EWM RINT X12 Page 31 Operating Instructions Manual Download | Manualshive

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Design and function

Process data monitoring (Phoenix / alpha Q)

099-000769-EW501

29.06.2015

31

The monitoring outputs are defined as follows:

Signals switched on

Signal

X8/1 on X8/3

Welding voltage outside the tolerances

X8/2 on X8/3

Welding voltage ok

X8/4 on 8/6

Welding current outside the tolerances

X8/5 on 8/6

Welding current ok

X8/7 on X8/9

Wire speed outside the tolerances

X8/8 on X8/9

Wire speed ok

X8/10 on X8/12

Motor current outside the tolerances

X8/11 on X8/12

Motor current ok

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Summary of Contents for RINT X12

Page 1: ...tions Analoge digital interface RINT X12 099 000769 EW501 Observe additional system documents 29 06 2015 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group com ...

Page 2: ... accepted This exclusion of liability shall be deemed accepted 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 re...

Page 3: ... 12 5 2 1 Select the welding system 12 5 2 2 Selecting the input logic 12 5 2 3 Main control signal standardisation 13 5 2 4 Selecting the JOB counting method 13 5 3 Permanently configurable standard signals 14 5 3 1 Enable start 14 5 3 2 Control voltage active 14 5 3 3 Inching mode 14 5 3 4 Operating modes 15 5 3 5 Pulse process 15 5 3 6 JOB selection 15 5 4 Special signals 16 5 4 1 Configuration...

Page 4: ...ith the positioning device 32 5 11 1 Ignition time TZ Zünd 32 5 11 2 TZ Set 32 5 11 3 Arc interruption time TZ LIBO 33 5 11 4 Return time TZ Reset 33 5 11 5 Output of analogue values 34 6 The diagnostics interface 35 6 1 PC system requirements 35 6 2 Commissioning 35 6 3 Scope of diagnostics 35 7 Overview of plug jumper configurations 36 7 1 Operating modes start machine functions 38 7 2 JOB selec...

Page 5: ...he 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 CAUTION Working and operating procedures which must be followed p...

Page 6: ...erve Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exit the menu 4 s 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: ...r 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 The regulations regarding work safety and accident prevention for the respective country Setting up and operating the machi...

Page 8: ... from our range of products Only insert and lock accessory components into the relevant connection socket when the machine is switched off 3 1 Applications 3 1 1 Automation Automated robot controlled welding production with the digital robot power sources 3 2 Revision Revision Date Change 1 0 XX XX XXXX Draft version 1 1 01 03 2015 MAG superPuls and lift arc signals selection of advanced JOBs EWM ...

Page 9: ... non permitted conversion work not specifically authorised by the manufacturer The original copy of the declaration of conformity is enclosed with the unit 3 4 3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be used in environments with an increased electrical hazard 3 4 4 Service documents spare parts and circuit diagrams D...

Page 10: ...ation on digital power sources in the Phoenix alpha Q MIG MAG and Tetrix forceTig WIG machine series The same RINT X12 can be used for both power sources To change from a Phoenix alpha Q to a Tetrix forceTig based welding system it is merely necessary to change the configuration The RINT X12 has numerous options for actuation and these are supported in full by the PC300 NET welding parameter softw...

Page 11: ...al with external assembly the parallel cabling for the actuation signals should be kept as short as possible to avoid interference in the signal lines The connection line on the system bus is designed to be interference free for a specific length and is therefore better suited to bridging the required connection length to the power source The RINT X12 is ready for communication after the system bu...

Page 12: ...nce the system starts In this case the system must be switched off and the jumper setting corrected JP 16 Input logic X Phoenix alpha Q welding system expected Tetrix forceTig welding system expected 5 2 2 Selecting the input logic Jumpers 4 and 5 are used to modify the physical logic of the input signals to the automation control The RINT X12 supports both a positive and a negative actuation logi...

