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Summary of Contents for EWM Tetrix XQ 300 puls DC Comfort 3.0
- Page 1 Operating instructions Power source Tetrix XQ 300 puls DC Comfort 3.0 Tetrix XQ 300 puls AC/DC Comfort 3.0 Tetrix XQ 300 puls DC Expert 3.0 Tetrix XQ 300 puls AC/DC Expert 3.0 099-005692-EW501 Observe additional system documents! 24.4.2023...
- 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.
- Page 3 Contents Notes on using these operating instructions 099-005692-EW501 24.4.2023...
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Page 4: Table Of Contents
Contents Notes on using these operating instructions Contents 1 Contents ............................4 2 For your safety..........................7 Notes on using these operating instructions ................7 Explanation of icons ....................... 7 Safety instructions ........................8 Transport and installation ..................... 12 3 Intended use ..........................14 Applications .......................... - Page 5 Contents Notes on using these operating instructions 6.3.1 Coolant error ......................36 6.3.2 Dirt filter ........................ 37 6.3.2.1 Power source ..................37 6.3.2.2 Cooling unit ................... 37 6.3.3 Power source (inverter) ..................38 6.3.4 Heat exchanger (torch cooling) ................38 6.3.5 Annual test (inspection and testing during operation) ..........
- Page 6 Contents Notes on using these operating instructions 099-005692-EW501 24.4.2023...
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Page 7: 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 8: Safety Instructions
For your safety Safety instructions 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 Incorrect / Invalid Switch Correct / Valid Turn Input Numerical value –... - Page 9 For your safety 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 10 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 11 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases may lead to shortness of breath and poisoning! The ultraviolet radia- tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso- nous phosgene. • Ensure sufficient fresh air! •...
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Page 12: 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 13 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 14: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and stand- ards applicable for use in industry and trade. It may only be used for the welding proce- dures indicated at the rating plate. -
Page 15: Documents Which Also Apply
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 16: Part Of The Complete Documentation
Intended use Documents which also apply 3.3.6 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 17: Machine Description - Quick Overview
Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-005692-EW501 24.4.2023... - Page 18 Machine description – quick overview Front view / rear view Item Symbol Description Machine control (see the relevant control operating instructions) Protective cap > see 5.1.10 chapter Connection socket (welding torch control cable) > see 5.2.1.1 chapter Connection socket, “+” welding current How to connect the accessories depends on the welding procedure.
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Page 19: 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 20: Ambient Conditions
Design and function Transport and installation 5.1.1 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 21: Transport Belt
Design and function Transport and installation 5.1.4 Transport belt 5.1.4.1 Adjusting the length of the carrying strap Figure 5-2 5.1.5 Dirt filter These accessory components can be retrofitted as an option > see 9 chapter. When using a dirt filter, the cooling air throughput is reduced and the duty cycle of the machine is reduced as a result. - Page 22 Design and function Transport and installation The modular design allows the power source to be retrofitted with a cooling unit for liquid torch cooling. For information about connection and installation, see the documentation for the cooling unit. Figure 5-3 1 Switch off the power source and disconnect the mains plug. 2 Place the power source to the side.
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Page 23: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 3 Loosen the screws on the lower cover. Move the cover to the park position towards the front. Screw the cover back on. 4 Undo all four Torx screws from the module connectors of the cooling unit. 5 Route the supply lines through the cable duct of the cooling unit. -
Page 24: Stray Welding Currents
Design and function Transport and installation • Use an individual welding lead to the workpiece for each welding machine! Figure 5-5 • Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! • Always keep leads as short as possible! Lay any excess cable lengths in meanders. -
Page 25: Mains Connection
Design and function Transport and installation 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. • Check that all welding current connections are firmly secured and electrical connections are in perfect condition. -
Page 26: Mains Configuration
Design and function Transport and installation 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 27: Led Status Bar - Display Of Operating Status
Design and function Transport and installation 5.1.9.2 LED status bar - display of operating status A light guide on the front of the housing (LED status bar) shows the user the current operating status of the device. Colour of the LED status bar Operating status white (change: light/dark) Booting (switching on up to welding readiness) -
Page 28: Tig Welding
5.2.1.1 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. Figure 5-12 099-005692-EW501 24.4.2023... -
Page 29: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function TIG welding 5.2.2 Shielding gas supply (shielding gas cylinder for welding machine) WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause seri- ous injuries! •... -
Page 30: Shielding Gas Hose Connection
