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EWM L1.04 - RC XQ Expert 2.0 Rob Operating Instructions Manual
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EWM L1.04 - RC XQ Expert 2.0 Rob Operating Instructions Manual

EWM L1.04 - RC XQ Expert 2.0 Rob Operating Instructions Manual

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Operating instructions
Control
L1.04 - RC XQ Expert 2.0 Rob
EN
L1.05 - RC XQ Expert 2.0 Rob
099-00L104-EW501
Observe additional system documents!
16.08.2024

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Summary of Contents for EWM L1.04 - RC XQ Expert 2.0 Rob

  • Page 1 Operating instructions Control L1.04 - RC XQ Expert 2.0 Rob L1.05 - RC XQ Expert 2.0 Rob 099-00L104-EW501 Observe additional system documents! 16.08.2024...
  • 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.
  • Page 3 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 Use and operation solely with the following machines ..........13 Software version ....................13 Applications......................13...
  • Page 4 Contents Notes on using these operating instructions 5.5.1 Save JOB(s) ...................33 5.5.2 Load JOB(s) ...................33 5.5.3 Save configuration ...................33 5.5.3.1 System ..................33 5.5.3.2 Xnet machine................33 5.5.4 Load conf iguration ...................33 5.5.4.1 System ..................33 5.5.4.2 Xnet machine................33 5.5.5 Load languages and texts .................33 5.5.6 Record on USB drive................34 5.5.6.1...
  • Page 5 Contents Notes on using these operating instructions 099-00L104-EW501 16.08.2024...
  • Page 6 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 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 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 poison- ous phosgene. • Ensure suf f icient f resh air! •...
  • Page 11 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 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.
  • Page 13 Titan XQ R AC Titan XQ R Phoenix XQ R All EWM React-based processes are available only in devices of type Ti- tan XQ R AC/Titan XQ R with an activated process license. Aluminium welding task. Documents which also apply •...
  • Page 14 Intended use Documents which also apply 3.4.1 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 15 Quick overview Machine control – Operating elements Quick overview Machine control – Operating elements Figure 4-1 Item Symbol Description Push-button for system settings Display f or system and conf iguration of system settings > see 5.4.4 chapter. Machine display Machine display showing all machine functions, menus and parameters with their val- ues >...
  • Page 16 Quick overview Screen icons Item Symbol Description Arc push-button • Initial state of main screen: Switch between main screen types 1 and 2. • Initial state of any sub-menu: Display switches back to the main screen. • Press and hold: Af ter 3 s the machine changes to the lock mode. To unlock, press and hold again f or 3 s.
  • Page 17 Quick overview Screen icons Symbol Description Xbutton version number not recognised Cancel operation Conf irm operation Wire diameter (f iller material) Menu navigation; one menu back Menu navigation; expanding the content of the display Save data to a USB medium Load data f rom a USB medium USB data recording Screen type 3/4, switching buttons...
  • Page 18 Quick overview Machine display Machine display The machine display shows all the inf ormation relevant to the user as text and/or graphics. 4.3.1 Actual values, nominal values, hold values Parameter Before welding During welding After welding Nominal value Actual value Nominal Hold Nominal...
  • Page 19 Quick overview Machine display Item Symbol Description Display area for process parameters Wire f eed speed, operating mode etc. Process parameter setting range Operating mode, voltage correction, program, welding type etc. Display area for system status Network status, error status etc. > see 4.2 chapter 4.3.3 Main screen variants Main screen type 1...
  • Page 20 Quick overview Machine display 4.3.4.1 Change system language During the start process the user can select or change the system language at the machine control. • Switch the machine of f and on again. • Press the context-dependent push-button [D] during the start phase (the word WELDING 4.0 is dis- played).
  • Page 21 Operating the machine control Welding power setting Operating the machine control In general the control is operated with the central control button below the machine display. Select the required menu item by turning (navigate) and pressing (confirm) the central control button. In addition, the context-dependent push-buttons below the machine display can be used f or conf irmation.
  • Page 22 Operating the machine control Context-dependent push-buttons 5.3.2 Lock function The lock function indicated by the signal light protects against accidental adjustment of the machine settings. All operating elements are disabled when the feature is enabled. The welding process cannot be started when the lock is activated.
  • Page 23 Operating the machine control Machine conf iguration (system) Machine configuration (system) In the System menu the user can set the basic machine conf iguration. Enter the menu: Figure 5-1 5.4.1 Power-saving mode (Standby) You can activate the power-saving mode by setting a parameter in the conf iguration menu (time-con- trolled power-saving mode).
