EWM TETRIX 1002 DC SYNERGIC Operating Instructions Manual
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EWM TETRIX 1002 DC SYNERGIC Operating Instructions Manual

EWM TETRIX 1002 DC SYNERGIC Operating Instructions Manual

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Operating instructions
Power sources for automated applications
TETRIX 1002 DC SYNERGIC
N. B. These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machines may only be operated by personnel who are familiar with the appropriate safety
regulations.
The machines bear the conformity mark and thus comply with the
•
EC Low Voltage Directive (2006/95/ EG)
•
EC EMC Directive (2004/108/ EG)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.
The content of the operating instructions does not constitute grounds for any claims on the part
©
of the buyer.
The copyright to these operating instructions remains with the manufacturer.
Reprinting, including extracts, only with written approval.
© 2009
Subject to alteration.
Dr. Günter-Henle-Straße 8 • D-56271 Mündersbach
Fon +49 2680 181-0 • Fax +49 2680 181-244
Item No.: 099-000155-EWM01
HIGHTEC WELDING GmbH
www.ewm.de
•
info@ewm.de
Revised: 22.07.2009
EWM

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Summary of Contents for EWM TETRIX 1002 DC SYNERGIC

  • Page 1 Operating instructions Power sources for automated applications TETRIX 1002 DC SYNERGIC N. B. These operating instructions must be read before commissioning. Failure to do so may be dangerous. Machines may only be operated by personnel who are familiar with the appropriate safety regulations.
  • Page 2 Perfection doesn't happen by coincidence: Every single component is 100% tested and the machine is “free welded” before it is delivered. Our comprehensive service offer and the highly developed modern EWM quality management system guarantee worldwide premium quality “Made in Germany” and a three-year warranty.
  • Page 3 Machine and Company Data Please enter the EWM machine data and your company’s data in the appropriate fields. EWM HIGHTEC WELDING GMBH D-56271 MÜNDERSBACH TYP: SNR: ART: PROJ: GEPRÜFT/CONTROL: Name of Customer / company Name of Customer / company Adress...

  • Page 4: Table Of Contents

    General............................9 Transport and installation......................12 Ambient conditions........................13 2.4.1 In operation........................13 2.4.2 Transport and storage ....................13 3 Technical data............................14 TETRIX 1002 DC SYNERGIC .....................14 4 Machine description..........................16 TETRIX 1002 DC SYNERGIC .....................16 4.1.1 Front view ........................16 4.1.2 Rear view........................18 5 Functional characteristics........................20 Machine control –...
  • Page 5 Resetting welding parameters to the factory settings..............65 Display machine control software version ................... 66 10 Circuit diagrams........................... 67 10.1 TETRIX 1002 DC SYNERGIC ..................... 67 11 Appendix A ............................72 11.1 Declaration of Conformity ......................72 Item No.: 099-000155-EWM01...
  • Page 6 Contents Notes on the use of these operating instructions Item No.: 099-000155-EWM01...

  • Page 7: Safety Instructions

    Safety instructions Notes on the use of these operating instructions Safety instructions Notes on the use of these operating instructions NOTE Special technical points which users must observe. • Notes include the "NOTE" keyword in the heading without a general warning symbol. •...
  • Page 8 Safety instructions Notes on the use of these operating instructions Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet points, e.g.: • Insert the welding current lead socket into the relevant socket and lock. Symbol Description Press Do not press...

  • Page 9: General

    Safety instructions General General WARNING Risk of accidents if these safety instructions are not observed! Non-observance of these safety instructions is potentially fatal! • Carefully read the safety information in this manual! • Observe the accident prevention regulations in your country. •...
  • Page 10 Safety instructions General WARNING Risk of injury due to radiation or heat! Arc radiation results in injury to skin and eyes. Contact with hot workpieces and sparks results in burns. • Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant regulations in the country in question! •...
  • Page 11 Safety instructions General DANGER 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. •...

  • Page 12: Transport And Installation

    Safety instructions Transport and installation Transport and installation CAUTION Equipment damage when not operated in an upright position! 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! CAUTION Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself...

  • Page 13: Ambient Conditions

    Safety instructions Ambient conditions Ambient conditions CAUTION Equipment damage due to dirt accumulation! Unusually high quantities of dust, acid, corrosive gases or substances may damage the equipment. • Avoid high volumes of smoke, vapour, oil vapour and grinding dust! • Avoid ambient air containing salt (sea air)! Non-permissible ambient conditions! Insufficient ventilation results in a reduction in performance and equipment damage.

