Related Manuals for EWM Titan XQ R 400 puls AC/DC D
Summary of Contents for EWM Titan XQ R 400 puls AC/DC D
- Page 1 Operating instructions Power source Titan XQ R 400 puls AC/DC D 099-005718-EW501 Observe additional system documents! 22.08.2024...
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Page 2: General Instructions
+49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted. -
Page 3: Table Of Contents
Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................6 Notes on using these operating instructions ................6 Explanation of icons ....................... 7 Safety instructions ........................8 Transport and installation ....................11 3 Intended use .......................... - Page 4 Dimensions and weighte ...................... 74 8.1.1 Welding torch cooling system ................74 Performance data ......................... 75 8.2.1 Titan XQ R 400 puls AC/DC D ................75 9 Accessories ..........................76 System components ......................76 9.1.1 Wire feed unit ......................76 9.1.2...
- Page 5 Contents Notes on using these operating instructions 9.8.1 Coolant - type blueCool ..................78 General accessories ......................78 10 Appendix ............................79 10.1 Average wire electrode usage ..................... 79 10.2 Average shielding gas usage ....................79 10.2.1 MIG/MAG welding ....................79 10.2.2 TIG welding ......................
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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. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 7: Explanation Of Icons
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn... -
Page 8: Safety Instructions
For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 9 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
- Page 10 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases 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 sufficient fresh 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 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 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 13: Intended Use
Intended use Use and operation solely with the following machines 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: Applications
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 3.3.1... -
Page 15: Service Documents (Spare Parts And Circuit Diagrams)
Intended use Documents which also apply 3.3.4 Service documents (spare parts and circuit diagrams) 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 16: 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 compo- nents, especially the safety instructions! The illustration shows a general example of a welding system. -
Page 17: 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 18: 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 4-2 099-005718-EW501 22.08.2024... - Page 19 Machine description – quick overview Front view / side view from the right Item Symbol Description Inspection window for the emergency-stop circuit - ex-factory op- tion > see 5.8 chapter WiFi antenna Factory-fit option, (version OW Expert XQ 2.0 WLG) Main Switch Switching the machine on or off.
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Page 20: Rear View / Side View From Left
Machine description – quick overview Rear view / side view from left Rear view / side view from left Figure 4-3 099-005718-EW501 22.08.2024... - Page 21 Machine description – quick overview Rear view / side view from left Item Symbol Description Cooling air inlet Dirt filter optional > see 9 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 22: Connection Panel
Machine description – quick overview Rear view / side view from left 4.3.1 Connection panel Figure 4-4 Item Symbol Description Connecting nipple - G¼" - ex-factory option shielding gas connection (inlet) Connecting nipple - G¼" - ex-factory option shielding gas connection (inlet) Connecting nipple - G¼”... -
Page 23: Connection Plan
Machine description – quick overview Connection plan Connection plan 4.4.1 Operation with one wire feeder 4.4.1.1 Standard M drive 4 Rob 5 Fassförderung pol – DV1 pol – DV1 RC XQ SPS / CU / ROB Titan XQ R Figure 4-5 099-005718-EW501 22.08.2024... - Page 24 Machine description – quick overview Connection plan Wire feeding Welding current (minus potential, workpiece) Shielding gas Torch coolant Coolant inlet Coolant outlet Supply voltage for the welding machine Welding current (plus potential) Interface for automated welding (19-pole) Control cable for wire feeder DV1 (23-pole) 23 pol Euro torch connector Compressed air connection to clean the welding torch nozzles...
