Related Manuals for EWM Phoenix XQ R 1004 puls
Summary of Contents for EWM Phoenix XQ R 1004 puls
- Page 1 Operating instructions Power source Phoenix XQ R 1004 puls 099-005728-EW501 Observe additional system documents! 10.02.2025...
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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 ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use .......................... - Page 4 Contents Notes on using these operating instructions Welding task selection ......................44 Interfaces for automation ..................... 45 5.4.1 Connection for the industrial bus interface ............46 5.4.2 System board ......................47 5.4.2.1 LED information field ................47 5.4.2.2 Access to DIP switches and data profile switches ........ 47 5.4.3 Sensor Voltage .....................
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Page 5: 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 6: 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 7: 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 8 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 9 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 10: 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 11 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 12: Intended Use
Machine series MIG/MAG standard arc MIG/ MAG - pulse arc Titan XQ R Phoenix XQ R All EWM React-based processes are available only in machines of type Titan XQ R with an activated process license. Aluminium welding tasks. 099-005728-EW501 10.02.2025... -
Page 13: Use And Operation Solely With The Following Machines
3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 14: Part Of The Complete Documentation
Intended use Documents which also apply 3.3.4 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: 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 machine series XQ R: Figure Transport properties Torch cooling P 1DV P 1DV P 1DV P 2DV P 2DV P 2DV... -
Page 16: Front View
Machine description – quick overview Front view Front view Figure 4-2 099-005728-EW501 10.02.2025... - Page 17 Machine description – quick overview Front view Item Symbol Description Inspection window for the system board • Information over the LED information field • Access to the dip switch Inspection window for the emergency-stop circuit - ex-factory op- tion > see 5.5 chapter Machine control (see the relevant control operating instructions) Main Switch Switching the machine on or off.
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Page 18: Rear View
Machine description – quick overview Rear view Rear view Figure 4-3 099-005728-EW501 10.02.2025... - Page 19 Machine description – quick overview Rear view Item Symbol Description Connection panel > see 4.3.1 chapter Intermediate hose package strain relief > see 5.2.4 chapter - option Cooling air inlet Dirt filter optional Load connection screwable potential (+) WF1 Welding current connection for wire feeder > see 5.2.1 chapter Load connection screwable potential (+) WF2 Welding current connection for wire feeder >...
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Page 20: Connection Panel
Machine description – quick overview Rear view 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” - ex-factory option Shielding gas connection (outlet) Connecting nipple - G¼”... -
Page 21: Connection Plan
Machine description – quick overview Connection plan Connection plan 4.4.1 Operation with one wire feeder M drive 4 Rob 5 Fassförderung pol – DV1 pol – DV1 RC XQ SPS / CU / ROB Phoenix XQ R Figure 4-5 099-005728-EW501 10.02.2025... -
Page 22: Legend
Machine description – quick overview Connection plan 4.4.1.1 Legend 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) Control cable for wire feeder DV1 (23-pole) 23 pol Euro torch connector Compressed air connection to clean the welding torch nozzles... -
Page 23: 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 Phoenix XQ R Figure 4-6 099-005728-EW501... -
Page 24: Legend
Machine description – quick overview Connection plan 4.4.2.1 Legend 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) Control cable for wire feeder DV1 (23-pole) 23 pol Control cable for wire feeder DV2 (23-pole) -
Page 25: 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 26: Craning Principle
Design and function Transport and installation 5.1.1.1 Craning principle The illustration serves as an example only. Figure 5-1 Figure 5-2 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! •... -
Page 27: Machine Cooling
Design and function Transport and installation In operation Temperature range of the ambient air: • -25 °C to +40 °C (-13 °F to 104 °F) Relative humidity: • up to 50 % at 40 °C (104 °F) • up to 90 % at 20 °C (68 °F) Transport and storage Storage in a closed room, temperature range of the ambient air: •... -
Page 28: Permitted Torch Coolant
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 29: 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 30: Assembly/Disassembly
Design and function Transport and installation 5.1.5.5 Assembly/disassembly For installation and removal, see the relevant operating instructions of the “Cooling unit”. 5.1.6 Notes on the installation of welding current leads • Incorrectly installed welding current leads can cause faults in the arc (flickering). •... -
Page 31: 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 32: 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 33: Gas Test - Setting The Shielding Gas Volume
Design and function Transport and installation 5.1.8.2 Gas test – setting the shielding gas volume • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. • Set the relevant gas quantity for the application on the pressure regulator. •... -
Page 34: Visual Inspection Of The Set Mains Voltage
Design and function Transport and installation 5.1.9.1 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. If the marked mains voltage range coincides with the supply voltage, further commissioning may take place. -
Page 35: Adjusting The Power Source To The Mains Voltage
Design and function Transport and installation 5.1.9.2 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 36: Mains Configuration
Design and function Transport and installation 5.1.9.4 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 37: Connection
Design and function Connection Connection 5.2.1 Connecting the current lead WARNING Electric current! When connecting connection leads and interfaces you may come into contact with fatal electric currents! • Follow the safety instructions entitled "For your safety" on the opening pages! •... -
Page 38: Connection For Workpiece Lead
Design and function Connection 5.2.2 Connection for workpiece lead WARNING Risk of fire from uneven load distribution! When welding, high currents flow that could overload individual cables. This may lead to excessive heating, insulation damage or even cable fires. • Connect the required number of workpiece leads. -
Page 39: Connecting The Intermediate Hose Package To The Power Source
Design and function Connection 5.2.3 Connecting the intermediate hose package to the power source 5.2.3.1 Operation with one wire feeder Figure 5-14 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 40 Design and function Connection • 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. • Insert the hose package end of the intermediate hose package from the outside through the strain re- lief of intermediate hose package and then lock by turning to the right.
