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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! 06.09.2023...
- 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 f orm 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 Saf ety instructions ....................8 Transport and installation ..................11 3 Intended use ........................13 Applications......................13 Documents which also apply ...................13 3.2.1... - Page 4 Fixing the pump shaft (coolant circuit) ..............58 8 Technical data ......................59 Dimensions and weighte ..................59 Welding torch cooling system..................60 Performance data....................61 8.3.1 Tetrix XQ 350 puls DC................61 8.3.2 Tetrix XQ 400 puls DC................62 8.3.3 Tetrix XQ 500 puls DC................63 8.3.4 Tetrix XQ 600 puls DC................64...
- Page 5 Contents Notes on using these operating instructions 099-005670-EW501 06.09.2023...
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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. • Saf ety 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 Activate and release / Tap / Tip user must observe. Switch of f machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn... -
Page 8: Safety Instructions
For your safety Saf ety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Caref ully read the saf ety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 9 For your safety Saf ety 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 Saf ety 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 suf f icient f resh 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 saf ety 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 bef ore 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 conf iguration Machine description – quick overview Machine configuration The f ollowing table shows the dif f erent design variants (expansion stages) of the device se ries XQ: Type Figure Transport properties Torch cooling Figure 4-1 099-005670-EW501 06.09.2023... -
Page 16: Front View / Side View From The Right
Machine description – quick overview Front view / side view f rom the right Front view / side view from the right Figure 4-2 099-005670-EW501 06.09.2023... - Page 17 Machine description – quick overview Front view / side view f rom the right Item Symbol Description Main Switch Switching the machine on or of f . LED status bar - display of operating status The operating status is indicated by a light guide > see 5.1.9.1 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 f rom lef t Rear view / side view from left Figure 4-3 099-005670-EW501 06.09.2023... - Page 19 Machine description – quick overview Rear view / side view f rom lef t Item Symbol Description Securing elements for shielding gas cylinder (strap/chain) Cooling air inlet Dirt f ilter 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...
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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 saf ety inf ormation on the f irst pages of the operating instructions! •... -
Page 21: Craning Principle
Design and function Transport and installation 5.1.1.1 Craning principle Figure 5-1 5.1.2 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 5.1.4 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 inf ormation 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-f ree installation is to be ensured, taking into account the max. delivery height. -
Page 24: Adding Coolant
Design and function Transport and installation 5.1.5.4 Adding coolant Af ter 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 5.1.6 Notes on the installation of welding current leads • Incorrectly installed welding current leads can cause f aults in the arc (f lickering). • 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 5.1.7 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 5.1.8.2 chapter • Carry out a safety check after intervention in the machine > see 5.1.8.3 chapter! 5.1.8.1 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 5.1.8.2 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 5.1.8.4 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: 5.1.10 Protective Flap, Welding Machine Control
Design and function Transport and installation 5.1.10 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 lef t, f rom top. 099-005670-EW501 06.09.2023... -
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 f or 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
(5- or 8-pole). All standard 5- and 8-pin TIG welding torches can be connected to this machine and operated (except f or 8-pin potentiometer torches). 5-pin EWM f unction torches with X-TECHNOLOGIE are also supposed. Figure 5-12 5.2.2... -
Page 33: Shielding Gas Hose Connection
Design and function TIG welding • Bef ore connecting the pressure regulator to the gas cylinder, open the cylinder valve brief ly 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: Rtg1 19Pol
Design and function Interf aces f or automation 5.4.2 RTG1 19POL Functions • Inf inite setting of the welding current (0% to 100%) depending on the main current preselected at the welding machine 5.4.3 RTF1 19POL Functions • Inf initely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. - Page 36 Design and function Interf aces f or automation Signal form Designation Output Connection f or cable shielding (PE) Output Current f low signal I>0, potential-f ree (max. +- 15 V / 100 mA) Switching of welding current potential (PWS) only for AC machines (ref erence Input potential 0 V) Output...
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Page 37: Automation Interface
Design and function Interf aces f or automation 5.5.2 Automation interface These accessory components can be retrofitted as an option > see 9 chapter. To activate and configure the interface, see the corresponding operating instructions for the “control”. WARNING No function of the external interrupt equipment (emergency stop switch)! If the emergency stop circuit has been set up using an external interrupt equipment connected to the interface for automated welding, the machine must be configured for this setup. -
Page 38: Pc Interface
Design and function PC interf ace PC interface Welding parameter software Set all welding parameters on the PC and simply transfer to one or more welding machines (accessory, set consisting of sof tware, interf ace, connection leads) • Data exchange between power source and PC •... -
Page 39: 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 40 Maintenance, care and disposal 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. • Clean the wire f eed rolls on a regular basis (depending on the degree of soiling).
