EWM Tetrix XQ 230 puls DC Comfort 3.0 Operating Instructions Manual
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- Page 1 Operating instructions Power source Tetrix XQ 230 puls DC Comfort 3.0 Tetrix XQ 230 puls AC/DC Comfort 3.0 Tetrix XQ 230 puls DC Expert 3.0 Tetrix XQ 230 puls AC/DC Expert 3.0 099-005630-EW501 Observe additional system documents! 02.03.2021...
- Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.
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Page 3: Table Of Contents
Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................6 Notes on using these operating instructions ................6 Explanation of icons ....................... 7 Safety instructions ........................8 Transport and installation ....................11 3 Intended use .......................... - Page 4 Contents Notes on using these operating instructions 6.3.3 Power source (inverter) ..................37 6.3.4 Heat exchanger (torch cooling)................39 6.3.5 Annual test (inspection and testing during operation) .......... 40 Disposing of equipment ......................40 7 Rectifying faults ..........................41 Checklist for rectifying faults ....................41 Warnings ..........................
- Page 5 Contents Notes on using these operating instructions 099-005630-EW501 02.03.2021...
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Page 6: For Your Safety
For your safety Notes on using these operating instructions For your safety Notes on using these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 7: Explanation Of Icons
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the u- Activate and release / Tap / Tip ser must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Correct / Valid... -
Page 8: Safety Instructions
For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 9 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
- Page 10 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases 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! •...
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Page 11: Transport And Installation
For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines. - Page 12 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.
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Page 13: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and stand- ards applicable for use in industry and trade. It may only be used for the welding proce- dures indicated at the rating plate. -
Page 14: 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 This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 15: Part Of The Complete Documentation
Intended use Documents which also apply 3.3.6 Part of the complete documentation This document is part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system. -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-005630-EW501 02.03.2021... - Page 17 Machine description – quick overview Front view / rear view Item Symbol Description Protective cap > see 5.1.11 chapter Machine control (see the relevant control operating instructions) Connection socket (welding torch control cable) > see 5.2.1.1 chapter Connection socket, “+” welding current How to connect the accessories depends on the welding procedure.
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Page 18: 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 19: Ambient Conditions
Design and function Transport and installation 5.1.1 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. -
Page 20: Transport Belt
Design and function Transport and installation 5.1.4 Transport belt 5.1.4.1 Adjusting the length of the carrying strap Figure 5-2 5.1.5 Dirt filter These accessory components can be retrofitted as an option > see 9.4 chapter. When using a dirt filter, the cooling air throughput is reduced and the duty cycle of the machine is reduced as a result. - Page 21 Design and function Transport and installation The modular design allows the power source to be retrofitted with a cooling unit for liquid torch cooling. For information about connection and installation, see the documentation for the cooling unit. Figure 5-3 1 Switch off the power source and disconnect the mains plug. 2 Place the power source to the side.
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Page 22: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 3 Loosen the screws on the lower cover. Move the cover to the park position towards the front. Screw the cover back on. 4 Undo all four Torx screws from the module connectors of the cooling unit. 5 Route the supply lines through the cable duct of the cooling unit. - Page 23 Design and function Transport and installation • Use an individual welding lead to the workpiece for each welding machine! Figure 5-5 • 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.
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Page 24: Stray Welding Currents
Design and function Transport and installation 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. •... -
Page 25: Mains Connection
Design and function Transport and installation 5.1.9 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • The connection (mains plug or cable), the repair or voltage adjustment of the device must be carried out by a qualified electrician in accordance with the respective local laws or nati- onal regulations! •... -
Page 26: 5.1.11 Protective Flap, Welding Machine Control
Design and function TIG welding 5.1.11 Protective flap, welding machine control Figure 5-9 • Open the protective cap. • Apply slight pressure on the left connecting bridge (figure) until the flap's fastening pin can be removed to the left, from top. 5.1.12 Wear part compartment The transport handles in this machine series have a wear part compartment for stowing typical wear parts, such as gas nozzles and electrodes. -
Page 27: Control Lead Connection
5.2.1.1 Control lead connection All standard 5- and 8-pin TIG welding torches can be connected to this machine and operated (except for 8-pin potentiometer torches). 5-pin EWM function torches with X-TECHNOLOGIE are also supposed. Figure 5-12 5.2.2 Shielding gas supply (shielding gas cylinder for welding machine) -
Page 28: Pressure Regulator Connection
Design and function TIG welding 5.2.2.1 Pressure regulator connection • Place shielding gas cylinder in the corresponding cylinder bracket and use securing equipment (belt/chain) to secure it against falling over. Figure 5-13 Item Symbol Description Pressure regulator Output side of the pressure regulator Shielding gas cylinder Cylinder valve •... -
Page 29: Mma Welding
Design and function MMA welding MMA welding 5.3.1 Connecting the electrode holder and workpiece lead CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. •... -
Page 30: Interfaces For Automation
