EWM Tetrix XQ 230 puls DC Comfort 3.0 Operating Instructions Manual
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Summary of Contents for EWM Tetrix XQ 230 puls DC Comfort 3.0
- Page 1 Operating instructions Power source Tetrix XQ 230 puls DC Comfort 3.0 Tetrix XQ 230 puls AC/DC Comfort 3.0 Tetrix XQ 230 puls DC Expert 3.0 Tetrix XQ 230 puls AC/DC Expert 3.0 099-005630-EW501 Observe additional system documents! 14.06.2024...
- 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 Use and operation solely with the following machines ..........13 Documents which also apply ...................14... - Page 4 Contents Notes on using these operating instructions Maintenance schedule ...................34 6.3.1 Coolant error...................35 6.3.2 Dirt filter ....................36 6.3.3 Power source (inverter) ................37 6.3.4 Heat exchanger (torch cooling) ..............39 6.3.5 Annual test (inspection and testing during operation)........40 Disposing of equipment..................41 7 Rectifying faults ......................42 Checklist for rectifying faults ...................42 Warnings ......................43 Error messages (power source)................45...
- Page 5 Contents Notes on using these operating instructions 099-005630-EW501 14.06.2024...
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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
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 14: 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 15: 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 16: Machine Description - Quick Overview
Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-005630-EW501 14.06.2024... - Page 17 Machine description – quick overview Front view / rear view Item Symbol Description Protective cap > see 5.1.10 chapter Machine control (see the relevant control operating instructions) 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 18: 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 19: 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 20: 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 9.5 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 21 Design and function Transport and installation The modular design allows the power source to be retrofitted with a cooling unit f or liquid torch cooling. For inf ormation about connection and installation, see the documentation f or the cooling unit. Figure 5-3 1 Switch of f the power source and disconnect the mains plug.
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Page 22: 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 f ront. Screw the cover back on. 4 Undo all f our Torx screws f rom the module connectors of the cooling unit. 5 Route the supply lines through the cable duct of the cooling unit. - Page 23 Design and function Transport and installation • Use an individual welding lead to the workpiece f or 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.
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Page 24: 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 25: Mains Configuration
Design and function Transport and installation 5.1.9.1 Mains configuration The machine may only be connected to a one-phase system with two conductors and an earthed neutral conductor. Figure 5-8 Legend Item Designation Colour code Outer conductor brown Neutral conductor blue Protective conductor green-yellow •... -
Page 26: 5.1.11 Wear Part Compartment
Design and function TIG welding 5.1.11 Wear part compartment The transport handle of this machine series holds a wear parts compartment for storing typical small wear parts. The compartment is closed with a p lastic f lap. Figure 5-10 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). -
Page 27: Control Lead Connection
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 f or 8-pin potentiometer torches). 5-pin EWM f unction torches with X-TECHNOLOGIE are also supposed. Figure 5-12 5.2.2 Shielding gas supply (shielding gas cylinder for welding machine) -
Page 28: Pressure Regulator Connection
Design and function TIG welding 5.2.2.1 Pressure regulator connection Figure 5-13 Item Symbol Description Pressure regulator Output side of the pressure regulator Shielding gas cylinder Cylinder valve • Bef ore connecting the pressure regulator to the gas cylinder, open the cylinder valve brief ly to blow out any dirt. -
Page 29: Gas Test - Setting The Shielding Gas Volume
Design and function MMA welding 5.2.2.3 Gas test – setting the shielding gas volume If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to f orm. Adjust the shielding gas quantity to suit the welding task! Rule of thumb f or the gas f low rate: Diameter of gas nozzle in mm corresponds to gas f low in l/min. -
Page 30: Rtf1 19Pol
Design and function Interf aces f or automation 5.4.3 RTF1 19POL Functions • Inf initely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. • Start/stop welding operation (TIG) activArc welding is not possible in combination with the foot-operated remote control. 5.4.4 RTF-X TIG 19Pol Functions... -
Page 31: Pc Interface
Design and function PC interf ace 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... -
Page 32: Network Connection
Design and function Network connection Network connection This accessory component is only available as a “factory-fit option”. The network connection allows the integration of the product into an existing network and exchanging data using the quality-management sof tware Xnet. Some f eatures of the sof tware: •... -
Page 33: 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 34: 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 35: 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 36: 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 >... -
Page 37: 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 38 Maintenance, care and disposal Maintenance schedule Figure 6-7 • Clean the machine f an with compressed air f ree of oil and water. Block the fan wheel of the machine fan mechanically (the machine fan may over-rotate due to the compressed air and be damaged as a result)! •...
