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Design and function

Installation

099-004854-EW501

19.02.2014

27

5.2

Installation

WARNING

Risk of accident due to improper transport of machines that may not be lifted!
Do not lift or suspend the machine! The machine can fall down and cause injuries! 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 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.

• Safe operation of the machine must be guaranteed at all times.

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.

• Comprehensive descriptions can be found in the operating instructions for the relevant

accessory components.

• Accessory components are detected automatically after the power source is switched on.

5.3

Machine cooling

To obtain an optimal duty cycle from the power components, the following precautions should be
observed:

•

Ensure that the working area is adequately ventilated.

•

Do not obstruct the air inlets and outlets of the machine.

•

Do not allow metal parts, dust or other objects to get into the machine.

5.4

Workpiece lead, general

CAUTION

Risk of burns due to incorrect 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 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!

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Содержание Tetrix 350

Страница 1: ...tructions Welding machine Tetrix 350 AC DC Synergic Plasma 099 004854 EW501 19 02 2014 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warranty www e...

Страница 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...

Страница 3: ...cuit diagrams 17 3 2 5 Calibration Validation 17 4 Machine description 18 4 1 Front view 18 4 2 Rear view 20 4 3 Machine control Operating elements 22 4 3 1 Function sequence 24 5 Design and function...

Страница 4: ...cal cup formation 50 5 9 11 Function sequences operating modes 51 5 9 11 1 Explanation of symbols 51 5 9 11 2 Non latched mode 52 5 9 11 3 Latched mode 53 5 9 11 4 TIG spotArc 54 5 9 11 5 Spotmatic 56...

Страница 5: ...5 13 4 Manual remote control RTP2 19POL 82 5 13 5 RTP3 spotArc 19POL manual remote control 82 5 13 6 Manual remote control RT AC 1 19POL 82 5 13 7 Manual remote control RT PWS 1 19POL 83 5 13 8 Foot...

Страница 6: ...st for rectifying faults 101 7 2 Machine faults error messages 103 7 3 Resetting welding parameters to the factory settings 105 7 4 Display machine control software version 106 7 5 General operating p...

Страница 7: ...Contents Notes on the use of these operating instructions 099 004854 EW501 19 02 2014 7...

Страница 8: ...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...

Страница 9: ...ess Do not press 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...

Страница 10: ...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...

Страница 11: ...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 prev...

Страница 12: ...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...

Страница 13: ...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...

Страница 14: ...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...

Страница 15: ...ge 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 redu...

Страница 16: ...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 am...

Страница 17: ...d 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 electrical hazar...

Страница 18: ...04854 EW501 19 02 2014 4 Machine description NOTE The maximum possible machine configuration is given in the text description If necessary the optional connection may need to be retrofitted see Access...

Страница 19: ...ocket Plasma welding torch nozzle potential 9 Connection socket welding current TIG Plasma welding current connection 10 5 pole connection socket welding torch control lead 11 G1 4 shielding gas conne...

Страница 20: ...Machine description Rear view 20 099 004854 EW501 19 02 2014 4 2 Rear view Figure 4 2...

Страница 21: ...re reducer 5 G1 4 connecting nipple shielding gas connection Connection to the pressure reducer 6 Cooling air outlet 7 Pilot current connection socket Plasma welding torch nozzle potential 8 Mains con...

Страница 22: ...and safe welding Aluminium magnesium alloys AC welding with trapezoidal current output wave form An all rounder suitable for most applications Aluminium silicon alloys AC welding with sinusoidal curre...

Страница 23: ...dicators Collective interference signal light Water deficiency signal light welding torch cooling Excess temperature signal light safety sign signal light 10 Display switching button Material thicknes...

Страница 24: ...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 from AMP to AMP Pulse tim...

Страница 25: ...ctory setting Optimisation of cleaning effect and fusion penetration characteristics Balance fast TIG DC pulses Setting range 1 to 99 1 increments 13 Alternating current frequency TIG AC 50 Hz to 200...

Страница 26: ...e not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by turning in clockwise direction if necessary Risk from electrical c...

Страница 27: ...d lock accessory components into the relevant connection socket when the machine is switched off Comprehensive descriptions can be found in the operating instructions for the relevant accessory compon...

Страница 28: ...etwork has to be suitable for operating devices according to protection class 1 5 5 1 Mains configuration NOTE The machine may be connected to a three phase system with four conductors and an earthed...

Страница 29: ...unit Figure 5 2 Item Symbol Description 0 1 8 pole connection socket Cooling unit control lead 2 4 pole connection socket Cooling unit voltage supply 3 Cooling module Control and supply lead to the we...

