EWM Drive XQ Operating Instructions Manual
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- Operating instructions manual (55 pages) ,
- Operating instructions manual (59 pages)
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Summary of Contents for EWM Drive XQ
- Page 1 Operating instructions Wire feed unit Drive XQ 099-005570-EW501 Observe additional system documents! 10.01.2022...
- 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 Error messages (power source) ................... 43 Warnings ..........................46 Checklist for rectifying faults ....................48 Vent coolant circuit ....................... 50 8 Technical data ..........................51 Drive XQ ..........................51 9 Accessories ..........................52 General accessories ......................52 Welding torch cooling system ....................52 9.2.1 Coolant - type blueCool ..................
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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 / side view from the right Machine description – quick overview Front view / side view from the right Figure 4-1 099-005570-EW501 10.01.2022... - Page 15 Machine description – quick overview Front view / side view from the right Item Symbol Description Carrying handle Protective cap, welding machine control > see 5.2.5 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 16: Rear View / Side View From Left
Machine description – quick overview Rear view / side view from left Rear view / side view from left Figure 4-2 099-005570-EW501 10.01.2022... - Page 17 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 Connection thread - G¼"...
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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: 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 20: 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 21: 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 22: 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 Connection thread - G¼" Shielding gas connection (inlet) Quick connect coupling (red) coolant return... -
Page 23: 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 5-6 5.2.2 Shielding gas supply (shielding gas cylinder for welding machine) WARNING... -
Page 24: Pressure Regulator Connection
Design and function Intermediate hose package connection 5.2.3 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 25: Protective Flap, Welding Machine Control
Design and function MIG/MAG welding 5.2.5 Protective flap, welding machine control Figure 5-8 Item Symbol Description Protective cap • Carefully click the suspension of the protective cap towards front top. MIG/MAG welding 5.3.1 Assemble the wire guide The Euro torch connector is factory-fitted with a guide tube for welding torches with steel liner. Conver- sion is necessary if a welding torch with a steel liner is used! •... - Page 26 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. •...
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Page 27: 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 coo- lant circuit is interrupted and equipment damage can occur. •... -
Page 28: 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 29: Changing The Wire Feed Rollers
Design and function MIG/MAG welding Figure 5-13 Observe the unwinding direction of the wire spool. 5.3.3.2 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. - Page 30 Design and function MIG/MAG welding • Rotate the tommy by 90° clockwise or anti-clockwise (tommy locks into place). • Fold the closure brackets outwards by 90°. • Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip up- wards).
- Page 31 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 32: 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 in- jury including injuries to the face and eyes! •... -
Page 33: Spool Brake Setting
Design and function MIG/MAG welding • 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. A table with the setting values can be found on a sticker near the wire drive. -
Page 34: Mig/Mag Special-Torches
Design and function TIG 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 specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. -
Page 35: Welding Task Selection
Design and function MMA welding or gouging Item Symbol Description Quick connect coupling (red) coolant return "-" welding current connection socket • ----------- TIG welding: Welding current connection for welding torch Power source • Insert the central plug for the welding torch into the central connector and screw together with crown nut. -
Page 36: Welding Task Selection
Design and function Remote control Item Symbol Description Electrode holder Gouging torch Note the additional system documents! Connection socket, welding current Welding current potential of the torch connector for MMA welding or gouging Intermediate hose package Power source Workpiece • Insert the electrode holder or gouge plug into the welding current connection socket (wire feeder) and lock in place by turning to the right. -
Page 37: 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 38: Remote Control Connection Socket, 19-Pole
Design and function Interfaces for automation 5.8.1 Remote control connection socket, 19-pole Figure 5-21 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 39: 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 40: 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 099-005570-EW501 10.01.2022... -
Page 41: Maintenance Schedule
Maintenance, care and disposal Maintenance schedule Maintenance schedule Maintenance step Only personnel designated as inspectors or repairers due to their trai- ning are allowed to carry out the relevant work step! Non-applicable in- spection points are omitted. • Check and clean the welding torch. Deposits in the welding torch may cause short circuits, impair the welding result and lead to welding torch damage! •... -
Page 42: Disposing Of Equipment
Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html. -
Page 43: 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 44 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 45 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 46: 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 47 Rectifying faults Warnings Warning Possible cause / remedy 8 Welding circuit The inductance of the welding circuit 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 of the coo- Check temperature and switching thresholds.
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Page 48: Checklist For Rectifying Faults
Rectifying faults Checklist for rectifying faults Warning Possible cause / remedy 38 Incomplete component informa- Check XNET component management. tion 39 Mains half-wave failure Check supply voltage. 40 Weak power grid Check supply voltage. 41 Cooling unit not recognised Check the cooling unit connection. 47 Battery (Bluetooth remote con- Battery level is low (replace battery) trol) - Page 49 Rectifying faults Checklist for rectifying faults Coolant error/no coolant flowing Insufficient coolant flow Check coolant level and refill if necessary Air in the coolant circuit Vent coolant circuit > see 7.4 chapter 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) >...
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Page 50: Vent Coolant Circuit
Rectifying faults Vent coolant circuit 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 (connection open). 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 7-2 •... -
Page 51: Technical Data
Technical data Drive XQ Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Drive XQ Supply voltage (from the welding machine) 42 VAC Duty cycle DC at 40° C 40 % 600 A 100 %... -
Page 52: 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 AK300 Wire spool adapter K300 094-001803-00001 HOSE BRIDGE UNI... -
Page 53: 19-Pole Remote Control
Accessories 19-pole remote control 19-pole remote control Type Designation Item no. R10 19POL Remote control 090-008087-00000 Remote control to set the wire speed and welding RG10 19POL 5M 090-008108-00000 voltage correction R20 19POL Program changeover remote control 090-008263-00000 9.4.1 Connection cables Type Designation Item no. -
Page 54: 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 55: 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 56: 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" 099-005570-EW501 10.01.2022...
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