EWM Tetrix 150 Synergic Plasma Operating Instructions Manual Download Page 27

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Design and function

Notes on the installation of welding current leads

099-007021-EW501

29.07.2015

Use an individual welding lead to the workpiece for each welding machine!

Figure 5-2

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.

Figure 5-3

Summary of Contents for Tetrix 150 Synergic Plasma

Page 1: ...ting instructions EN Welding machine Tetrix 150 Synergic Plasma 099 007021 EW501 29 07 2015 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm grou...

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 m...

Page 3: ...sequence 22 5 Design and function 24 5 1 General 24 5 2 Machine cooling 25 5 3 Workpiece lead general 25 5 4 Transport and installation 25 5 5 Notes on the installation of welding current leads 26 5...

Page 4: ...on 60 5 11 15 Torch mode and up down speed setting 61 5 11 15 1Standard TIG torch 5 pole 62 5 11 15 2TIG up down torch 8 pole 64 5 11 15 3Potentiometer torch 8 pole 66 5 11 15 4Configuring the TIG pot...

Page 5: ...s 92 6 2 1 1 Visual inspection 92 6 2 1 2 Functional test 92 6 2 2 Monthly maintenance tasks 92 6 2 2 1 Visual inspection 92 6 2 2 2 Functional test 92 6 2 3 Annual test inspection and testing during...

Page 6: ...e 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 i...

Page 7: ...rve 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 Exi...

Page 8: ...hocks 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 Connection cables and leads must be free of faults Swit...

Page 9: ...accidents if these safety instructions are not observed Non observance of these safety instructions is potentially fatal Carefully read the safety information in this manual Observe the accident preve...

Page 10: ...currents Stray welding currents can destroy protective earth conductors damage equipment and electronic devices and cause overheating of components leading to fire Make sure all welding leads are sec...

Page 11: ...ard The user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the user must consider the foll...

Page 12: ...itable for transport by hand only The machine may not be lifted by crane or suspended CAUTION Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself d...

Page 13: ...amage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambient conditions Insufficient ventilation results in a r...

Page 14: ...h 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 vic...

Page 15: ...is enclosed with the unit 3 2 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 elect...

Page 16: ...Machine description Front view 16 099 007021 EW501 29 07 2015 4 Machine description 4 1 Front view Figure 4 1...

Page 17: ...current TIG Plasma welding current connection 7 Connection socket welding current with DC polarity Connection for workpiece lead 8 Pilot arc button with signal light Signal light off pilot arc off Sig...

Page 18: ...Machine description Rear view 18 099 007021 EW501 29 07 2015 4 2 Rear view Figure 4 2...

Page 19: ...e machine Reset triggered automatic cutout by pressing 4 Ignition type changeover switch See 5 9 7 Arc ignition chapter Liftarc contact ignition HF ignition 5 Mains connection cable See 5 7 Mains conn...

Page 20: ...ding synergic parameter setting TIG manual welding manual parameter setting 2 Tungsten electrode diameter Ignition optimisation key button 1 0mm 1 6mm 2 0mm 2 4mm 3 2mm 4 0mm or greater Optimum igniti...

Page 21: ...package button See 5 10 2 2 Setting the shielding gas quantity chapter 8 Error status indicators Collective interference signal light Water deficiency signal light welding torch cooling Excess temper...

Page 22: ...e MMA Setting ranges 0 00 s to 20 0 s 0 1 s increments 5 AMP Main current TIG pulse current I min to I max 1 A increments Main current MMA I min to I max 1 A increments 6 sec Pulse time slope time fro...

Page 23: ...ing ranges 0 00 sec to 40 0 sec 0 1 sec increments 12 Balance TIG kHz pulsing metallurgical pulsing Setting range 1 to 99 increments of 1 MMA pulse welding Setting range 1 to 99 increments of 1 13 Fre...

Page 24: ...he welding current connection If the welding current connections are not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by...

