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EWM Taurus XQ 400 Synergic C Operating Instructions Manual
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EWM Taurus XQ 400 Synergic C Operating Instructions Manual

EWM Taurus XQ 400 Synergic C Operating Instructions Manual

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Operating instructions
Power source
Taurus XQ 350 Synergic C
EN
Taurus XQ 400 Synergic C
099-005653-EW501
Observe additional system documents!
7.11.2024

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Summary of Contents for EWM Taurus XQ 400 Synergic C

  • Page 1 Operating instructions Power source Taurus XQ 350 Synergic C Taurus XQ 400 Synergic C 099-005653-EW501 Observe additional system documents! 7.11.2024...
  • 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 form 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 Safety instructions ........................8 Transport and installation ....................11 3 Intended use ..........................
  • Page 4 Welding torch cooling system ....................68 Performance data ......................... 69 8.3.1 Taurus XQ 350 Synergic C ................... 69 8.3.2 Taurus XQ 400 Synergic C ................... 70 9 Accessories ..........................71 Welding torch cooling system ....................71 9.1.1 Coolant - type blueCool ..................71 7-pole remote control ......................
  • Page 5 Contents Notes on using these operating instructions 11 Appendix ............................76 11.1 Average wire electrode usage ..................... 76 11.2 Average shielding gas usage ....................76 11.2.1 MIG/MAG welding ....................76 11.2.2 TIG welding ......................76 11.3 Searching for a dealer......................77 099-005653-EW501 7.11.2024...
  • 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. • Safety 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 off machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn...
  • Page 8 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 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 sufficient fresh 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 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 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 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 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 4-1 099-005653-EW501 7.11.2024...
  • Page 16 Machine description – quick overview Front view / side view from the right Front view / side view from the right Figure 4-2 099-005653-EW501 7.11.2024...
  • 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 5.1.9.1 chapter. 19-pole connection socket - analogue For connecting analogue accessory components (remote control, welding torch control lead, etc.)
  • Page 18 Machine description – quick overview Rear view / side view from left Rear view / side view from left Figure 4-3 099-005653-EW501 7.11.2024...
  • 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...
  • Page 20 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 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 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 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 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 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 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 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 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 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 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 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. 5.1.10.3 Setting the shielding gas volume (gas test)/rinse hose package •...
  • Page 32 Design and function Transport and installation 5.1.11 Protective flap, welding machine control Figure 5-12 • 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. 5.1.12 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.
  • Page 33 Design and function MIG/MAG welding MIG/MAG welding 5.2.1 Assemble the wire guide The Euro torch connector is factory-fitted with a guide tube for welding torches with steel liner. Conver- sion is necessary if a welding torch with a steel liner is used! •...
  • Page 34 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 Design and function MIG/MAG welding Figure 5-15 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 5.1.12 chapter • Insert the polarity selection plug into the "+" welding current connection socket and lock in place by turning to the right.
  • Page 36 Design and function MIG/MAG welding Item Symbol Description Connection socket (–) 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. self-shielding cored wire) are welded using negative polarity. In this case, the welding current lead should be connected to the "-"...
  • Page 37 Design and function MIG/MAG welding • Unlock and open protective flap. • Loosen knurled nut from spool holder. • Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore. • Fasten wire spool using knurled nut. Figure 5-18 Observe the unwinding direction of the wire spool.
  • Page 38 Design and function MIG/MAG welding Item Symbol Description Clamping unit Wire feed roller see the Wire feed roller overview table • Rotate the tommy by 90° clockwise or anti-clockwise (tommy locks into place). • Fold the closure brackets outwards by 90°. •...
