Related Manuals for EWM Phoenix XQ R 355 puls
Summary of Contents for EWM Phoenix XQ R 355 puls
- Page 1 Operating instructions Power source Phoenix XQ R 355 puls Phoenix XQ R 405 puls 099-005704-EW501 Observe additional system documents! 23.01.2024...
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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 Vent coolant circuit ....................... 54 8 Technical data ..........................55 Dimensions and weighte ...................... 55 Performance data ......................... 56 8.2.1 Phoenix XQ R 355 puls ..................56 8.2.2 Phoenix XQ R 405 puls ..................57 9 Accessories ..........................58 System components ......................58 9.1.1...
- Page 5 Contents Notes on using these operating instructions 099-005704-EW501 23.01.2024...
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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. • 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
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: Use And Operation Solely With The Following Machines
A suitable wire feed unit (system component) is required in order to operate the welding machine! The following system components can be combined: Power source Phoenix XQ R 355 puls Phoenix XQ R 405 puls Wire feed unit M drive 4 Rob 5 XR LI... -
Page 15: Part Of The Complete Documentation
Intended use Use and operation solely with the following machines 3.3.1 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 16: Machine Description - Quick Overview
Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-005704-EW501 23.01.2024... - Page 17 Machine description – quick overview Front view / rear view Item Symbol Description Inspection window for the system board • Information over the LED information field > see 5.4.3.1 chapter • Access to the dip switch Inspection window for the emergency-stop circuit - ex-factory op- tion >...
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Page 18: Connection Panel
Machine description – quick overview Front view / rear view 4.1.1 Connection panel Figure 4-2 Item Symbol Description Connection socket - 23-pole - ex-factory option Wire feeder control cable connection Connection socket - 23-pole Wire feeder control cable connection Key button, Automatic cutout Wire feed motor supply voltage fuse (press to reset a triggered fuse) 7-pole connection socket (digital) -
Page 19: Connection Plan
Machine description – quick overview Connection plan Connection plan M drive 4 Rob 5 Fassförderung pol - DV2 pol – DV1 pol - DV2 pol – DV1 RC XQ Phoenix XQ R SPS / CU / ROB Cool XQ R 50 Figure 4-3 099-005704-EW501 23.01.2024... -
Page 20: Legend
Machine description – quick overview Connection plan 4.2.1 Legend Wire feeding Welding current (minus potential, workpiece) Shielding gas Torch coolant Coolant inlet Coolant outlet Supply voltage to the welding machine Welding current (plus potential) Interface for automated welding (19-pole) Connection from wire feeder to welding torch - push/push drive (12-pole) Control cable for wire feeder DV1 (23-pole) 23 pol Control cable for wire feeder DV2 (23-pole) -
Page 21: Design And Function
Design and function Transport and installation Design and function WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •... -
Page 22: Machine Cooling
Design and function Transport and installation Transport and storage Storage in a closed room, temperature range of the ambient air: • -30 °C to +70 °C (-22 °F to 158 °F) Relative humidity • up to 90 % at 20 °C (68 °F) Ambient temperature dependent on coolant! Observe the coolant temperature range of the torch cool- 5.1.2 Machine cooling... -
Page 23: Connecting The Intermediate Hose Package To The Power Source
Design and function Transport and installation 5.1.5 Connecting the intermediate hose package to the power source With this machine series, the earth cable on the intermediate hose package must not be con- nected to the welding machine or wire feeder! Remove the earth cable or push back into the hose package! Figure 5-2 Item Symbol... -
Page 24: Intermediate Hose Package Strain Relief
Design and function Transport and installation • Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right. The strain relief for fastening the intermediate hose package is provided on the transport cart used (see corresponding documentation). -
Page 25: Visual Inspection Of The Set Mains Voltage
Design and function Transport and installation • Adaptation and marking of the mains voltage > see 5.1.7.2 chapter • Carry out a safety check after intervention in the machine > see 5.1.7.3 chapter! 5.1.7.1 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 26: Adjusting The Power Source To The Mains Voltage
Design and function Transport and installation 5.1.7.2 Adjusting the power source to the mains voltage If the power source is to be operated at mains voltages greater than 400 V in conjunction with a cooling unit for torch cooling, the Cool XQ R 50 U40 MV multi-voltage cooling unit must be used >... -
Page 27: Mains Configuration
Design and function Transport and installation 5.1.7.4 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 28: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.9 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 29: 5.1.10 Stray Welding Currents
Design and function Transport and installation 5.1.10 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 30: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.2.1 Connection for workpiece lead 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 "-" welding current socket, and the workpiece lead should be connected to the "+"... -