Page 13: ... A 0 to nominal system current factory setting 1 1 The nominal system current comes from the type designation and is automatically detected by the RINT X12 when the system is switched on 5 2 4 Selecting the JOB counting method The counting method for welding characteristics JOBs usually is 1 to 255 The values are stored in an 8 bit field so that in general 256 JOBs can be selected System displays ...

Page 14: ... accepted signal X10 3 is not required 5 3 2 Control voltage active For operation with nominal values via analogue control voltages jumper JP7 can be set as a fixed value This enables control signal operation to be set permanently without external wiring except for analogue voltages Alternatively the signal can also be actuated by an external signal JP7 Operating mode No external control signals a...

Page 15: ...fined on the RINT X12 Alternatively the signal can also be actuated by an external signal JP11 Operating mode Standard welding is active This signal can be overridden by the external X5 5 signal Factory setting X Pulse welding is active an external X5 5 signal is not necessary In Tetrix forceTig systems thermal pulsing is controlled with this signal 5 3 6 JOB selection The RINT X12 can be permanen...

Page 16: ...led For example a process can be started with a start program but ended without an end program or vice versa The advanced JOB mode disables the input for control signal mode the control signal mode can then no longer be selected 5 5 Standard signals for free actuation The signals described below should be actuated using external signals as required The signal to be created is based on the pre sele...

Page 17: ...e modes to be actuated in different processes The process DC or AC determines the pre selection of the possible actuations An actuation that is not applicable is automatically overridden X5 5 X4 5 Possible process Operating mode Signal not active Signal not active DC AC No pulse mode active Signal active Signal not active DC AC superPuls is active pulsing alternates between main and secondary prog...

Page 18: ...sma gas X10 6 Operating mode Signal not active Blow out plasma gas valve not actuated Signal active Blow out plasma gas valve actuated 5 5 10 Inching The signal controls the wire inching mode selected on input X10 9 X10 7 Operating mode Signal not active Wire inching is ended Signal active Selected wire inching mode is carried out With Tetrix forceTig systems without cold wire the signal has no fu...

Page 19: ...t active Cold wire is stopped Signal active Cold wire is started The signal cannot be actuated during the welding process The effect of the signal depends on the machine equipment In special cases this signal has no function 5 5 13 tigSpeed on With Tetrix forceTig systems with tigSpeed equipment input X5 8 starts the tigSpeed oscillation X10 11 Operating mode Signal not active Oscillation is stopp...

Page 20: ...ssible from RINT X12 JOBs can be selected using control units for example Signal active JOB selection is carried out via RINT X12 This signal can be permanently configured using jumper JP12 5 6 2 JOB selection For JOB number preselection inputs X9 3 to X9 10 are used Depending on the configuration of JP3 this enables the selection of 255 or 256 JOBs When configuring the possibility to select 256 J...

Page 21: ...meters of the working points can be modified with a control panel or more comfortable by using the parameter software PC300 NET In program mode the following parameters are assigned to each working point Process System type Parameter MIG MAG Phoenix alpha Q Wire speed arc length correction dynamic correction operating mode and welding type TIG Tetrix forceTig Welding current cold wire speed operat...

Page 22: ...ent for pulse modes 0 10 V equivalent to 0 to maximum value in A according to the chosen nominal value standardisation TIG Tetrix forceTig X6 6 Nominal value for the pulse time frequency depending on the pulse mode Thermal pulsing 0 10 V equivalent to min freq to max freq Pulse length Metallurgical pulsing 2 TIG Tetrix forceTig X6 7 Nominal value for the pause time balance depending on the pulse m...

Page 23: ...and lower limits can be set in the PC300 theses parameters refer to the expert model constants With the previous RINT X11 control it was necessary to activate the signal for control signal mode and select program number 0 With RINT X12 it is no longer necessary to additionally select program 0 As a special feature control signal default settings by an alternative control such as Expert 2 0 or by a...

Page 24: ... activated at the beginning of the process it is switched on automatically The gas cannot be deactivated while a process is running if this is necessary the gas is shut off automatically when the process is switched off This corresponds to a gas post flow duration of 0 Cold wire in control in Tetrix forceTig systems enables any function to be carried out in the process The cold wire behaves in the...

