole Figure 5-19 Signal form Short description Output Connection for PE cable screen Output Reference voltage for potentiometer 10 V (max. 10 mA) Input Control voltage specification (0 V–10 V) – wire feed speed Output Reference potential (0 V) Input... -
Page 36: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed. -
Page 37: Maintenance Work, Intervals
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! 099-005613-EW501 23.04.2019... -
Page 38: 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. 099-005613-EW501 23.04.2019... -
Page 39: 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 40 Rectifying faults Error messages (power source) Category Error Possible cause Remedy error Pre-pressure too low Remove kinks in the hose package; nominal value: 4-6 bar primary pressure Sec. overvolta- Overvoltage at output: Inverter Inform Service error Earth fault (PE Connection between welding Remove electrical connection error) wire and machine casing...
- Page 41 Rectifying faults Warnings Category Error Possible cause Remedy Permanent overload of the wire Do not place the liner in tight drive (slave drive) radii; check wire core for smooth movement Short circuit Check welding circuit for short Check welding circuit; isolate circuit welding torch before deposi- ting...
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Page 42: Warnings
Rectifying faults Warnings Warnings A warning is denoted by the letter A on the machine display, or Att in case of multiple machine displays. The possible cause of the warning is signalled by the respective warning code (see table). • In case of multiple warnings, these are displayed in sequence. -
Page 43: 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 Checklist for rectifying faults The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation! Legend... - Page 44 Rectifying faults Checklist for rectifying faults 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 flowing across the protective e- arth).
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Page 45: Technical Data
Technical data Drive XQ AC Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Drive XQ AC Supply voltage (from the welding machine) 42 VAC Duty cycle DC at 40° C 40 % 600 A... -
Page 46: Accessories
Accessories Welding torch, electrode holder and workpiece lead Accessories Welding torch, electrode holder and workpiece lead Type Designation Item no. PM 551 W AC RD3 X M9 3 m MIG/MAG function torch with OLED graphic display, 094-700005-40600 Ø 1,0 mm water-cooled, X technology PM 551 W AC RD3 X M9 4 m MIG/MAG function torch with OLED graphic display,... -
Page 47: Extension Cable
Accessories Options 9.4.2 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 PS EXT D01 Retrofit set: Extension turning mandrel, for holding a 092-002871-00000 wire feeder with wheel kit ON WAK D01... -
Page 48: 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 49: 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 50: 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" 099-005613-EW501 23.04.2019...
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