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Page 41: Operation With Two Wire Feeders
Design and function Connection 5.2.3.2 Operation with two wire feeders Figure 5-15 Item Symbol Description Wire feed unit Intermediate hose package Connection socket - 23-pole Wire feeder control cable connection Intermediate hose package strain relief > see 5.2.4 chapter - op- tion >... -
Page 42: Intermediate Hose Package Strain Relief
Design and function Connection Item Symbol Description Load connection screwable potential (+) WF1 Welding current connection for wire feeder > see 5.2.1 chapter Load connection screwable potential (+) WF2 Welding current connection for wire feeder > see 5.2.1 chapter Intermediate hose package strain relief > see 5.2.4 chapter Connecting nipple - G¼”... -
Page 43: Possible Attachment Points
Design and function Connection 5.2.4.1 Possible attachment points Figure 5-16 5.2.4.2 Locking the strain relief EWM intermediate hose package Figure 5-17 099-005728-EW501 10.02.2025... -
Page 44: Remote Control
Design and function Welding task selection Intermediate hose package made of corrugated tube Select the required middle jaw according to the nominal intermediate hose package diameter. Figure 5-18 5.2.5 Remote control Figure 5-19 Item Symbol Description Operating panel Connection cable between operating panel and power source Welding task selection For selection of the welding task and for general operation see the relevant Control operating instructions. -
Page 45: 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 46: Connection For The Industrial Bus Interface
Design and function Interfaces for automation 5.4.1 Connection for the industrial bus interface Figure 5-20 Item Symbol Description Switching cabinet Connection lead between power source and interface Connection socket for industrial bus interface - ex-factory option Robot interface / Industrial bus interface Only one variant can ever be operated at any one time. -
Page 47: System Board
Design and function Interfaces for automation 5.4.2 System board 5.4.2.1 LED information field For information on the LED information field, please refer to the relevant operating instructions “Interface for digital power sources”. Figure 5-21 Item Symbol Description DIP switches For addressing and activating functions Switch for selecting the data profile used LED information field 5.4.2.2... -
Page 48: Sensor Voltage
Design and function Interfaces for automation 5.4.3 Sensor Voltage 5.4.3.1 Pin assignment Figure 5-23 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 49: External Power Supply And External Signals
Design and function Emergency stop circuit 5.4.4 External power supply and external signals 5.4.4.1 Pin assignment Figure 5-24 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... -
Page 50: Activating The Emergency Stop Circuit
Design and function Emergency stop circuit 5.5.1 Activating the emergency stop circuit Figure 5-25 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 51: 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 5-27... -
Page 52: 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 53: Power-Saving Mode (Standby)
Design and function Power-saving mode (Standby) Power-saving mode (Standby) The time-dependent energy saving function is deactivated at the factory and must be activated when required. Power-saving mode: • You can activate the power-saving mode using a time-dependent energy saving function or lock func- tion. -
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! 099-005728-EW501 10.02.2025... -
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 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 68 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 ...
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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 8.2 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) 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 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 A04 G A04P G A04RS G Dimensions (l x b inch inch inch x h) 1146 45,1 1256 49.5 1299... -
Page 75: Performance Data
Technical data Performance data Performance data Welding current I 5 A to 1000 A Welding voltage according to standard U 14,3 V to 44 V Duty cycle DC at 40°C/104°F 1000 A (60 %) / 750 A (100 %) Open circuit voltage U 380 - 400 V 82 V Open circuit voltage U... -
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: 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 78: 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 79: 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" 099-005728-EW501 10.02.2025...
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