Страница 30: ...he connection between the welding machine and the GMU is created using the supplied gas connection lines with G 1 4 crown nuts connected on both sides The GMU can be used for plasma or TIG welding Ada...

Страница 31: ...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...

Страница 32: ...ter 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...

Страница 33: ...the gas manufacturer and in any relevant regulations concerning the use of compressed air Place shielding gas cylinders in the holders provided for them and secure with fixing devices Avoid heating th...

Страница 34: ...ylinder bracket Secure the shielding gas cylinder using a securing chain NOTE Before connecting the pressure regulator to the gas cylinder open the cylinder valve briefly to expel any dirt Tighten the...

Страница 35: ...gas connection Connection to the pressure reducer Screw the connection coupling of the plasma gas line onto the G1 4 connecting nipple plasma gas connection Screw the connection coupling of the shield...

Страница 36: ...the shielding gas quantity to suit the welding task 5 7 4 3 Gas test Operating element Action Result 1 x Select gas test Gas pre flow time TIG signal light is on Shielding gas flows for approx 20 seco...

Страница 37: ...ma automation 1 6 mm 5 A to 100 A DC 132 Plasma automation 1 6 mm 5 A to 150 A DC 140 Manual plasma welding 3 2 mm 5 A to 40 A DC 150 Manual plasma welding 3 2 mm 5 A to 120 A AC NOTE All JOBs can be...

Страница 38: ...in addition to the Material thickness signal light the user is in program mode programs 1 15 see chap Welding programs If the JOB number signal light is on in addition to the Material thickness light...

Страница 39: ...button illuminates CAUTION Oxidation of the tungsten electrode To protect the tungsten electrode against oxidation carry out the following actions before switching off the power source Switch off the...

Страница 40: ...tly When using a gas cooled welding torch add a tube bridge to the coolant circuit see chapter Accessories NOTE Prepare welding torch according to the welding task in hand see operating instructions f...

Страница 41: ...g gas supply shielding gas cylinder for welding machine WARNING Incorrect handling of shielding gas cylinders Incorrect handling of shielding gas cylinders can result in serious and even fatal injury...

Страница 42: ...linder bracket Secure the shielding gas cylinder using a securing chain NOTE Before connecting the pressure regulator to the gas cylinder open the cylinder valve briefly to expel any dirt Tighten the...

Страница 43: ...e shielding gas quantity to suit the welding task 5 8 2 3 Gas test Operating element Action Result 1 x Select gas test Gas pre flow time TIG signal light is on Shielding gas flows for approx 20 second...

Страница 44: ...e 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 curre...

Страница 45: ...ameter setting in the functional sequence Figure 5 10 5 9 2 Conventional parameter setting in the functional sequence All welding parameters in the functional sequence can also be adjusted regardless...

Страница 46: ...g factory setting off conventional parameter setting NOTE 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...

Страница 47: ...Manual Select ignition optimisation Select and display material type or welding current polarity TIG Synergic Select material type welding current polarity is determined automatically TIG Manual Selec...

Страница 48: ...aterial thickness after approx 4 seconds If the Program number signal light is on in addition to the Material thickness signal light the user is in program mode programs 1 15 see chap Welding programs...

Страница 49: ...d 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 of app...

Страница 50: ...er value less ignition power 5 9 10 Optimal and fast spherical cup formation NOTE A conically ground tungsten electrode approx 35 is generally required to form an ideal spherical cup Operating element...

Страница 51: ...meters such as welding current sheet metal thickness gas pre flow time etc 5 9 11 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 I Current t Time Gas pre flows I...

Страница 52: ...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 th...

Страница 53: ...times for secondary current AMP or pulse edges 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 trig...

Страница 54: ...Yes Yes Yes Short 5 999 ms 1 ms No No No When selecting the spotArc operating mode the long interval is automatically preselected When selecting the Spotmatic operating mode the short interval is auto...

Страница 55: ...ss and hold torch trigger 1 The gas pre flow time elapses HF ignition pulses jump from the electrode to the workpiece the arc ignites The welding current flows and immediately assumes the value set fo...

Страница 56: ...r is used for process activation The process can be activated separately for each spot or permanently see chapter Advanced settings Separate process activation The welding process has to be reactivate...

Страница 57: ...carefully against the workpiece Incline the torch over the torch gas nozzle until there is a gap of approx 2 3 mm between the electrode tip and the workpiece Shielding gas flows in the set gas pre fl...

