EWM Tetrix 352 AC/DC RC Operating Instructions Manual
Power sources for automated applications
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- Page 1 Operating instructions Power sources for automated applications Tetrix 352 AC/DC RC Observe additional system documents! 099-000139-EW501 01.08.2011 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
- Page 2 © EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer.
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Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents..............................3 2 Safety instructions..........................5 Notes on the use of these operating instructions ................5 Explanation of icons........................6 General ............................7 Transport and installation ......................11 2.4.1 Lifting by crane ......................12 Ambient conditions........................ - Page 4 Connection cables, connection sockets..................45 General accessories ........................45 Options ............................45 Transport systems........................45 Interfaces .............................45 Computer communication ......................45 Cooling units ..........................45 10 Circuit diagrams ...........................46 10.1 Tetrix 352 AC/DC .........................46 11 Appendix A............................49 11.1 JOB-List............................49 12 Appendix B............................53 12.1 Overview of EWM branches......................53 099-000139-EW501 01.08.2011...
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Page 5: 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 6: 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 the menu) NAVIGATION (Navigating in the menu) 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 7: General
Safety instructions General General DANGER Electric shock! Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents. • Do not touch any live parts in or on the machine! •... - Page 8 Safety instructions General WARNING 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! Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning.
- Page 9 Safety instructions General 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 10 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.
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Page 11: 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 12: Lifting By Crane
Safety instructions Transport and installation 2.4.1 Lifting by crane DANGER Risk of injury during lifting by crane! When lifting the equipment by crane, serious injuries can be inflicted by falling equipment or add-on units. • Transport on all lifting lugs at the same time (see Fig. -
Page 13: Ambient Conditions
Safety instructions Ambient conditions 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
3.1.2 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: Documents Which Also Apply
Intended use Documents which also apply Documents which also apply 3.3.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.3.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Tetrix 352 AC/DC Machine description – quick overview Tetrix 352 AC/DC 4.1.1 Front view Figure 4-1 099-000139-EW501 01.08.2011... - Page 17 Machine description – quick overview Tetrix 352 AC/DC Item Symbol Description Lifting lug Operating state signal lamp Lights up when the machine is ready for use. "Fault" display "Collective interference" signal light If the signal light is on, the power unit is automatically switched off. Because some interference is short-term and one-off (e.g.
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Page 18: Tetrix 352 Ac/Dc
Machine description – quick overview Tetrix 352 AC/DC Tetrix 352 AC/DC 4.2.1 Rear view Figure 4-2 099-000139-EW501 01.08.2011... - Page 19 Machine description – quick overview Tetrix 352 AC/DC Item Symbol Description Interfaces Optional interface in the extension casing for assembly onto the power source • RINTX11 robot interface digital • BUSINTX10 industrial bus interface 19-pole mechanised welding interface (analogue) (See chapter entitled "Design and function > interfaces".) analog 8-pole connection socket Cooling unit control lead...
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Page 20: Design And Function
Design and function General Design and function NOTE Observe documentation of other system components when connecting! 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. •... -
Page 21: Installation
Design and function Installation 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 22: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system 5.5.1 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 23: 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 (any phase sequence for three-phase machines)! -
Page 24: Shielding Gas Supply
Design and function Shielding gas supply Shielding gas supply 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 25: Gas Supply
Design and function Gas supply Gas supply Figure 5-3 Item Symbol Description Shielding gas Shielding gas hose G¼" connection thread, shielding gas connection, inlet • Screw the crown nut on the shielding gas lead gastight to the connecting thread (G¼"). 099-000139-EW501 01.08.2011... -
Page 26: Connect The Cooling Module To The Power Source
Design and function Connect the cooling module to the power source Connect 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 5-4 Item Symbol Description Connection socket, 5-pole Cooling unit voltage supply 8-pole connection socket... -
Page 27: Welding Torch Connection
Design and function Welding torch connection 5.10 Welding torch connection Figure 5-5 Item Symbol Description 19-pole (analogue) connection socket Collision protection / sensor voltage control signals Connection nipple for rapid-action closure coupling, shielding gas supply, G¼" Connection socket, welding current - Welding torch connection Welding torch hose package Welding torch... -
Page 28: Connection For Workpiece Lead
Design and function Connection for workpiece lead 5.11 Connection for workpiece lead Figure 5-6 Item Symbol Description Workpiece Connection socket, “+” welding current Workpiece connection • Insert cable plug on the workpiece lead into the connection socket for workpiece lead and lock by turning to the right. -
Page 29: Arc Ignition
Design and function Arc ignition 5.12 Arc ignition 5.12.1 HF ignition Figure 5-7 The arc is started without contact from high-voltage ignition pulses. a) Position the welding torch in welding position over the workpiece (distance between the electrode tip and workpiece should be approx. 2-3 mm). b) Robot start signal (high voltage ignition pulses ignite the arc). -
Page 30: Tig Welding Task Definition
Design and function TIG welding task definition 5.14 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: Interfaces
Design and function Interfaces 5.15 Interfaces 5.15.1 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 32: Rint X11 Robot Interface
Design and function Interfaces Figure 5-8 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 cables, 12-, 19- and 23-pole Connection between interface casing and switching cabinet 5.15.1.1 RINT X11 robot interface The standard digital interface for mechanised applications•... -
Page 33: Connecting The Pc 300.Net Welding Parameterisation Software
Design and function Interfaces 5.15.2 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 5-9 Item Symbol Description PC interface, serial (D-Sub connection socket, 9-pole) -
Page 34: Connecting The Q-Doc 9000 Welding Data Documentation Software
Design and function Interfaces 5.15.3 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 5-10 Item Symbol Description... -
Page 35: Connecting The Weldqas Welding Data Monitoring And Documentation System
Design and function Interfaces 5.15.4 Connecting the WELDQAS welding data monitoring and documentation system Network-compatible welding data monitoring and documentation system for digital power sources. Figure 5-11 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 36: Automation Interface
Design and function Interfaces 5.15.5 Automation interface WARNING No function of the external shut-down devices (emergency stop switch)! If the emergency stop circuit has been realised using an external shut-down device via the interface for mechanised welding, the device must be set for this setup. If this is not observed, the power source will ignore the external shut-down devices and will not shut down! •... - Page 37 Design and function 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...
