EWM Titan XQ 400 puls D, Titan XQ 350 puls D, Titan XQ 500 puls D, Titan XQ 600 puls D Operating Instructions Manual

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Operating instructions

Power source

Titan XQ 350 puls D Titan XQ 400 puls D Titan XQ 500 puls D Titan XQ 600 puls D

099-005560-EW501

Observe additional system documents!

09.03.2018

General instructions

WARNING

Read the operating instructions! The operating instructions provide an introduction to the safe use of the products.

• Read and observe the operating instructions for all system components, especially the safety instructions and warning notices!

• Observe the accident prevention regulations and any regional regulations!

• The operating instructions must be kept at the location where the machine is operated.

• Safety and warning labels on the machine indicate any possible risks.

Keep these labels clean and legible at all times.

• The machine has been constructed to state-of-the-art standards in line with any applicable regulations and industrial standards. Only trained personnel may operate, service and repair the machine.

• Technical changes due to further development in machine technology may lead to a differing welding behaviour.

In the event of queries on installation, commissioning, operation or special conditions at the installation site, or on usage, please contact your sales partner or our customer service department on +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. This exclusion of liability shall be deemed accepted by the user on commissioning the equipment. The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are observed during installation, operation, usage and maintenance of the equipment.

An incorrectly performed installation can result in material damage and injure persons as a result. For this reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation, improper operation or incorrect usage and maintenance or any actions connected to this in any way.

Dr. Günter-Henle-Strasse 8 56271 Mündersbach Germany Tel.: +49 2680 181-0, Fax: -244 Email: info@ewm-group.com

www.ewm-group.com

The copyright to this document remains the property of the manufacturer. Copying, including extracts, only permitted with written approval. The content of this document has been prepared and reviewed with all reasonable care. The information

provided is subject to change; errors excepted.

Contents

Notes on the use of these operating instructions

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1 Contents

1 Contents .................................................................................................................................................. 3

2 For your safety ....................................................................................................................................... 6

2.1 Notes on the use of these operating instructions .......................................................................... 6

2.2 Explanation of icons ....................................................................................................................... 7

2.3 Part of the complete documentation .............................................................................................. 8

2.4 Safety instructions .......................................................................................................................... 8

2.5 Transport and installation ............................................................................................................ 11

3 Intended use ......................................................................................................................................... 13

3.1 Use and operation solely with the following machines ................................................................ 13

3.2 Applications .................................................................................................................................. 13

3.3 Documents which also apply ....................................................................................................... 13

3.3.1 Warranty ....................................................................................................................... 13

3.3.2 Declaration of Conformity ............................................................................................. 13

3.3.3 Welding in environments with increased electrical hazards ......................................... 13

3.3.4 Service documents (spare parts and circuit diagrams) ................................................ 14

3.3.5 Calibration/Validation ................................................................................................... 14

4 Machine description – quick overview .............................................................................................. 15

4.1 Machine configuration .................................................................................................................. 15

4.2 Front view / side view from the right ............................................................................................ 16

4.3 Rear view / side view from left ..................................................................................................... 18

5 Design and function ............................................................................................................................. 20

5.1 Transport and installation ............................................................................................................ 20

5.1.1 Lifting by crane ............................................................................................................. 20

5.1.2 Craning principle ........................................................................................................... 20

5.1.3 Ambient conditions ....................................................................................................... 21

5.1.3.1 In operation ................................................................................................... 21

5.1.3.2 Transport and storage ................................................................................... 21

5.1.4 Machine cooling ............................................................................................................ 21

5.1.5 Workpiece lead, general ............................................................................................... 21

5.1.6 Welding torch cooling system ....................................................................................... 21

5.1.6.1 Functional characteristics ............................................................................. 21

5.1.6.2 Approved coolants overview ......................................................................... 22

5.1.6.3 Maximal hose package length ...................................................................... 22

5.1.6.4 Adding coolant .............................................................................................. 23

5.1.7 Notes on the installation of welding current leads ........................................................ 24

5.1.8 Stray welding currents .................................................................................................. 25

5.1.9 Connecting the intermediate hose package to the power source ................................ 26

5.1.10 Shielding gas supply (shielding gas cylinder for welding machine) ............................. 27

5.1.10.1 Pressure regulator connection ...................................................................... 27

5.1.11 Mains connection .......................................................................................................... 28

5.1.11.1 Visual inspection of the set mains voltage .................................................... 28

5.1.11.2 Adjusting the power source to the mains voltage ......................................... 29

5.1.11.3 Re-commissioning ......................................................................................... 29

5.1.11.4 Mains configuration ....................................................................................... 30

5.2 Switching on and system diagnosis ............................................................................................. 30

5.3 Infoline - display of operating status ............................................................................................ 30

5.4 Protective flap, welding machine control ..................................................................................... 31

5.5 MIG/MAG welding ........................................................................................................................ 32

5.5.1 Connection for workpiece lead ..................................................................................... 32

5.5.2 Welding task selection .................................................................................................. 32

5.5.3 Setting the shielding gas volume (gas test)/rinse hose package ................................. 33

5.6 TIG welding .................................................................................................................................. 34

5.6.1 Connecting the intermediate hose package to the power source ................................ 34

5.6.2 Connection for workpiece lead ..................................................................................... 35

5.6.3 Welding task selection .................................................................................................. 36

5.7 MMA welding ............................................................................................................................... 36

5.7.1 Connecting the electrode holder and workpiece lead .................................................. 36

5.7.2 Welding task selection .................................................................................................. 37

Contents

Notes on the use of these operating instructions

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5.8 Remote control ............................................................................................................................. 37

5.9 Interfaces for automation ............................................................................................................. 37

5.9.1 Automation interface ..................................................................................................... 37

5.9.2 RINT X12 robot interface .............................................................................................. 38

5.9.3 BUSINT X11 Industrial bus interface ............................................................................ 38

5.10 PC interface ................................................................................................................................. 39

6 Maintenance, care and disposal ......................................................................................................... 40

6.1 General......................................................................................................................................... 40

6.2 Explanation of icons ..................................................................................................................... 41

6.3 Maintenance schedule ................................................................................................................. 42

6.3.1 Dirt filter......................................................................................................................... 43

6.3.2 Coolant error ................................................................................................................. 44