  • Page 14: Technical Data

    Technical data TETRIX 1002 DC SYNERGIC Technical data TETRIX 1002 DC SYNERGIC TETRIX 1002 DC SYNERGIC Welding current setting range 10 – 1000 A Welding voltage setting range 10,4 – 34 V Duty cycle 20°C ambient temperature 60%DC 80%DC 1000 A...
  • Page 15 Technical data TETRIX 1002 DC SYNERGIC 380 mm 660 mm 495 mm 785 mm Figure 3-1 Item No.: 099-000155-EWM01...

  • Page 16: Machine Description

    Machine description TETRIX 1002 DC SYNERGIC Machine description TETRIX 1002 DC SYNERGIC 4.1.1 Front view Figure 4-1 Item No.: 099-000155-EWM01...
  • Page 17 Machine description TETRIX 1002 DC SYNERGIC Item Symbol Description Machine control See Machine control – operating elements chapter Key switch for protection against unauthorised use Position “1” > changes possible, Position “0” > changes not possible. Please take note of chapter “Key switch”...

  • Page 18: Rear View

    Machine description TETRIX 1002 DC SYNERGIC 4.1.2 Rear view Figure 4-2 Item No.: 099-000155-EWM01...
  • Page 19 Machine description TETRIX 1002 DC SYNERGIC Item Symbol Description Interfaces (customised) Optional interface in the extension casing for assembly onto the power source • RINTX11 robot interface digital • BUSINTX10 industrial bus interface Key button, automatic cutout Wire feed motor supply voltage fuse...

  • Page 20: Functional Characteristics

    Functional characteristics Machine control – Operating elements Functional characteristics Machine control – Operating elements SYNERGIC T 3.27 Puls Automatic AMP% AMP% AMP% > activArc HOLD VOLT PROG CrNi Fe/St Synergic CuZn Manuell Spez Figure 5-1 Item Symbol Description "Welding process" button MMA welding, lights up in green / arcforce setting, lights up in red TIG synergic welding (synergic parameter setting) TIG manual welding (manual parameter setting)
  • Page 21 Functional characteristics Machine control – Operating elements Item Symbol Description Select seam type button Fillet weld Butt joint Fillet weld - lap joint Vertical-down Operating mode button spotArc (spot time setting range 0.01 sec. to 20.0 sec.) Non-latched Latched Puls TIG pulses key button / Select activArc key button Automatic TIG automated pulses (frequency and balance)

  • Page 22: Function Sequence

    Functional characteristics Machine control – Operating elements 5.1.1.1 Function sequence Figure 5-2 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. Gas pre-flow time (TIG), absolute setting range 0.0 sec to 20.0 sec (0.1s increments). Ignition current (TIG) AMP% Percentage of the main current.

  • Page 23: Tig Synergic Operating Principle

    Functional characteristics TIG Synergic operating principle TIG Synergic operating principle Figure 5-3 The machine is operated according to the TIG Synergic operating principle: The three basic parameters • tungsten electrode diameter (A), • material type (B) and • seam type (C) are used to select the welding task (JOB).

  • Page 24: Synergic Parameter Setting In The Functional Sequence

    Functional characteristics TIG Synergic operating principle 5.2.1 Synergic parameter setting in the functional sequence When setting the welding current, all the necessary welding parameters are adjusted automatically during the functional sequence (see chap. “TIG functional sequences”) with the exception of the gas pre-flow time.

  • Page 25: Change Conventional Setting / Synergic Parameter Setting

    Functional characteristics TIG Synergic operating principle 5.2.2.1 Change conventional setting / synergic parameter setting Operating Action Result Display element Switch off the welding machine Press and hold key button Switch on the welding machine Select the Configuration menu option Confirm Configuration menu option Select the operating mode: on = Synergic method off = Conventional method...

  • Page 26: Select Welding Task

    Functional characteristics TIG Synergic operating principle 5.2.3 Select welding task The welding task is selected using the buttons on the machine control on the welding machine. Signal lights (LED) display the welding parameter selection. NOTE It is only possible to change the 3 basic welding parameters if: •...

  • Page 27: Select Welding Current

    Functional characteristics TIG Synergic operating principle 5.2.4 Select welding current The user has two options for setting the required welding current: • Using the sheet metal thickness • Directly as welding current NOTE The welding current is displayed in the left-hand display. The “Material thickness” parameter can be selected in the right-hand display.

  • Page 28: Welding Parameter Setting

    Functional characteristics TIG welding 5.2.5.1 Welding parameter setting During the welding parameter setting process, the parameter value being set is displayed on the left-hand display. The right-hand display shows the “Factory setting” or a variation of it upwards or downwards. Displays, e.g.

