EWM Titan XQ 350 puls C Operating Instructions Manual
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EWM Titan XQ 350 puls C Operating Instructions Manual

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Operating instructions
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Titan XQ 350 puls C
EN
Titan XQ 400 puls C
099-005609-EW501
Observe additional system documents!
26.10.2022

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Summary of Contents for EWM Titan XQ 350 puls C

  • Page 1 Operating instructions Power source Titan XQ 350 puls C Titan XQ 400 puls C 099-005609-EW501 Observe additional system documents! 26.10.2022...
  • 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.

  • 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..........................68 Dimensions and weighte ...................... 68 Welding torch cooling system ....................68 Performance data ......................... 69 8.3.1 Titan XQ 350 puls C ..................... 69 8.3.2 Titan XQ 400 puls C ..................... 70 9 Accessories ..........................71 General accessories ......................71 Welding torch cooling system ....................
  • Page 5 Contents Notes on using these operating instructions 099-005609-EW501 26.10.2022...

  • 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 Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn...

  • 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! •...

  • 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.

  • 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: Welding In Environments With Increased Electrical Hazards

    Intended use Documents which also apply 3.2.3 Welding in environments with increased electrical hazards Power sources with this marking can be used for welding in an environment with increased electrical hazard (e.g. boilers). For this purpose, appropriate national or international regulations must be followed.

  • 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 4-1 099-005609-EW501 26.10.2022...

  • 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 4-2 099-005609-EW501 26.10.2022...
  • 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 5.1.11.1 chapter. 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.)

  • 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 4-3 099-005609-EW501 26.10.2022...
  • 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 Securing elements for shielding gas cylinder (strap/chain) Bracket for shielding gas cylinder Aluminium extrusion profile flexFit Individual mounting option for accessories and options Gas cylinder holder...

  • Page 20: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-4 Item Symbol Description Key switch for protection against unauthorised use > see 5.6 chapter --------- changes possible,G front drive-4x-EX ---------- changes not possible. Welding torch function changeover switch (special welding torch required) --- Changing over programs or JOBs --- Infinite adjustment of welding performance.

  • Page 21: 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 22: Ambient Conditions

    Design and function Transport and installation 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 23: 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 24: Adding Coolant

    Design and function Transport and installation 5.1.5.4 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 5.1.6 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 5.1.7 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: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Transport and installation 5.1.10 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 serious injuries! •...

  • Page 31: 5.1.10.2 Shielding Gas Hose Connection

    Design and function Transport and installation 5.1.10.2 Shielding gas hose connection Figure 5-11 Item Symbol Description Connection thread - G¼" Shielding gas connection (inlet) • Screw the gas hose connection to the shielding gas connection (inlet) on the machine gas-tight. 5.1.11 Setting the shielding gas volume (gas test)/rinse hose package •...

  • Page 32: 5.1.11.1 Led Status Bar - Display Of Operating Status

    Design and function Transport and installation 5.1.11.1 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 33: 5.1.13 Polarity Selection Plug - Changing The Welding Current Polarity

    Design and function MIG/MAG welding 5.1.13 Polarity selection plug - changing the welding current polarity The polarity selection plug allows the adjustment of the welding current polarity (+/-) at the welding torch connection. For example, when welding with varying types of electrodes that require different polarities according to the manufacturer, the welding current polarity can be changed by switching to the correspon- ding connection socket (+) or (-) for the welding current.

  • Page 34: Welding Torch Connection

    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. •...

  • Page 35: Connection For Workpiece Lead

    Design and function MIG/MAG welding Item Symbol Description Welding torch hose package Connection of coolant lines (welding torch) Quick connect couplings Polarity selection plug, welding current cable > see 5.1.13 chapter • Insert the polarity selection plug into the "+" welding current connection socket and lock in place by turning to the right.

  • Page 36: Wire Feed

    Design and function MIG/MAG welding 5.2.4 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 37: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding Figure 5-18 Observe the unwinding direction of the wire spool. 5.2.4.2 Changing the wire feed rollers Figure 5-19 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 38 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 39 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 >...

  • Page 40: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.2.4.3 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 41: 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 42: Tig Welding

    Design and function TIG welding TIG welding 5.3.1 Welding torch connection Figure 5-23 Item Symbol Description Welding torch Welding torch hose package Connection of coolant lines (welding torch) Quick connect couplings Polarity selection plug, welding current cable > see 5.1.13 chapter •...