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Page 25: React Xq
Machine description – quick overview Connection plan 4.4.1.2 React XQ M drive 4 Rob 5 Fassförderung pol – DV2 pol – DV1 pol – DV2 pol – DV1 RC XQ SPS / CU / ROB Titan XQ R Figure 4-6 099-005718-EW501 22.08.2024... - Page 26 Machine description – quick overview Connection plan Wire feeding Welding current (minus potential, workpiece) Shielding gas Torch coolant Coolant inlet Coolant outlet Supply voltage for the welding machine Welding current (plus potential) Interface for automated welding (19-pole) Control cable for the wire feeder on the WDU C W ROB welding torch (12-pole) Control cable for wire feeder DV1 (23-pole) 23 pol Control cable for the wire feeder on the welding torch React drive (23-pole)
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Page 27: Operation With Two Wire Feeders
Machine description – quick overview Connection plan 4.4.2 Operation with two wire feeders M drive 4 Rob 5 M drive 4 Rob 5 pol – DV1 pol – DV2 pol – DV1 pol – DV2 RC XQ SPS / CU / ROB Titan XQ R Figure 4-7 099-005718-EW501... - Page 28 Machine description – quick overview Connection plan Wire feeding Welding current (minus potential, workpiece) Shielding gas Torch coolant Coolant inlet / shielding gas Coolant outlet / shielding gas Supply voltage to the welding machine Welding current (plus potential) Interface for automated welding (19-pole) Control cable for wire feeder DV1 (23-pole) 23 pol Control cable for wire feeder DV2 (23-pole)
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Page 29: 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 30: Ambient Conditions
Design and function Transport and installation 5.1.2 Ambient conditions The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 31: 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 32: Adding Coolant
Design and function Transport and installation 5.1.5.4 Adding coolant After switching on the machine, the coolant pump runs for a defined time (filling the hose package). If the machine does not detect sufficient coolant flow during this time, the coolant pump is switched off (protec- tion against damage caused by dry running). -
Page 33: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.6 Notes on the installation of welding current leads • Incorrectly installed welding current leads can cause faults in the arc (flickering). • Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel. -
Page 34: Stray Welding Currents
Design and function Transport and installation 5.1.7 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. •... -
Page 35: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Transport and installation 5.1.8 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 36: Mains Connection
Design and function Transport and installation 5.1.9 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 37: 5.1.10.1 Led Status Bar - Display Of Operating Status
Design and function Transport and installation 5.1.10.1 LED status bar - display of operating status A light guide on the front of the housing (LED status bar) shows the user the current operating status of the device. Colour of the LED status bar Operating status white (change: light/dark) Booting (switching on up to welding readiness) -
Page 38: Connecting The Intermediate Hose Package To The Power Source
Design and function Connecting the intermediate hose package to the power source Connecting the intermediate hose package to the power source 5.2.1 Operation with one wire feeder 5.2.1.1 Standard Figure 5-10 Item Symbol Description Shielding gas cylinder Wire feed unit Intermediate hose package Connecting nipple - G¼"... - Page 39 Design and function Connecting the intermediate hose package to the power source • 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. •...
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Page 40: React Xq
Design and function Connecting the intermediate hose package to the power source 5.2.1.2 React XQ Figure 5-11 Item Symbol Description Shielding gas cylinder Wire feed unit Intermediate hose package Connecting nipple - G¼" - ex-factory option shielding gas connection (inlet) Connecting nipple - G¼”... - Page 41 Design and function Connecting the intermediate hose package to the power source • 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. •...
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Page 42: Operation With Two Wire Feeders
Design and function Connecting the intermediate hose package to the power source 5.2.2 Operation with two wire feeders Figure 5-12 Item Symbol Description Wire feed unit Intermediate hose package Connection socket - 23-pole Wire feeder control cable connection Connecting nipple - G¼” - ex-factory option Shielding gas connection (outlet) Intermediate hose package strain relief >... - Page 43 Design and function Connecting the intermediate hose package to the power source Item Symbol Description Connection socket welding current - DV1 Quick connect coupling - red coolant return Quick connect coupling - blue coolant supply Connection socket welding current – DV2 Connecting nipple - G¼”...