  • Page 29: Optimising The Ignition Characteristics For Pure Tungsten Electrodes

    Functional characteristics TIG welding 5.3.2 Optimising the ignition characteristics for pure tungsten electrodes This parameter can be used to improve the ignition characteristics of “pure tungsten electrodes”, for example. The parameter is a %-value (factory-set to 20) and is changed across all JOBs. Control element Action Result...

  • Page 30: Tig Welding Task Definition

    Functional characteristics TIG welding 5.3.4 TIG welding task definition The user defines the welding tasks using JOB numbers. Each JOB number stores all the parameters relating to the welding task. The user can either load an existing JOB, load an existing JOB and change it, or define a completely new JOB via the various interfaces.

  • Page 31: Key Switch

    Functional characteristics Key switch Key switch To protect against unauthorised or unintentional adjustment of the welding parameters on the machine, the control input can be locked with the aid of a key switch. Key position 1 = All parameters can be set Key position 0 = Only the following operating elements are functional: •...

  • Page 32: Specifying Max. No. Of Accessible Programs

    Functional characteristics Welding programs 5.5.1 Specifying max. no. of accessible programs NOTE This function can be used to specify the maximum number of programs which can be called up (only applies to the welding torch). According to the factory setting, all 16 programs can be called up.

  • Page 33: Example "Program With Synergetic Setting

    Functional characteristics Welding programs 5.5.2 Example "Program with synergetic setting" Figure 5-7 5.5.3 Example "Program with conventional setting" Figure 5-8 5.5.4 Accessories for switching over programs The user can change, retrieve and save programs using the following components. Programs Component Create and change Retrieve Welding machine control...

  • Page 34: Organising Welding Tasks (Mode "Job Manager")

    Functional characteristics Organising welding tasks (Mode "JOB Manager") Organising welding tasks (Mode "JOB Manager") NOTE Welding jobs (JOBs) / programs are organised (configured, managed, created) using the parameterisation software PCT 300. JOBs are switched with an interface (e.g., RINT X11). Please note the relevant documentation of the accessory components.

  • Page 35: Creating A New Job In The Memory Or Copying A Job

    Functional characteristics Organising welding tasks (Mode "JOB Manager") 5.6.2 Creating a new JOB in the memory or copying a JOB NOTE It is normally possible to adjust all 256 JOBs individually. However, it is a good idea to assign specific JOB numbers in the free memory (JOB 128 to 256) for specific welding tasks.

  • Page 36: Loading An Existing Job From The Free Memory

    Functional characteristics Organising welding tasks (Mode "JOB Manager") 5.6.3 Loading an existing JOB from the free memory Operating Action Result Display element Select JOB Manager mode Press until the “VOLT” VOLT signal light is on PROG Select JOB Manager mode 2 sec.

  • Page 37: Resetting Jobs 1-128 To The Factory Setting (Reset All Jobs)

    Functional characteristics Organising welding tasks (Mode "JOB Manager") 5.6.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs) Operating Action Result Display element Select JOB Manager mode Press until the “VOLT” signal light is on VOLT PROG Select JOB Manager mode 2 sec.

  • Page 38: Specifying Max. No. Of Accessible Jobs

    Functional characteristics Organising welding tasks (Mode "JOB Manager") 5.6.7 Specifying max. no. of accessible JOBs This function can be used to specify the maximum number of JOBs which can be retrieved from the free memory. The factory setting is for 10 JOBs to be accessible on the welding machine, but this figure can be increased to up to 128 if required.
  • Page 39 Functional characteristics Organising welding tasks (Mode "JOB Manager") Operating Action Result Display element Switch off the welding machine Press and hold key button Switch on the welding machine Select "Torch mode" torch mode Select "Number of JOBs" Set maximum no. of JOBs for selection (max.

  • Page 40: Interfaces

    Functional characteristics Interfaces Interfaces 5.7.1 Connecting the RINT X11 robot interface/BUSINT X11 industrial bus interface CAUTION Damage due to the use of non-genuine parts! 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! •...
  • Page 41 Functional characteristics Interfaces Figure 5-10 Item Symbol Description 7-pole connection socket (digital) For connecting digital accessory components Switching cabinet Robot interface, TETRIX, RINT X11 Industrial bus interface, TETRIX, BUSINT X11 Interface casing Connection cable, 7-pole Item No.: 099-000155-EWM01...

