EWM Trolly XQ 55-3 User manual

Operating instructions
EN
Transport systems
Trolly XQ 55-3
099-008637-EW501
Observe additional system documents!
1.6.2023

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 sa-
fety 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 re-
pair the machine.
• Technical changes due to further development in machine technology may lead to a dif-
fering 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 [phone].
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 ac-
cepted 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.
© EWM GmbH
Dr. Günter-Henle-Strasse 8
56271 Mündersbach Germany
Tel.: [phone], Fax: -244
Email: [email protected]
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.
Data security
The user is responsible for backing up data of all changes from the factory setting. The user is liable for
erased personal settings. The manufacturer does not assume any liability for this.

Contents
Notes on using these operating instructions
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1 Contents
1Contents .......................................................................................................................................... 3
2For your safety ............................................................................................................................... 5
2.1 Notes on using these operating instructions .......................................................................... 5
2.2 Explanation of icons ............................................................................................................... 6
2.3 Safety instructions .................................................................................................................. 7
2.4 Transport and installation .................................................................................................... 10
3Intended use ................................................................................................................................. 12
3.1 Applications .......................................................................................................................... 12
3.2 Use and operation solely with the following machines ........................................................ 12
3.3 Documents which also apply ............................................................................................... 12
3.3.1 Warranty ............................................................................................................... 12
3.3.2 Service documents (spare parts) ......................................................................... 12
3.3.3 Part of the complete documentation ..................................................................... 13
4Machine description – quick overview ...................................................................................... 14
4.1 Rear view / side view from right ........................................................................................... 14
5Design and function ..................................................................................................................... 16
5.1 Mounting the machine ......................................................................................................... 16
5.2 Securing the shielding gas cylinder ..................................................................................... 20
5.2.1 Attach the clamping belt to secure the shielding gas cylinder ............................. 21
5.3 Transport and installation .................................................................................................... 22
6Maintenance, care and disposal ................................................................................................. 23
6.1 Maintenance work, intervals ................................................................................................ 23
6.1.1 Daily maintenance tasks ...................................................................................... 23
6.1.2 Monthly maintenance tasks .................................................................................. 23
6.2 Disposing of equipment ....................................................................................................... 23
7Technical data .............................................................................................................................. 24
7.1 Trolly XQ 55-3 ...................................................................................................................... 24
8Accessories .................................................................................................................................. 25
8.1 General accessories ............................................................................................................ 25
9Appendix ....................................................................................................................................... 26
9.1 Searching for a dealer ......................................................................................................... 26

Contents
Notes on using these operating instructions
4
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For your safety
Notes on using these operating instructions
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2 For your safety
2.1 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.
• 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 sym-
bol.
• 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
Incorrect / Invalid
Switch
Correct / Valid
Turn
Input
Numerical value – adjustable
Navigation
Signal light lights up in green
Output
Signal light flashes green
Time representation (e.g.: wait 4 s / ac-
tuate)
Signal light lights up in red
Interruption in the menu display (other
setting options possible)
Signal light flashes red
Tool not required/do not use
Signal light lights up in blue
Tool required/use
Signal light flashes blue

For your safety
Safety instructions
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2.3 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 vol-
tages 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!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a techni-
cal specialist may interconnect the sources as per standard IEC 60974-9:2010: Installa-
tion 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 com-
bined, which is not permitted.
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 appli-
cation).
• 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!

For your safety
Safety instructions
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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. 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 environ-
ments with conditions comparable to ambient temperatures of 100 °C or higher and arcing
and work on live components.
• Hearing protection against harming noise.
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 may lead to shortness of breath and poisoning! The ultraviolet radia-
tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso-
nous phosgene.
• Ensure sufficient fresh air!
• Keep solvent vapours away from the arc beam field!
• Wear suitable respiratory protection if necessary!
• To prevent the formation of phosgene, residues of chlorinated solvents on workpieces must
first be neutralised using appropriate measures.
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 electroma-
gnetic compatibility (the EMC class can be found in the Technical data) > see 7 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, in-
cluding 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 can create electrical or electromagnetic fields that may impair the
function of electronic systems such as EDP and CNC devices, telecommunication,
power and signal lines as well as pacemakers and defibrillators.
• Follow the maintenance instructions > see 6.1 chapter!
• Unwind the welding leads completely!
• Shield radiation-sensitive equipment or facilities appropriately!
• The function of pacemakers may be impaired (seek medical advice if necessary).

For your safety
Transport and installation
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CAUTION
Obligations of the operator!
The respective national directives and laws must be complied with when operating the
machine!
• Implementation of national legislation relating to framework directive 89/391/EEC on the in-
troduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
• 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 hold-
ers, 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 ma-
chine 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.
2.4 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 seri-
ous injuries!
• Observe the instructions from the gas manufacturer and any relevant regulations concern-
ing the use of compressed air!
• Do not attach any element to the shielding gas cylinder valve!
• Prevent the shielding gas cylinder from heating up.