  • Page 43: Connection For Workpiece Lead

    Design and function MMA welding 5.3.2 Connection for workpiece lead Figure 5-24 Item Symbol Description Workpiece Connection socket for "+" welding current Workpiece lead connection • Insert the plug on the workpiece lead into the "-" welding current connection socket and lock. Some wire electrodes (e.g.

  • Page 44: Welding Task Selection

    Design and function Remote control Item Symbol Description Polarity selection plug, welding current cable > see 5.1.13 chapter Workpiece Connection socket, “+” welding current Connection socket, welding current “–” Electrode holder • Insert the polarity selection plug in the park socket and lock in place by turning to the right. •...

  • Page 45: Rint X12 Robot Interface

    Design and function PC interface Input / Name Figure Output Output PE ------- Connection for cable screen Output IGRO ---- Current flows signal I>0 (maximum load 20 mA / (open collec- 15 V) 0 V = welding current flows tor) Input Not-Aus - Emergency stop for higher level shut-down of the power source.

  • Page 46: Connection

    Only together with the device control Expert XQ 2.0 in the LAN gateway or LAN/Wi-Fi gateway version. Bar codes predefined in ewm Xnet are recorded with a manual scanner. Component data are retrieved and displayed in the control. These accessory components can be retrofitted as an option > see 9 chapter.

  • Page 47: 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 48: Explanation Of Icons

    Maintenance, care and disposal Explanation of icons Explanation of icons Personnel Welder / operator Qualified person (authorised service personnel) Tests Visual inspection Functional test Period, interval One-shift operation Multi-shift operation Every 8 hours Daily Weekly Monthly Every 6 months Annually Maintenance schedule Maintenance step Only personnel designated as inspectors or repairers due to their trai-...
  • Page 49 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. • Transport elements (strap, lifting eyes, handle, wheels, parking brake) corresponding safety elements (if necessary fuse caps) are present and flawless? •...

  • Page 50: 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 51: 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 5.1.5 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 52 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 53: 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 54: 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! 099-005609-EW501 26.10.2022...

  • Page 55: 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 56: 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 57 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 58 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 59 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 60 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 61 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 62: Warnings

    Rectifying faults Warnings 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. ...
  • Page 63 Rectifying faults Warnings Warning Potential cause / remedy 2 Half-wave failures Check process parameters. 3 Torch cooling warning Check coolant level and top up if necessary. 4 Shielding gas Check shielding gas supply. 5 Coolant flow Check min. flow rate. 6 Wire reserve Only a small amount of wire is left on the spool.

  • Page 64: Checklist For Rectifying Faults

    Rectifying faults Checklist for rectifying faults Warning Potential cause / remedy 34 JOB unknown JOB selection was not carried out because the JOB number is unknown. 35 Excess current on the wire feed Excess current detected on wire feed motor slave (push/push motor slave system or intermediate drive).
  • Page 65 Rectifying faults Checklist for rectifying faults Collective interference signal light illuminates  Excess temperature, welding machine Allow the machine to cool down whilst still switched on   Welding current monitoring device triggered (stray welding currents flowing across the protective e- arth).

  • Page 66: 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 67: 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 68: 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 69: Performance Data

    Technical data Performance data Performance data 8.3.1 Titan XQ 350 puls C MIG/MAG Welding current (I 5 A to 350 A Welding voltage according to standard (U 14,3 V to 31,5 V 20,2 V to 34,0 V 10,2 V to 24,0 V Duty cycle DC at 40°...

  • Page 70: Titan Xq 400 Puls C

    Technical data Performance data 8.3.2 Titan XQ 400 puls C MIG/MAG Welding current (I 5 A to 400 A Welding voltage according to standard (U 14,3 V to 34 V 20,2 V to 36,0 V 10,2 V to 26,0 V Duty cycle DC at 40°...

  • Page 71: 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. 32A 5POLE/CEE Machine plug 094-000207-00000 KLF-L1-L2-L3-PE Label of mains cable 094-023697-00000 DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 Sharpener for liner...

  • Page 72: 19-Pole Remote Control

    Accessories 19-pole remote control 19-pole remote control Type Designation Item no. R10 19POL Remote control 090-008087-00000 RG10 19POL 5M Remote control to set the wire speed and welding 090-008108-00000 voltage correction R20 19POL Program changeover remote control 090-008263-00000 9.4.1 Connection cables Type Designation Item no.

  • Page 73: 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 74: 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 092-002848-00010 FUEL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for BLUE/ORANGE flux cored wire...

  • Page 75: 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" 099-005609-EW501 26.10.2022...

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