Design and function MMA welding 5.2.2.2 Shielding gas hose connection Figure 5-14 Item Symbol Description Connection thread - G¼" Shielding gas connection (inlet) Shielding gas hose • Screw the gas hose connection to the shielding gas connection (inlet) on the machine gas-tight. 5.2.2.3 Gas test –... -
Page 31: Remote Control
Design and function Remote control Item Symbol Description Electrode holder Welding current lead Workpiece Workpiece lead • Insert the electrode holder plug and workpiece lead into the welding current socket depending on ap- plication and lock in place by turning to the right. The corresponding polarity will be based on the infor- mation of the electrode manufacturer on the electrode packaging. -
Page 32: Remote Control Connection Socket, 19-Pole
Design and function PC interface 5.5.1 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 33: 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 34: 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 35: 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! Inapplicable checkpoints 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 36: Coolant Error
Maintenance, care and disposal Maintenance schedule 6.3.1 Coolant error Figure 6-1 • Switch off the machine and disconnect the mains plug. Position a suitable collecting container under the drain plug of the coolant tank. • Unscrew the drain plug of the coolant tank (remove the tank cap to ventilate). Figure 6-2 •... -
Page 37: Dirt Filter
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. -
Page 38: Power Source (Inverter)
Maintenance, care and disposal Maintenance schedule 6.3.3 Power source (inverter) 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 39: Annual Test (Inspection And Testing During Operation)
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 40: Rectifying Faults
Rectifying faults Checklist for rectifying faults 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 41: Warnings
Rectifying faults Warnings Unstable arc Material inclusions in the tungsten electrode due to contact with filler material or workpiece Regrind or replace the tungsten electrode Incompatible parameter settings Check settings and correct if necessary Pore formation ... - Page 42 Rectifying faults Warnings Warning Potential cause / remedy 13 Contact error The resistance in the welding circuit is too high. Check earth connection. 14 Alignment error Switch the machine off and on. If the error persists, notify Ser- vice. 15 Mains fuse The power limit of the mains fuse is reached and the welding power is reduced.
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Page 43: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) The possible error numbers displayed depend on the machine series and version! Depending on the options of the machine display, a fault is shown as follows: Display type - machine control Display Graphic display two 7-segment displays... - Page 44 Rectifying faults Error messages (power source) Error 7: Low coolant level Category B Low flow rate. Fill with coolant. Check coolant flow - remove kinks in the hose package. Adjust the flow threshold Clean the cooler. ...
- Page 45 Rectifying faults Error messages (power source) Error 16: Pilot arc power source - collective error Category A The external emergency stop circuit has been interrupted. Check the emergency stop circuit and eliminate the cause of the error. The emergency stop circuit of the power source has been activated (internally configurable). Deactivate the emergency stop circuit.
- Page 46 Rectifying faults Error messages (power source) Error 20: Low coolant level Category B Low flow rate. Fill with coolant. Check coolant flow - remove kinks in the hose package. Adjust the flow threshold Clean the cooler. ...
- Page 47 Rectifying faults Error messages (power source) Error 32: Error I>0 Current recording is faulty. Request service. Error 33: Error UIST Voltage recording is faulty. Eliminate the short circuit in the welding circuit. Remove the external sensor voltage. ...
- Page 48 Rectifying faults Error messages (power source) Error 48: Ignition error Category B No ignition at process start (automated machines). Check the wire feeding Check the load cable connections in the welding circuit. Clean corroded surfaces on the workpiece before welding if necessary. ...
- Page 49 Rectifying faults Error messages (power source) Error 57: Slave tacho error Category B Fault in the wire feeder (slave drive). Check the connections (connectors, lines). Permanent overload of the wire drive (slave drive). Do not lay the liner in tight radii. ...
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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 Dimensions and weighte Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Dimensions and weighte Tetrix XQ 300 puls DC Tetrix XQ 300 puls AC/DC Dimensions (l x b x h) 257 mm / 10.1 inch 224 mm / 8.8 inch 550 mm / 21.7 inch 415 mm / 16.3 inch... -
Page 52: Performance Data
Technical data Performance data Performance data 8.2.1 Tetrix XQ 300 puls DC Welding current (I 3 A to 300 A 5 A to 300 A Welding voltage according to standard 10,1 V to 22 V 20,2 V to 32 V Duty cycle DC at 40°... - Page 53 Technical data Performance data Ambient temperature dependent on coolant! Observe coolant temperature range! 099-005692-EW501 24.4.2023...
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Page 54: Tetrix Xq 300 Puls Ac/Dc
Technical data Performance data 8.2.2 Tetrix XQ 300 puls AC/DC Welding current (I 3 A to 300 A 5 A to 300 A Welding voltage according to standard 10,1 V to 22 V 20,2 V to 32 V Duty cycle DC at 40° C 30 % 300 A 40 %... -
Page 55: 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. GH 2X1/4'' 2M Gas hose 094-000010-00001 DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 Remote controls and accessories... -
Page 56: Options
Accessories Options Type Designation Item no. Trolly XQ 35-3 Transport cart (2 casters) for transporting a power 090-008847-00000 source, cooling unit and shielding gas cylinder Trolly XQ 55-3 Transport cart 090-008637-00000 Options Type Designation Item no. ON Filter Dirt filter for air inlet 092-004516-00000 ON CC TG.11 Transparent cover cap for protection of control... -
Page 57: 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" 099-005692-EW501 24.4.2023...
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