  • Page 42: Connecting The Pc 300.Net Welding Parameterisation Software

    Functional characteristics Interfaces 5.7.2 Connecting the PC 300.net welding parameterisation software Create all welding parameters quickly on the PC and easily transfer them to one or more welding machines (accessories, set consisting of software, interface, connection leads) Figure 5-11 Item Symbol Description PC interface, serial (D-SUB connection socket, 9-pole) Connection cable, 9-pole, serial...

  • Page 43: Connecting The Q-Doc 9000 Welding Data Documentation Software

    Functional characteristics Interfaces 5.7.3 Connecting the Q-DOC 9000 welding data documentation software (Accessories: Set consisting of software, interface, connection leads) The ideal tool for welding data documentation of, for example: welding voltage and current, wire speed and motor current. Figure 5-12 Item Symbol Description 7-pole connection socket (digital)

  • Page 44: Connecting The Weldqas Welding Data Monitoring And Documentation System

    Functional characteristics Interfaces 5.7.4 Connecting the WELDQAS welding data monitoring and documentation system Network-compatible welding data monitoring and documentation system for digital PHOENIX and TETRIX machines Figure 5-13 Item Symbol Description 7-pole connection socket (digital) For connecting digital accessory components Windows PC WELDQAS welding data monitoring and documentation system Connection cable, 7-pole...

  • Page 45: Automation Interface

    Functional characteristics Interfaces 5.7.5 Automation interface The welding power sources feature a very high safety standard. This safety standard is also maintained when peripheral equipment is connected for mechanised welding, if this peripheral equipment meets the same criteria, particularly with regard to isolation from the mains supply.
  • Page 46 Functional characteristics Interfaces 19-pole connection assignments for mechanised welding interface (X6): Signal Circuit diagram Function shape signal name Output Connection for cable screen Input PULSEN EIN Thermal pulse mode up to max. 50 Hz, fixed balance of Input SYN_E Synchronisation for master/slave operation Input IGRO RELAY Current flows signal...

  • Page 47: Connection Socket Automation Torch

    Functional characteristics Interfaces 5.7.6 Connection socket automation torch X22- 2n2F BR KOLL1 BR KOLL1 BR KOLL2 BR KOLL2 Fühlerspannung TETRIX TETRIX DRIVE 4 ROB DRIVE 4 ROB only! only! Gastest Einfädeln codiert Figure 5-15 Connection socket19-pole Automation torch (X22): Signal Signal name designation shape...

  • Page 48: Menus And Sub-Menus On The Machine Control

    Functional characteristics Menus and sub-menus on the machine control Menus and sub-menus on the machine control 5.8.1 Direct menus (direct access to parameters) Functions, parameters and their values can be accessed directly, e.g. can be selected by pressing a button once. 5.8.2 Expert menu (TIG) The expert menu includes functions and parameters which are either not set on the machine control, or...

  • Page 49: Machine Configuration Menu

    Functional characteristics Menus and sub-menus on the machine control 5.8.3 Machine configuration menu The machine menu includes basic functions such as torch modes, display settings and the service menu. Figure 5-17 Item No.: 099-000155-EWM01...

  • Page 50: Display, Explanation Of Symbols

    Functional characteristics Menus and sub-menus on the machine control 5.8.3.1 Display, explanation of symbols Display Menu/setting/selection Exit Exit the machine configuration menu Torch configuration Torch mode Setting: 1 to 16 (factory setting 1) 1. Increment (Delta I) Setting: 1 to 20 (factory setting 1) Up/down speed Setting: 1 to 100 (factory setting 10) Number of jobs...

  • Page 51: Commissioning

    Commissioning General Commissioning General CAUTION Risk of burns on the welding current connection! If the welding current connections are not locked, connections and leads heat up and can cause burns, if touched! • Check the welding current connections every day and lock by turning in clockwise direction, if necessary.

  • Page 52: Installation

    Commissioning Installation Installation CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work.

  • Page 53: Machine Cooling

    Commissioning Machine cooling Machine cooling To obtain an optimal duty cycle from the power components, the following precautions should be observed: Ensure that the working area is adequately ventilated. • Do not obstruct the air inlets and outlets of the machine. •...

  • Page 54: Connecting The Welding Torch And Accessory Components

    Commissioning Connecting the welding torch and accessory components Connecting the welding torch and accessory components Figure 6-2 Item Symbol Description Connection socket, welding current - Welding torch connection 7-pole connection socket For connecting Control lead, Welding torch 19-pole connection socket (analogue) Mechanised welding torch connection 7-pole connection socket (digital) For connecting digital accessory components...