  • Page 24 5.4.2 Access permission (Xbutton) Xbutton is a system for the intelligent control of access rights in EWM welding machines and components that are equipped with Expert control. Using convenient, programmable recognition memories (Xbutton), varying usage rights can be granted to users.
  • Page 25 Operating the machine control Machine conf iguration (system) 5.4.3 Status information This menu provides the user with information on current system interf erences and warnings.. 5.4.3.1 Errors and warnings Figure 5-3 Item Symbol Description Error number > see 8.2 chapter Error icons -------- Warning (prior to interf erence) -------- Interf erence (welding process will be stopped)
  • Page 26 Operating the machine control Machine conf iguration (system) 5.4.3.2 Running time Menu item / parameter Value Comment Values can be reset by pressing and turning The operating time can be reset: 0:00 h the central control knob The arc time can be reset: 0:00 h Overall operating time: 0:00 h...
  • Page 27 Operating the machine control Machine conf iguration (system) 5.4.4 System settings In this area the user can conf igure advanced system settings. 5.4.4.1 Date Menu item/parameter Value Comment Year: 2014 Month: Day: Date f ormat: DD.MM.YYYY YYYY.MM.DD 5.4.4.2 Time Menu item/parameter Value Comment Hour:...
  • Page 28 Operating the machine control Machine conf iguration (system) 5.4.5 Operating panel settings Menu item / parameter Value Comment Type of main screen Automatic selection of welding power Of f –30 s Display brightness: 0-100 % Display contrast: 0-100 % Display negative: Non-latched selectable Special non-latched selectable Spot welding selectable...
  • Page 29 Operating the machine control Machine conf iguration (system) 5.4.6 Aligning the cable resistance The resistance value of cables can either be set directly or it can be aligned using the power source. The f actory setting of the power sources is 8 mΩ. This value correponds to a 5 m earth cable, a 1.5 m inter- mediate hose package and a 3 m water-cooled welding torch.
  • Page 30 Operating the machine control Machine conf iguration (system) 50mm DE - Abgleich Leitungswiderstand EN - Cable resistance alignment FR - Alignement résistance ligne IT - Compensazione resistenza circuito ES - Compensación de la resistencia del cable NL - Compensatie leidingsweerstand SE - Kalibrering av ledningsmotståndet PL - Porównanie rezystancji przewodu RU - Компенсация...
  • Page 31 The message can be reset and a new QR code may be requested f rom the network. 5.4.7.2 Component identification Bar codes predefined in ewm Xnet are recorded with a manual scanner. Component data are retrieved and displayed in the control. Figure 5-6...
  • Page 32 Operating the machine control Of f line data transf er (USB) 5.4.7.4 Errors and warnings A list of all ewm Xnet-specific errors and warnings are displayed with their ID number and description. 5.4.7.5 Status information Figure 5-8 5.4.7.6 Network Figure 5-9 5.4.7.7...
  • Page 33 Operating the machine control Of f line data transf er (USB) Using the USB interface, data can be transferred between the machine control and a USB storage me- dium. Figure 5-10 5.5.1 Save JOB(s) Saving a single (JOB) or a range of welding tasks (JOB)s) (from–to) from the welding machine to the stor- age media (USB).
  • Page 34 Operating the machine control Welding task administration (Menu) 5.5.6 Record on USB drive You can record welding data on a storage medium and read or analyse them using the Xnet quality man- agement sof tware when required. For machine variants with network capability (LG/WLG) only! 5.5.6.1 Register USB drive To identify and allocate the welding data between power source and storage medium the storage medium...
  • Page 35 Operating the machine control Welding task administration (Menu) 5.6.1 JOB selection (material/wire/gas) The welding task (JOB) can be set in two ways: a) Enter the relevant JOB number. Each welding task has a unique JOB number (f or predef ined JOBs >...
  • Page 36 Operating the machine control Welding task administration (Menu) 5.6.3.1 MIG/MAG welding In every JOB, separate settings can be made for the ignition program, reduced main program and end program as to whether or not to alternate with the pulse process. These properties are stored on the welding machine with the JOB.
  • Page 37 Operating the machine control Setup mode 5.6.3.2 Advanced settings Menu item / parameter Value Comment Process switching Of f Start program pulsing Of f End program pulsing Of f Wire retraction ignition Of f Lif t arc (PP) Lif t arc End pulse duration 0.0–20 ms U correction limit...
  • Page 38 Operating the machine control Setup mode Item Symbol Description Push-button, gas test/purge hose package • ----------- Gas test: Shielding gas (symbol flashes slowly) will flow for approximately 20 seconds af ter pressing the push-button once. Press the button again to cancel the pro- cess early.
