EWM Tetrix 352 AC/DC SYNERGIC PL. AW GR Operating Instructions Manual
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EWM Tetrix 352 AC/DC SYNERGIC PL. AW GR Operating Instructions Manual

EWM Tetrix 352 AC/DC SYNERGIC PL. AW GR Operating Instructions Manual

Power sources for automated applications
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Operating instructions
Power sources for automated applications
Tetrix 352 AC/DC SYNERGIC PL. AW GR
(SCO 3133)
099-003133-SCO01
Observe additional system documents!
07.04.2014

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Summary of Contents for EWM Tetrix 352 AC/DC SYNERGIC PL. AW GR

  • Page 1 Operating instructions Power sources for automated applications Tetrix 352 AC/DC SYNERGIC PL. AW GR (SCO 3133) 099-003133-SCO01 Observe additional system documents! 07.04.2014...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 General ............................8 Transport and installation ......................12 2.4.1 Ambient conditions .......................
  • Page 4 Contents Notes on the use of these operating instructions 5.10 Welding torch connection ......................45 5.11 "Insufficient wire" sensor connection ................... 47 5.12 Connecting the wire feed unit....................... 48 5.13 Hot wire power source connection ....................49 5.14 Cooling unit connection ........................ 50 5.15 Connection for workpiece lead .....................
  • Page 5 Computer communication ......................97 Interfaces ............................. 98 Connection and extension cables ....................98 10 Circuit diagrams ........................... 99 10.1 Tetrix 352 AC/DC SYNERGIC PL. AW GR ................. 99 11 Appendix A ............................105 11.1 JOB-List ............................. 105 12 Appendix B ............................109 12.1 Overview of EWM branches ......................

  • Page 6: Safety Instructions

    Safety instructions Notes on the use of these operating instructions Safety instructions 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. •...

  • Page 7: Explanation Of Icons

    Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu) EXIT EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use...

  • Page 8: General

    Safety instructions General 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 9 Safety instructions General WARNING 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! •...
  • Page 10 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
  • Page 11 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.

  • Page 12: Transport And Installation

    Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •...

  • Page 13: Ambient Conditions

    Safety instructions Transport and installation 2.4.1 Ambient conditions 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 14: Intended Use

    3.3.1 TIG activArc welding The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power supplied is kept virtually constant in the event of changes in the distance between the welding torch and the weld pool, e.g. during manual welding. Voltage losses as a result of a shortening of the distance between the torch and molten pool are compensated by a current rise (ampere per volt - A/V), and vice versa.

  • Page 15: Use And Operation Solely With The Following Machines

    Intended use Use and operation solely with the following machines Use and operation solely with the following machines • BUSINT X11 • RINT X12 • T drive 4 Rob 3 RE • T drive 4 Rob 3 LI • cool82 U44 •...

  • Page 16: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-003133-SCO01 07.04.2014...
  • Page 17 Machine description – quick overview Front view Item Symbol Description Carrier plate for system components only hot wire version Machine control See Machine control – operating elements chapter Cooling air inlet Main switch, machine on/off ROB XX2 pallet Transport pallet Operating state signal lamp Lights up when the machine is ready for use.

  • Page 18: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-003133-SCO01 07.04.2014...
  • Page 19 Machine description – quick overview Rear view Item Symbol Description Interfaces connection socket (15-pole) Mains connection cable Mains connection, hot wire power source Power supply for hot wire power source 19-pole mechanised welding interface (analogue) (See chapter entitled "Design and function > interfaces".) Key button, automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse...

  • Page 20: Machine Control (Mode Rc - On)

    Machine description – quick overview Machine control (Mode RC - on) Machine control (Mode RC - on) NOTE This welding machine is operated in the „RC – on, remote-controlled“ mode as a factory setting. RC - on: The machine is operated via an external interface in this mode. The majority of the machine control’s operating elements will be deactivated and are only used to monitor the welding data.
  • Page 21 Machine description – quick overview Machine control (Mode RC - on) Item Symbol Description Function sequence (see next chapter) Status displays After each completed welding task, the last values used in the welding process for the welding current and welding voltage are shown on the displays, and the signal light will be on Direct current welding Alternating current welding...

  • Page 22: Function Sequence

    Machine description – quick overview Machine control (Mode RC - on) 4.3.1 Function sequence Figure 4-4 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).
  • Page 23 Machine description – quick overview Machine control (Mode RC - on) Item Symbol Description Down-slope time (TIG) 0.00 s to 20.0 s (0.1 s increments). The down-slope time can be set separately for non-latched and latched. AMP% End-crater current (TIG) Setting range 1 % to 200 % (1 % increments).

