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Summary of Contents for EWM Phoenix XQ R 350 puls
- Page 1 Operating instructions Power source Phoenix XQ R 350 puls Phoenix XQ R 400 puls Phoenix XQ R 500 puls Phoenix XQ R 600 puls 099-005684-EW501 Observe additional system documents! 20.07.2022...
- Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.
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Page 3: Table Of Contents
Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use .......................... - Page 4 Dimensions and weighte ...................... 67 8.1.1 Welding torch cooling system ................67 Performance data ......................... 68 8.2.1 Phoenix XQ R 350 puls ..................68 8.2.2 Phoenix XQ R 400 puls ..................69 8.2.3 Phoenix XQ R 500 puls ..................70 8.2.4...
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Page 5: For Your Safety
For your safety Notes on using these operating instructions For your safety Notes on using these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 6: Explanation Of Icons
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Correct / Valid Numerical value –... -
Page 7: Safety Instructions
For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 8 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
- Page 9 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
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Page 10: Transport And Installation
For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the in- troduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines. - Page 11 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.
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Page 12: Intended Use
3.2.1 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 13: 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 compo- nents, especially the safety instructions! The illustration shows a general example of a welding system. -
Page 14: 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 R: Type Figure Transport properties Torch cooling A06 P 1DV A06 P 1DV A06 P 1DV A06 P 2DV A06 P 2DV... -
Page 15: 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 4-2 099-005684-EW501 20.07.2022... - Page 16 Machine description – quick overview Front view / side view from the right Item Symbol Description Connection socket (9-pole) - D-Sub PC interface > see 5.5.6 chapter WiFi antenna Factory-fit option, (version OW Expert XQ 2.0 WLG) Main Switch Switching the machine on or off. LED status bar - display of operating status The operating status is indicated by a light guide >...
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Page 17: Rear View / Side View From Left
Machine description – quick overview Rear view / side view from left Rear view / side view from left Figure 4-3 099-005684-EW501 20.07.2022... - Page 18 Machine description – quick overview Rear view / side view from left Item Symbol Description Cooling air inlet Dirt filter optional > see 6.3.1 chapter Connection socket, “+” welding current How to connect the accessories depends on the welding procedure. Please observe the connection description for the corresponding welding procedure >...
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Page 19: Connection Plan
Machine description – quick overview Connection plan Item Symbol Description Cable bushing for industrial bus interface > see 5.5.2 chapter 12-pole connection socket Robot interface RINT X12 23-pole connection socket Robot interface RINT X12 Connection plan M drive 4 Rob 5 Fassförderung RC XQ SPS / CU / ROB... -
Page 20: Legend
Machine description – quick overview Connection plan 4.4.1 Legend Wire feeding Welding current (minus potential, workpiece) Shielding gas Welding torch coolant Coolant inlet Coolant outlet Welding machine supply voltage Welding current (plus potential) Interface for automated welding (19-pole) Control cable for wire feeder (23-pole) Euro torch connector Compressed air connection to clean the welding torch nozzles Hose package (HP = hose package) -
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 5.1.3 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 23: Welding Torch Cooling System
All information relates to the total hose package length of the complete welding system and presents ex- emplary configurations (of components of the EWM product portfolio with standard lengths). Make sure that the laying is straight and kink-free considering the maximum 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: Connecting The Intermediate Hose Package To The Power Source
Design and function Transport and installation 5.1.9 Connecting the intermediate hose package to the power source Figure 5-7 Item Symbol Description Shielding gas cylinder Wire feed unit Intermediate hose package Shielding gas connection (outlet) Connection thread, G¼" Shielding gas connection (inlet) Connecting nipple, G¼”... -