Page 25: ...witching duration approx 200 ms As long as an error persists When switching on thy system after initialisation the signal is activated Signals activated Signal X7 6 to X7 4 System ready for welding X7 6 to X7 5 System not ready for welding 5 8 3 Sticking The signal displays any sticking of the welding wire onto the workpiece via the internal detection system This signal should be evaluated using a...

Page 26: ...It is used by positioning equipment as an additional trigger signal when using the current start and end programs in the non latched special operating mode These are normally used for pre heating or for treating the end of the seam Signals switched on Signal X8 6 on X8 4 Main current phase active X8 6 on X8 5 Main current phase not active 5 8 7 Workpiece touch detection This signal is used to dete...

Page 27: ...be used for the Tetrix forceTig series Signals switched on Signal X8 12 on X8 10 Arc auxiliary process detected X8 12 on X8 11 Arc auxiliary process not detected 5 8 9 Process signals diagram To explain the process signals the non latched special operating mode is shown below For the non latched operating mode the start program Pstart and end program Pend therefore no longer apply Figure 5 2 ...

Page 28: ...utput Parameter Standardisation X11 1 Welding voltage 0 10 V equivalent to 0 to 100 V process voltage X11 3 Welding current 0 10 V equivalent to 0 to 1000 A process current of the main arc The analogue output signals are updated with an average time constant of approx 40 ms and are only used for display purposes For faster signal processing the signals of the interface for mechanised welding can b...

Page 29: ...rocess 5 9 2 TANDEM operation only Phoenix alpha Q This function is available as a software option and in Phoenix alpha Q systems permits the control of one power source in each case for TANDEM systems 2 RINT X12 are required The X5 7 input signal is used to determine which power source is subordinate in the TANDEM combination Signals switched on Signal Signal active Power source takes over master...

Page 30: ...o avoid errors being detected from transient procedures which are common at the start and end of the process There is a single tolerance value available for each of the following welding voltage welding current and wire speed These can each be used to set a permissible percentage deviation from the current nominal value The motor current is set as an absolute value A response speed can be set for ...

Page 31: ...s switched on Signal X8 1 on X8 3 Welding voltage outside the tolerances X8 2 on X8 3 Welding voltage ok X8 4 on 8 6 Welding current outside the tolerances X8 5 on 8 6 Welding current ok X8 7 on X8 9 Wire speed outside the tolerances X8 8 on X8 9 Wire speed ok X8 10 on X8 12 Motor current outside the tolerances X8 11 on X8 12 Motor current ok ...

Page 32: ...nition process is very important during the process start phase especially with tandem processes with more than one power source The ignition phase is evaluated using an adjustable ignition time A successful ignition process is detected if a stable flow of current occurs for more than the set time period after ignition The I 0 signal is saved in this phase However if there is no ignition process f...

Page 33: ...or message The arc interruption monitoring can be shut down by setting TZ LIBO to the value 0 The diagram shows the detection of an arc interruption Figure 5 5 Legend Description A Short misfire within the detection period B Start signal C Internal start D Start of arc interruption detection E Expiry of memory time for I 0 signal F Automatic cut out and arc interruption error message 5 11 4 Return...

Page 34: ...t of analogue values For the output of welding voltage and welding current the RINT X12 has two analogue outputs as follows Output Parameter Standardisation X11 1 Welding voltage 0 10 V equivalent to 0 to 100 V process voltage X11 3 Welding current 0 10 V equivalent to 0 to 1000 A process current of the main arc ...

Page 35: ...ble item no 094 013051 XXXXX When using a RINT X12 ATCASE the adapter cable is not necessary as the connection cable can be inserted directly into the casing Jumper 17 must be plugged in for operation Start the program use the Windows Device Manager to identify and set the assigned COM port The diagnostics are now ready for use 6 3 Scope of diagnostics Various information can be determined using t...