  • Page 24: Machine Control (Mode Rc - Off)

    Machine description – quick overview Machine control (Mode RC - off) Machine control (Mode RC - off) NOTE As the plasma welding process is based directly on the TIG welding process, the TIG descriptions are used for plasma welding, with just a few differences. Figure 4-5 Item Symbol Description...
  • Page 25 Machine description – quick overview Machine control (Mode RC - off) Item Symbol Description Tungsten electrode diameter / Ignition optimisation / Spherical cap formation button ∅ 1.0mm, ∅ 1.6mm, ∅ 2.0mm, ∅ 2.4mm, ∅ 3.2mm, ∅ 4.0mm or greater Best ignition and stabilisation of the arc (DC, AC) and optimum spherical cup formation in the tungsten electrode according to the electrode diameter being used.
  • Page 26 Machine description – quick overview Machine control (Mode RC - off) Item Symbol Description Function sequence (see next chapter) 099-003133-SCO01 07.04.2014...

  • Page 27: Function Sequence

    Machine description – quick overview Machine control (Mode RC - off) 4.4.1 Function sequence Figure 4-6 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).
  • Page 28 Machine description – quick overview Machine control (Mode RC - off) Item Symbol Description Down-slope time (TIG) 0.00 s to 20.0 s (0.1 s increments). The down-slope time can be set separately for non-latched and latched. AMP% End-crater current (TIG) Setting range 1 % to 200 % (1 % increments).

  • Page 29: Plasmadrive

    Machine description – quick overview Plasmadrive Plasmadrive Figure 4-7 Item Symbol Description Welding torch head Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside. Plasmadrive Filler wire drive Sensor voltage connection for the filler wire fusing detection...

  • Page 30: Insufficient Wire" Sensor

    Machine description – quick overview "Insufficient wire" sensor "Insufficient wire" sensor Figure 4-8 Item Symbol Description "Insufficient wire" sensor control lead plug Wire feed rapid-action closure Connection to wire source Wire exit rapid-action closure Connection to wire feed connection hose "Insufficient wire"...

  • Page 31: Design And Function

    Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •...
  • Page 32 Design and function General CAUTION Damage due to incorrect connection! 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. •...

  • Page 33: System Integration

    Design and function System integration System integration 5.2.1 Plasma application with hot wire Drahtmangel-Sensor Tetrix drive 4 Rob 3 Fassförderung Plasmadrive hotwire hotwire Tetrix Hotwire digital at Case Tetrix 352 AC/DC AW SPS / CU / ROB Figure 5-1 099-003133-SCO01 07.04.2014...

  • Page 34: Legend

    Design and function System integration 5.2.1.1 Legend Wire feed (cold wire) Welding torch control lead (19-pole) connection socket Pilot arc current Welding current (minus potential) Shielding gas Plasma gas Welding torch coolant Input Output Reverse cooling unit supply voltage (230 V/AC, one-phase) Welding current (plus potential, workpiece) Wire feed unit control lead (12-pole) connection socket Wire feed unit control lead (7-pole) connection socket...

  • Page 35: Transport And Installation

    Design and function Transport and installation Transport and installation WARNING Risk of accident due to improper transport of machines that may not be lifted! Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only! •...

  • Page 36: Power Source For Hot Wire Welding

    Design and function Machine cooling 5.3.1 Power source for hot wire welding Figure 5-2 Item Symbol Description Carrier platform for hot wire power source Front holder Push the hot wire power source with the machine feet into the holder Rear holder To fix, push the holder into the machine feet and secure with fixing screws.

  • Page 37: Workpiece Lead, General

    Design and function Workpiece lead, general Workpiece lead, general CAUTION Risk of burns due to incorrect connection of the workpiece lead! Paint, rust and dirt on the connection restrict the power flow and may lead to stray welding currents. Stray welding currents may cause fires and injuries! •...

  • Page 38: Notes On The Installation Of Welding Current Leads

    Design and function Notes on the installation of welding current leads Notes on the installation of welding current leads NOTE 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.
  • Page 39 Design and function Notes on the installation of welding current leads NOTE Use an individual welding lead to the workpiece for each welding machine! Figure 5-4 NOTE 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.

  • Page 40: Welding Torch Cooling System

    Design and function Welding torch cooling system Welding torch cooling system 5.7.1 General CAUTION 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). •...

