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Design and function

Notes on the installation of welding current leads

099-000141-EW501

12.01.2016

5.7

Notes on the installation of welding current leads

Incorrectly installed welding current leads can cause faults in the arc (flickering).

Lay the workpiece lead and hose package of 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 parallel with a distance of 20 cm to avoid HF sparkover.

Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences

Always keep leads as short as possible! For optimum welding results max. 30 m (welding lead +
intermediate hose p torch lead).

≈

20 cm

≥

20 cm

≥

20 cm

WIG / MIG / MAG

≥

20 cm

≈

20 cm

≥

20 cm

≈

20 cm

≥

20 cm

≈

20 cm

WIG

≥

20 cm

≥

20 cm

≥

20 cm

MIG / MAG

Figure 5-2

Содержание Tetrix 352 Synergic

Страница 1: ...EN Power source Tetrix 352 452 552 Synergic 099 000141 EW501 Observe additional system documents 12 01 2016 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details v...

Страница 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...

Страница 3: ...General 28 5 2 Installation 29 5 3 Machine cooling 29 5 4 Workpiece lead general 29 5 5 Welding torch cooling system 30 5 5 1 List of coolants 30 5 5 2 Maximal hose package length 30 5 6 Mains connec...

Страница 4: ...tivArc welding 59 5 21 Interfaces 60 5 21 1 Connecting the robot interface industrial bus interface 60 5 21 1 1 RINT X12 robot interface 61 5 21 1 2 BUSINT X11 industrial bus interface 61 5 21 2 Conne...

Страница 5: ...l software version 86 7 6 General operating problems 86 7 6 1 Interface for automated welding 86 7 7 Vent coolant circuit 87 8 Technical data 88 8 1 Tetrix 352 452 552 88 9 Accessories 89 9 1 Connecti...

Страница 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...

Страница 7: ...rs must observe Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time...

Страница 8: ...t sensitive to radiation accordingly The correct functioning of pacemakers may be affected obtain advice from a doctor if necessary Do not carry out any unauthorised repairs or modifications To avoid...

Страница 9: ...hand in the working area Thoroughly remove any residue of flammable substances from the workpiece before starting welding Only continue work on welded workpieces once they have cooled down Do not allo...

Страница 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...

Страница 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...

Страница 12: ...during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to EN 60974 A2 Set up and transport the machine on level solid ground Secure add on parts using suitable equipme...

Страница 13: ...s always lift all lifting eyes simultaneously When using retrofitted craning frames etc always use at least two lifting points positioned as far apart as possible observe option description Avoid any...

Страница 14: ...ties of dust acid corrosive gases or substances may damage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambie...

Страница 15: ...mproper usage The equipment must only be used in line with proper usage and by trained or expert staff Do not modify or convert the equipment improperly Arc welding machine for TIG DC welding with HF...

Страница 16: ...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...

Страница 17: ...See 4 3 Machine control Mode RC on chapter 3 PC interface serial D Sub connection socket 9 pole Retrofitting option 4 Key switch for protection against unauthorised use Position 1 changes possible Po...

Страница 18: ...19 pole mechanised welding interface analogue See 5 21 5 Automation interface chapter 3 8 pole connection socket Cooling unit control lead 4 19 pole analogue connection socket Collision protection se...

Страница 19: ...cutout Wire feed motor supply voltage fuse press to reset a triggered fuse 10 G connection thread shielding gas connection inlet 11 Cooling air outlet 12 Mains connection cable See 5 6 Mains connectio...

Страница 20: ...ls Manuell Synergic sec kHz kHz Spez Fe St CrNi CuZn Cu S 2 4 3 2 4 0 Synergic S 000 000 2 1 6 8 7 7 5 3 4 Figure 4 3 Item Symbol Description 0 1 Ignition optimisation key button Optimum ignition and...

Страница 21: ...ption 0 6 Welding parameter setting rotary dial Setting currents times and parameters 7 Welding data display 3 digit Displays the welding parameters and the corresponding values 8 Display switching bu...

Страница 22: ...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 from AMP...