Page 28: 5.1.10 Intermediate Hose Package Strain Relief
Design and function Transport and installation • Connect the hose of the shielding gas cylinder to the G¼“ (inlet) connecting nipple. • Connect the shielding gas hose of the wire feed unit to the G¼“ (outlet) connecting nipple. • Insert the hose package end of the intermediate hose package from the outside through the strain re- lief of intermediate hose package and then lock by turning to the right. -
Page 29: 5.1.10.2 Locking The Strain Relief
Design and function Transport and installation 5.1.10.2 Locking the strain relief EWM intermediate hose package Figure 5-9 099-005684-EW501 20.07.2022... -
Page 30: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Transport and installation 5.1.11 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: 5.1.12 Mains Connection
Design and function Transport and installation 5.1.12 Mains connection 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 na- tional regulations! •... -
Page 32: 5.1.12.2 Adjusting The Power Source To The Mains Voltage
Design and function Transport and installation 5.1.12.2 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 33: 5.1.12.4 Mains Configuration
Design and function Transport and installation 5.1.12.4 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 34: 5.1.14 Protective Flap, Welding Machine Control
Design and function Transport and installation 5.1.14 Protective flap, welding machine control Figure 5-14 • 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. 099-005684-EW501 20.07.2022... -
Page 35: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.2.1 Connection for workpiece lead Figure 5-15 Item Symbol Description Workpiece Connection socket, “–” welding current Workpiece lead connection • Insert the plug on the workpiece lead into the "-" welding current connection socket and lock. 5.2.2 Welding task selection For selection of the welding task and for general operation see the relevant Control operating instructions. -
Page 36: Setting The Shielding Gas Volume (Gas Test)/Rinse Hose Package
Design and function TIG welding 5.2.3 Setting the shielding gas volume (gas test)/rinse hose package • Shielding gas supply as described in chapter Transport and positioning > see 5.1.11 chapter. • Slowly open the gas cylinder valve. • Open the pressure regulator. •... -
Page 37: Welding Task Selection
Design and function Remote control • Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by turning to the right. 5.3.2 Welding task selection For selection of the welding task and for general operation see the relevant Control operating instructions. Remote control The remote controls are operated via the 19-pole remote control connection socket (analogue) or the 7-pole remote control connection socket (digital), depending on the model. -
Page 38: Interfaces For Automation
Design and function Interfaces for automation Interfaces for automation WARNING No improper repairs and modifications! To prevent injuries and damage to the machine, only competent personnel (authorised service personnel) are allowed to repair or modify the machine. Unauthorised manipulations will invalidate the warranty! •... -
Page 39: Connecting The Robot Interface / Industrial Bus Interface
Design and function Interfaces for automation 5.5.2 Connecting the robot interface / industrial bus interface Figure 5-18 Item Symbol Description Switching cabinet Connection lead between power source and interface Robot interface / Industrial bus interface Only one variant can ever be operated at any one time. 5.5.2.1 RINT X12 robot interface The standard digital interface for mechanised applications ... -
Page 40: Sensor Voltage
Design and function Interfaces for automation 5.5.3 Sensor Voltage 5.5.3.1 Pin assignment Figure 5-19 Pin assignment for 19-pole interface (X60): Input/output Name Note Output Cable screen connection Input +24V Suche ein Sensor voltage supply Input 0V Suche ein Output Erk. Werkstück +24 V for detected workpiece Input +24V Extern... -
Page 41: Automation Interface
Design and function Interfaces for automation 5.5.4 Automation interface WARNING No function of the external shutdown devices (emergency-stop-switch)! If the emergency stop circuit is implemented by an external shutdown device connected to the interface for automated welding, the machine must be set accordingly. If this is not observed, the power source will ignore the external shutdown device and will not shut down! •... - Page 42 Design and function Interfaces for automation Pin assignment, 19-pole of interface for automated welding (X40): Input/output Name Note Output Cable screen connection Output IGR0 Maximum load 100 mA. Current flowing signal (I>0). Not isolated! 0 V = welding current. 15 V = no welding current. Input Not-Aus Connect the emergency stop circuit...