Page 25: ...ean the connections Fix the workpiece lead securely Do not use structural parts of the workpiece as a return lead for the welding current Take care to ensure faultless power connections 5 4 Transport...

Page 26: ...power sources without HF igniter MIG MAG for as long and as close as possible in parallel Lay the workpiece lead and hose package of power sources with HF igniter TIG for as long as possible in parall...

Page 27: ...29 07 2015 27 Use an individual welding lead to the workpiece for each welding machine Figure 5 2 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Alw...

Page 28: ...tion socket Cooling unit voltage supply 3 Cooling module Control and supply lead to the welding machine The cooling module and welding machine are connected using two leads Insert the control lead plu...

Page 29: ...uctions The resulting network has to be suitable for operating devices according to protection class 1 5 7 1 Mains configuration The machine may be connected to a three phase system with four conducto...

Page 30: ...addition to the Material thickness signal light the user is in program mode programs 1 15 See 5 13 Welding programs chapter If the JOB number signal light is on in addition to the Material thickness...

Page 31: ...ary end and hotstart currents Pro welding current display as a percentage of the main current factory setting Abs absolute welding current display 5 9 Plasma welding 5 9 1 Welding torch connection wit...

Page 32: ...Design and function Plasma welding 32 099 007021 EW501 29 07 2015 Figure 5 7...

Page 33: ...t Plasma welding torch nozzle potential 13 5 pole connection socket welding torch control lead Create the connection between the G1 4 shielding gas connecting nipple welding machine output and the G1...

Page 34: ...r G1 8 plug in nipple 8 G1 4 plasma gas connecting nipple welding machine output Connection to the welding torch or gas metering unit GDE Insert the plug on the welding current lead into the welding c...

Page 35: ...nipple plasma gas connection Connection to the pressure reducer 2 G1 4 connecting nipple shielding gas connection Connection to the pressure reducer Screw the connection coupling of the plasma gas li...

Page 36: ...150 plasma 3 2 mm needle up to 250 A Other JOBs can be added as follows See 5 14 Organising welding tasks Mode JOB Manager chapter It is only possible to change the basic welding parameters if No wel...

Page 37: ...n 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...

Page 38: ...o establish the coolant circuit See 9 Accessories chapter The TIG welding torch is to be equipped to suit the relevant welding task Fit suitable tungsten electrodes and an appropriate shielding gas no...

Page 39: ...rch into the welding current connection socket and lock by turning to the right Screw the connection coupling of the shielding gas line onto the G1 4 connecting nipple shielding gas connection Insert...

Page 40: ...ding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch...

Page 41: ...required amount of shielding gas on the pressure reducer about 4 15 l min depending on the current strength and the material 5 10 2 3 Gas test Operating element Action Result 1 x Select gas test Gas p...

Page 42: ...re used to select the welding 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 curr...

Page 43: ...ter setting in the functional sequence chapter Figure 5 14 5 11 2 Conventional parameter setting in the functional sequence All welding parameters in the functional sequence can also be adjusted regar...

Page 44: ...ting factory setting off conventional parameter setting 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 s...

Page 45: ...ights LED display the welding parameter selection It is only possible to change the basic welding parameters if No welding current is flowing and The key switch option is set to position 1 Operating e...

Page 46: ...ing current or sheet metal thickness Welding current and sheet metal thickness are displayed 5 11 6 Optimising the ignition characteristics for pure tungsten electrodes This parameter can be used to i...

Page 47: ...he machine will return automatically to the ready to operate status The expert menu includes functions and parameters which are either not set on the machine control or which do not require regular se...

Page 48: ...le and tungsten electrode tip onto the workpiece and press the torch trigger liftarc current flowing regardless of the main current set b Incline the torch over the torch gas nozzle to produce a gap o...

Page 49: ...meters such as welding current sheet metal thickness gas pre flow time etc 5 11 9 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 I Current t Time Gas pre flows I...