Page 31: 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 32: Connection For The Industrial Bus Interface
Design and function Interfaces for automation 5.4.1 Connection for the industrial bus interface Figure 5-12 Item Symbol Description Switching cabinet Connection lead between power source and interface Connection socket for industrial bus interface - ex-factory option Industrial bus interface Only one variant can ever be operated at any one time. 5.4.1.1 Industrial bus interface BUSINT XQ 4.0 The solution for integration with automated production with e.g. -
Page 33: Connecting The Robot Interface
Design and function Interfaces for automation 5.4.2 Connecting the robot interface Figure 5-13 Item Symbol Description Switching cabinet Connection lead between power source and interface 7-pole connection socket (digital) For connecting digital accessory components Robot interface 5.4.2.1 RINT X12 robot interface The standard digital interface for mechanised applications ... -
Page 34: System Board
Design and function Interfaces for automation 5.4.3 System board 5.4.3.1 LED information field For information on the LED information field, please refer to the relevant operating instructions “Interface for digital power sources”. Figure 5-14 Item Symbol Description DIP switches For addressing and activating functions Switch for selecting the data profile used >... -
Page 35: Sensor Voltage
Design and function Interfaces for automation 5.4.4 Sensor Voltage 5.4.4.1 Pin assignment Figure 5-16 Pin assignment for 12-pole interface (X60): Pin / designation Input / output Note A / PE Output Cable screen connection B-C / NC H / +24V Suche ein Input Sensor voltage supply J / 0V Suche ein... -
Page 36: External Power Supply
Design and function Interfaces for automation 5.4.5 External power supply 5.4.5.1 Pin assignment Figure 5-17 Pin assignment for 12-pole interface (X54): Pin / designation Input / output Note A / PE Output Cable screen connection B / +24V Input External power supply C / +0V Input External power supply... -
Page 37: Automation Interface
Design and function Interfaces for automation 5.4.6 Automation interface Figure 5-18 Pin assignment, 19-pole interface for automated welding (X40): Pin / designation Input / output Note A / PE Output Cable screen connection B/C / NC D / IGR0 Output Current flow signal (I>0). -
Page 38: Emergency Stop Circuit
Design and function Emergency stop circuit Emergency stop circuit The emergency stop circuit ensures that the power source switches off safely in the event of an emer- gency. This entails an immediate shutdown of the welding circuit via the safety relay. The emergency stop circuit is deactivated by default. -
Page 39: Switching On And Controlling
In the case of a fault, the LED flashes. If this status persists even after switching the emergency stop cir- cuit off and on again, the safety switching device is faulty (please notify the EWM-Service or send in the interface). -
Page 40: 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 41: Maintenance, Care And Disposal
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 42: Maintenance Work, Intervals
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! 099-005704-EW501 23.01.2024... -
Page 43: 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 44: 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 45 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 46 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 47 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 48 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. ...
- Page 49 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 welding machine and peripheral unit. Note the documentation for the data interface with radio transmission. ...
- Page 50 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 51: 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 52: Checklist For Rectifying Faults
Rectifying faults Checklist for rectifying faults Warning Potential cause / remedy 24 Coolant flow warning Check coolant supply. Check coolant level and top up if necessary. Check flow and switching thresholds. 25 Flow 2 reserved 26 Flow 3 reserved 27 Flow 4 reserved 28 Wire stock warning Check wire feeding. - Page 53 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 54: 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 55: 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 Dimensions (l x b x h) 625 x 298 x 580 mm 24.6 x 11.7 x 22.8 inch Weight 44,0 kg 97.0 lb... -
Page 56: Performance Data
Technical data Performance data Performance data 8.2.1 Phoenix XQ R 355 puls Welding current (I 5 A to 350 A Welding voltage according to standard (U 14,3 V to 31,5 V Duty cycle DC at 40° C 350 A (100%) -
Page 57: Phoenix Xq R 405 Puls
Technical data Performance data 8.2.2 Phoenix XQ R 405 puls Welding current (I 5 A to 400 A Welding voltage according to standard (U 14,3 V to 34 V Duty cycle DC at 40° C 350 A (100 %) 400 A (60 %) Mains voltage / Tolerance / mains fuse 3 x 380 to 400 V / -25 % to +20 % / 3 x 25 A... -
Page 58: 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 090-005534-00502 M drive 4 Rob 5 XR RE... -
Page 59: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
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 60: 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 61: 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" 099-005704-EW501 23.01.2024...
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