6.3.3 Heat exchanger (torch cooling) .................................................................................... 46

6.3.4 Power source (inverter) ................................................................................................ 47

6.3.5 Annual test (inspection and testing during operation) .................................................. 47

6.4 Disposing of equipment ................................................................................................................ 48

7 Rectifying faults.................................................................................................................................... 49

7.1 Error messages (power source) ................................................................................................... 49

7.2 Warnings ...................................................................................................................................... 51

7.3 Checklist for rectifying faults ........................................................................................................ 52

7.4 Vent coolant circuit ....................................................................................................................... 53

7.5 Fixing the pump shaft (coolant circuit) ......................................................................................... 53

8 Technical data....................................................................................................................................... 54

8.1 Dimensions and weighte .............................................................................................................. 54

8.2 Welding torch cooling system ...................................................................................................... 54

8.3 Performance data ......................................................................................................................... 55

8.3.1 Titan XQ 350 puls D ..................................................................................................... 55

8.3.2 Titan XQ 400 puls D ..................................................................................................... 56

8.3.3 Titan XQ 500 puls D ..................................................................................................... 57

8.3.4 Titan XQ 600 puls D ..................................................................................................... 58

8.3.5 Footnotes ...................................................................................................................... 59

9 Accessories .......................................................................................................................................... 60

9.1 General accessories .................................................................................................................... 60

9.2 Options ......................................................................................................................................... 60

9.3 Remote control/connecting and extension cable ......................................................................... 60

9.3.1 7-pole connection ......................................................................................................... 60

9.4 Computer communication ............................................................................................................ 61

10 Appendix A ............................................................................................................................................ 62

10.1 Searching for a dealer .................................................................................................................. 62

Contents

Notes on the use of these operating instructions

099-005560-EW501

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For your safety

Notes on the use of these operating instructions

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2 For your safety

2.1 Notes on the use of 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.

• The hazard is also highlighted using a symbol on the edge of the page.

WARNING

Working or operating procedures which must be closely observed to prevent serious and even fatal injuries.

• Safety notes include the "WARNING" keyword in the heading with a general warning symbol.

• The hazard is also highlighted using a symbol in the page margin.

CAUTION

Working or operating procedures which must be closely observed to prevent possible minor personal injury.

• The safety information includes the "CAUTION" keyword in its heading with a general warning symbol.

• The risk is explained using a symbol on the edge of the page.

Technical aspects which the user must observe to avoid material or equipment damage.

Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet points, e.g.:

• Insert the welding current lead socket into the relevant socket and lock.

For your safety

Explanation of icons

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2.2 Explanation of icons

Symbol

Description

Symbol

Description

Indicates technical aspects which the user must observe.

Activate and release / Tap / Tip

Switch off machine

Release

Switch on machine

Press and hold Switch

Incorrect / Invalid

Turn

Correct / Valid

Numerical value – adjustable

Input

Signal light lights up in green

Navigation

Signal light flashes green

Output

Signal light lights up in red

Time representation (e.g.: wait 4 s / actuate)

Signal light flashes red Interruption in the menu display

(other setting options possible)

Tool not required/do not use

Tool required/use

For your safety

Part of the complete documentation

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2.3 Part of the complete documentation

These operating instructions are 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 components, especially the safety instructions!

The illustration shows a general example of a welding system.

Figure 2-1

The illustration shows a general example of a welding system.

Item

Documentation

A.1

Wire feeder

A.2

Remote adjuster

A.3

Controller

A.4

Power source

A.5

Welding torch

Complete documentation

2.4 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!

• Inform persons in the working area that they must comply with the regulations!

Risk of injury from electrical voltage! Voltages can cause potentially fatal electric shocks and burns on contact. Even low

voltages can cause a shock and lead to accidents.

• Never touch live components such as welding current sockets or stick, tungsten or wire electrodes!

• Always place torches and electrode holders on an insulated surface!

• Wear the full personal protective equipment (depending on the application)!

• The machine may only be opened by qualified personnel!

• The device must not be used to defrost pipes!

For your safety

Safety instructions

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WARNING

Hazard when interconnecting multiple power sources! If a number of power sources are to be connected in parallel or in series, only a

technical specialist may interconnect the sources as per standard IEC 60974-9:2010: Installation and use and German Accident Prevention Regulation BVG D1 (formerly VBG

15) or country-specific regulations.

Before commencing arc welding, a test must verify that the equipment cannot exceed the maximum permitted open circuit voltage.

• Only qualified personnel may connect the machine.

• When taking individual power sources out of operation, all mains and welding current leads

must be safely disconnected from the welding system as a whole. (Hazard due to reverse polarity voltage!)

• Do not interconnect welding machines with pole reversing switch (PWS series) or machines for AC welding since a minor error in operation can cause the welding voltages to be combined, which is not permitted.

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. The protective equipment has to include:

• Respiratory protection against hazardous substances and mixtures (fumes and vapours); otherwise implement suitable measures such as extraction facilities.

• Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and heat.

• Dry welding clothing (shoes, gloves and body protection) to protect against warm environments with conditions comparable to ambient temperatures of 100 °C or higher and arcing and work on live components.

• Hearing protection against harming noise.

Risk of injury due to radiation or heat! Arc radiation can lead to skin and eye injuries.

Contact with hot workpieces and sparks can lead to burns.

• Use hand shield or welding helmet with the appropriate safety level (depends on the application).

• Wear dry protective clothing (e.g. hand shield, gloves, etc.) in accordance with the applicable regulations of your country.

• Persons who are not directly involved should be protected with a welding curtain or suitable safety screen against radiation and the risk of blinding!

Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure

when heated.

• Move containers with inflammable or explosive liquids away from the working area!

• Never heat explosive liquids, dusts or gases by welding or cutting!

Fire hazard! Due to the high temperatures, sparks, glowing parts and hot slag that occur during

welding, there is a risk of flames.

• Be watchful of potential sources of fire in the working area!

• Do not carry any easily inflammable objects, e.g. matches or lighters.

• Ensure suitable fire extinguishers are available in the working area!

• Thoroughly remove any residue of flammable materials from the workpiece prior to starting

to weld.

• Only further process workpieces after they have cooled down. Do not allow them to contact any flammable materials!

