EWM TETRIX 1002 DC SYNERGIC Operating Instructions Manual Download Page 6

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Contents

Notes on the use of these operating instructions

Item No.: 099-000155-EWM01

Summary of Contents for TETRIX 1002 DC SYNERGIC

Page 1: ...propriate 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 0...

Page 2: ...y and a three year warranty Continual further development and optimisation has made us Germany s market leader in the manufacture of light arc welding machines We have manufacturing training and servi...

Page 3: ...ields CE EWM HIGHTEC WELDING GMBH D 56271 M NDERSBACH TYP ART SNR PROJ GEPR FT CONTROL Name of Customer company Adress Post code Place Country Stamp Signature of EWM distibutor Date of purchase Name o...

Page 4: ...ectrodes 29 5 3 3 TIG automatic cut out 29 5 3 4 TIG welding task definition 30 5 4 Key switch 31 5 5 Welding programs 31 5 5 1 Specifying max no of accessible programs 32 5 5 2 Example Program with s...

Page 5: ...7 7 3 1 Test equipment 57 7 3 2 Scope of the test 58 7 3 3 Visual inspection 58 7 3 4 Measuring the open circuit voltage 58 7 3 5 Measurement of insulation resistance 58 7 3 6 Measuring the leakage cu...

Page 6: ...Contents Notes on the use of these operating instructions 6 Item No 099 000155 EWM01...

Page 7: ...edge of the page 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 wit...

Page 8: ...ns 8 Item No 099 000155 EWM01 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...

Page 9: ...t prevention regulations of the relevant country e g in Germany BGV D 1 Check at regular intervals that users are working in a safety conscious way Damage due to the use of non genuine parts The manuf...

Page 10: ...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 fres...

Page 11: ...s To avoid injury and equipment damage the unit must only be repaired or modified by specialist skilled persons The warranty becomes null and void in the event of unauthorised interference Appoint onl...

Page 12: ...1 3 10 Set up and transport the machine on level solid ground Secure add on parts using suitable equipment Damage due to supply lines not being disconnected During transport supply lines which have n...

Page 13: ...s Keep the cooling air inlet and outlet clear Observe the minimum distance of 0 5 m from obstacles Installation site The machine must not be operated in the open air and must only be set up and operat...

Page 14: ...00 DC 750 A Load alternation 10min 60 DC 6 min welding 4min break Open circuit voltage 79 V 3 x 400V 25 to 20 Mains voltage tolerance 3 x 415V 25 to 15 Frequency 50 60Hz Mains fuse 3 x 63 A Mains conn...

Page 15: ...Technical data TETRIX 1002 DC SYNERGIC Item No 099 000155 EWM01 15 785 mm 1310 mm 660 mm 380 mm 495 mm 1110 mm Figure 3 1...

Page 16: ...Machine description TETRIX 1002 DC SYNERGIC 16 Item No 099 000155 EWM01 4 Machine description 4 1 TETRIX 1002 DC SYNERGIC 4 1 1 Front view 6 7 4 3 2 1 10 5 9 8 Figure 4 1...

Page 17: ...ference 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 excess mains voltage the signal light will go off ag...

Page 18: ...Machine description TETRIX 1002 DC SYNERGIC 18 Item No 099 000155 EWM01 4 1 2 Rear view 6 7 4 3 2 1 18 17 10 5 9 14 11 12 15 16 8 13 Figure 4 2...

Page 19: ...ed welding torch connection 6 12 pole connection socket For connecting Wire feed unit 7 7 pole connection socket For connecting Control lead Welding torch 8 12 pole connection socket For connecting Wi...

Page 20: ...ng 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 Tungsten electrode diamet...

Page 21: ...indicators Collective interference signal light see Operating problems chapter Water deficiency signal light welding torch cooling Excess temperature signal light 8 S S safety sign signal light 9 Disp...

Page 22: ...lue is specified by a control voltage 6 Pulse time slope time from AMP to AMP Value is specified by a control voltage and shown on the display 7 AMP Secondary current TIG Value is specified by a contr...

Page 23: ...ing task JOB All welding parameters specified here are the optimum settings for a variety of applications but they can also be modified individually The required welding current can be set as the shee...

Page 24: ...functional sequence Figure 5 4 5 2 2 Conventional parameter setting in the functional sequence All welding parameters in the functional sequence can also be adjusted regardless of the welding current...

Page 25: ...Action Result Display Switch off the welding machine Press and hold key button Switch on the welding machine Select the Configuration menu option 1 x Confirm Configuration menu option Select the opera...