Страница 23: ...ments 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 Frequency TIG kHz pulsing metallurgical pulsing...

Страница 24: ...ing lights up in red TIG synergic welding 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...

Страница 25: ...hose package button See 5 8 2 Shielding gas setting chapter 8 Error status indicators Collective interference signal light Water deficiency signal light welding torch cooling Excess temperature signal...

Страница 26: ...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 from AMP...

Страница 27: ...ments 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 Frequency TIG kHz pulsing metallurgical pulsing...

Страница 28: ...y regulations Even low voltages can cause a shock and lead to accidents Wear dry and undamaged protective clothing shoes with rubber soles welder s gloves made from leather without any studs or braces...

Страница 29: ...ION 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...

Страница 30: ...protection tester Replace coolant as necessary if frost protection is inadequate The disposal of coolant must be carried out according to official regulations and observing the relevant safety data s...

Страница 31: ...esulting network has to be suitable for operating devices according to protection class 1 5 6 1 Mains configuration The machine may be connected to a three phase system with four conductors and an ear...

Страница 32: ...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 parallel with a distance of 20 cm to avoid HF sparkove...

Страница 33: ...12 01 2016 33 Use an individual welding lead to the workpiece for each welding machine Figure 5 3 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Alw...

Страница 34: ...results In addition a blocked shielding gas supply may result in the welding torch being destroyed Always re fit the yellow protective cap when not using the shielding gas connection All shielding gas...

Страница 35: ...onduct a gas test See 5 8 3 Gas test chapter Set the required amount of shielding gas on the pressure reducer about 4 15 l min depending on the current strength and the material 5 8 3 Gas test Operati...

Страница 36: ...1 EW501 12 01 2016 5 9 Gas supply Figure 5 6 Item Symbol Description 0 1 Shielding gas 2 Shielding gas hose 3 G connection thread shielding gas connection inlet Screw the crown nut on the shielding ga...

Страница 37: ...onents Figure 5 7 Item Symbol Description 0 1 5 pole connection socket Cooling unit voltage supply 2 8 pole connection socket Cooling unit control lead 3 Cooling module Insert and lock the 8 pole cont...

Страница 38: ...thread shielding gas connection outlet 3 Connection socket welding current Welding torch connection 4 Welding torch hose package 5 Welding torch Insert the welding current plug on the welding torch i...

Страница 39: ...logue Mechanised welding torch connection Insert the plug on the welding current lead into the welding current connection socket and lock Lock the connecting nipples on the cooling water hoses into pl...

Страница 40: ...Symbol Description 0 1 TIG TORCH BOX Observe additional system documents 2 Connecting hose package 3 19 pole connection socket analogue Connection socket for analogue control signals collision protect...

Страница 41: ...1 2016 41 5 12 Connection for workpiece lead Figure 5 11 Item Symbol Description 0 1 Workpiece 2 Connection socket welding current Workpiece connection Insert cable plug on the workpiece lead into the...

Страница 42: ...rameters tungsten electrode diameter A material type B and seam type C are used to select the welding task JOB All welding parameters specified here are the optimum settings for a variety of applicati...

Страница 43: ...ter setting in the functional sequence chapter Figure 5 13 5 13 2 Conventional parameter setting in the functional sequence All welding parameters in the functional sequence can also be adjusted regar...

Страница 44: ...tting 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...

Страница 45: ...lay seam type Select and display material type Select and display electrode diameter ignition optimisation Select and display operating mode 5 13 4 Select welding current The user has two options for...

Страница 46: ...5 20 2 Creating a new JOB in the memory or copying a JOB chapter 5 13 5 1 Welding parameter setting During the welding parameter setting process the parameter value being set is displayed on the left...

Страница 47: ...ameter 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 transducer during this time Set para...

Страница 48: ...t welding parameters are displayed directly and can be modified where required Operating point The operating point can be set via up to 15 PROG 1 to PROG 15 freely definable programs using a robot int...

Страница 49: ...MP Figure 5 17 5 17 2 KHz pulses metallurgic pulses The kHz pulses metallurgic pulses use the plasma pressure produced at high currents arc pressure which is used to achieve a constricted arc with con...