  • 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 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 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 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 5.1.12 chapter •...
  • Page 43 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 Design and function Remote control Item Symbol Description Polarity selection plug welding current cable > see 5.1.12 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 Design and function Interfaces for automation 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) Not-Aus - Emergency stop for higher level shut-down of the Input...
  • Page 46 Design and function PC interface Signal form Short description Output Connection for PE cable screen Output Reference voltage for potentiometer 10 V (max. 10 mA) Input Control voltage specification (0 V–10 V) – wire feed speed Output Reference potential (0 V) Input Welding power start/stop (S1) Input...
  • Page 47 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 48 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 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. • Clean the wire feed rolls on a regular basis (depending on the degree of soiling).
  • Page 50 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 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 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 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! 099-005653-EW501 7.11.2024...
  • Page 55 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 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 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 faulty. Check the fan and clean or replace it. ...
  • Page 61 Rectifying faults Error messages (power source) Error 40: Electronics error  Error in the power supply of the electronics Request service.  Error 47: Radio link (BT) Category B  Connection error between the welding machine and peripheral unit. Note the documentation for the data interface with radio transmission. ...
  • Page 62 Rectifying faults Error messages (power source) Error 55: Excess wire feeder current Category B  Excess current detected in the wire feed mechanism. Do not lay the liner in tight radii.  Check the liner for ease of movement.  Error 56: Mains phase failure ...
  • Page 63 Rectifying faults Warnings Warnings Depending on the display options of the machine display, a warning message is displayed as follows: 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 64 Rectifying faults Checklist for rectifying faults Warning Potential cause / remedy 24 Coolant flow warning Check the coolant supply. Check the coolant level and top up if necessary. Check flow and switching thresholds. 25 Flow 2 reserved 26 Flow 3 reserved 27 Flow 4 reserved...
  • Page 65 Rectifying faults Checklist for rectifying faults Functional errors  Mains fuse triggers - unsuitable mains fuse Set up recommended mains fuse > see 8.3 chapter.   Machine does not start up after switching on (device fan and possibly coolant pump have no function). Connect the control cable of the wire feeder.
  • Page 66 Rectifying faults Vent coolant circuit Wire feed problems  Wire feed roll holder is worn (wire feed rolls must be firmly seated on their holders and must not have any play) Replace wire feed roll holder (092-002960-E0000) > see 10.1.4 chapter ...
  • Page 67 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 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 Technical data Performance data Performance data 8.3.1 Taurus XQ 350 Synergic 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°C/104°F 350 A (80 %) 320 A (100%)
  • Page 70 Technical data Performance data 8.3.2 Taurus XQ 400 Synergic 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°C/104°F...
  • Page 71 Accessories Welding torch cooling system Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Welding torch cooling system Type Designation Item no. HOSE BRIDGE UNI Tube bridge 092-007843-00000 LFMG HANNA DIST 3 Conductivity meter 094-026184-00000 9.1.1...
  • Page 72 Accessories Option for retrofitting Option for retrofitting Type Designation Item no. ON Partbox F.06 Box for storing wear parts and smaller accessories 092-004426-00000 such as wire feed rolls for mounting on a flexFit housing system ON PS F.06 + TG.11/K.06 Cross arm to accommodate a modular Tetrix XQ 092-004590-00000 and a cooling unit...
  • Page 73 Accessories Shielding gas supply (shielding gas cylinder for welding machine) Shielding gas supply (shielding gas cylinder for welding machine) Type Designation Item no. Proreg Ar/CO2 230bar 15l D Pressure regulator with manometer 394-008488-10015 Proreg Ar/CO2 230bar 30l D Pressure regulator with manometer 394-008488-10030 DM 842 Ar/CO2 230bar 15l D Pressure regulator with manometer...
  • Page 74 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 75 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 FUEL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00010 BLUE/ORANGE...
  • Page 76 Appendix Average wire electrode usage Appendix 11.1 Average wire electrode usage 5 m/min – 197 ipm inch .040 .045 .060 Steel kg/h 10.3 lb/h Stainless steel 10.5 Aluminium 10 m/min – 394 ipm Steel kg/h 11.6 20.9 lb/h Stainless steel 11.9 21.1 Aluminium...
  • Page 77 Appendix Searching for a dealer 11.3 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005653-EW501 7.11.2024...

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