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Page 38: 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 39: Maintenance Work
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 40: Rectifying Faults
Rectifying faults Customer checklist Rectifying faults Customer checklist Legend a: Fault/Cause #: Remedy NOTE The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation! Coolant error/no coolant flowing a Insufficient coolant flow Check coolant level and refill if necessary Eliminate kinks in conduit system (hose packages) Reset automatic cutout of the coolant pump by activating... - Page 41 Rectifying faults Customer checklist Wire feed problems a 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 a Contact tip blocked Clean, spray with anti-spatter spray and replace if necessary a Setting the spool brake (see "Setting the spool brake"...
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Page 42: Error Messages (Power Source)
Excess secondary circuit voltage Phoenix/alpha Q/Te No, switch off trix machine Protective conductor error Phoenix/alpha Q/Te No, switch off trix machine System quick stop Phoenix/alpha Q/Te trix Internal error, please contact EWM Phoenix/alpha Q/Te No, switch off trix machine 099-000139-EW501 01.08.2011... -
Page 43: Interface For Mechanised Welding
Rectifying faults Error messages (power source) Error Meaning Relevance Error can be reset number to system (value) Process error Ignition process error Phoenix/Tetrix Arc interruption error Phoenix/Tetrix Emergency stop/excess temperature Phoenix/Tetrix No, resets itself WF missing in MIG/MAG system or is not Phoenix correctly configured In a system with the option for WF case... -
Page 44: Technical Data
Technical data Tetrix 352 AC/DC Technical data Tetrix 352 AC/DC NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Welding current setting range 5 A–350 A Welding voltage setting range 10.2 V–24.0 V Duty cycle 25 °C ambient temperature 80%DC 350 A 100%DC... -
Page 45: Accessories
ATCASE 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 set incl. 090-008265-00000 cable and SECINT X10 USB interface WELDQAS1 Station Stationary welding data monitoring and docu set for... -
Page 46: Circuit Diagrams
Circuit diagrams Tetrix 352 AC/DC Circuit diagrams NOTE Original format circuit diagrams are located inside the machine. 10.1 Tetrix 352 AC/DC Figure 10-1 099-000139-EW501 01.08.2011... - Page 47 Circuit diagrams Tetrix 352 AC/DC Figure 10-2 099-000139-EW501 01.08.2011...
- Page 48 Circuit diagrams Tetrix 352 AC/DC Figure 10-3 099-000139-EW501 01.08.2011...
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Page 49: 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 ; ; ; CrNi/ Fe/ St ; ; ; CrNi/ Fe/ St >3.2 CrNi/ Fe/ St CrNi/ Fe/ St... - Page 50 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 Cu/CuZn Cu/CuZn Cu/CuZn Cu/CuZn Cu/CuZn Cu/CuZn >3.2 AlMg AlMg AlMg ; ; ; AlMg ; ; ; AlMg ; ; ; AlMg >3.2 AlMg...
- Page 51 Appendix A JOB-List Process Material Wire Seam position ∅ AlSi AlSi AlSi AlSi AlSi AlSi >3.2 AlSi AlSi AlSi AlSi AlSi AlSi >3.2 AlSi AlSi AlSi AlSi AlSi AlSi >3.2 AlSi AlSi AlSi AlSi AlSi AlSi >3.2 Al99 Al99 Al99 Al99 Al99 Al99...
- Page 52 Appendix A JOB-List Process Material Wire Seam position ∅ Al99 Al99 Al99 Al99 >3.2 Al99 Al99 Al99 Al99 Al99 Al99 >3.2 TIG manual/TIG classic Classic electrode Reserved Reserved Reserved Electrode JOB Reserved 129-179 Free JOBs or SCO (e.g. plasma) ; ; ; CrNi/FeSt ;...
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Page 53: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-000139-EW501 01.08.2011...
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