  • Page 41: Mains Connection

    Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations! •...

  • Page 42: System Gas Connection

    Design and function System gas connection System gas connection WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •...
  • Page 43 Design and function System gas connection Figure 5-7 Item Symbol Description G1/4" connecting nipple, shielding gas connection Connection to the pressure reducer G1/4" connecting nipple, plasma gas connection Connection to the pressure reducer • Screw the connection coupling of the plasma gas line onto the G1/4" connecting nipple, plasma gas connection.

  • Page 44: Connecting The Shielding Gas Supply

    Design and function System gas connection 5.9.1 Connecting the shielding gas supply Figure 5-8 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve • Place the shielding gas cylinder into the relevant cylinder bracket. •...

  • Page 45: Welding Torch Connection

    Design and function Welding torch connection 5.10 Welding torch connection CAUTION Use of unsuitable coolants results in damage to the welding torch! Unsuitable coolants can cause damage to the welding torch! • Use only KF 23E coolants (observe temperature range of - 10 °C bis + 40°C). NOTE Please note the relevant documentation of the accessory components.
  • Page 46 Design and function Welding torch connection Item Symbol Description Plasma torch Welding torch hose package 23-pole connection socket (analogue) Mechanised welding torch connection Connection socket, welding current - Welding torch connection Pilot current connection socket Plasma welding torch nozzle potential G1/4"...

  • Page 47: Insufficient Wire" Sensor Connection

    Design and function "Insufficient wire" sensor connection 5.11 "Insufficient wire" sensor connection Figure 5-10 Item Symbol Description "Insufficient wire" sensor A warning is issued as soon as the end of the wire (insufficient wire) is reached. The process will not be shut down. "Insufficient wire"...

  • Page 48: Connecting The Wire Feed Unit

    Design and function Connecting the wire feed unit 5.12 Connecting the wire feed unit Figure 5-11 Item Symbol Description Wire feed unit Control lead assembly 7-pole connection socket (digital) Wire feed unit connection 12-pole connection socket (analogue) Wire feed unit connection •...

  • Page 49: Hot Wire Power Source Connection

    Design and function Hot wire power source connection 5.13 Hot wire power source connection Figure 5-12 Item Symbol Description Hot wire power source Mains connection, hot wire power source Power supply for hot wire power source hotWire Control lead connection, hot wire power source 4-pole connection to the hot wire power source Connection socket for “+”...

  • Page 50: Cooling Unit Connection

    Design and function Cooling unit connection 5.14 Cooling unit connection CAUTION Use of unsuitable coolants results in damage to the welding torch! Unsuitable coolants can cause damage to the welding torch! • Use only KF 23E coolants (observe temperature range of - 10 °C bis + 40°C). NOTE Observe the fitting and connection instructions given in the relevant operating instructions for the cooling unit.
  • Page 51 Design and function Cooling unit connection Item Symbol Description Cooling unit Cooling unit voltage supply Protective contact socket Quick connect coupling (red) Coolant return to cooling unit Rapid-action closure nipple Coolant return from welding torch Plasma torch Quick connect coupling, blue Coolant supply to the welding torch •...

  • Page 52: Connection For Workpiece Lead

    Design and function Connection for workpiece lead 5.15 Connection for workpiece lead Figure 5-14 Item Symbol Description Workpiece Connection socket, “+” welding current Connection for workpiece lead • Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by turning to the right.

  • Page 53: Tig Synergic Operating Principle

    Design and function TIG Synergic operating principle 5.16 TIG Synergic operating principle Figure 5-15 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 54: Synergic Parameter Setting In The Functional Sequence

    Design and function TIG Synergic operating principle 5.16.1 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 55: Set The Operating Principle (Conventional/Synergic)

    Design and function TIG Synergic operating principle 5.16.2.1 Set the operating principle (conventional/synergic) ENTER EXIT NAVIGATION Figure 5-18 Display Setting/selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display Operating principle • on = synergic parameter setting (factory setting) •...

  • Page 56: Select Welding Task

    Design and function TIG Synergic operating principle 5.16.3 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 basic welding parameters if: •...

  • Page 57: Welding Data Display

    Design and function TIG Synergic operating principle 5.16.5 Welding data display The following welding parameters can be displayed before (nominal values), during (actual values) or after welding (hold values): “Left-hand display” Parameter Before welding During welding After welding (nominal values) (actual values) (hold values) ...