  • Page 55: Connecting The Cooling Module To The Power Source

    Commissioning Connecting the welding torch and accessory components 6.7.1 Connecting the cooling module to the power source NOTE Observe the fitting and connection instructions given in the relevant operating instructions for the cooling unit. Figure 6-3 Item Symbol Description 8-pole connection socket Cooling unit control lead Connection socket, 5-pole Cooling unit voltage supply...

  • Page 56: Maintenance And Testing

    NOTE The maintenance, cleaning and testing work described below must be conducted correctly and on an annual basis in order qualify for claims under the EWM warranty. General When used in the specified environmental conditions and under normal operating conditions, this machine is largely maintenance-free and requires a minimum of care.

  • Page 57: Test

    DIN EN 61010-1 Appendix A – Measuring Circuit A1. You as the user are tasked with ensuring that your EWM machines conform to the standard IEC/DIN EN 60974-4 and are tested with the relevant test equipment and measuring devices given above.

  • Page 58: Scope Of The Test

    Maintenance and testing Test 7.3.2 Scope of the test a) Visual inspection b) Electrical test: measurement of • open circuit voltage • insulation resistance, or alternatively • leakage currents • protective conductor resistance c) Functional test d) Documentation 7.3.3 Visual inspection The key areas in the test are: 1.

  • Page 59: Measuring The Leakage Current (Protective Conductor And Contact Current)

    Note: Even if the leakage current measurement according to the standard is only an alternative to the insulation resistance measurement, EWM recommends always performing both measurements, especially following repair work. The leakage current is based for the greater part on a physical effect other than the insulation resistance.

  • Page 60: Repair Work

    Maintenance and testing Repair Work Repair Work Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine. Return deliveries of defective equipment subject to warranty may only be made through your dealer.

  • Page 61: Disposing Of Equipment

    Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922. •...

  • Page 62: Warranty

    • Wire feeds • Cooling units • Trolleys * If these are operated with genuine EWM accessories (such as intermediate tube package, remote control, remote control extension cable, coolant, etc.). 1-year warranty on: • Used EWM machines • Automation and mechanisation components •...

  • Page 63: Warranty Declaration

    This limitation does not apply to personal injuries or damage to property caused by negligent behaviour on the part of EWM. In no way will EWM be responsible for lost profits, indirect or subsequent damage. EWM is not liable for damages based on the claims of third parties.

  • Page 64: Operating Problems, Causes And Remedies

    Operating problems, causes and remedies Error messages (power source) Operating problems, causes and remedies All machines are subject to rigorous production checks and final checks. If despite this, anything fails to work at any time, please check the machine using the following chart. If none of the fault rectification procedures described leads to the correct functioning of the machine, please inform your authorised dealer.

  • Page 65: Resetting Welding Parameters To The Factory Settings

    Operating problems, causes and remedies Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings. Figure 9-1 Display Setting/selection Exit the menu Exit Service menu Modifications to the service menu may only be carried out by authorised maintenance...

  • Page 66: Display Machine Control Software Version

    Operating problems, causes and remedies Display machine control software version Display machine control software version NOTE The query of the software versions only serves to inform the authorised service staff! Figure 9-2 Display Setting/selection Exit the menu Exit Service menu Modifications to the service menu may only be carried out by authorised maintenance staff! Software version query (example)

  • Page 67: Circuit Diagrams

    Circuit diagrams TETRIX 1002 DC SYNERGIC Circuit diagrams NOTE Original format circuit diagrams are located inside the machine. 10.1 TETRIX 1002 DC SYNERGIC Figure 10-1 Item No.: 099-000155-EWM01...
  • Page 68 Circuit diagrams TETRIX 1002 DC SYNERGIC Figure 10-2 Item No.: 099-000155-EWM01...
  • Page 69 Circuit diagrams TETRIX 1002 DC SYNERGIC Figure 10-3 Item No.: 099-000155-EWM01...
  • Page 70 Circuit diagrams TETRIX 1002 DC SYNERGIC D-Sub. D-Sub. D-Sub. D-Sub. 15polig 15polig 15polig 15polig Figure 10-4 Item No.: 099-000155-EWM01...
  • Page 71 Circuit diagrams TETRIX 1002 DC SYNERGIC Figure 10-5 Item No.: 099-000155-EWM01...

  • Page 72: Declaration Of Conformity

    Umbauten, die nicht ausdrücklich von authorised by EWM. bées n’ayant pas été autorisés expressé- EWM autorisiert sind, verliert diese ment par EWM, cette déclaration devient Erklärung ihre Gültigkeit. caduque. Gerätebezeichnung: Description of the machine: Déscription de la machine: Gerätetyp:...

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