Design and function Interfaces for automation Interfaces for automation Damage to the machine due to improper connection! Unsuitable control leads or incorrect connection of input and output signals can cause damage to the machine. • Only use shielded control leads! •... -
Page 31: Network Connection
Design and function Network connection Network connection This accessory component is only available as a “factory-fit option”. The network connection allows the integration of the product into an existing network and exchanging data using the quality-management software Xnet. Some features of the software: •... -
Page 32: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal 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, know- ledge 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 im- plement the required safety procedures. -
Page 33: Explanation Of Icons
Maintenance, care and disposal Explanation of icons 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 099-005630-EW501 02.03.2021... -
Page 34: Maintenance Schedule
Maintenance, care and disposal Maintenance schedule Maintenance schedule Maintenance step Only personnel designated as inspectors or repairers due to their trai- ning are allowed to carry out the relevant work step! Inapplicable checkpoints are omitted. • Check and clean the welding torch. Deposits in the welding torch may cause short circuits, impair the welding result and lead to welding torch damage! •... -
Page 35: Coolant Error
Maintenance, care and disposal Maintenance schedule 6.3.1 Coolant error Figure 6-1 • Switch off the machine and disconnect the mains plug. Position a suitable collecting container under the drain plug of the coolant tank. • Unscrew the drain plug of the coolant tank (remove the tank cap to ventilate). Figure 6-2 •... -
Page 36: Dirt Filter
Insert the cleaned filter screen into the filler neck and screw the drain plug with seal back into the tank. • Fill the tank with original EWM coolant up to the maximum level. After filling, refit the tank cap and vent the coolant circuit > see 7.4 chapter. -
Page 37: Power Source (Inverter)
Maintenance, care and disposal Maintenance schedule 6.3.3 Power source (inverter) WARNING Risk of injury due to insufficient training! An appropriate training is necessary for the following maintenance steps to avoid inju- ries. • This maintenance step may only be carried out by trained and authorized specialist staff. •... - Page 38 Maintenance, care and disposal Maintenance schedule Figure 6-7 • Clean the machine fan with compressed air free of oil and water. Block the fan wheel of the machine fan mechanically (the machine fan may over-rotate due to the compressed air and be damaged as a result)! •...
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Page 39: Heat Exchanger (Torch Cooling)
Maintenance, care and disposal Maintenance schedule Figure 6-9 • Reconnect all four power lines to the main switch (note inputs / outputs). • Reinstall the side panels and secure with the screws. • Check the machine according to applicable regulations. 6.3.4 Heat exchanger (torch cooling) WARNING... -
Page 40: Annual Test (Inspection And Testing During Operation)
• 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. 099-005630-EW501 02.03.2021... -
Page 41: Rectifying Faults
Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dea- ler. -
Page 42: Warnings
Rectifying faults Warnings Unstable arc Material inclusions in the tungsten electrode due to contact with filler material or workpiece Regrind or replace the tungsten electrode Incompatible parameter settings Check settings and correct if necessary Pore formation ... - Page 43 Rectifying faults Warnings Warning Possible cause / remedy 16 Protective gas warning Check the gas supply. 17 Plasma gas warning Check the gas supply. 18 Forming gas warning Check the gas supply. 19 Gas warning 4 reserved 20 Coolant temperature warning Check coolant level and top up if necessary.
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Page 44: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) The possible error numbers displayed depend on the machine series and version! Depending on the options of the machine display, a fault is shown as follows: Display type - machine control Display Graphic display two 7-segment displays... - Page 45 Rectifying faults Error messages (power source) Error (category) Possible cause Remedy Low coolant level low flow rate Fill coolant. Check coolant flow - remove kinks in hose package. Adjust flow threshold. [1] [3] Clean water block. Pump does not turn Turn the pump shaft.
- Page 46 Rectifying faults Error messages (power source) Error (category) Possible cause Remedy 33 Error UIST Voltage recording faulty Eliminate short circuit in welding cir- cuit. remove external sensor voltage. Request service. 34 Electronics error A/D-channel error Switch the machine off and on again. Request service.
- Page 47 Rectifying faults Error messages (power source) Error (category) Possible cause Remedy 56 Mains phase failure One phase of the mains voltage Check mains connection, mains plug has failed. and mains fuses. Slave tacho error Wire feeder fault (slave drive). Check connectors, cables, connec- tions.
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Page 48: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit Figure 7-1 • Switch off the machine and fill the coolant tank to the maximum level. • Unlock the quick-connect coupling with a suitable tool (connection open). To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-2 •... -
Page 49: 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 Tetrix XQ 230 puls DC Tetrix XQ 230 puls AC/DC Dimensions (l x b x h) inch 10.1 21.7 16.3... -
Page 50: Tetrix Xq 230 Puls Dc
Technical data Tetrix XQ 230 puls DC Tetrix XQ 230 puls DC Welding current (I 3 A to 230 A 5 A to 190 A Welding voltage according to standard 10,1 V to 19,2 V 20,2 V to 27,6 V Duty cycle DC at 40°... -
Page 51: Tetrix Xq 230 Puls Ac/Dc
Technical data Tetrix XQ 230 puls AC/DC Tetrix XQ 230 puls AC/DC Welding current (I 3 A to 230 A 5 A to 190 A Welding voltage according to standard 10,1 V to 19,2 V 20,2 V to 27,6 V Duty cycle DC at 40°... -
Page 52: Accessories
Accessories General accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. GH 2X1/4'' 2M Gas hose 094-000010-00001 DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 Remote controls and accessories... -
Page 53: Options
Accessories Options Options Type Designation Item no. ON TS TG.11 Torch holder 092-004054-00000 ON Filter TG.11/K.06 Dirt filter for air inlet 092-004056-00000 ON CC TG.11 Transparent cover cap for protection of control 092-004057-00000 099-005630-EW501 02.03.2021... -
Page 54: Appendix
Appendix Searching for a dealer Appendix 10.1 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005630-EW501 02.03.2021...
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