Page 36: ... is set X Start signal is always accepted no X10 3 signal required 7 Control voltage active default setting No external control signals are accepted except when overriding by means of signal X10 4 factory setting X External control signals are always accepted no external X10 4 signal required 8 Inching mode default setting Inching by means of a ramp function which can be overridden by the external...

Page 37: ...ernal X9 11 signal required 13 Advanced JOB mode No advanced JOB mode X Advanced JOB mode is enabled 14 Special signals active The relays are used for the monitoring function X The relays are used for process signals 15 Reserved 16 Selecting the welding system Tetrix forceTig welding system expected X Phoenix alpha Q welding system expected 17 Diagnostics programming interface switching Firmware p...

Page 38: ...x forceTig Active master power source assignment Phoenix alpha Q X5 8 n c X10 1 0 V 4 X10 2 24 V 1 X10 4 Control voltage Digital input See 5 3 4 Operating modes chapter X10 3 Enable start Digital input Active enable process X10 5 Gas test 1 Digital input Active gas test 1 on X10 6 Gas test 2 blow out Digital input Active gas test 2 on blow out machine X10 7 Inching motor on Digital input Active in...

Page 39: ...JOB bit 6 Digital input active high X9 10 JOB bit 7 Digital input active high MSB X9 11 JOB selection Digital input See 5 3 6 JOB selection chapter X9 12 n c 7 3 Program selection Digital inputs X4 8 pole Pin no Function Meaning Signal form for RINT X12 Standardisation logic X4 1 Program bit 0 Digital input LSB Active high Prog 0 15 X4 2 Program bit 1 Digital input Active high X4 3 Program bit 2 D...

Page 40: ...log input 0 10 V Thermal pulsing 0 01 s to 10 00 s Metallurgical pulsing 1 X6 7 Tetrix forceTig only Thermal pulsing Pause time Metallurgical pulsing Balance Analog input 10 V Thermal pulsing 0 01 s to 10 00 s Metallurgical pulsing 1 to 100 X6 8 Tetrix forceTig only Depending on the configuration nominal value for hot wire hot wire oscillation frequency or filler wire down slope value Analog input...

Page 41: ... output 1 2 3 I 0 X7 2 I 0 Relay output 1 1 3 I 0 X7 3 I 0 Relay output 1 X7 4 ready for welding Relay output 2 5 6 not ready X7 5 ready for welding Relay output 2 4 6 ready X7 6 ready for welding Relay output 2 X7 7 Sticking Relay output 3 8 9 no fusing X7 8 Sticking Relay output 3 7 9 fusing X7 9 Sticking Relay output 3 2 X7 10 Error Relay output 4 11 12 error X7 11 Error Relay output 4 10 12 no...

Page 42: ... active Tetrix forceTig X8 6 Relay output 6 X8 7 Wire speed monitoring or workpiece detection Phoenix alpha Q Workpiece detection Tetrix forceTig Relay output 7 8 9 wire speed OK Phoenix alpha Q 8 9 electrode cold wire has not been touched Tetrix forceTig X8 8 Relay output 7 7 9 wire speed error Phoenix alpha Q 7 9 electrode cold wire touched workpiece Tetrix forceTig X8 9 Relay output 7 X8 10 Mot...

Page 43: ...ine 3 Inverter inverter emergency stop circuit temperature error 1 No automatic reset 4 Low coolant level No switch off machine 5 Wire feed error Yes 6 Shielding gas error Yes 7 Secondary circuit overvoltage No switch off machine 8 Protective conductor error No switch off machine 9 System quick stop 1 Yes 10 Arc break error Yes 11 Process ignition error Yes 14 Wire feeder not detected Yes 15 Wire ...

Page 44: ...e 11 System quick stop Yes 12 Open circuit voltage reduction error No switch off machine Errors specific to AC systems 36 Collision sensor according to S Sign No switch off machine 37 AC unit temperature error No automatic reset 32 35 38 39 Special error contact service No switch off machine Errors specific to plasma welding systems 16 Pilot arc current error Yes 17 Cold wire error Yes 18 Plasma g...

