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Summary of Contents for EWM Tetrix XQ 350 puls DC
- Page 1 Operating instructions Power source Tetrix XQ 350 puls DC Tetrix XQ 400 puls DC Tetrix XQ 500 puls DC Tetrix XQ 600 puls DC 099-005670-EW501 Observe additional system documents! 7.03.2022...
- 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 ..........................6 Notes on using these operating instructions ................6 Explanation of icons ....................... 7 Safety instructions ........................8 Transport and installation ....................11 3 Intended use .......................... - Page 4 8 Technical data ..........................57 Dimensions and weighte ...................... 57 Welding torch cooling system ....................57 Performance data ......................... 58 8.3.1 Tetrix XQ 350 puls DC ..................58 8.3.2 Tetrix XQ 400 puls DC ..................59 8.3.3 Tetrix XQ 500 puls DC ..................60 8.3.4...
- Page 5 Contents Notes on using these operating instructions 099-005670-EW501 7.03.2022...
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Page 6: 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 7: 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 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 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 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 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 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
3.2.1 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 This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 14: Part Of The Complete Documentation
Intended use Documents which also apply 3.2.6 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 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 XQ: Type Figure Transport properties Torch cooling Figure 4-1 099-005670-EW501 7.03.2022... -
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 4-2 099-005670-EW501 7.03.2022... - Page 17 Machine description – quick overview Front view / side view from the right Item Symbol Description Main Switch Switching the machine on or off. LED status bar - display of operating status The operating status is indicated by a light guide > see 5.1.10.1 chapter. 19-pole connection socket (analogue) For connecting the control lead.
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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 4-3 099-005670-EW501 7.03.2022... - 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 Connection socket, “-” welding current Electrode holder connection Securing elements for shielding gas cylinder (strap/chain) Bracket for shielding gas cylinder Aluminium extrusion profile flexFit...
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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: Craning Principle
Design and function Transport and installation 5.1.2 Craning principle Figure 5-1 5.1.3 Ambient conditions The 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: Workpiece Lead, General
Design and function Transport and installation 5.1.5 Workpiece lead, general CAUTION Risk of burning due to incorrect welding current connection! If the welding current plugs (machine connections) are not locked or if the workpiece connection is contaminated (paint, corrosion), these connections and leads can heat up and cause burns when touched! •... -
Page 23: 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 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 defined time (filling the hose package). If the machine does not detect sufficient coolant flow during this time, the coolant pump is switched off (protec- tion against damage caused by dry running). -
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: Visual Inspection Of The Set Mains Voltage
Design and function Transport and installation • Adaptation and marking of the mains voltage > see 5.1.9.2 chapter • Carry out a safety check after intervention in the machine > see 5.1.9.3 chapter! 5.1.9.1 Visual inspection of the set mains voltage The set mains voltage is marked on the rating plate and the label on the mains connection cable by a marking. -
Page 28: Adjusting The Power Source To The Mains Voltage
Design and function Transport and installation 5.1.9.2 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 29: Mains Configuration
Design and function Transport and installation 5.1.9.4 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 30: 5.1.11 Protective Flap, Welding Machine Control
Design and function Transport and installation 5.1.11 Protective flap, welding machine control Figure 5-10 • 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. 099-005670-EW501 7.03.2022... -
Page 31: Tig Welding
Design and function TIG welding TIG welding 5.2.1 Welding torch and workpiece line connection Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-11 Item Symbol Description Welding torch Welding torch hose package Connection socket (welding torch control cable) >... -
Page 32: Control Lead Connection
All standard 5- and 8-pin TIG welding torches can be connected to this machine and operated (except for 8-pin potentiometer torches). 5-pin EWM function torches with X-TECHNOLOGIE are also supposed. TIG welding machines are equipped ex works with a dedicated connection socket for the welding torch control cable (5- or 8-pole). -
Page 33: Shielding Gas Hose Connection
Design and function TIG welding • 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 34: Mma Welding
Design and function MMA welding MMA welding 5.3.1 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 35: Interfaces For Automation
Design and function Interfaces for automation Interfaces for automation Damage to the machine due to improper connection! Unsuitable control leads or incorrect connection of input and output signals can cause damage to the machine. • Only use shielded control leads! •... -
Page 36: Remote Control Connection Socket, 19-Pole
Design and function PC interface 5.5.2 Remote control connection socket, 19-pole Figure 5-16 Signal form Designation Output Connection for cable shielding (PE) Output Current flow signal I>0, potential-free (max. +- 15 V / 100 mA) Input Switching of welding current potential (PWS) only for AC machines (reference potential 0 V) Output Reference voltage for potentiometer 10 V (max 10 mA) -
Page 37: Connection
Design and function Network connection 5.6.1 Connection Equipment damage or faults may occur if the PC is connected incorrectly! Not using the SECINT X10USB interface results in equipment damage or faults in signal trans- mission. The PC may be destroyed due to high frequency ignition pulses. •... -
Page 38: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General WARNING Improper maintenance, testing and repairs! Maintenance, testing and repair of the machine may only be carried out by skilled and qualified personnel (authorised service personnel). A competent person is someone who, based on training, knowledge and experience, can recognize the hazards and pos- sible consequential damage that may occur when testing power sources and can take the necessary safety precautions. -
Page 39: 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 40: Dirt Filter
Maintenance, care and disposal Maintenance schedule 6.3.1 Dirt filter When using a dirt filter, the cooling air throughput is reduced and the duty cycle of the machine is reduced as a result. The duty cycle decreases with the increasing contamination of the filter. The dirt filter must be remove at regular intervals and cleaned by blowing out with compressed air (depending on the level of soiling). -
Page 41: 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 6-3 • Switch off the machine and disconnect the mains plug. Position a suitable collecting container under the drain plug of the coolant tank. - Page 42 Insert the cleaned filter screen into the filler neck and screw the drain plug with seal back into the tank. • Fill the tank with original EWM coolant up to the maximum level. After filling, refit the tank cap and vent the coolant circuit > see 7.4 chapter.