  • Page 58: Arc Ignition

    Design and function TIG Synergic operating principle 5.16.6 Arc ignition The pilot arc is activated/deactivated by pressing the "Pilot arc on/off" push-button. After activating the pilot arc, the pre-set gas pre-flow time runs, the pilot arc current ignites without workpiece contact between the electrode and nozzle, and the control lamp in the push-button illuminates. CAUTION Oxidation of the tungsten electrode! To protect the tungsten electrode against oxidation carry out the following actions...

  • Page 59: Optimal And Fast Spherical Cup Formation

    Design and function TIG Synergic operating principle 5.16.9 Optimal and fast spherical cup formation NOTE A conically ground tungsten electrode (approx. 35°) is generally required to form an ideal spherical cup. Operating Action Result element Select AC/DC welding with appropriate material: AlMg aluminium and magnesium alloys.

  • Page 60: Welding Task Definition

    Design and function Welding task definition 5.17 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 61: Protecting Welding Parameters From Unauthorised Access

    Design and function Protecting welding parameters from unauthorised access 5.18 Protecting welding parameters from unauthorised access 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 =...

  • Page 62: Selection And Adjustment

    Design and function Welding programs 5.19.1 Selection and adjustment Setting welding programs using the welding machine control Operatin Action Result Display element Press button until signal light comes on. Welding current (left) and program no. (right) Select or retrieve program no., e.g. no. 1 Set operating mode (can be specified separately for each No change program).

  • Page 63: Example "Program With Synergetic Setting

    Design and function Welding programs 5.19.3 Example "Program with synergetic setting" Figure 5-19 5.19.4 Example "Program with conventional setting" Figure 5-20 5.19.5 Accessories for switching over programs The user can change, retrieve and save programs using the following components. Programs Component create and change call up...

  • Page 64: Organising Welding Tasks (Mode "Job Manager")

    Design and function Organising welding tasks (Mode "JOB Manager") 5.20 Organising welding tasks (Mode "JOB Manager") NOTE Welding jobs (JOBs) / programs are organised (configured, managed, created) using the parameterisation software PC300.Net. JOBs are switched with an interface (e.g., RINT X12). Please note the relevant documentation of the accessory components.

  • Page 65: Creating A New Job In The Memory Or Copying A Job

    Design and function Organising welding tasks (Mode "JOB Manager") 5.20.2 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 66: Loading An Existing Job From The Free Memory

    Design and function Organising welding tasks (Mode "JOB Manager") 5.20.3 Loading an existing JOB from the free memory Operating Action Result Display element Select JOB Manager mode Press until the “VOLT” signal light is on Select JOB Manager mode 2 sec. Select the required JOB number using the rotary transducer (e.g.

  • Page 67: Resetting Jobs 1-128 To The Factory Setting (Reset All Jobs)

    Design and function Organising welding tasks (Mode "JOB Manager") 5.20.5 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 Select JOB Manager mode 2 sec.

  • Page 68: Interfaces

    Design and function Interfaces 5.21 Interfaces 5.21.1 Connecting the robot interface / 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 69: Rint X12 Robot Interface

    Design and function Interfaces Figure 5-21 Item Symbol Description 7-pole connection socket (digital) For connecting digital accessory components Switching cabinet Robot interface / Industrial bus interface Interface casing ATCASE Connection cable, 7-pole Connection between switching cabinet and power source Connection lead Connection between interface casing and switching cabinet 5.21.1.1 RINT X12 robot interface The standard digital interface for mechanised applications 
...

  • Page 70: Connecting The Pc 300.Net Welding Parameterisation Software

    Design and function Interfaces 5.21.2 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 5-22 Item Symbol Description PC interface, serial (D-Sub connection socket, 9-pole)

  • Page 71: Connecting The Q-Doc 9000 V2.0 Welding Data Documentation Software

    Design and function Interfaces 5.21.3 Connecting the Q-DOC 9000 V2.0 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 5-23 Item Symbol Description...

  • Page 72: Connecting The Weldqas Welding Data Monitoring And Documentation System

    Design and function Interfaces 5.21.4 Connecting the WELDQAS welding data monitoring and documentation system Network-compatible welding data monitoring and documentation system for digital power sources. Figure 5-24 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 Connection between switching cabinet and power source...