  • Page 39 Operating the machine control Setup mode Item Symbol Description Advanced settings Display and setting of advanced process parameters WPQR welding data assistant > see 5.7.1 chapter Menu item / parameter Value Comment Automatic The welding monitoring window opens auto- matically from the main screen after a welding start.
  • Page 40 Operating the machine control Setup mode 5.7.2.1 Process parameters 5.7.2.2 Ignition parameters Menu item/parameter Value Comment I-ign: 1–1000 A WF-ign: 0.0–100.0% 0.0- WF-ign 1: 20.0 m/min. U-ign: 0.0–38.2 V T-ign: 0.1–20.0 ms I-sense: 0–500 A 0.0– WF-sense: 20.0 m/min. 5.7.2.3 Wire retraction ignition Menu item/parameter Value...
  • Page 41 Operating the machine control Online data transf er (network) 5.7.3 JOB display setting Menu item/parameter Value Comment Text f or material: Standard Alternative Text f or gas: Standard Alternative Start current, secondary current and end cur- Absolute value set point: rent are set and displayed as absolute values.
  • Page 42 Welding procedure MIG/MAG welding Welding procedure The welding task is selected in the JOB selection menu (material/wire/gas) > see 5.6.1 chapter. The basic settings of the relevant welding procedure, such as operating mode or arc length correction, can be selected on the main screen on the process parameter panel > see 4.3.2 chapter. The program sequence settings are set in the program sequence menu >...
  • Page 43 Welding procedure MIG/MAG welding Non-latched mode Figure 6-1 Step 1 • Robot issues the start signal to the power source. • Shielding gas is expelled (gas pre-f lows). • Wire f eed motor runs at “creep speed”. • Arc ignites af ter the wire electrode makes contact with the workpiece; welding current f lows. •...
  • Page 44 Welding procedure MIG/MAG welding Non-latched operation with superpulse For machine versions with pulsed arc welding procedures only. Figure 6-2 Step 1 • Robot issues the start signal to the power source. • Shielding gas is expelled (gas pre-f lows). • Wire f eed motor runs at “creep speed”. •...
  • Page 45 Welding procedure MIG/MAG welding Special, non-latched Figure 6-3 Step 1 • Robot issues the start signal to the power source. • Shielding gas is expelled (gas pre-f lows) • Wire f eed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is f lowing (start program P f or the time t START...
  • Page 46 Welding procedure MIG/MAG welding Special, non-latched with superpulse For machine versions with pulsed arc welding procedures only. Figure 6-4 Step 1 • Robot issues the start signal to the power source. • Shielding gas is expelled (gas pre-f lows) • Wire f eed motor runs at “creep speed”. •...
  • Page 47 Welding procedure MIG/MAG welding 6.1.2 coldArc / coldArc puls Heat-reduced, low-spatter short arc for high dimensional stability welding and brazing of thin metal sheets with excellent gap-bridging. Figure 6-5 Af ter selecting the coldArc process > see 5.6 chapter you benef it f rom: •...
  • Page 48 (molten metal) decreases and the penetration reduces. Figure 6-8 With the EWM wiredArc arc with wire control, the welding current (AMP) changes with the change of the stick-out only slightly. The compensation of the welding current takes place with an active control of wire f eed speed (DG).
  • Page 49 Welding procedure MIG/MAG welding 6.1.6 acArc puls XQ The alternating current welding process acArc puls XQ makes MIG aluminium welding even easier in manual and automated modes. Clean weld seams with no traces of powder on the thinnest metal sheets, even with AlMg alloys, are possible with acArc puls XQ.
  • Page 50 Welding procedure MIG/MAG welding With the rotary knob “arc dynamics”, the negative phase in the process can be influenced. Setting of the dynamics Welding properties Lef t turn (more minus), negative phase • ----------- More power on the wire gets longer •...
  • Page 51 The React RCC XQ welding procedure requires suitable wire feeding. The selection and use of the EWM React RCC XQ welding process is only possible with the addi- tional components WB XM EZA and WDU C W ROB and an activated licence.
  • Page 52 Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed.
  • Page 53 Maintenance, care and disposal Calibration / validation 7.2.1 Activating the calibration and validation mode If the machine has a special calibration and validation mode, this mode can be switched on using the slide switch Mode off/on (push-button D) (an update of the machine sof tware may enable this mode). When this mode is activated, the cable resistance value is set to 0 Ω.
  • Page 54 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 55 Rectifying faults The sof tware versions of the system components 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 f unctioning of the product, please inf orm your authorised dealer.