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Page 43: Connection Variant - Industrial Bus Interface Busint X11
Design and function Interfaces for automation 5.5.4.2 Connection variant - industrial bus interface BUSINT X11 Figure 5-21 Pin assignment, 19-pole of interface for automated welding (X73): Input/output Name Note Output Cable screen connection Input Not-Aus Connect the emergency stop circuit with E = +24V and R = 0V of the Open = welding current is switched emergency stop circuit. -
Page 44: Emergency Stop Circuit
Design and function Interfaces for automation 5.5.5 Emergency stop circuit The emergency stop circuit is deactivated by default. 5.5.5.1 Activating the emergency stop circuit Figure 5-22 Item Symbol Description 4-pole connector plug Emergency stop circuit connection 4-pole connection socket Emergency stop circuit connection •... -
Page 45: Pc Interface
Design and function Interfaces for automation 5.5.6 PC interface 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 46: 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 47: 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 train-... - Page 48 Maintenance, care and disposal Maintenance schedule Maintenance step Only personnel designated as inspectors or repairers due to their train- ing 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? •...
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Page 49: 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 50: 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 51 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 52: 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 53: 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! 099-005684-EW501 20.07.2022... -
Page 54: 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 55: 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 dealer. - Page 56 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 57 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 58 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 59 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 60 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. ...
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Page 61: 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 62 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.
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Page 63: 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 64 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 earth).
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Page 65: 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 66: 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 67: 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 A06RS 1DV A06RS 2DV A06P 1DV A06P 2DV Dimensions (l x b inch inch inch inch x h) 1051 41,4 1051... -
Page 68: Performance Data
Technical data Performance data Performance data 8.2.1 Phoenix XQ R 350 puls MIG/MAG Welding current (I 5 A to 350 A Welding voltage according to standard 14,3 V to 31,5 V 10,2 V to 24,0 V Duty cycle DC at 40° C... -
Page 69: Phoenix Xq R 400 Puls
Technical data Performance data 8.2.2 Phoenix XQ R 400 puls MIG/MAG Welding current (I 5 A to 400 A Welding voltage according to standard 14,3 V to 34 V 10,2 V to 26,0 V Duty cycle DC at 40° C [1] 400 A (80 %) / 370 A (100 %) Open circuit voltage (U ) 380 - 400 V... -
Page 70: Phoenix Xq R 500 Puls
Technical data Performance data 8.2.3 Phoenix XQ R 500 puls MIG/MAG Welding current (I 5 A to 500 A Welding voltage according to standard 14,3 V to 39 V 10,2 V to 30,0 V Duty cycle DC at 40° C 500 A (80 %) / 470 A (100 %) Open circuit voltage (U )380 - 400 V... -
Page 71: Phoenix Xq R 600 Puls
Technical data Performance data 8.2.4 Phoenix XQ R 600 puls MIG/MAG Welding current (I 5 A to 600 A Welding voltage according to standard 14,3 V to 44 V 10,2 V to 34,0 V Duty cycle DC at 40° C 600 A (40 %) / 550 A (60 %) / 470 A (100 %) Open circuit voltage (U ) 380 - 400 V... -
Page 72: Accessories
Accessories General accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or interme- diate 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... -
Page 73: Connection Cables
Accessories Interfaces for automation 9.3.2.1 Connection cables Type Designation Item no. RA5 19POL 5M Remote control e.g. connection cable 092-001470-00005 RA10 19POL 10m Remote control e.g. connection cable 092-001470-00010 RA20 19POL 20m Remote control e.g. connection cable 092-001470-00020 9.3.2.2 Extension cable Type Designation Item no. -
Page 74: Welding Torch Cooling System
Accessories Welding torch cooling system Welding torch cooling system Type Designation Item no. HOSE BRIDGE UNI Tube bridge 092-007843-00000 9.8.1 Coolant - type blueCool Type Designation Item no. blueCool -10 5 l Coolant up to -10 °C (14 °F), 5 l 094-024141-00005 blueCool -10 25 l Coolant up to -10 °C (14 °F), 25 l... -
Page 75: 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" 099-005684-EW501 20.07.2022...
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