EWM Tetrix 152 RC Plasma CW GR Operating Instructions Manual Download Page 1

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Operating instructions

Power sources for automated applications

Tetrix 152 RC Plasma CW GR
Tetrix 352 RC Plasma CW GR
Tetrix 552 RC Plasma CW GR

099-008724-EW501

Observe additional system documents!

08.01.2012

Summary of Contents for Tetrix 152 RC Plasma CW GR

Page 1: ...ing instructions Power sources for automated applications GB Tetrix 152 RC Plasma CW GR Tetrix 352 RC Plasma CW GR Tetrix 552 RC Plasma CW GR 099 008724 EW501 Observe additional system documents 08 01...

Page 2: ...ther form of liability regardless of type shall be accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whethe...

Page 3: ...uit diagrams 14 4 Machine description quick overview 15 4 1 Tetrix 152 352 552 RC Plasma CW GR 15 4 1 1 Front view 15 4 1 2 Rear view 17 4 2 Machine control 19 4 2 1 Function sequence 21 4 3 Plasmadri...

Page 4: ...ks 50 6 2 2 Monthly maintenance tasks 50 6 2 3 Annual test inspection and testing during operation 51 6 3 Maintenance work 51 6 4 Disposing of equipment 52 6 4 1 Manufacturer s declaration to the end...

Page 5: ...l 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...

Page 6: ...scription Press Do not press Turn Switch l 0 Switch off machine l 0 Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display example wait 4s press Inter...

Page 7: ...s 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 Switchin...

Page 8: ...ith flammable material Connect welding leads correctly Risk of accidents if these safety instructions are not observed Non observance of these safety instructions is potentially fatal Carefully read t...

Page 9: ...suspend all conductive power source components like casing transport vehicle and crane frames so they are insulated Do not place any other electronic devices such as drillers or angle grinders etc on...

Page 10: ...he 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 following...

Page 11: ...d by crane or suspended CAUTION Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up Tilt resistance is guaranteed up to...

Page 12: ...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 reducti...

Page 13: ...3 1 3 TIG cold wire welding Cold wire welding is a variant of TIG welding featuring mechanically fed filler material With this process cold welding wire is melted without power in the arc of a tungst...

Page 14: ...ns improperly conducted repairs non observance of the deadlines for the repetition test and or non permitted conversion work not specifically authorised by the manufacturer The original copy of the de...

Page 15: ...4 Machine description quick overview 4 1 Tetrix 152 352 552 RC Plasma CW GR NOTE The maximum possible machine configuration is given in the text description If necessary the optional connection may n...

Page 16: ...erse cooling unit s protective contact socket back of machine 5 ROB XX2 pallet Transport pallet 6 Operating state signal lamp Lights up when the machine is ready for use 7 Operating problem signal lig...

Page 17: ...Machine description quick overview Tetrix 152 352 552 RC Plasma CW GR 099 008724 EW501 08 01 2012 17 4 1 2 Rear view 6 7 4 3 2 1 18 19 20 20 21 21 17 10 5 9 14 11 12 15 16 8 13 Figure 4 2...

Page 18: ...welding current Connection for workpiece lead 9 7 pole connection socket digital Wire feed unit connection 10 12 pole connection socket analogue Wire feed unit connection 11 X13 Insufficient wire sens...

Page 19: ...e tungsten electrode 2 Puls TIG pulses TIG automated pulses frequency and balance TIG pulses with times lights up in green fast TIG DC pulses with frequency and balance lights up in red 3 Gas test rin...

Page 20: ...0 9 Signal light for wire feeder 10 Signal light for hot wire power source 11 Operating mode spotArc Setting range for spot time 0 01 s to 20 0 s Non latched Latched 12 Display switching key button A...

Page 21: ...ately for non latched and latched Hotstart time 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...

Page 22: ...ents Percentage of the main current 11 sec Gas post flow time TIG Setting ranges 0 00 sec to 40 0 sec 0 1 sec increments 12 Balance TIG DC pulses 15 kHz Setting range 1 to 99 1 increments 13 Frequency...

Page 23: ...ve 4 Sensor voltage connection for the filler wire fusing detection 5 Contact pressure roller lock 6 Contact pressure setting hexagon socket 7 Drive rollers 8 Anticollision device connection 9 Reverse...

Page 24: ...ymbol Description 0 1 Insufficient wire sensor control lead plug 2 Wire feed rapid action closure Connection to wire source 3 Wire exit rapid action closure Connection to wire feed connection hose 4 I...