For your safety

Safety instructions

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CAUTION

Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to

the ultraviolet radiation of the arc!

• Ensure that there is sufficient fresh air!

• Keep solvent vapour away from the arc beam field!

• Wear suitable breathing apparatus if appropriate!

Noise exposure! Noise exceeding 70 dBA can cause permanent hearing damage!

• Wear suitable ear protection!

• Persons located within the working area must wear suitable ear protection!

According to IEC 60974-10, welding machines are divided into two classes of electromagnetic compatibility (the EMC class can be found in the Technical data) > see 8 chapter: Class A machines are not intended for use in residential areas where the power supply comes

from the low-voltage public mains network. When ensuring the electromagnetic compatibility of class A machines, difficulties can arise in these areas due to interference not only in the supply lines but also in the form of radiated interference. Class B machines fulfil the EMC requirements in industrial as well as residential areas, including residential areas connected to the low-voltage public mains network.

Setting up and operating

When operating arc welding systems, in some cases, electro-magnetic interference can occur although all of the welding machines comply with the emission limits specified in the standard. The user is responsible for any interference caused by welding. In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)

• Mains, control, signal and telecommunication lines

• Radios and televisions

• Computers and other control systems

• Safety equipment

• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing

aid

• Calibration and measuring equipment

• The immunity to interference of other equipment in the surrounding area

• The time of day at which the welding work must be carried out

Recommendations for reducing interference emission

• Mains connection, e.g. additional mains filter or shielding with a metal tube

• Maintenance of the arc welding system

• Welding leads should be as short as possible and run closely together along the ground

• Potential equalization

• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,

it should be connected by means of suitable capacitors.

• Shielding from other equipment in the surrounding area or the entire welding system

Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices,

telecommunication lines, power cables, signal lines and pacemakers.

• Observe the maintenance instructions > see 6.3 chapter!

• Unwind welding leads completely!

• Shield devices or equipment sensitive to radiation accordingly!

• The correct functioning of pacemakers may be affected (obtain advice from a doctor if

necessary).

For your safety

Transport and installation

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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 introduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.

• In particular, directive 89/655/EEC concerning the minimum safety and health requirements for the use of work equipment by workers at work.

• The regulations applicable to occupational safety and accident prevention in the country concerned.

• Setting up and operating the machine as per IEC 60974.-9.

• Brief the user on safety-conscious work practices on a regular basis.

• Regularly inspect the machine as per IEC 60974.-4.

The manufacturer's warranty becomes void if non-genuine parts are used!

• Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products!

• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.

Requirements for connection to the public mains network High-performance machines can influence the mains quality by taking current from the mains

network. For some types of machines, connection restrictions or requirements relating to the maximum possible line impedance or the necessary minimum supply capacity at the interface with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect, attention is also drawn to the machines' technical data. In this case, it is the responsibility of the operator, where necessary in consultation with the mains network operator, to ensure that the machine can be connected.

2.5 Transport and installation

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!

• Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air!

• Do not attach any element to the shielding gas cylinder valve!

• Prevent the shielding gas cylinder from heating up.

For your safety

Transport and installation

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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. Tilt resistance is guaranteed up to an angle of 10°

(according to IEC 60974-1).

• Set up and transport the machine on level, solid ground.

• Secure add-on parts using suitable equipment.

Risk of accidents due to incorrectly installed leads! Incorrectly installed leads (mains, control and welding leads or intermediate hose

packages ) can present a tripping hazard.

• Lay the supply lines flat on the floor (avoid loops).

• Avoid laying the leads on passage ways.

The units are designed for operation in an upright position! Operation in non-permissible positions can cause equipment damage.

• Only transport and operate in an upright position!

Accessory components and the power source itself can be damaged by incorrect connection!

• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.

• Comprehensive descriptions can be found in the operating instructions for the relevant accessory components.

• Accessory components are detected automatically after the power source is switched on.

Protective dust caps protect the connection sockets and therefore the machine against dirt and damage.

• The protective dust cap must be fitted if there is no accessory component being operated on that connection.

• The cap must be replaced if faulty or if lost!

Intended use

Use and operation solely with the following machines

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3 Intended use

WARNING

Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate. Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any

damages arising from improper usage!

• The equipment must only be used in line with its designated purpose and by trained or expert personnel!

• Do not improperly modify or convert the equipment!

3.1 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 with this machine:

Titan XQ 350-600 puls D

Drive XQ

3.2 Applications

Arc welding machine for standard and pulsed gas-shielded metal-arc welding with TIG welding and lift arc (touch starting) or MMA welding as secondary process. It may be possible to expand the functionality by using accessories (see the documentation in the relevant chapter).

3.3 Documents which also apply

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

The labelled machine complies with the following EC directives in terms of its design and construction:

• Low Voltage Directive (LVD)

• Electromagnetic Compatibility Directive (EMC)

• Restriction of Hazardous Substance (RoHS)

In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation," and/or prohibited modifications which have not been explicitly authorised by the manufacturer, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product.

3.3.3 Welding in environments with increased electrical hazards

In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in environments with an increased electrical hazard.

Intended use

Documents which also apply

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3.3.4 Service documents (spare parts and circuit diagrams)

WARNING

Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by

specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference.

• Appoint only skilled persons for repair work (trained service personnel)!

Original copies of the circuit diagrams are enclosed with the unit. Spare parts can be obtained from the relevant authorised dealer.

3.3.5 Calibration/Validation

We hereby confirm that this machine has been tested using calibrated measuring equipment, as stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances. Recommended calibration interval: 12 months

Machine description – quick overview

Machine configuration

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4 Machine description – quick overview

4.1 Machine configuration

The following table shows the different design variants (development stages) of the device series Titan XQ:

Type

Figure

Transport properties

Torch cooling

Wheel kit, narrow track,

without cylinder bracket

Pallet bottom, without cylinder

bracket

Wheel kit, single cylinder

bracket

Wheel kit, double cylinder

bracket

Gas

Water (coolant)

Water (coolant), reinforced

pump

F06

WRF

F06

WRF

F06

WRF

F06 P G

F06 P W

F06 P WRF

Figure 4-1

Machine description – quick overview

Front view / side view from the right

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4.2 Front view / side view from the right

Figure 4-2

Machine description – quick overview

Front view / side view from the right

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Item

Symbol

Description 0

WiFi antenna

Factory-fit option, (version OW Expert XQ 2.0 WLG)

Main switch, machine on/off

Infoline - display of operating status

The operating status is indicated by fibre optics > see 5.3 chapter.