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Page 41: 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 42: Coolant Error
Maintenance, care and disposal Maintenance schedule 6.3.2 Coolant error Observe all instructions f or handling, use and disposal of torch coolant > see 5.1.5 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 43 • 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 >...
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Page 44: 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 45: 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 06.09.2023... -
Page 46: Disposing Of Equipment
Inf ormation on returning used equipment or collections can be obtained f rom the respective municipal administration of f ice. Devices can also be returned to EWM sales partners across Europe. Further inf ormation 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 47: 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 f ails to work at any time, please check the product using the following flowchart. If none of the f ault rectif ication procedures described leads to the correct functioning of the product, please inform your authorised dea- ler. - Page 48 Rectifying faults Error messages (power source) Error 6: Mains undervoltage Category A 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 ...
- Page 49 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 conf igurable). Deactivate the emergency stop circuit.
- Page 50 Rectifying faults Error messages (power source) Error 20: Low coolant level Category B Low f low rate. Fill with coolant. Check coolant f low - remove kinks in the hose package. Adjust the f low threshold Clean the cooler.
- Page 51 Rectifying faults Error messages (power source) Error 26: Excess pilot arc module temperature Category A The power source is overheating. Allow the switched-on machine to cool. Fan is blocked, dirty or f aulty. Check the f an and clean or replace. ...
- Page 52 Rectifying faults Error messages (power source) Error 40: Electronics error Error I>0 Request service. Error 47: Radio link (BT) Category B Connection error between welding machine and peripheral unit. Note the documentation f or the data interf ace with radio transmission. ...
- Page 53 Rectifying faults Error messages (power source) Error 56: Mains phase failure One phase of the mains voltage has f ailed. Check the mains connection, mains plug and mains f uses. Error 57: Slave tacho error Category B Fault in the wire f eeder (slave drive). Check the connections (connectors, lines).
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Page 54: Warnings
Rectifying faults Warnings Warnings Depending on the display options of the machine display, a warning message is displayed as f ollows: Display type - machine control Display Graphic display two 7-segment displays one 7-segment display The cause of the warning is indicated by a corresponding warning number (see table). •... -
Page 55: Checklist For Rectifying Faults
Rectifying faults Checklist f or rectif ying f aults Warning Potential cause / remedy 24 Coolant f low warning Check coolant supply. Check coolant level and top up if necessary. Check f low and switching thresholds. 25 Flow 2 reserved 26 Flow 3 reserved 27 Flow 4... - Page 56 Rectifying faults Checklist f or rectif ying f aults Functional errors Insuf f icient coolant f low Check coolant level and ref ill if necessary Eliminate kinks in conduit system (hose packages) Reset automatic cutout of the coolant pump by activating ...
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Page 57: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit Figure 7-1 • Switch of f the machine and f ill 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 58: Fixing The Pump Shaft (Coolant Circuit)
Rectifying faults Fixing the pump shaf t (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 of f machine at the main switch. •... -
Page 59: 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 60: Welding Torch Cooling System
Technical data Welding torch cooling system Welding torch cooling system Torch cooling F06W F06WRF Cooling capacity at 1 l/min (+25°C/77°F) 1,5 kW 5 l/min 20 l/min max. Flow rate 1.3 gal/min 5.2 gal/min 35 m 45 m max. Delivery height 115 f t 148 f t 3,5 bar... -
Page 61: Performance Data
Technical data Perf ormance 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 62: Tetrix Xq 400 Puls Dc
Technical data Perf ormance 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°... -
Page 63: Tetrix Xq 500 Puls Dc
Technical data Perf ormance 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°... -
Page 64: Tetrix Xq 600 Puls Dc
Technical data Perf ormance 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°... -
Page 65: 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 66: Option For Retrofitting
Accessories Option f or retrof itting Option for retrofitting Type Designation Item no. Box for storing wear parts and smaller accessories ON Partbox F.06 092-004426-00000 such as wire f eed rolls f or mounting on a f lexFit housing system ON PS F.06 + tigSpeed/TG.10 Cross arm f or holding a tigSpeed wire f eeder 092-004435-00000 ON IHPHOLD F.06 tigSpeed Intermediate hose package bracket for tigSpeed on... -
Page 67: General Accessories
Accessories General accessories General accessories Type Designation Item no. 32A 5POLE/CEE Machine plug 094-000207-00000 KLF-L1-L2-L3-PE Label of mains cable 094-023697-00000 ON AL D13/27 Cap f or load sockets 092-003282-00000 Adapter f or TIG welding torches f rom ADAP EZA/DZA 094-008284-00000 Euro torch connector to decentral connection on the machine side GH L85MM GR1... -
Page 68: Appendix
Appendix Searching f or 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 06.09.2023...
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