Page 45: ... 00001 00 01 Range of metallurgical pulsing extended to cover 50 Hz to 15 kHz This function is only guaranteed if the version of the Tetrix power source software is at least 0 2 D 0 With older software versions it will be scaled automatically for the range up to 2500 Hz 0 0 5 0 042 00973 00001 02 superPuls and lift arc signals for Phoenix alpha Q power sources from version 0 6 5 0 and MM tigSpeed ...

Page 46: ...unction in which contact is detected 0 0 5 0 Inching mode System External In MAG systems inching is carried out with the system ramp from 1 0 to 6 0 m min Inching is carried out using the analogue WF value to create individual inching functions 0 0 5 0 Suppress missing wire feeder show error suppress error For MAG systems a WF mechanism is required for the process by default An error caused by a m...

Page 47: ...ols the hot wire current The control voltage controls the oscillation frequency for tigSpeed The control voltage controls the down slope value of the filler wire for thermal pulsing mode 0 0 5 0 Control voltage scaling Value Defines the input scaling for the hot wire current 0 0 5 0 Filler wire control signal scaling 10 0 m min 24 0 m min Defines the scaling when selecting the filler wire resoluti...

Page 48: ... 6 5 NC 6 6 NC 6 7 NC 6 8 NC 6 9 NC 7 0 Optional DV Umschaltung choice wire feeder 7 1 Reset Fehler reset error 7 2 10VDC Uref 7 3 0V 7 4 DV 7 5 9 9V 9 9V Korrektur correction 7 6 40V 40V Dynamik dynamic 7 7 NC 7 8 NC 7 9 NC 80 Uist voltage over Prozess aktiv process active 81 82 83 Iist current over Hauptstrom main current 84 Iist current over Hauptstrom main current 85 Iist current over Hauptstr...

Page 49: ...es 6 9 NC 7 0 Optional DV Umschaltung choice wire feeder 7 1 Reset Fehler reset error 7 2 10VDC Uref 7 3 0V 7 4 Hauptstrom main current 7 5 Kaltdrahtwert cold wire value 7 6 Absenkstrom low current 7 7 Pulsdauer pulse time 0 01s 10 00s Frequenz freqency 50 2500Hz 7 8 Pulspause pulse pause 0 01s 10 00s Balance balance 0 100 7 9 NC 80 Uist voltage over Prozess aktiv process active 81 82 83 Iist curr...

Page 50: ...0 6 5 Bit 1 6 6 Bit 2 6 7 Bit 3 6 8 NC 6 9 NC 7 0 Optional DV Umschaltung choice wire feeder 7 1 Reset Fehler reset error 7 2 10VDC Uref 7 3 0V 7 4 NC 7 5 NC 7 6 NC 7 7 NC 7 8 NC 7 9 NC 80 Uist voltage over Prozess aktiv process active 81 82 83 Iist current over Hauptstrom main current 84 Iist current over Hauptstrom main current 85 Iist current over Hauptstrom main current 86 DVist wire speed ove...

Page 51: ...2 5 7 Job Bit 3 5 8 Job Bit 4 5 9 Job Bit 5 6 0 Job Bit 6 6 1 Job Bit 7 6 2 Jobanwahl enable job control 6 3 NC 6 4 Bit 0 6 5 Bit 1 6 6 Bit 2 6 7 Bit 3 6 8 Pulsmodus pulse modes 6 9 NC 7 0 Optional DV Umschaltung choice wire feeder 7 1 Reset Fehler reset error 7 2 10VDC Uref 7 3 0V 7 4 NC 7 5 NC 7 6 NC 7 7 NC 7 8 NC 7 9 NC 80 Prozess aktiv process active 81 82 83 Hauptstrom main current 84 Hauptst...

Page 52: ...Appendix A Overview of EWM branches 52 099 000769 EW501 29 06 2015 12 Appendix A 12 1 Overview of EWM branches ...

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