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Page 44: Intermediate Hose Package Strain Relief
Possible attachment points Figure 5-13 Item Symbol Description Intermediate hose package strain relief For wire feeder 1 Intermediate hose package Intermediate hose package strain relief For wire feeder 2 5.2.4.1 Locking the strain relief EWM intermediate hose package Figure 5-14 099-005718-EW501 22.08.2024... -
Page 45: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.3.1 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. 5.3.2 Welding task selection For selection of the welding task and for general operation see the relevant Control operating instructions. -
Page 46: Welding Task Selection
Design and function Remote control Item Symbol Description • TIG welding: Workpiece connection • Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by turning to the right. 5.4.2 Welding task selection For selection of the welding task and for general operation see the relevant Control operating instructions. -
Page 47: 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 48: System Board
Design and function Interfaces for automation Item Symbol Description Robot interface / Industrial bus interface Only one variant can ever be operated at any one time. 5.6.2 System board 5.6.2.1 LED information field For information on the LED information field, please refer to the relevant operating instructions “Interface for digital power sources”. -
Page 49: Sensor Voltage
Design and function Interfaces for automation 5.6.3 Sensor Voltage 5.6.3.1 Pin assignment Figure 5-20 Pin assignment for 12-pole interface (X60): Pin / designation Input / output Note A / PE Output Cable screen connection B-G / NC H / +24V Suche ein Input Sensor voltage supply J / 0V Suche ein... -
Page 50: External Power Supply And External Signals
Design and function External power supply and external signals External power supply and external signals 5.7.1 Pin assignment Figure 5-21 Pin assignment for 12-pole interface (X54): Pin / designation Input / output Note A / PE Output Cable screen connection B / +24V Input External power supply... -
Page 51: Activating The Emergency Stop Circuit
Design and function Emergency stop circuit 5.8.1 Activating the emergency stop circuit Figure 5-22 Item Symbol Description 2-pole connector plug Emergency stop circuit connection 2-pole connection socket Emergency stop circuit connection • Open the housing • Remove the 2-pole connector plug from the 2-pole connection socket •... -
Page 52: Connection Variant For Safety Switching Device
LED must light up indicating proper function. In the case of a fault, the “Fault” LED flashes. If this status persists even after switching the emergency stop circuit off and on again, the safety switching device is faulty (please notify the EWM-Service). Figure 5-24... -
Page 53: Pc Interface
Design and function PC interface 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 54: 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 55 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. • Clean the wire feed rolls on a regular basis (depending on the degree of soiling).
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Page 56: 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 57: Coolant Error
Maintenance, care and disposal Maintenance schedule 6.3.2 Coolant error Observe all instructions for handling, use and disposal of torch coolant > see 5.1.5 chapter. Figure 6-3 • Switch off the machine and disconnect the mains plug. Position a suitable collecting container under the drain plug of the coolant tank. - Page 58 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 59: 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 60: 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! 099-005718-EW501 22.08.2024... -
Page 61: 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 62: 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 63 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 64 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 65 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 66 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 67 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 for the data interface with radio transmission. ...
- Page 68 Rectifying faults Error messages (power source) Error 56: Mains phase failure One phase of the mains voltage has failed. Check the mains connection, mains plug and mains fuses. Error 57: Slave tacho error Category B Fault in the wire feeder (slave drive). Check the connections (connectors, lines).
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Page 69: Warnings
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 70: Checklist For Rectifying Faults
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 71 Rectifying faults Checklist for rectifying faults Functional errors Mains fuse triggers - unsuitable mains fuse Set up recommended mains fuse > see 8 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.
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Page 72: Vent Coolant Circuit
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) Contact tip blocked Clean and, if necessary, replace. -
Page 73: 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 74: 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 75: Performance Data
Technical data Performance data Performance data 8.2.1 Titan XQ R 400 puls AC/DC D Mains voltage 3 x 380-400 V 3 x 440-460 V 3 x 480-500 V Welding current (I 5 A to 400 A Welding voltage according to standard... -
Page 76: Accessories
Accessories System components Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or interme- diate hose packages are available from your authorised dealer. System components 9.1.1 Wire feed unit Type Designation Item no. M drive 4 Rob 5 XR LI MIG wire feeder 090-005722-00xxx M drive 4 Rob 5 XR RE... -
Page 77: Option For Retrofitting
Accessories Option for retrofitting Option for retrofitting Type Designation Item no. ON EWM React LC1 EWM React licence 092-004711-00000 ON Shock Protect F06 Ram protection 092-003334-00000 ON Filter F06 Dirt filter for air inlet 092-003337-00000 OU F06W Conversion kit, water block... -
Page 78: Connection Cables
Accessories Connection cables 9.5.2.1 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 Connection cables 9.6.1 23-pole connection Type Designation... -
Page 79: Appendix
Appendix Average wire electrode usage Appendix 10.1 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 80: Searching For A Dealer
Appendix Searching for a dealer 10.3 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005718-EW501 22.08.2024...
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