7-pole connection socket (digital)

For connecting digital accessory components

Cooling air outlet

Coolant tank cap

Coolant tank > see 5.1.6 chapter

Coolant drain plug > see 6.3.2 chapter

Carrying handle

Lifting lug > see 5.1.1 chapter

Wheel

The machine can be secured against rolling away on a wheel with a foot lock.

Inlet opening for cooling air (torch cooling)

Dirt filter can be retrofitted

Wheels, fixed castors

Lifting lug > see 5.1.1 chapter

Intermediate hose package strain relief > see 5.1.9 chapter

Aluminium continuous casting profile flexFit

Individual mounting option for accessories and options

Connection socket, “+” welding current

How to connect the accessories depends on the welding procedure. Please observe the connection description for the corresponding welding procedure > see 5 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 > see 5 chapter.

Machine control, see the relevant control operating instructions

Protective cap > see 5.4 chapter

Machine description – quick overview

Rear view / side view from left

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4.3 Rear view / side view from left

Figure 4-3

Machine description – quick overview

Rear view / side view from left

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Item

Symbol

Description 0

Securing elements for shielding gas cylinder (strap/chain)

Cooling air inlet

Dirt filter can be retrofitted

Connection socket, “+” welding current

How to connect the accessories depends on the welding procedure. Please observe the connection description for the corresponding welding procedure > see 5 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 > see 5 chapter.

Quick connect coupling (red)

coolant return

Quick connect coupling (blue)

coolant supply

Securing elements for shielding gas cylinder (strap/chain)

Bracket for shielding gas cylinder

Aluminium continuous casting profile flexFit

Individual mounting option for accessories and options

Intermediate hose package strain relief > see 5.1.9 chapter

Mains connection cable > see 5.1.11 chapter

Outlet opening cooling air (torch cooling)

Service opening for coolant pump > see 7.5 chapter

Lifting lug > see 5.1.1 chapter

Wheels, fixed castors

Wheels, guide castors

Lifting lug > see 5.1.1 chapter

Carrying handle

PC interface, serial (D-Sub connection socket, 9-pole)

Automation interface 19-pin (analogue)

Option for retrofitting > see 5.9.1 chapter

Key button, Automatic cutout

Wire feed motor supply voltage fuse (press to reset a triggered fuse)

7-pole connection socket (digital)

For connecting digital accessory components

RJ45 connection socket, mains connection

(ON - Retrofitting Option)

Connection socket, hand scanner

Material management Xnet (ON - retrofitting option)

DV1

14-pole connection socket

Wire feeder control cable connection

Design and function

Transport and installation

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5 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!

• Connect connection or power cables while the machine is switched off!

Read and observe the documentation to all system and accessory components!

5.1 Transport and installation

5.1.1 Lifting by crane

WARNING

Risk of injury during lifting by crane! When lifting the machine by crane, persons may be severely injured by falling machines

or mount-on components.

• Simultaneous lifting of system components such as power source, wire feeder or cooling unit without suitable crane components is not allowed. Each system component has to be lifted separately!

• Remove any supply leads and accessories before lifting by crane (e.g. hose package, wire spool, shielding gas cylinder, toolbox, wire feeder, remote control, etc.)!

• Properly close and lock all casing covers and protective caps before lifting by crane!

• Use the correct number of hoisting equipment of the right size in the correct position!

Observe craning principle > see 5.1.2 chapter!

• Devices with lifting eyes: Always lift all lifting eyes simultaneously!

• Devices with pallet bottom (feet): Pull the straps through the openings of the feet (hooking

hoisting equipment in the openings is not sufficient).

• When using retrofitted craning frames etc.: always use at least two lifting points positioned as far apart as possible – observe option description.

• Avoid any jerky movements!

• Ensure that the load is distributed evenly! • Use chain hoists and chain slings of the same

length only!

• Stay outside the danger zone underneath the machine!

• Observe the regulations regarding occupational safety and accident prevention for the

respective country.

5.1.2 Craning principle

Figure 5-1

Design and function

Transport and installation

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5.1.3 Ambient conditions

T he 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.

• Safe operation of the machine must be guaranteed at all times.

Equipment damage due to contamination! Unusually high amounts of dust, acids, corrosive gases or substances can damage the machine

(observe maintenance intervals<dg_ref_source_inline>Wartungstabelle</dg_ref_source_inline>).

• Avoid large amounts of smoke, steam, oily fumes, grinding dust and corrosive ambient air!

5.1.3.1 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)

5.1.3.2 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)

5.1.4 Machine cooling

Insufficient ventilation results in a reduction in performance and equipment damage.

• Observe the ambient conditions!

• Keep the cooling air inlet and outlet clear!

• Observe the minimum distance of 0.5 m from obstacles!

5.1.5 Workpiece lead, general

CAUTION

Risk of burning due to incorrect welding current connection! If the welding current plugs (machine connections) are not locked or if the workpiece connection is contaminated (paint, corrosion), these connections and leads can heat up

and cause burns when touched!

• Check welding current connections on a daily basis and lock by turning to the right when necessary.

• Clean workpiece connection thoroughly and secure properly. Do not use structural parts of the workpiece as welding current return lead!

5.1.6 Welding torch cooling system

5.1.6.1 Functional characteristics

The cooling system of this machine series is designed to optimise the operating conditions and is temperature- and flow-monitored to protect against damage. Limit values > see 8.2 chapterfor warnings and errors in the machine (adjustable depending on control system) are stored for monitoring and control of the cooling system. If the cooling system is faulty or overloaded, an error message appears and the welding process is switched off in a controlled manner.

Design and function

Transport and installation

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Insufficient frost protection in the welding torch coolant! Depending on the ambient conditions, different liquids are used for cooling the welding

torch > see 5.1.6.2 chapter. Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components.

• The coolant must be checked for adequate frost protection with the TYP 1 frost protection tester .

• Replace coolant as necessary if frost protection is inadequate!

Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and

renders the manufacturer's warranty void!