Page 25: ...njury due to moving parts The wire feed units are equipped with moving parts which can trap hands hair clothing or tools and thus injure persons Do not reach into rotating or moving parts or drive com...

Page 26: ...s The handles and brackets are suitable for transport by hand only The machine may not be lifted by crane or suspended CAUTION Installation site The machine must not be operated in the open air and mu...

Page 27: ...fferent coolants When changing the coolant the entire volume of liquid must be changed NOTE The disposal of coolant must be carried out according to official regulations and observing the relevant saf...

Page 28: ...it is earthed as stated in the operating instructions The resulting network has to be suitable for operating devices according to protection class 1 5 6 1 Mains configuration NOTE The machine may only...

Page 29: ...safety data sheets of the gasses used Make sure the working area is adequately ventilated CAUTION Faults in the shielding gas supply An unhindered shielding gas supply from the shielding gas cylinder...

Page 30: ...as connection Connection to the pressure reducer 2 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 co...

Page 31: ...he pressure regulator Fit the gas hose and G1 4 crown nut onto the relevant connection on the welding machine and fit the wire feed unit if present on this version 5 7 1 1 Gas test Operating element A...

Page 32: ...ON Use of unsuitable coolants results in damage to the welding torch Unsuitable coolants can cause damage to the welding torch Use only DKF 23E coolants observe temperature range of 0 C bis 40 C NOTE...

Page 33: ...connect coupling red Coolant return to cooling unit Insert the 23 pole control lead plug into the 23 pole connection socket analogue and lock Insert the welding current plug on the welding torch into...

Page 34: ...pter G1 4 G1 8 3 Adapter G1 8 cap 4 G1 4 plasma gas connecting nipple welding machine output Connection to the welding torch or gas metering unit GDE 5 Adapter G1 8 plug in nipple Screw adapter G1 4 G...

Page 35: ...n socket digital Wire feed unit connection 4 12 pole connection socket analogue Wire feed unit connection Insert 7 pole plug on the intermediate tube package lead into the 7 pole connection socket and...

Page 36: ...end of the wire insufficient wire is reached The process will not be shut down 2 X13 Insufficient wire sensor connection NOTE The cold wire supply is monitored by the Insufficient wire sensor which is...

Page 37: ...of unsuitable coolants results in damage to the welding torch Unsuitable coolants can cause damage to the welding torch Use only DKF 23E coolants observe temperature range of 0 C bis 40 C NOTE Observ...

Page 38: ...oolant flow monitoring After switching on the system monitoring sets in with a time delay of 30 s to allow for the system pressure to build up The flow rate depends on the torch used At the moment mon...

Page 39: ...39 5 12 Connection for workpiece lead 2 1 Figure 5 9 Item Symbol Description 0 1 Workpiece 2 Connection socket welding current Connection for workpiece lead Insert the cable plug on the work piece lea...

Page 40: ...sted individually using the PC300 NET software 5A to 80A Please note the relevant documentation of the accessory components 5 13 1 TIG automatic cut out NOTE The automatic cut out function will be tri...

Page 41: ...omponents into the relevant connection socket when the machine is switched off Damage due to incorrect connection Accessory components and the power source itself can be damaged by incorrect connectio...

Page 42: ...standard digital interface for mechanised applications optional retrofitting on the machine or external fitting by the customer Functions and signals Digital inputs start stop operating modes JOB and...

Page 43: ...face 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 c...

Page 44: ...gital 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 Connection between switching cabinet and power source...

Page 45: ...r sources 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 welding data monitoring and documentat...

Page 46: ...eads only The welding power sources feature a very high safety standard This safety standard is also maintained when peripheral equipment is connected for mechanised welding if this peripheral equipme...

Page 47: ...0 10 V 0 V Imin 10 V Imax G Output IGRO RELAY Current flows signal I 0 Contact closed current flows forms contact with signal D H Output UACTUAL Welding voltage measured on pin S 0 10 V 0 V 0 V 10 V 1...

Page 48: ...gnal name designation A Output PE Connection for cable screen B Input Brennerkoll Emergency shut down for anticollision device C Output 24V Brenn Emergency shut down for anticollision device 24 V D Ou...

Page 49: ...ich detects sticking when the feeder or wire has contact with the workpiece at the end of the process If the power source is used in combination with a TIG torch please note that the torch electrode h...