Page 50: ...ng the main current phase the welding current drops at the slope time set tS1 to the secondary current AMP After torch trigger 2 is released the welding current rises at the slope time set tS2 back to...

Page 51: ...Step 3 Press torch trigger 1 The main current drops with the set down slope time to the end crater current Iend minimum current Step 4 Release torch trigger 1 the arc extinguishes The set gas post flo...

Page 52: ...omatically preselected The user can change the interval in the Configuration menu See 5 19 Machine configuration menu chapter Selecting and setting TIG spotArc Operating element Action Result Signal l...

Page 53: ...e electrode to the workpiece the arc ignites The welding current flows and immediately assumes the value set for the ignition current Istart HF is switched off The welding current increases in the adj...

Page 54: ...chapter Figure 5 24 As an example the process is shown with HF ignition Arc ignition with lift arc is also possible however See 5 9 7 Arc ignition chapter Select the process activation type See 5 19...

Page 55: ...welding current increases in the set up slope time to the main current AMP Pressing torch trigger 1 starts the slope tS1 from main current AMP to secondary current AMP Releasing the torch trigger star...

Page 56: ...ard welding but during the main current phase there is a continual switching back and forth between the pulse and pause currents at the relevant times The pulse function can also be deactivated if nec...

Page 57: ...s With thermal pulses the pulse and pause times frequency up to 200 Hz and the pulse edges ts1 and ts2 are entered in seconds on the control Figure 5 28 Operating element Action Result Display Select...

Page 58: ...re 5 29 Operating element Action Result Select kHz pulses Press TIG pulses key button until signal light comes on in red Select balance Setting range 1 to 99 1 increments Select frequency Setting rang...

Page 59: ...activArc parameter Press until LED flashes Switch parameter on Switch parameter off Parameter setting The activArc parameter control can be adjusted specifically for the welding task panel thickness...

Page 60: ...elements such as torch triggers TT rockers or potentiometers can be modified individually via torch modes Explanation of symbols for operating elements Symbol Description Press torch trigger Tap torch...

Page 61: ...ns in the individual modes can be found in the tables for the corresponding torch types The welding process can of course be switched on and off in all modes using torch trigger 1 TT 1 ENTER EXIT NAVI...

Page 62: ...pping function Functions mode Operating elements Welding current On Off 1 factory set Secondary current Latched mode Standard torch with two torch triggers Diagram Operating elements Explanation of sy...

Page 63: ...lanation of symbols BRT 1 torch trigger 1 BRT 2 torch trigger 2 Functions mode Operating elements Welding current On Off 1 factory set Secondary current Secondary current tapping mode latched mode Wel...

Page 64: ...tions Mode Operating elements Welding current on off 1 factory set Secondary current tapping mode latched mode Increase welding current infinite adjustment up function Reduce welding current infinite...

Page 65: ...1 factory set Secondary current Secondary current tapping mode latched mode Increase welding current infinite adjustment up function Reduce welding current infinite adjustment down function Welding cu...

Page 66: ...nation of symbols BRT 1 torch trigger 1 Functions Mode Operating elements Welding current On Off 3 Secondary current tapping mode Increase welding current infinite adjustment Reduce welding current in...

Page 67: ...ad the safety information in this manual Observe the accident prevention regulations in your country Inform persons in the working area that they must observe the regulations CAUTION Test Before re co...

Page 68: ...first increment Figure 5 33 ENTER EXIT NAVIGATION l 0 Figure 5 34 Display Setting selection Exit the menu Exit Torch configuration menu Set welding torch functions Setting the first increment Setting...

Page 69: ...shielding gas connection G connecting nipple Place yellow insulating cap on the G connection nipple protects against electrical voltage and dirt 5 12 1 Connecting the electrode holder and workpiece le...

Page 70: ...p in green 5 12 3 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current a Hotstart time b Hotstart current I Welding current t Time 5 12 3 1 Ho...