• Only use the coolant described in this manual (overview of coolants).

• Do not mix different coolants.

• When changing the coolant, the entire volume of liquid must be changed.

Dispose of the coolant in accordance with local regulations and the material safety data sheets.

5.1.6.2 Approved coolants overview

Coolant

Temperature range

KF 23E (Standard)

-10 °C to +40 °C

KF 37E

-20 °C to +30 °C

5.1.6.3 Maximal hose package length

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.

Pump: Pmax = 3,5 bar (0.35 MPa)

--------------------------------------------------------------------------------------------------------------------- ►

Power source

Hose package

Wire feeder

miniDrive

Welding torch

Max.

Compact

(25 m / 82 ft.)

(5 m / 16 ft.)

30 m 98 ft.

(20 m / 65 ft.)

(5 m / 16 ft.)

Decompact

(25 m / 82 ft.)

(5 m / 16 ft.)

(15 m / 49 ft.)

(10 m / 32 ft.)

(5 m / 16 ft.)

Pump: Pmax = 4.5 bar (0.45 MPa)

--------------------------------------------------------------------------------------------------------------------- ►

Power source

Hose package

Wire feeder

miniDrive

Welding torch

Max.

Compact

(25 m / 82 ft.)

(5 m / 16 ft.)

30 m 98 ft.

(30 m / 98 ft.)

(5 m / 16 ft.)

40 m

131 ft.

Decompact

(40 m / 131 ft.)

(5 m / 16 ft.)

45 m

147 ft.

(40 m / 131 ft.)

(25 m / 82 ft.)

(5 m / 16 ft.)

70 m

229 ft.

Design and function

Transport and installation

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5.1.6.4 Adding coolant

The unit is supplied ex works with a minimum level of coolant.

Figure 5-2

Item

Symbol

Description 0

Coolant tank cap

Coolant filter sieve

Coolant tank > see 5.1.6 chapter

Filling level display

MIN ------ minimum coolant level MAX ----- maximum coolant level

• Pull off the coolant tank sealing cover.

• Check filter sieve for cleanliness, clean if necessary and reinsert.

• Top up coolant up to the upper filling level gauge "MAX" and push sealing cover back on.

• Switch on the power source at the main switch.

The level of coolant must never fall below the “MIN” mark.

After switching on the machine, the coolant pump runs for a maximum of 2 min. (Filling hose package). If the machine does not detect a sufficient coolant flow during this time, the coolant pump is switched off (protection against damage in dry run). At the same time, the welding data display signals the coolant error. If there is a sufficient coolant flow, the coolant pump is switched off already 2 min. before the end (ready for operation).

If there is less coolant in the coolant tank than the minimum required you may need to vent the coolant circuit. In this case the welding machine will automatically shut down the coolant pump and signal an error, > see 7.4 chapter.

Design and function

Transport and installation

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5.1.7 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. Lay the workpiece lead and hose package of power sources with HF igniter (TIG) for as long as

possible in parallel with a distance of 20 cm to avoid HF sparkover. Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences Always keep leads as short as possible! For optimum welding results max. 30 m (welding lead +

intermediate hose package + torch lead).

Figure 5-3

Use an individual welding lead to the workpiece for each welding machine!

Figure 5-4

Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops!

Always keep leads as short as possible!

Lay any excess cable lengths in meanders.

Figure 5-5

Design and function

Transport and installation

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5.1.8 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.

• Check that all welding current connections are firmly secured and electrical connections are in perfect condition.

• Set up, attach or suspend all conductive power source components such as casing, transport vehicles and crane frames so they are insulated.

• Do not place any other electronic devices such as drills or angle grinders on the power source, transport vehicle or crane frames unless they are insulated.

• Always put welding torches and electrode holders on an insulated surface when they are not in use.

Figure 5-6

Design and function

Transport and installation

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5.1.9 Connecting the intermediate hose package to the power source

Figure 5-7

Item

Symbol

Description 0

Wire feed unit

Intermediate hose package

DV1

14-pole connection socket

Wire feeder control cable connection

Intermediate hose package strain relief > see 5.6.1 chapter

Connection socket, “+” welding current

• Standard MIG/MAG welding (intermediate hose package)

Connection socket, “-” welding current

• MIG/MAG cored wire welding:

Welding current to wire feed/torch

Quick connect coupling (blue)

coolant supply

Quick connect coupling (red)

coolant return

Design and function

Transport and installation

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• Insert the hose package end of the intermediate hose package from the outside through the strain relief of intermediate hose package and then lock by turning to the right.

• Insert the control cable through the recess in the gas cylinder bracket, insert the cable plug into the into the connection socket (14-pole) and secure with crown nut (the plug can only be inserted into the connection socket in one position).

• Insert the plug on the welding current lead into the welding current connection socket "+" and lock.

• Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings:

Return line red to quick connect coupling, red (coolant return) and supply line blue to quick connect coupling, blue (coolant supply).

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 "+" welding current socket. Observe the information from the electrode manufacturer!

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!

• Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air!

• Lift the shielding gas cylinder onto the receptacle of the shielding gas cylinder and secure with both safety belts provided on the device as standard! Belts must be tight.

• Do not attach any element to the shielding gas cylinder valve!

• Prevent the shielding gas cylinder from heating up.

An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results. In addition, a blocked shielding gas supply may result in the welding torch being destroyed.

• All shielding gas connections must be gas tight.

5.1.10.1 Pressure regulator connection

Figure 5-8

Item

Symbol

Description 0

Pressure regulator

Output side of the pressure regulator

Shielding gas cylinder

Cylinder valve

Design and function

Transport and installation

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• Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out any dirt.

• Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.

• Screw gas hose connection crown nut onto the output side of the pressure regulator.

5.1.11 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 national regulations!

• The mains voltage indicated on the rating plate must match the supply voltage.

• Only operate machine using a socket that has correctly fitted protective earth.

• Mains plug, socket and lead must be checked by a qualified electrician on a regular basis!

• When operating the generator, always ensure it is earthed as stipulated in the operating

instructions. The network created must be suitable for operating machines according to protection class I.