Page 26: ...the welding parameter selection NOTE It is only possible to change the 3 basic welding parameters if No welding current is flowing and The key switch option is set to position 1 Operating element Acti...

Page 27: ...welding parameters can be displayed before nominal values during actual values or after welding hold values Left hand display Parameter Before welding nominal values During welding actual values After...

Page 28: ...e factory settings Factory setting Parameter value is on the optimum setting Reduce parameter value To restore the factory settings 5 3 TIG welding 5 3 1 Arc ignition 5 3 1 1 HF ignition Figure 5 6 Th...

Page 29: ...ect Ignition Characteristics parameter The signal lights for the selected electrode diameter and ignition current AMP flash for approx 5 seconds The parameter value can be optimised on the rotary tran...

Page 30: ...ng point can be set via up to 15 PROG 1 to PROG 15 freely definable programs using a robot interface RINTX11 BUSINTX10 for example The welding current operating mode and pulse function are stored in e...

Page 31: ...can be set saved and called up In program 0 default setting the welding current can be infinitely adjusted across the entire range In programs 1 15 15 different welding currents incl operating mode a...

Page 32: ...up on the welding torch Setting welding programs using the welding machine control Operating element Action Result Display VOLT JOB PROG Press button until signal light PROG comes on Welding current...

Page 33: ...ith 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 Ret...

Page 34: ...h JOB Up to 16 programs P0 to P15 can be set in each program sequence The user has a total of 249 JOBs available 121 of these JOBs are pre programmed A further 128 JOBs can be freely defined A distinc...

Page 35: ...memory JOBs 1 to 128 to the free memory JOBs 129 256 NOTE Define welding task which most closely matches the required application Operating element Action Result Display VOLT JOB PROG x x Select JOB...

Page 36: ...OB loaded machine switches back to Display mode The JOB can be customised as required Current value and JOB number displayed 5 6 4 Resetting an existing JOB to the factory setting Reset JOB Operating...

Page 37: ...OB PROG 3 x Switch from Load JOB to Reset All JOBs ON Reset all JOBs to factory settings OFF Do not reset JOBs VOLT JOB PROG 1 x All JOBs reset to factory settings machine switches back to Display mod...

Page 38: ...et as required NOTE 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 machi...

Page 39: ...h 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 128 JOBs Select Start JOB...

Page 40: ...n be found in the operating instructions for the relevant accessory components Accessory components are detected automatically after the power source is switched on The interfaces can be operated dire...

Page 41: ...6 1 4 3 Figure 5 10 Item Symbol Description 0 1 7 pole connection socket digital For connecting digital accessory components 2 Switching cabinet 3 Robot interface TETRIX RINT X11 4 Industrial bus int...

Page 42: ...rface serial D SUB connection socket 9 pole 2 Connection cable 9 pole serial 3 Windows PC 4 RC300 tablet PC 5 USB connection 6 SECINT X10 USB CAUTION Equipment damage or faults may occur if the PC is...

Page 43: ...digital For connecting digital accessory components 2 Windows PC 3 RC300 tablet PC 4 SECINT X10 USB 5 Connection cable 9 pole serial 6 PCINT X10 7 Connection cable 7 pole CAUTION Equipment damage or...

Page 44: ...ystem for digital PHOENIX and TETRIX machines 3 1 6 2 5 4 Figure 5 13 Item Symbol Description 0 1 7 pole connection socket digital For connecting digital accessory components 2 Windows PC 3 WELDQAS we...

Page 45: ...ol leads can cause damage to the power source and accessory components Use shielded control leads only A B C N P R S T U V D E F G H J K L M A B C D E F G H J K L M N P R S T U V PE Pulsen ein Pulsen...

Page 46: ...l I 0 Contact closed welding current flowing forms contact with signal D H Output UACTUAL Actual welding voltage measured on pin F 0 10 V 0 V 0 V 10 V 100 V J Output SYN_AE K Input SYN_AC Synchronisat...

Page 47: ...n collision protection 24 V D NC not used E NC not used F Output F hlerspannung see Chapter sensor voltage G NC not used H NC not used J NC not used K NC not used L NC not used M Input Gastest Shieldi...

Page 48: ...on the machine control or which do not require regular setting Figure 5 16 Display Setting selection Expert menu Slope time tS1 main current to secondary current Setting 0 00 s to 20 0 s factory setti...

Page 49: ...s Menus and sub menus on the machine control Item No 099 000155 EWM01 49 5 8 3 Machine configuration menu The machine menu includes basic functions such as torch modes display settings and the service...