  • Page 73: Automation Interface

    Design and function Interfaces 5.21.5 Automation interface WARNING No function of the external interrupt equipment (emergency stop switch)! If the emergency stop circuit has been realised using an external interrupt equipment via 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! •...
  • Page 74 Design and function Interfaces 19-pole pin assignment for interface for automated welding (X6): Signal form Signal name circuit Function diagram Output Connection for cable screen Input PULSING ON Thermal pulse mode up to max. 50 Hz, fixed balance of Output Sticking Analysis signal to detect sticking of the filler wire to the workpiece 24 V = sticking...

  • Page 75: Connection Socket Automation Torch

    Design and function Interfaces 5.21.6 Connection socket automation torch Figure 5-26 Connection socket 23-pole Automation torch: Signal Signal name designation shape Output Connection for cable screen Input Brennerkoll. Emergency shut-down for anticollision device Output +24V Brenn. Emergency shut-down for anticollision device +24 V Output 0V Brenner* GND for torch speedometer...

  • Page 76: Sensor Current

    Design and function Interfaces 5.21.7 Sensor current The sensor current is transferred via the connection socket of the automated welding torch. At the torch, the signal has to be connected to the conducting part of the cold wire feeder. This means outside the welding process an electric potential is active which detects sticking when the feeder or wire has contact with the workpiece at the end of the process.

  • Page 77: Advanced Settings

    Design and function Advanced settings 5.22 Advanced settings 5.22.1 Setting slope times for secondary current AMP% or pulse edges Figure 5-27 ENTER EXIT NAVIGATION Figure 5-28 Display Setting/selection Expert menu Slope time tS1 (main current to secondary current) Setting: 0.00 s to 20.0 s (factory setting 0.00 s) Slope time tS2 (secondary current to main current) Setting: 0.00 s to 20.0 s (factory setting 0.00 s) 099-003133-SCO01...

  • Page 78: Welding Current Display (Ignition, Secondary, End And Hotstart Currents)

    Design and function Advanced settings 5.22.2 Welding current display (ignition, secondary, end and hotstart currents) The welding currents for secondary current, ignition current and end current (expert menu) can be displayed as percentages or absolute values on the machine display. ENTER EXIT NAVIGATION...

  • Page 79: Menus And Sub-Menus On The Machine Control

    Design and function Menus and sub-menus on the machine control 5.23 Menus and sub-menus on the machine control 5.23.1 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.
  • Page 80 Design and function Menus and sub-menus on the machine control Display Setting/selection Expert menu Slope time tS1 (main current to secondary current) Setting: 0.00 s to 20.0 s (factory setting 0.00 s) Slope time tS2 (secondary current to main current) Setting: 0.00 s to 20.0 s (factory setting 0.00 s) activArc parameter Parameter can also be set after activating TIG activArc welding.

  • Page 81: Machine Configuration Menu

    Design and function Menus and sub-menus on the machine control 5.23.3 Machine configuration menu NOTE ENTER (enter the menu) • Switch off machine at the main switch • Press and hold the "welding parameters" button and switch the machine on again at the same time.
  • Page 82 Design and function Menus and sub-menus on the machine control ENTER EXIT NAVIGATION Figure 5-31 099-003133-SCO01 07.04.2014...
  • Page 83 Design and function Menus and sub-menus on the machine control Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (factory setting 1) Up-/Down speed Increase value = rapid current change (factory setting 10) Reduce value = slow current change Setting the first increment Setting: 1 to 20 (factory setting 1)
  • Page 84 Design and function Menus and sub-menus on the machine control Display Setting/selection Welding current polarity switching • on = polarity switching at the RT PWS 1 19POL remote control (ex works) • off = polarity switching at the welding machine control spotMatic Variation of operation mode spotArc, ignition with workpiece contact •...
  • Page 85 Design and function Menus and sub-menus on the machine control Display Setting/selection Service menu Modifications to the service menu may only be carried out by authorised maintenance staff! Reset (reset to factory settings) • off = aus (factory setting) • CFG = Reset the values in the machine configuration menu •...

  • Page 86: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! •...

  • Page 87: Annual Test (Inspection And Testing During Operation)

    Maintenance, care and disposal Maintenance work 6.2.3 Annual test (inspection and testing during operation) NOTE The welding machine may only be tested by competent, capable personsl. A capable person is one who, because of his 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.

  • Page 88: Disposing Of Equipment

    In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).

  • Page 89: 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 dealer.
  • Page 90 Rectifying faults Checklist for rectifying faults Wire feed problems  Unsuitable or worn welding torch equipment  Adjust contact tip (cold wire/hot wire) to wire diameter, blow through and replace if necessary  Adjust wire guide to material in use, blow through and replace if necessary ...