The welding power source is equipped with an internal clamp device for multiple mains voltages. The currently set mains voltage of the power source must match the supply voltage! The following steps have to be carried out:

• Visual inspection - comparison between the currently set mains voltage at the power source and the supply voltage > see 5.1.11.1 chapter

• Adaptation and marking of the mains voltage > see 5.1.11.2 chapter

• Carry out a safety check after intervention in the machine > see 5.1.11.3 chapter!

5.1.11.1 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. If the specifications for mains and supply voltage do not match, the mains voltage in the machine must be reconnected to the supply voltage > see 5.1.11.2 chapter.

Removed or not clearly identifiable adhesive labels must be replaced!

Example of rating plate

Adhesive label of mains connection cable

Figure 5-9

Design and function

Transport and installation

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5.1.11.2 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. 380 V to 400 V (ex works)

2. 440 V to 460 V

3. 480 V to 500 V

Figure 5-10

• Switch off machine at the main switch.

• Disconnect mains plug.

• Loosen the fastening screws from the housing cover. Open the housing cover at the side and lift it up.

• Reconnect operating voltage plug (printed circuit board VB xx0) to the corresponding voltage range of

the supply voltage (380V/400V ex works).

• Hook housing cover from above into the aluminium continuous casting profile flexFit and secure with fastening screws.

• Install a mains plug which is permissible for the selected mains voltage to the mains cable. Identify the selected mains voltage on the rating plate and on the adhesive label of mains connection cable.

5.1.11.3 Re-commissioning

Before reconnection, “Inspection and Testing during Operation” according to IEC/BS EN 60974-4 “Arc welding systems – Inspection and Testing during Operation” has to be performed!

Design and function

Switching on and system diagnosis

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5.1.11.4 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. the outer conductor

Figure 5-11

Legend

Item

Designation

Colour code

Outer conductor 1

brown

Outer conductor 2

black

Outer conductor 3

grey

Neutral conductor

blue

Protective conductor

green-yellow

• Insert mains plug of the switched-off machine into the appropriate socket.

5.2 Switching on and system diagnosis

Each time the system is switched on, the entire welding system runs data synchronization and the system diagnostics of the individual components. The duration of the start time (switching on up to welding readiness) depends on the number of connected system components and the information to be exchanged under these devices. This time can take from several seconds to several minutes (e.g. for the system components interconnected for the first time). During this start phase, the system components will display the controller type and, if applicable, software information in the welding data display (if available). This start phase is terminated by display of the nominal valuesfor current, voltage or wire feed speed.

Operation of machine fan and coolant pump

The machine fan and coolant pump in this machine series are temperature- and state-controlled. This ensures that subsystems of the welding machine run only when they are needed. After each switching on, the machine fans run at full power for approx. 2 s, e.g. to blow out dust deposits.

5.3 Infoline - display of operating status

A fibre optics on the front side of the housing shows the user the current operating status of the device.

Infoline colour

Operating status

white (change: light/dark)

Booting (switching on up to welding readiness)

blue

Ready for welding

blue (change: light/dark)

Power-saving mode Standby

green

Welding

yellow

Warning > see 7.2 chapter

red

Error > see 7.1 chapter

Design and function

Protective flap, welding machine control

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5.4 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.

Design and function

MIG/MAG welding

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5.5 MIG/MAG welding

5.5.1 Connection for workpiece lead

Figure 5-13

Item

Symbol

Description 0

Connection socket, “–” welding current

Workpiece lead connection

Workpiece

• Insert the plug on the workpiece lead into the "-" welding current connection socket and lock.

5.5.2 Welding task selection

For selection of the welding task and for general operation see the relevant Control operating instructions.

Design and function

TIG welding

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5.5.3 Setting the shielding gas volume (gas test)/rinse hose package

• Shielding gas supply as described in chapter Transport and positioning > see 5.1 chapter.

• 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.

• You can activate the gas test on the machine control (see Control operating instructions) or by

pressing the "Gas test/rinse hose package " push-button briefly (welding voltage and wire feed motor remain switched off – no unintentional ignition of the arc). Some welding systems have several push-buttons to set the shielding gas. The push-button is generally found near a wire feeder.

Shielding gas flows for around 25 seconds or until the button is pressed again. If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause

pores to form. Adjust the shielding gas quantity to suit the welding task!

Welding process

Recommended shielding gas quantity

MAG welding

Wire diameter x 11.5 = l/min

MIG brazing

Wire diameter x 11.5 = l/min

MIG welding (aluminium)

Wire diameter x 13.5 = l/min (100 % argon)

Helium-rich gas mixtures require a higher gas volume!

The table below can be used to correct the gas volume calculated where necessary:

Shielding gas

Factor

75% Ar/25% He

1.14

50% Ar/50% He

1.35

25% Ar/75% He

1.75

100% He

3.16

Design and function

TIG welding

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5.6 TIG welding

5.6.1 Connecting the intermediate hose package to the power source

TIG combi welding torches are connected to wire feed unit and power source. The welding current for the intermediate hose package must be connected to the welding current connection (-) at the rear of the unit!

Figure 5-14

Design and function

TIG welding

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Item

Symbol

Description 0

Welding torch

Wire feed unit

Intermediate hose package

DV1

14-pole connection socket

Wire feeder control cable connection

Intermediate hose package strain relief > see 5.1.9 chapter

Connection socket, “-” welding current

Connection for welding current plug from intermediate hose package

• MIG/MAG flux cored wire welding

• TIG welding

Quick connect coupling (red)

coolant return

Quick connect coupling (blue)

coolant supply

• Insert the hose package end of the intermediate hose package from the outside through the strain relief of intermediate hose package and then lock by turning to the right.

• Plug the welding current lead plug into the welding current "-" connection socket and lock.

• Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings:

Return line red to quick connect coupling, red (coolant return) and supply line blue to quick connect coupling, blue (coolant supply).

5.6.2 Connection for workpiece lead

Figure 5-15

Design and function

MMA welding

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Item

Symbol

Description 0

Workpiece

Connection socket, "+" welding current

• 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.

5.6.3 Welding task selection

For selection of the welding task and for general operation see the relevant Control operating instructions.

5.7 MMA welding

CAUTION

Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns!

• Wear appropriate and dry protective gloves.

• Use an insulated pair of tongs to remove the used stick electrode or to move welded

workpieces.