  • Page 56 Rectifying faults Error messages (power source) Error 5: Mains overvoltage Category A  Mains voltage is too high. Check the mains voltages and compare them with the connection voltages of the power source.  Error 6: Mains undervoltage Category A ...
  • 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 conf igurable). Deactivate the emergency stop circuit.
  • Page 58 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 59 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 60 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 61 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).
  • Page 62 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 63 Rectifying faults Resetting JOBs (welding tasks) to the f actory settings Warning Potential cause / remedy 24 Coolant f low warning Check the coolant supply. Check the coolant level and top up if necessary. Check f low and switching thresholds. 25 Flow 2 reserved 26 Flow 3...
  • Page 64 Appendix Parameter overview – setting ranges Appendix Parameter overview – setting ranges Parameter Setting range Comment MIG/MAG Gas pre-f low time Gas nominal value l/min GFE option Start program P START WF relative Duration 0,00 - 20,0 U correction -9,9 Slope time 0,00 20,0...
  • Page 65 Appendix JOB-List JOB-List Diameter JOB no. Procedure Material [mm] GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 Standard GMAW / pulse G3Si1 / G4Si1 Ar-82 / CO2-18 (M21)
  • Page 66 Appendix JOB-List Diameter JOB no. Procedure Material [mm] coldArc / coldArc puls CrNi 19 9 / 1.4316 Ar-97.5 / CO2-2.5 (M12) coldArc / coldArc puls CrNi 19 9 / 1.4316 Ar-97.5 / CO2-2.5 (M12) coldArc / coldArc puls CrNi 19 9 / 1.4316 Ar-97.5 / CO2-2.5 (M12) coldArc / coldArc puls AlMg4.5Mn...
  • Page 67 Appendix JOB-List Diameter JOB no. Procedure Material [mm] Standard GMAW / pulse CuAl Ar-100 (I1) Standard GMAW / pulse CuAl Ar-100 (I1) Standard GMAW / pulse CuAl Ar-100 (I1) Standard GMAW / pulse CuAl Ar-100 (I1) Brazing CuSi Ar-97.5 / CO2-2.5 (M12) Brazing CuSi Ar-97.5 / CO2-2.5 (M12)
  • Page 68 Appendix JOB-List Diameter JOB no. Procedure Material [mm] Block 2/ JOB4 Block 2/ JOB5 Block 2/ JOB6 Block 2/ JOB7 Block 2/ JOB8 Block 2/ JOB9 Block 2/ JOB10 Block 3/ JOB1 Block 3/ JOB2 Block 3/ JOB3 Block 3/ JOB4 Block 3/ JOB5 Block 3/ JOB6 Block 3/ JOB7...
  • Page 69 Appendix JOB-List Diameter JOB no. Procedure Material [mm] Flux-cored wire rutile FCW CrNi Rutile CO2-100 (C1) Standard GMAW / pulse AlMg3 Ar-100 (I1) Standard GMAW / pulse AlMg3 Ar-100 (I1) Standard GMAW / pulse AlMg3 Ar-100 (I1) coldArc - St/Al ZnAl Ar-100 (I1) coldArc - St/Al...
  • Page 70 Appendix JOB-List Diameter JOB no. Procedure Material [mm] Ar-78 / He-20 / CO2-2 Cladding NiCr 6625 / 2.4831 (M12) Standard GMAW / pulse CrNi 25 20 / 1.4842 Ar-97.5 / CO2-2.5 (M12) Standard GMAW / pulse CrNi 25 20 / 1.4842 Ar-97.5 / CO2-2.5 (M12) Standard GMAW / pulse CrNi 23 12 / 1.4332 Ar-97.5 / CO2-2.5 (M12)
  • Page 71 Appendix JOB-List Diameter JOB no. Procedure Material [mm] CrNi 22 9 3 / 1.4462 / coldArc / coldArc puls Ar-97.5 / CO2-2.5 (M12) Duplex CrNi 22 9 3 / 1.4462 / coldArc / coldArc puls Ar-97.5 / CO2-2.5 (M12) Duplex CrNi 22 9 3 / 1.4462 / coldArc / coldArc puls Ar-97.5 / CO2-2.5 (M12)
  • Page 72 Appendix JOB-List Diameter JOB no. Procedure Material [mm] React Speed RCC / React Speed RCC puls AlSi Ar-100 (I1) React Speed RCC / React NiCr 6625 / 2.4831 Ar-70 / He-30 (I3) Speed RCC puls React Speed RCC / React Speed RCC puls NiCr 6625 / 2.4831 Ar-70 / He-30 (I3)
  • Page 73 Appendix Searching f or a dealer Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-00L104-EW501 16.08.2024...

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