  • Page 91: Machine Faults (Error Messages)

    Rectifying faults Machine faults (error messages) Machine faults (error messages) NOTE A welding machine error is indicated by the collective fault signal lamp (A1) lighting up and an error code (see table) being displayed in the machine control display. In the event of a machine error, the power unit shuts down.
  • Page 92 Rectifying faults Machine faults (error messages) Error message Possible cause Remedy Err 20 Coolant Check coolant level and refill if necessary • The flow quantity of the torch coolant Check coolant level in the reverse cooler • has fallen below the permissible Check coolant lines for leaks and kinks •...

  • Page 93: Resetting Welding Parameters To The Factory Settings

    Rectifying faults 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. ENTER EXIT NAVIGATION Figure 7-1 Display Setting/selection Exit the menu Exit Service menu Modifications to the service menu may only be carried out by authorised maintenance...

  • Page 94: Display Machine Control Software Version

    Rectifying faults 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! ENTER EXIT NAVIGATION Figure 7-2 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 95: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit NOTE Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. 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 7-3 099-003133-SCO01...

  • Page 96: Technical Data

    Technical data Tetrix 352 AC/DC SYNERGIC PL. AW GR Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 352 AC/DC SYNERGIC PL. AW GR Welding current 5 A to 350 Welding voltage 25.2 V to 39.0 V...

  • Page 97: Accessories

    092-001190-00000 Computer communication Type Designation Item no. RC 300 EWM tablet PC incl. software, adapter and interface 090-008238-00002 PC300.Net PC300.Net welding parameter software kit incl. 090-008777-00000 cable and SECINT X10 USB interface QDOC9000 V2.0 Set consisting of interface, documentation software,...

  • Page 98: Interfaces

    Accessories Interfaces Interfaces Type Designation Item no. Tetrix BUSINT X11 PLASMA RUGGED LINE industrial bus interface in casing 090-008623-00000 RUGGED LINE Tetrix BUSINT X11 PLASMA PROFIBUS industrial bus interface in casing 090-008624-00000 PROFIBUS ATCASE Tetrix BUSINT X11 PLASMA PROFINET LWL industrial bus interface in casing 090-008625-00000 PROFINET LWL ATCASE Tetrix BUSINT X11 PLASMA...

  • Page 99: Circuit Diagrams

    Circuit diagrams Tetrix 352 AC/DC SYNERGIC PL. AW GR Circuit diagrams NOTE Original format circuit diagrams are located inside the machine. 10.1 Tetrix 352 AC/DC SYNERGIC PL. AW GR Figure 10-1 099-003133-SCO01 07.04.2014...
  • Page 100 Circuit diagrams Tetrix 352 AC/DC SYNERGIC PL. AW GR Figure 10-2 099-003133-SCO01 07.04.2014...
  • Page 101 Circuit diagrams Tetrix 352 AC/DC SYNERGIC PL. AW GR Figure 10-3 099-003133-SCO01 07.04.2014...
  • Page 102 Circuit diagrams Tetrix 352 AC/DC SYNERGIC PL. AW GR Figure 10-4 099-003133-SCO01 07.04.2014...
  • Page 103 Circuit diagrams Tetrix 352 AC/DC SYNERGIC PL. AW GR Figure 10-5 099-003133-SCO01 07.04.2014...
  • Page 104 Circuit diagrams Tetrix 352 AC/DC SYNERGIC PL. AW GR Figure 10-6 099-003133-SCO01 07.04.2014...

  • Page 105: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List Process Material Wire Seam position ∅ Reserved   CrNi/ Fe/ St   CrNi/ Fe/ St   CrNi/ Fe/ St       CrNi/ Fe/ St   ...
  • Page 106 Appendix A JOB-List Process Material Wire Seam position ∅     Cu/CuZn   Cu/CuZn >3.2   Cu/CuZn   Cu/CuZn   Cu/CuZn     Cu/CuZn     Cu/CuZn   Cu/CuZn >3.2 ...
  • Page 107 Appendix A JOB-List Process Material Wire Seam position ∅   AlSi   AlSi   AlSi     AlSi     AlSi     AlSi >3.2   AlSi   AlSi ...
  • Page 108 Appendix A JOB-List Process Material Wire Seam position ∅   Al99     Al99     Al99     Al99 >3.2   Al99   Al99   Al99    ...

  • Page 109: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-003133-SCO01 07.04.2014...

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