5.7.1 Connecting the electrode holder and workpiece lead

Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

Figure 5-16

Design and function

Remote control

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Item

Symbol

Description 0

Connection socket, “-” welding current

Connection socket, “+” welding current

Workpiece

Electrode holder

• Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right.

• Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and lock by turning to the right.

5.7.2 Welding task selection

For selection of the welding task and for general operation see the relevant Control operating instructions.

5.8 Remote control

Remote controls are used for the remote operation of various machine functions (see operating instructions for remote control). Depending on the machine design, the remote control connection can be 7- or 19-pole (connection see chapter Machine description).

5.9 Interfaces for automation

WARNING

Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons!

The warranty becomes null and void in the event of unauthorised interference.

• Appoint only skilled persons for repair work (trained service personnel)!

Unsuitable control cables or incorrect input/output signal assignment can cause damage to the machine. Use shielded control cables only.

5.9.1 Automation interface

WARNING

No function of the external interrupt equipment (emergency stop switch)! If the emergency stop circuit has been set up using an external interrupt equipment connected to the interface for automated welding, the machine must be configured for this setup. If this is not observed, the power source will ignore the external interrupt

equipment and will not shut down!

• Remove jumper 1 on the corresponding control board (to be done only by qualified service personnel)!

These accessory components can be retrofitted as an option > see 9 chapter.

Design and function

Interfaces for automation

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Input / Output

Designation

Figure A

Output

PE -------- Connection for cable screen

Output (open collector)

IGRO ---- Current flows signal I>0 (maximum load 20 mA /

15 V) 0 V = welding current flows

E +R

Input

Not-Aus - Emergency stop for higher level shut-down of the

power source.

Output

0V -------- Reference potential

G/P

Output

IGRO ---- Current relay contact to the user, potential-free

(max. +/-15 V / 100 mA)

Output

Uist ------- Welding voltage, measured on pin F, 0-10 V (0 V

= 0 V, 10 V = 100 V)

Input

STA/STP Start = 15 V / Stop = 0 V

[1]

Output

+15 V ---- Power supply (max. 75 mA)

Output

-15 V ----- Power supply (max. 25 mA)

Output

0 V ------- Reference potential

Output

Iist -------- Welding current, measured on pin F

0-10V (0V = 0A, 10V = 1000A)

[1]

The operating mode is specified by the wire feeder (the start / stop function corresponds to the

operation of the torch trigger and is used, for instance, in mechanized applications).

5.9.2 RINT X12 robot interface

The standard digital interface for mechanised applications

Functions and signals:

• Digital inputs: start/stop, operating modes, JOB and program selection, inching, gas test

• Analogue inputs: control voltages, e.g. for welding performance, welding current, etc.

• Relay outputs: process signal, ready for welding, system composite fault, etc.

5.9.3 BUSINT X11 Industrial bus interface

The solution for easy integration with automated production with e.g.

• Profinet/Profibus

• EnthernetIP/DeviceNet

• EtherCAT

etc.

Design and function

PC interface

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5.10 PC interface

PC 300 welding parameter software

Set all welding parameters on the PC and simply transfer to one or more welding machines (accessory, set consisting of software, interface, connection leads)

• Manage up to 510 JOBs

• Exchange JOBs with the welding machine

• Online data communication

• Default settings for welding data monitoring

• Always up-to-date thanks to standard update function for new welding parameters

• Data backup by easy communication between power source and PC

Figure 5-17

Item

Symbol

Description 0

PC interface, serial (D-Sub connection socket, 9-pole)

Connection cable, 9-pole, serial

SECINT X10 USB

USB connection

Windows PC

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

transmission. The PC may be destroyed due to high frequency ignition pulses.

• Interface SECINT X10USB must be connected between the PC and the welding machine!

• The connection must only be made using the cables supplied (do not use any additional

extension cables)!

Maintenance, care and disposal

General

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6 Maintenance, care and disposal

6.1 General

WARNING

Incorrect maintenance, testing and repair! Maintenance, testing and repair of the machine may only be carried out by skilled and qualified personnel. A qualified person is one who, because of his or her training, knowledge and experience, is able to recognise the dangers that can occur while testing welding power sources as well as possible subsequent damage, and who is able to

implement the required safety procedures.

Observe the maintenance instructions > see 6.3 chapter.

• In the event that the provisions of one of the below-stated tests are not met, the machine must not be operated again until it has been repaired and a new test has been carried out!

As a rule, contact your specialised dealer, i.e. the supplier of the machine, with respect to all servicing matters. Any return deliveries in the case of warranty claims can be made via your specialised dealer only.

Only use original spare parts to replace any part. When ordering a spare part, always specify the type, serial number and article number of the machine, and the type designation and article number of the spare part.

Under the specified ambient conditions and normal working conditions this machine is essentially maintenance-free and requires just a minimum of care.

Contamination of the machine may impair service life and duty cycle. The cleaning intervals depend on the ambient conditions and the resulting contamination of the machine. The minimum interval is every six months.

Maintenance, care and disposal

Explanation of icons

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6.2 Explanation of icons

Person

Welder / operator

Service staff / expert, qualified person

Test

Visual inspection

Functional check

Period, interval

One-shift operation

Multi-shift operation

every 8 hours

Daily

Weekly

Monthly

Every 6 months

Annually

Maintenance, care and disposal

Maintenance schedule

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6.3 Maintenance schedule

Examiner

Type of test

Maintenance step

Only the person who has been certified as an examiner or repairer may carry out the

relevant work step on the basis of their training! Non-applicable checkpoints are omitted.

Repairer

• Check and clean the welding torch. Deposits in the torch can cause short circuits and have a negative impact on the welding result, ultimately causing damage to the welding torch!

• Check wire drive, welding torches, and liner elements for application-related equipment and setting.

• Clean the wire feed rolls on a regular basis (depending on the degree of soiling). Replace worn wire feed rollers.

• Connections of welding current leads (check that they are fitted correctly and secured).

• Is shielding gas cylinder with gas cylinder securing elements (chain/belt) secured?

• Strain relief: Are hose packages secured with strain relief?

• Checking all supply lines and their connections (pipes, hoses, hose packages) for

damage or leaks.

• Checking the welding system for damage to the housing.

• Transport elements (strap, lifting eyes, handle, wheels, parking brake) corresponding

safety elements (if necessary fuse caps) are present and flawless?

