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Summary of Contents for EWM Drive XQ IC D200
- Page 1 Operating instructions Wire feed unit Drive XQ IC D200 099-005637-EW501 Observe additional system documents! 27.04.2021...
- 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 using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use .......................... - Page 4 Contents Notes on using these operating instructions Maintenance work, intervals....................39 6.2.1 Daily maintenance tasks ..................39 6.2.2 Monthly maintenance tasks .................. 39 6.2.3 Annual test (inspection and testing during operation) .......... 39 Disposing of equipment ......................40 7 Rectifying faults ..........................41 Error messages (power source) ...................
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Page 5: For Your Safety
For your safety Notes on using these operating instructions For your safety Notes on using these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 6: Explanation Of Icons
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the u- Activate and release / Tap / Tip ser must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Correct / Valid... -
Page 7: 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 8 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
- Page 9 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 10: Transport And Installation
For your safety Transport and installation CAUTION 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 int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines. - Page 11 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 12: 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 This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 13: Part Of The Complete Documentation
Intended use Documents which also apply 3.3.5 Part of the complete documentation This document is 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 14: Machine Description - Quick Overview
Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted > see 9 chapter. Figure 4-1 099-005637-EW501 27.04.2021... - Page 15 Machine description – quick overview Front view / rear view Item Symbol Description Transport elements Transport handle and transport belt > see 5.1.2 chapter Machine control (see the relevant control operating instructions) Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Connection depending on the device version 19-pole connection socket - optional...
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Page 16: Side View From Left And Right
Machine description – quick overview Side view from left and right Side view from left and right The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted > see 9 chapter. Figure 4-2 099-005637-EW501 27.04.2021... - Page 17 Machine description – quick overview Side view from left and right Item Symbol Description Wire spool holder Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, additional stickers with information on the replace- ment parts and JOB lists will be located on the inside.
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Page 18: 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 19: Transport Elements
Design and function Transport and installation 5.1.2 Transport elements Depending on the version, a transport handle and / or a transport belt are factory fitted to the machine. If required, the respective transport element can be converted or retrofitted > see 9 chapter. Figure 5-1 The machine can be carried either centrally by the transport handle (1) or with the transport belt (2). -
Page 20: 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 21: Intermediate Hose Package Connection
Design and function Intermediate hose package connection Intermediate hose package connection Figure 5-2 Item Symbol Description Power source Intermediate hose package Intermediate hose package strain relief > see 5.2.1 chapter Connection thread - G¼" Shielding gas connection (inlet) 14-pole connection socket Wire feeder control cable Quick connect coupling (red) coolant return... -
Page 22: 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! 5.2.1.1 Locking the strain relief EWM intermediate hose package Figure 5-3 5.2.2 Shielding gas supply (shielding gas cylinder for welding machine) WARNING... -
Page 23: Pressure Regulator Connection
Design and function Intermediate hose package connection 5.2.3 Pressure regulator connection Figure 5-4 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 24: Notes On The Installation Of Welding Current Leads
Design and function Intermediate hose package connection 5.2.5 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 Intermediate hose package connection 5.2.6 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: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.3.1 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 coo- lant circuit is interrupted and equipment damage can occur. •... -
Page 27: Assemble The Wire Guide
Design and function Assemble the wire guide • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the welding torch control cable into the 19-pole connection socket and lock (MIG/MAG torches with additional control cables only). -
Page 28: Wire Feed
Design and function Assemble the wire guide 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 29 Design and function Assemble the wire guide Figure 5-12 Item Symbol Description Carrier pin For fixing the wire spool Knurled nut For fixing the wire spool • Unlock and open protective flap. • Loosen knurled nut from spool holder. • Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore.
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Page 30: Changing The Wire Feed Rollers
Design and function Assemble the wire guide 5.4.1.2 Changing the wire feed rollers Figure 5-14 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 31 Design and function Assemble the wire guide 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 32: Inching The Wire Electrode
Design and function Assemble the wire guide 5.4.1.3 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 in- jury including injuries to the face and eyes! •... -
Page 33: Spool Brake Setting
Design and function Assemble the wire guide 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 5.3.1 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 34: Tig Welding
Design and function TIG welding TIG welding 5.5.1 Welding torch connection Figure 5-18 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 (red) coolant return Quick connect coupling (blue) coolant supply... -
Page 35: Mma Welding Or Gouging
Design and function MMA welding or gouging MMA welding or gouging 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 36: 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 37: Remote Control Connection Socket, 19-Pole
Design and function Interfaces for automation 5.9.1 Remote control connection socket, 19-pole Figure 5-20 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 38: 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 39: 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! 099-005637-EW501 27.04.2021... -
Page 40: 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. 099-005637-EW501 27.04.2021... -
Page 41: 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 42 Rectifying faults Error messages (power source) Error (category) Possible cause Remedy Low coolant level low flow rate Fill coolant. Check coolant flow - remove kinks in hose package. Adjust flow threshold. [1] [3] Clean water block. Pump does not turn Turn the pump shaft.
- Page 43 Rectifying faults Error messages (power source) Error (category) Possible cause Remedy 33 Error UIST Voltage recording faulty Eliminate short circuit in welding cir- cuit. remove external sensor voltage. Request service. 34 Electronics error A/D-channel error Switch the machine off and on again. Request service.
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Page 44: Warnings
Rectifying faults Warnings Error (category) Possible cause Remedy 56 Mains phase failure One phase of the mains voltage Check mains connection, mains plug has failed. and mains fuses. Slave tacho error Wire feeder fault (slave drive). Check connectors, cables, connec- tions. - Page 45 Rectifying faults Warnings Warning Possible cause / remedy 8 Welding circuit The welding circuit inductance is too high for the selected welding task. 9 WF configuration Check WF configuration. 10 Partial inverter One of several partial inverters is not supplying welding current. 11 Excess temperature, coolant Check temperature and switching thresholds.
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Page 46: Checklist For Rectifying Faults
Rectifying faults Checklist for rectifying faults only for XQ machine series See technical data for values and other switching thresholds > see 8 chapter. 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... -
Page 47: 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 48: Technical Data
Technical data Drive XQ IC 200 Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Drive XQ IC 200 Supply voltage (from the welding machine) 42 VAC Duty cycle DC at 40° C 40 % 500 A 100 % 360 A... -
Page 49: 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. DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 HOSE BRIDGE UNI Tube bridge 092-007843-00000 Sharpener for liner... -
Page 50: Options
Accessories Options Options Type Designation Item no. ON PDM LP-XQ-S D12 Transparent protective screen for the wire feed con- 092-004179-00000 trols ON Cool W D12 Retrofitting option: Water cooling for the wire feeder 092-004180-00000 ON FLOWMETER Option analogue gas flow control with gas flow me- 092-003374-00000 Retrofitting option: Carrying handle and carrying ON Handle/ON TG D12... -
Page 51: 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 52: 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 53: 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" 099-005637-EW501 27.04.2021...
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