Страница 58: ...ime to the main current AMP NOTE Pressing torch trigger 1 starts the slope tS1 from main current AMP to secondary current AMP Releasing the torch trigger starts the slope tS2 from the secondary curren...

Страница 59: ...in standard 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 deactivat...

Страница 60: ...s 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 23 Operating element Action Result Select TIG pulses function Signal l...

Страница 61: ...Figure 5 24 Operating element Action Result Display Select kHz pulses Press the TIG pulses button until the signal light lights up in red Select balance Setting range 1 to 99 1 increments Select frequ...

Страница 62: ...time tpause pulse pause time Figure 5 25 5 9 13 5 AC special Application e g for welding thick metal sheets onto thin metal sheets Operating element Action Result Select TIG AC special Press the TIG...

Страница 63: ...his helps prevents the tungsten electrode sticking in the molten pool and the tungsten inclusions are reduced This is particularly useful in tacking and in spot welding Operating element Action Result...

Страница 64: ...ments 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 tr...

Страница 65: ...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 NAVIGAT...

Страница 66: ...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...

Страница 67: ...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...

Страница 68: ...rst increment Figure 5 29 ENTER EXIT NAVIGATION l 0 Figure 5 30 Display Setting selection Exit the menu Exit Torch configuration menu Set welding torch functions Setting the first increment Setting 1...

Страница 69: ...n an insulated surface Shielding gas connection During MMA welding open circuit voltage is applied at the shielding gas connection G connecting nipple Place yellow insulating cap on the G connection n...

Страница 70: ...with DC polarity Connection for workpiece lead Insert cable plug of the electrode holder into either the or welding current connection socket and lock by turning to the right Insert cable plug of the...

Страница 71: ...or which different polarities are stipulated by the manufacturer the welding current polarity can be switched easily on the control 5 10 3 1 Selection and adjustment Operating element Action Result Di...

Страница 72: ...Press until signal light comes on Set the alternating current balance Factory setting see displays 5 10 5 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased...

Страница 73: ...revent the electrode sticking Operating element Action Result Displays 1 x Select arcforcing welding parameter The signal light comes on in red Set arcforcing 40 rutile electrode types 0 basic electro...

Страница 74: ...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 and pulse function are defined Example Progr...

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

Страница 76: ...th conventional setting Figure 5 33 5 11 5 Accessories for switching over programs The user can change retrieve and save programs using the following components Programs Component Create and change Re...

Страница 77: ...using 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 progra...

Страница 78: ...However 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 t...

Страница 79: ...1 x JOB loaded machine switches back to Display mode The JOB can be customised as required Current value and JOB number displayed 5 12 4 Resetting an existing JOB to the factory setting Reset JOB Oper...

Страница 80: ...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...

Страница 81: ...rs 129 to 138 The first JOB can be set as required The following graphic gives an example with the settings for max JOBs available 5 and first available JOB 145 This gives the available JOBs 145 to 15...

Страница 82: ...table 5 13 4 Manual remote control RTP2 19POL Functions TIG MMA Infinitely adjustable welding current 0 to 100 depending on the preselected main current on the welding machine Pulse spot normal Freque...

Страница 83: ...bol Meaning Actuate foot operated remote control start welding process Operate foot operated remote control set welding current according to application Release foot operated remote control end weldin...

Страница 84: ...erating elements functions cannot be changed Welding process button Welding current polarity button Parameter values in the function sequence can be displayed but not changed 5 15 PC interface CAUTION...

Страница 85: ...her 5 16 1 Synchronisation via mains voltage 50Hz 60Hz NOTE This application relates to two types of synchronisation Synchronisation between a Tetrix series machine and a competitor machine Synchronis...

Страница 86: ...synchronisation interface connector plug to the 19 pole TIG interface for mechanised welding on the rear of a welding machine from the TETRIX series master HINWEIS The machine connected to the synchr...

Страница 87: ...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...

Страница 88: ...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...

Страница 89: ...ed settings 5 18 1 TIG non latched operating mode C version ENTER EXIT NAVIGATION l 0 Figure 5 38 Display Setting selection Exit the menu Exit Machine configuration Settings for machine functions and...

Страница 90: ...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 commissio...

Страница 91: ...can be displayed as percentages factory setting or absolute values on the machine display ENTER EXIT NAVIGATION l 0 Figure 5 40 Display Setting selection Exit the menu Exit Machine configuration Setti...

Страница 92: ...TER EXIT NAVIGATION l 0 Figure 5 41 Display Setting selection Exit the menu Exit Machine configuration part two Settings for machine functions and parameter display Ramp function Remote control RTF 1...