• Cleaning connections of coolant pipes (quick connect coupling, connections) from soil and install protective caps if not used.

• Gas test solenoid valve opens and closes properly.

• Checking operating, signalling and indicator lights, protective devices and actuators.

• Cleaning dirt filter (if

applicable)<dg_ref_source_inline>Schmutzfilter</dg_ref_source_inline>

• Checking correct mounting of the wire spool.

• Cleaning the outer surfaces with a moist cloth (no aggressive cleaning agents).

• Cleaning power source (inverter)<dg_ref_source_inline>Stromquelle

(Inverter)</dg_ref_source_inline>

• Cleaning heat exchanger (torch cooling)<dg_ref_source_inline>Wärmetauscher</dg_ref_source_inline>

• Coolant change (welding torch cooling)<dg_ref_source_inline>Kühlmittelwechsel</dg_ref_source_inline>

• Periodic inspection and testing<dg_ref_source_inline>Jährliche Prüfung (Inspektion und Prüfung während des Betriebes)</dg_ref_source_inline>

Maintenance, care and disposal

Maintenance schedule

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6.3.1 Dirt filter

The duty cycle of the welding machine decreases as an effect of the reduced cooling air volume. The dirt filter must be remove at regular intervals and cleaned by blowing out with compressed air (depending on the level of soiling).

Figure 6-1

1. Two dirt filters (option for retrofitting) can be installed on the device. One at the air inlet of the power unit (inverter) and one at the air inlet of the heat exchanger (torch cooling).

2. Loosen the locking screws of the filters.

 Pull filter power unit down / back.  Pull filter heat exchanger down / sidewards.

3. Blow out dirt filter using compressed air that is free of oil and water.

Observe local regulations on disposal!

• After cleaning, refit the filters in reverse order.

Maintenance, care and disposal

Maintenance schedule

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6.3.2 Coolant error

Observe all instructions for handling, use and disposal of torch coolant > see 5.1.6 chapter.

Figure 6-2

Maintenance, care and disposal

Maintenance schedule

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1. Switch off the machine and pull out the mains plug. Position a suitable collecting container (approx. 8 l) under the drain plug.

2. Open tank screw plug for ventilation. Unscrew the drain plug with tank seal downwards. The coolant is now flowing out.

3. Wait until the coolant has been completely drained from the tank into the container, then remove and clean the filter screen from the filler neck. Then rinse out the tank with water (empty the collecting container, if necessary).

Observe local regulations on disposal!

4. Screw the drain plug with seal back into the tank from bottom (tightly), insert the cleaned filter screen into the filler neck. Fill tank with original -EWM- coolant. (For type and item no.: see sticker near filler). After filling, close the tank screw plug and vent the coolant circuit > see 7.4 chapter.

Maintenance, care and disposal

Maintenance schedule

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6.3.3 Heat exchanger (torch cooling)

WARNING

Risk of injury due to insufficient training! An appropriate training is necessary for the following maintenance steps to avoid injuries.

• This maintenance step may only be carried out by trained and authorized specialist staff.

• Observe warnings and maintenance instructions at the beginning of this chapter!

Figure 6-3

1. Switch off the machine and pull out the mains plug. Remove the screws of the side panel. Remove the side panel from the system (lift up and sidewards).

2. Use only oil and water-free compressed air. Do not blow on electronic components directly. The machine fans can be overturned by to the compressed air and thus be damaged. Therefore mechanically block the machine fan with a screwdriver. Please note: The strips of the heat exchanger behind the machine fans must not be damaged by the screwdriver.

3. Blow out heat exchanger by the fan over the entire area.

4. The impurities escape through the openings in the side panel.

Observe local regulations on disposal!

• After cleaning, remove mechanical locks on the fans and close the unit in the reverse order and check according to applicable regulations.

Maintenance, care and disposal

Maintenance schedule

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6.3.4 Power source (inverter)

WARNING

Risk of injury due to insufficient training! An appropriate training is necessary for the following maintenance steps to avoid

injuries.

• This maintenance step may only be carried out by trained and authorized specialist staff.

• Observe warnings and maintenance instructions at the beginning of this chapter!

Figure 6-4

1. Switch off the machine and pull out the mains plug. Remove the screws of the side panels and the grille at the rear. Remove side panels (lift upwards and sidewards). Remove grille (lift downwards and backwards).

3. Blow out the areas in front of the inverter side.

Observe local regulations on disposal!

• After cleaning, remove mechanical locks on the fans and close the unit in the reverse order and check according to applicable regulations.

6.3.5 Annual test (inspection and testing during operation)

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!

Maintenance, care and disposal

Disposing of equipment

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6.4 Disposing of equipment

Proper disposal! The machine contains valuable raw materials, which should be recycled, and electronic

components, which must be disposed of.

• Do not dispose of in household waste!

• Observe the local regulations regarding disposal!

• According to European provisions (Directive 2012/19/EU on Waste of Electrical and Electronic Equipment), used electric and electronic equipment may no longer be placed in unsorted municipal waste. It must be collected separately. The symbol depicting a waste container on wheels indicates that the equipment must be collected separately. This machine has to be disposed of, or recycled, in accordance with the waste separation systems in use.

• According to German law (law governing the distribution, taking back and environmentally correct disposal of electric and electronic equipment (ElektroG)), used machines are to be placed in a collection system separate from unsorted municipal waste. The public waste management utilities (communities) have created collection points at which used equipment from private households can be disposed of free of charge.

• Information about returning used equipment or about collections can be obtained from the respective municipal administration office.

• In addition to this, returns are also possible throughout Europe via EWM sales partners.

Rectifying faults

Error messages (power source)

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7 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.

7.1 Error messages (power source)

A welding machine error will be signalled by an error code (see table) on the control display. In the event of an error, the power unit shuts down.

The display of possible error numbers depends on the machine version (interfaces/functions).

• Document machine warning and inform service personnel, if required.

• If there are several errors in a control system of "LP" or "HP" type, the error with the lowest error

number (Err) is displayed. If this error is corrected, the next higher error number appears. This process is repeated until all errors have been resolved.

Categories legend (resetting the error)

a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a push-button :

c) The error message can only be reset by switching the machine off and on again.

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