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Page 39: Heat Exchanger (Torch Cooling)
Maintenance, care and disposal Maintenance schedule Figure 6-9 • Reconnect all f our power lines to the main switch (note inputs / outputs). • Reinstall the side panels and secure with the screws. • Check the machine according to applicable regulations. 6.3.4 Heat exchanger (torch cooling) WARNING... -
Page 40: Annual Test (Inspection And Testing During Operation)
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! 099-005630-EW501 14.06.2024... -
Page 41: 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 42: Rectifying Faults
Rectifying faults Checklist f or rectif ying f aults Rectifying faults All products are subject to rigorous production checks and final checks. If , despite this, something f ail s 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 43: Warnings
Rectifying faults Warnings Bad arc ignition Material inclusions in the tungsten electrode due to contact with f iller material or workpiece Regrind or replace the tungsten electrode Bad current transf er on ignition Check the setting on the "Tungsten electrode diameter/Ignition optimisation" rotary dial and in- ... - Page 44 Rectifying faults Warnings Warning Potential cause / remedy 10 Partial inverter One of several partial inverters is not supplying welding current. 11 Excess temperature of the coo- Check temperature and switching thresholds. lant The actual value of a welding parameter is outside the specified 12 Welding monitoring tolerance range.
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Page 45: Error Messages (Power Source)
Rectifying faults Error messages (power source) Warning Potential cause / remedy A liquid-cooled welding torch was connected but no cooling unit 41 Cooling unit not recognised has been detected. • Check the connection of the cooling unit • Use a gas-cooled welding torch 47 Battery (remote control, type Battery level is low (replace battery) only f or the XQ machine series... - Page 46 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 47 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 48 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 49 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 it. ...
- Page 50 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 the welding machine and peripheral unit. Note the documentation f or the data interf ace with radio transmission. ...
- Page 51 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 ...
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Page 52: 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 53: 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 230 puls DC Tetrix XQ 230 puls AC/DC Dimensions (l x b x h) inch 10.1 21.7 16.3... -
Page 54: Performance Data
Technical data Perf ormance data Performance data 8.2.1 Tetrix XQ 230 puls DC 8.2.1.1 Mains voltage 230 V Welding current (I 3 A to 230 A 5 A to 190 A Welding voltage according to standard 10,1 V to 19,2 V 20,2 V to 27,6 V Duty cycle DC at 40°... - Page 55 Technical data Perf ormance data 099-005630-EW501 14.06.2024...
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Page 56: Mains Voltage 120 V
Technical data Perf ormance data 8.2.1.2 Mains voltage 120 V The performance specifications refer to machines with several mains voltage variants (multivolt capability). Please note the information on the relevant rating plate. The increased current consumption at a lower mains voltage requires the installation of a suitable mains plug >... -
Page 57: Tetrix Xq 230 Puls Ac/Dc
Technical data Perf ormance data 8.2.2 Tetrix XQ 230 puls AC/DC 8.2.2.1 Mains voltage 230 V Welding current (I 3 A to 230 A 5 A to 190 A Welding voltage according to standard 10,1 V to 19,2 V 20,2 V to 27,6 V Duty cycle DC at 40°... -
Page 58: Mains Voltage 120 V
Technical data Perf ormance data 8.2.2.2 Mains voltage 120 V The performance specifications refer to machines with several mains voltage variants (multivolt capability). Please note the information on the relevant rating plate. The increased current consumption at a lower mains voltage requires the installation of a suitable mains plug >... - Page 59 Technical data Perf ormance data 099-005630-EW501 14.06.2024...
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Page 60: 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. Cool XQ 40 Cooling unit 090-005632-00000 Cool XQ 40 MV Cooling unit 090-005633-00000 ON Water Filter K.06... -
Page 61: Remote Controls And Accessories
Accessories Remote controls and accessories Remote controls and accessories 9.4.1 19-pole connection Type Designation Item no. Foot-operated remote control, current, with connec- RTF-X TIG 19pol 5 m 090-008855-00005 tion cable Foot-operated remote control current with connec- RTF1 19POL 5 M 094-006680-00000 tion cable RT1 19POL... -
Page 62: Appendix
Appendix Average shielding gas usage Appendix 10.1 Average shielding gas usage Gas nozzle number 12.5 inch 0.26 0.31 0.37 0.43 0.63 l/min gal/min 1.58 2.11 2.64 3.17 3.96 099-005630-EW501 14.06.2024... -
Page 63: 10.2 Searching For A Dealer
Appendix Searching f or a dealer 10.2 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005630-EW501 14.06.2024...
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