Page 50: ...Check torch hose package and power connections for exterior damage and replace or have repaired by specialist staff as necessary Check the wearing parts in the torch Mains supply lead and its strain...

Page 51: ...must only be repaired or modified by specialist skilled persons The warranty becomes null and void in the event of unauthorised interference Appoint only skilled persons for repair work trained servic...

Page 52: ...his purpose According to German law law governing the distribution taking back and environmentally correct disposal of electric and electronic equipment ElektroG from 16 03 2005 used machines are to b...

Page 53: ...ctional errors a Machine control without displaying the signal lights after switching on Phase failure check mains connection fuses a No welding performance Phase failure check mains connection fuses...

Page 54: ...cessary a Wire feed motor without supply voltage automatic cutout triggered by overloading Reset triggered fuse rear of the power source by pressing the key button a Kinked hose packages Extend and la...

Page 55: ...dary overvoltage Err 10 PE error Switch the machine off and on again If the error persists inform the service dept Err 11 FastStop position Edge Acknowledge error signal 0 to 1 via robot interface if...

Page 56: ...cy blocking inductor excess temperature The excess temperature of the high frequency blocking inductor has triggered Allow equipment to cool down Adjust processing cycle times if necessary Reset error...

Page 57: ...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...

Page 58: ...oad alternation 10 min 60 DC 6 min welding 4 min pause Floating voltage 79 V Mains voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 16 A 3 x 35 A 3 x 35 A...

Page 59: ...pressure regulator 096 000000 00000 DM H2 Constant pressure regulator 096 000001 00000 GH 2X1 4 2M Gas hose 094 000010 00001 2M G1 4 G3 8 DIN EN 559 Gas tube 2 m 092 000525 00001 ON Key Switch Optiona...

Page 60: ...BUSINT X11 PLASMA CAN OPEN ATCASE CAN OPEN industrial bus interface in casing 090 008689 00000 Tetrix BUSINT X11 PLASMA DEVICE NET ATCASE DEVICE NET industrial bus interface in casing 090 008690 0000...

Page 61: ...1 0VAC 2 20VAC 1 24VDC 3 0VDC 1 0V 3 15V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 TXD RS 12V 42VAC 42VAC 0V42 0V42 NC PE RXD RSGND 42V NC 0VAC NC PE X4 G 2 3 H 2 3 6 400V 415V 11 25V 2 0V 10 20V 230V Temp...

Page 62: ...0V1 0V1 5V1 5V1 15V 15V 15V 15V WR1 RD1 CS1 CS2 CLK1 CLK1 B1 A1 B2 BRT1 BRT2 IH Down Uref 10V 0V NC NC IH Up 0V P UD ein X5 1 X5 2 X5 3 X5 4 X5 5 X5 6 X5 7 X5 8 X5 9 X5 Robo Auto X5 10 X5 11 X5 12 X5...

Page 63: ...7 X22 6 X22 5 X22 4 X22 3 X22 2 X22 1 X22 10 Erdung BRT1 BRT2 IH Down Uref 10V 0V NC NC IH Up 0V P UD ein WA2 CS3 RD2 CLK2 0V NC NC CS4 0V 5V X5 1 X5 2 X5 3 X5 4 X5 5 X5 6 X5 7 X5 8 X5 9 X5 Robo Auto...

Page 64: ...h 10 3 W 12 2 R 13 1 2 24V g 10 3 9 Fehler 1 0 IGR0 i 10 3 m 4 3 2 0V d 10 3 7 Draht 4 24V 1 Sensor vorh p 5 4 b 13 2 o 5 4 1 2 Brennerkollition 1 1 24V Brenner Z 16 2 Y 16 2 2 3 4 5 6 7 8 9 10 11 12...

Page 65: ...7 X4 8 X4 9 X4 10 X4 11 X4 12 X4 4M7 BTF1 ohne C1 C7 2 3 4 5 6 7 8 9 10 11 12 1 A18 X2 X3 X2 2 X2 1 X3 4 X3 3 X3 2 X3 1 X2 6 X2 5 X2 4 X2 3 X2 2 X2 1 X2 7 X2 8 X1 1 X1 2 X1 3 X1 4 X1 5 X1 6 X1 7 X1 8...

Page 66: ...wire MMA 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 2...

Page 67: ...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 68: ...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 69: ...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 70: ...Appendix B Overview of EWM branches 70 099 008724 EW501 08 01 2012 12 Appendix B 12 1 Overview of EWM branches...

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