Page 71: ...ing electrode types at low current strengths with a short arc in particular Operating element Action Result Displays 1 x Select arcforcing welding parameter The signal light comes on in red Set arcfor...

Page 72: ...dependent on the main current Signal light AMP on Setting range 1 to 200 increments of 1 142 ex works Pulse pause current selection percentage dependent on the main current Signal light AMP on Settin...

Page 73: ...efault setting the welding current can be infinitely adjusted across the entire range In programs 1 15 15 different welding currents incl operating mode and pulse function are defined Example Program...

Page 74: ...equivalent way Set welding current for the corresponding program e g 75 A in program 1 When connecting a potentiometer torch or up down torch or operating a standard torch in up down mode the program...

Page 75: ...th conventional setting Figure 5 38 5 13 5 Accessories for switching over programs The user can change retrieve and save programs using the following components Programs Component Create and change Re...

Page 76: ...ng the 4 main welding parameters welding process material type electrode diameter and seam type One program sequence can be defined in each JOB Up to 16 programs P0 to P15 can be set in each program s...

Page 77: ...wever it is a good idea to assign specific JOB numbers in the free memory JOB 128 to 256 for specific welding tasks Operating element Action Result Display x x Select JOB Manager mode Press until the...

Page 78: ...1 x JOB loaded machine switches back to Display mode The JOB can be customised as required Current value and JOB number displayed 5 14 4 Resetting an existing JOB to the factory setting Reset JOB Oper...

Page 79: ...x Switch from Load JOB to Reset All JOBs ON Reset all JOBs to factory settings OFF Do not reset JOBs 1 x All JOBs reset to factory settings machine switches back to Display mode Current value and JOB...

Page 80: ...depending on the preselected main current on the welding machine Pulse spot normal Pulse spot and break times are infinitely adjustable 5 15 4 Manual remote control RTP2 19POL Functions TIG MMA Infini...

Page 81: ...on TIG ActivArc welding is not possible in combination with the foot operated remote control Figure 5 39 Symbol Meaning Actuate foot operated remote control start welding process Operate foot operated...

Page 82: ...ENTER EXIT NAVIGATION l 0 Figure 5 40 Display Setting selection Exit the menu Exit Machine configuration part two Settings for machine functions and parameter display Ramp function Remote control RTF...

Page 83: ...ation for master slave operation D Input no c IGRO Current flows signal I 0 maximum load 20mA 15V 0V welding current flowing E R Input Output Not Aus Emergency stop for higher level shut down of the p...

Page 84: ...cification for main current 0 10V 0V Imin 10V Imax 5 D Input Control value specification for secondary current 0 10V 0V Imin 10V Imax 6 J U Output Reference 0V 7 K Output Power supply 15V max 75mA 8 V...

Page 85: ...esults in equipment damage or faults in signal transmission The PC may be destroyed due to high frequency ignition pulses Interface SECINT X10USB must be connected between the PC and the welding machi...

Page 86: ...Design and function Machine configuration menu 86 099 007021 EW501 29 07 2015 EXIT NAVIGATION ENTER l 0 Figure 5 42...

Page 87: ...ercentage of the main current factory setting Abs absolute welding current display Non latched operation C version on on off off factory setting Setting for the primary setpoint value display Defines...

Page 88: ...inst the workpiece Torch cooling mode AUt automatic operation ex works on permanently switched on off permanently switched off Welding torch cooling system pre flow time Setting 1 60 min ex works 5 Ti...

Page 89: ...n with external control voltages signals off with machine control Software version query example 07 System bus ID 03A0 Version number System bus ID and version number are separated by a dot Only quali...

Page 90: ...nt such as the welding torch or the intermediate hose package AW has been changed The resistance value of the cables can be set directly or can be aligned by the power source In the delivery state the...

Page 91: ...ssure press the welding torch with the collet against a clean purged location on the workpiece and then press the torch trigger for approx 2 seconds A short circuit current will flow briefly which is...