Страница 93: ...5 42 Display Setting selection Expert menu Slope time tS1 main current to secondary current Setting 0 00 s to 20 0 s factory setting 0 00 s Slope time tS2 secondary current to main current Setting 0 0...

Страница 94: ...welding parameters button and switch the machine on again at the same time NAVIGATION navigating in the menu Parameters are selected by pressing the welding parameters button Set or change the parame...

Страница 95: ...Design and function Menus and sub menus on the machine control 099 004854 EW501 19 02 2014 95 EXIT NAVIGATION ENTER l 0 Figure 5 43...

Страница 96: ...art currents Pro welding current display as a percentage of the main current factory setting Abs absolute welding current display Non latched operation C version on on off off factory setting Setting...

Страница 97: ...5 Expert menu AC mean value controller on on factory setting off off Switching option for welding current potential dc with TIG DC off Select option for TIG DC is blocked factory setting Serves to pr...

Страница 98: ...t the values in the machine configuration menu CPL Complete reset of all values and settings The reset is performed when leaving the menu EXIT Software version query example 07 System bus ID 0340 Vers...

Страница 99: ...es Functional test Welding current cables check that they are fitted correctly and secured Gas tubes and their switching equipment solenoid valve Gas cylinder securing elements 6 2 2 Monthly maintenan...

Страница 100: ...ng to European provisions guideline 2002 96 EG of the European Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal wast...

Страница 101: ...ow Check coolant level and refill if necessary Eliminate kinks in conduit system hose packages Reset automatic cutout of the coolant pump by activating Air in the coolant circuit see chapter Vent cool...

Страница 102: ...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...

Страница 103: ...voltage 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 availa...

Страница 104: ...e The excess temperature of the high frequency blocking inductor has triggered Allow equipment to cool down Adjust processing cycle times if necessary Reset error via robot interface reset error Err 3...

Страница 105: ...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...

Страница 106: ...tware version query example 07 System bus ID 0340 Version number System bus ID and version number are separated by a dot 7 5 General operating problems 7 5 1 Interface for automated welding WARNING No...

Страница 107: ...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 whic...

Страница 108: ...00 DC 350 A 325 A 260 A 350 A 290 A 230 A Load alternation 10 min 60 DC 6 min welding 4 min pause Open circuit voltage with AC and DC 100 V Mains voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60...

Страница 109: ...antity meters 090 008081 00000 5POLE CEE 32A M Machine plug 094 000207 00000 2M G1 4 G3 8 DIN EN 559 Gas tube 2 m 092 000525 00001 GH 2X1 4 2M Gas hose 094 000010 00001 ADAP3 G1 4 G1 4 LKS Threaded ad...

Страница 110: ...ultaneous two sided welding according to the master slave principle both welding machines must be fitted with the 19 pole connection socket ON 19POL Note different retrofitting options depending on th...

Страница 111: ...e St 2 5 CrNi Fe St 2 4 6 CrNi Fe St 3 2 7 CrNi Fe St 3 2 8 CrNi Fe St 1 9 CrNi Fe St 1 6 10 CrNi Fe St 2 11 CrNi Fe St 2 4 12 CrNi Fe St 3 2 13 CrNi Fe St 3 2 14 CrNi Fe St 1 15 CrNi Fe St 1 6 16 CrN...

Страница 112: ...uZn 3 2 38 Cu CuZn 1 39 Cu CuZn 1 6 40 Cu CuZn 2 41 Cu CuZn 2 4 42 Cu CuZn 3 2 43 Cu CuZn 3 2 44 Cu CuZn 1 45 Cu CuZn 1 6 46 Cu CuZn 2 47 Cu CuZn 2 4 48 Cu CuZn 3 2 49 Cu CuZn 3 2 50 AlMg 1 51 AlMg 1...

Страница 113: ...i 1 75 AlSi 1 6 76 AlSi 2 77 AlSi 2 4 78 AlSi 3 2 79 AlSi 3 2 80 AlSi 1 81 AlSi 1 6 82 AlSi 2 83 AlSi 2 4 84 AlSi 3 2 85 AlSi 3 2 86 AlSi 1 87 AlSi 1 6 88 AlSi 2 89 AlSi 2 4 90 AlSi 3 2 91 AlSi 3 2 92...

Страница 114: ...3 2 121 Al99 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 FeSt 2 4 181 CrNi F...

Страница 115: ...Appendix B Overview of EWM branches 099 004854 EW501 19 02 2014 115 11 Appendix B 11 1 Overview of EWM branches...

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