Page 50: ...ersion on off factory setting Primary display for setpoint values right hand display vol priority display of the welding voltage bld priority display of the panel thickness Cold wire mode I 0 cold wir...

Page 51: ...ched off 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...

Page 52: ...n 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 electrici...

Page 53: ...ct 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 Clean the c...

Page 54: ...he right Where necessary use a third party strain relief in accordance with the manufacturer s instructions Insert the welding current plug of the WF unit in the welding current connection socket and...

Page 55: ...erating instructions for the cooling unit 2 1 Figure 6 3 Item Symbol Description 0 1 8 pole connection socket Cooling unit control lead 2 Connection socket 5 pole Cooling unit voltage supply Insert an...

Page 56: ...s 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 In the event of fai...

Page 57: ...ard but is also specific to arc welding equipment NOTE The former term of repetition test has been replaced due to a change in the corresponding standard with Inspection and testing during operation I...

Page 58: ...lding current sockets The voltmeter must display mean values and have an internal resistance 1 M In the case of step switch controlled devices set the maximum output voltage step switch Adjust the pot...

Page 59: ...nductor current 5 mA 2 Leakage current from the welding sockets separately to PE 10 mA 7 3 7 Measurement of protective conductor resistance Measure between the plug earthed contact and accessible live...

Page 60: ...en ordering spare parts please quote the machine type serial number and item number of the machine as well as the type designation and item number of the spare part We hereby certify that we have corr...

Page 61: ...rately This machine is to be placed for disposal or recycling in the waste separation systems provided for this purpose According to German law law governing the distribution taking back and environme...

Page 62: ...ll additional parts used by EWM but manufactured by other companies e g motors pumps fans torches etc Non reproducible software errors and parts subject to mechanical ageing are excluded from the warr...

Page 63: ...remote control remote control extension cable coolant etc The warranty does not apply to products that are damaged due to accidents misuse improper operation incorrect installation use of force disre...

Page 64: ...ce staff as necessary Error message Possible cause Remedy Speedometer error Check wire guide tube package Err 3 Wire feed unit not connected Switch off cold wire mode in the device configuration menu...

Page 65: ...menu Exit 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 ma...

Page 66: ...of the software versions only serves to inform the authorised service staff 0 1 0 1 Figure 9 2 Display Setting selection Exit the menu Exit Service menu Modifications to the service menu may only be...

Page 67: ...C 2 0VAC Temp 105 C 8 6 4 2 16 14 15 11 9 T1 10 0V 42V 1 25VAC 3 0VAC 3 3 A 3 3 B 3 3 C 12 3 M 12 3 L Q 16 4 42V RSGND RXD TXD RS 12V 0V Schirm X1 7 X1 6 X1 5 X1 4 X1 3 X1 2 X1 1 42V RXD RSGND TXD RS...

Page 68: ...4 10 X14 9 X14 8 X14 7 X14 6 X14 5 X14 4 X14 3 X14 2 X14 1 D Sub 15polig X11 1 X11 2 X11 3 X11 4 X11 5 X11 6 X11 7 X11 8 X11 9 X11 10 X11 11 X11 12 X11 13 X11 14 X11 15 X11 16 X11 17 X11 18 X11 19 X11...

Page 69: ...D C 4 A13 X2 4 X2 3 X2 2 X2 1 X2 L fter X3 8 X3 7 X3 6 X3 5 X3 4 X3 3 X3 2 X3 1 Inverter prim r X3 X16 18 X16 17 X16 16 X16 15 X16 14 X16 13 X16 12 X16 11 X16 10 X16 9 X16 8 X16 7 X16 6 X16 5 X16 4 X1...

Page 70: ...7 NC NC NC Tacho 0V Tacho Signal NC Schirm X9 A B C D E F G H J K L M N P R S T U V PE BR KOLL1 BR KOLL2 NC NC F hlerspannung NC NC NC NC NC Gastest Einf deln 0V codiert NC NC NC NC X10 1 Gastest 5 0...

Page 71: ...o B PE X20 PE O 9 1 A B C D E F G H J K L M PE NC NC Einf deln Brenner NC Einf deln Brenner Tacho VCC 5V Tacho Signal Tacho GND 0V NC M M X11 1A 2A 3A PE 1E 2E 3E HF1 3 A22 PE PE Ringkern 2 3 4 5 6 7...

Page 72: ...he event of unau thorised modifications improperly con ducted repairs non observance of the deadlines for the repetition test and or non permitted conversion work not specifically authorised by EWM Pa...

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