Page 92: ...arts 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 6 1 General When used in the specified environmental c...

Page 93: ...an Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be collected separately The symbol depicting a was...

Page 94: ...ymbol Description Fault Cause Remedy Functional errors Insufficient coolant flow Check coolant level and refill if necessary Eliminate kinks in conduit system hose packages Reset automatic cutout of t...

Page 95: ...sary higher ignition energy Unstable arc Material inclusions in the tungsten electrode due to contact with filler material or workpiece Regrind or replace the tungsten electrode Incompatible parameter...

Page 96: ...necessary Warning code Possible cause Remedy 1 Machine excess temperature Allow the machine to cool down 2 Half wave failures Check process parameters 3 Welding torch cooling warning Check coolant lev...

Page 97: ...tage Switch machine off and on again inform the service department if the error continues Err 10 PE error Err 11 FastStop position Edge Acknowledge error signal 0 to 1 via robot interface if available...

Page 98: ...igh frequency blocking inductor has triggered Allow equipment to cool down Adjust processing cycle times if necessary Reset error via robot interface reset error Err 24 Pilot arc ignition error Check...

Page 99: ...nu 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 machi...

Page 100: ...ersion query example 07 System bus ID 03A0 Version number System bus ID and version number are separated by a dot 7 6 General operating problems 7 6 1 Interface for automated welding WARNING No functi...

Page 101: ...nt circuit 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 i...

Page 102: ...oad alternation 10 min 60 DC 6 min welding 4 min pause Open circuit voltage 98 V Mains voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 10 A Mains connecti...

Page 103: ...ing unit with 2 gas quantity meters 090 008077 00000 GDE2 1 Gas metering unit 090 S08077 01033 GDE3 Gas metering unit with 3 gas quantity meters 090 008081 00000 5POLE CEE 32A M Machine plug 094 00020...

Page 104: ...etrofit connection socket Accessory components and digital interfaces 092 001826 00000 ON Key Switch Optional retrofit kit for key switch 092 001828 00000 9 6 Computer communication Type Designation I...

Page 105: ...down weld 0 6 0 8 1 0 1 2 1 6 1 Reserved 2 CrNi 1 3 CrNi 1 6 4 CrNi 2 5 CrNi 2 4 6 CrNi 3 2 7 CrNi 3 2 8 CrNi 1 9 CrNi 1 6 10 CrNi 2 11 CrNi 2 4 12 CrNi 3 2 13 CrNi 3 2 14 CrNi 1 15 CrNi 1 6 16 CrNi...

Page 106: ...0 8 1 0 1 2 1 6 36 Fe St 3 2 37 Fe St 3 2 38 Fe St 1 39 Fe St 1 6 40 Fe St 2 41 Fe St 2 4 42 Fe St 3 2 43 Fe St 3 2 44 Fe St 1 45 Fe St 1 6 46 Fe St 2 47 Fe St 2 4 48 Fe St 3 2 49 Fe St 3 2 50 Cu 1 51...

Page 107: ...Zn 2 77 CuZn 2 4 78 CuZn 3 2 79 CuZn 3 2 80 CuZn 1 81 CuZn 1 6 82 CuZn 2 83 CuZn 2 4 84 CuZn 3 2 85 CuZn 3 2 86 CuZn 1 87 CuZn 1 6 88 CuZn 2 89 CuZn 2 4 90 CuZn 3 2 91 CuZn 3 2 92 CuZn 1 93 CuZn 1 6 9...

Page 108: ...3 2 121 Special 3 2 122 TIG manual TIG classic 123 Classic electrode 124 Reserved 125 Reserved 126 Reserved 127 Electrode JOB 128 Reserved 129 179 Free JOBs or SCO e g plasma 180 CrNi 2 4 181 CrNi 3 2...

Page 109: ...Appendix B Overview of EWM branches 099 007021 EW501 29 07 2015 109 11 Appendix B 11 1 Overview of EWM branches...

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