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Page 43: 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! Appropriate training is required for the following maintenance steps to prevent injuries. • Only authorised service personnel may carry out this maintenance step. •... -
Page 44: 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! 099-005670-EW501 7.03.2022... -
Page 45: 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 46: 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 47 Rectifying faults Error messages (power source) Error 6: Mains undervoltage Mains voltage is too low. Check the mains voltages and compare them with the connection voltages of the power source. Error 7: Low coolant level Category B Low flow rate. Fill with coolant.
- Page 48 Rectifying faults Error messages (power source) Error 16: Fast shut-down Category A Error in the emergency stop circuit. Check the emergency stop circuit. Temperature error Allow the switched-on machine to cool. Check fan and clean or replace. ...
- Page 49 Rectifying faults Error messages (power source) Error 22: Excess coolant temperature Category B Coolant is overheating Allow the switched-on machine to cool. Fan is blocked, dirty or defective. Check, clean or replace the fan. Air inlet or outlet is blocked. Check the air inlet and outlet.
- Page 50 Rectifying faults Error messages (power source) Error 36: S errors S conditions are violated. Switch the machine off and on. Request service. Error 37: Electronics error Temperature error. Allow the switched-on machine to cool. Error 38: Error IIST ...
- Page 51 Rectifying faults Error messages (power source) Error 53: No wire feeder 2 Category B Wire feeder 2 was not detected. Check the control cable connections. Error 54: VRD error Error in the open-circuit voltage reduction. If necessary, disconnect the external machine from the welding circuit. ...
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Page 52: Warnings
Rectifying faults Warnings Error 63: Mains voltage error Operating and mains voltage are incompatible. Check or adjust the operating and mains voltage. See technical data for values and other switching thresholds > see 8.3 chapter. Warnings Depending on the display options of the machine display, a warning message is displayed as follows: Display type - machine control Display Graphic display... -
Page 53: Checklist For Rectifying Faults
Rectifying faults Checklist for rectifying faults Warning Potential cause / remedy 20 Coolant temperature warning Check coolant level and top up if necessary. 21 Excess temperature 2 reserved 22 Excess temperature 3 reserved 23 Excess temperature 4 reserved 24 Coolant flow warning Check coolant supply. - Page 54 Rectifying faults Checklist for rectifying faults Functional errors Insufficient coolant flow Check coolant level and refill if necessary Eliminate kinks in conduit system (hose packages) Reset automatic cutout of the coolant pump by activating Air in the coolant circuit Vent coolant circuit >...
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Page 55: 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 56: 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 7-3 • Switch off machine at the main switch. •... -
Page 57: 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 F06R1/R2 F06RS F06P Dimensions (l x b x h) inch inch inch 1152 45.3 33.6 33.6 27.0 23.2 15.7 38.4... -
Page 58: Performance Data
Technical data Performance data Performance data 8.3.1 Tetrix XQ 350 puls DC Welding current (I 3 A to 350 A 5 A to 350 A Welding voltage according to standard (U 10,1 V to 24 V 20,2 V to 34,0 V Duty cycle DC at 40°... -
Page 59: Tetrix Xq 400 Puls Dc
Technical data Performance data 8.3.2 Tetrix XQ 400 puls DC Welding current (I 3 A to 400 A 5 A to 400 A Welding voltage according to standard (U 10,1 V to 26 V 20,2 V to 36,0 V Duty cycle DC at 40° C 400 A (80%) 370 A (100%) Mains voltage... -
Page 60: Tetrix Xq 500 Puls Dc
Technical data Performance data 8.3.3 Tetrix XQ 500 puls DC Welding current (I 3 A to 500 A 5 A to 500 A Welding voltage according to standard (U 10,1 V to 30,0 V 20,2 V to 40,0 V Duty cycle DC at 40° C 500 A (80%) 470 A (100%) Mains voltage... -
Page 61: Tetrix Xq 600 Puls Dc
Technical data Performance data 8.3.4 Tetrix XQ 600 puls DC Welding current (I 3 A to 600 A 5 A to 600 A Welding voltage according to standard (U 10,1 V to 34,0 V 20,2 V to 44,0 V Duty cycle DC at 40° C 600 A (40%) 550 A (60%) 470 A (100%) -
Page 62: Accessories
Accessories Welding torch cooling system Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Welding torch cooling system Type Designation Item no. HOSE BRIDGE UNI Tube bridge 092-007843-00000 9.1.1 Coolant - type blueCool Type Designation Item no. -
Page 63: Options
Accessories Options Options Type Designation Item no. ON Filter F06 Dirt filter for air inlet 092-003337-00000 ON Shock Protect F06 Ram protection 092-003334-00000 ON TS F06 R Torch holder, right 092-003335-00000 ON TS F06 L Torch holder, left 092-003360-00000 ON HS F06 Holder for holding long hose packages and welding 092-003333-00000 torch... -
Page 64: Appendix
Appendix Searching for a dealer Appendix 10.1 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005670-EW501 7.03.2022...
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