Страница 50: ...hange to the welding parameters is saved immediately in the JOB The welding machine has 16 programs which you can change during welding In each selected welding task JOB See 5 13 3 Welding task select...

Страница 51: ...ing mode can be specified separately for each program No change Press until a P for program no is displayed in the left hand section of the right hand display Any parameter can be selected and changed...

Страница 52: ...9 3 Example Program with conventional setting Figure 5 20 5 19 4 Accessories for switching over programs The user can change retrieve and save programs using the following components Programs Componen...

Страница 53: ...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 distinct...

Страница 54: ...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...

Страница 55: ...1 x JOB loaded machine switches back to Display mode The JOB can be customised as required Current value and JOB number displayed 5 20 4 Resetting an existing JOB to the factory setting Reset JOB Oper...

Страница 56: ...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 57: ...different intervals i e a long or short interval which are defined as follows Interval Setting range Up down slope Pulsing AC Display Display Long 0 01 20 0 s 10 ms Yes Yes Yes Short 5 999 ms 1 ms No...

Страница 58: ...d 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 for the...

Страница 59: ...ts 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 Display n x Sel...

Страница 60: ...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...

Страница 61: ...rd 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 progra...

Страница 62: ...l 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 connected i...

Страница 63: ...essory components 2 Windows PC 3 RC300 tablet PC 4 SECINT X10 USB 5 Connection cable 9 pole serial 6 PCINT X10 7 7 pole connection cable Connection between switching cabinet and power source CAUTION E...

Страница 64: ...l power sources Figure 5 26 Item Symbol Description 0 1 7 pole connection socket digital For connecting digital accessory components 2 Windows PC 3 WELDQAS welding data monitoring and documentation sy...

Страница 65: ...The power sources satisfy an extremely high safety standard even in combination with peripheral devices for mechanised welding provided these devices comply with the same criteria especially with rega...

Страница 66: ...closed welding current flowing forms contact with signal D H Output Proze spannung Uist Actual welding voltage measured on pin S 0 10 V 0 V 0 V 10 V 100 V J Output SYN_A E Synchronisation for master...

Страница 67: ...on sensor emergency shut down 24 V C Input BR KOLL2 Collision sensor emergency shut down D Output 0VB B reference potential E Output 0VAC Gas relay reference voltage F Output Sensor voltage see Sensor...

Страница 68: ...oltage of approx 12 V on the welding torch electrode If the electrode comes into contact with the workpiece or the molten pool the short circuit produced means that when using the relevant interface B...

Страница 69: ...5 22 Advanced settings 5 22 1 TIG non latched operating mode C version l 0 Figure 5 29 Display Setting selection Exit the menu Exit Machine configuration Settings for machine functions and parameter d...

Страница 70: ...pert menu can be displayed as percentages or absolute values on the machine display l 0 Figure 5 30 Display Setting selection Exit the menu Exit Machine configuration Settings for machine functions an...

Страница 71: ...ng 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 00 s to 20 0 s fact...

Страница 72: ...setting a parameter in the machine configuration menu time controlled power saving mode When power saving mode is activated the machine displays show the horizontal digit in the centre of the display...

Страница 73: ...ameters 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 parameters by turn...

Страница 74: ...Design and function Machine configuration menu 74 099 000141 EW501 12 01 2016 ENTER EXIT NAVIGATION Figure 5 32...

Страница 75: ...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...

Страница 76: ...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...

Страница 77: ...CFG Reset the values in the machine configuration menu CPL Complete reset of all values and settings The reset is performed when leaving the menu EXIT Automated Manual rC on off operating mode Select...

Страница 78: ...ur dealer When replacing parts use only original spare parts When ordering spare parts please quote the machine type serial number and item number of the machine as well as the type designation and it...

Страница 79: ...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...

Страница 80: ...olant pump by activating Air in the coolant circuit Vent coolant circuit See 7 7 Vent coolant circuit chapter Functional errors Machine control without displaying the signal lights after switching on...

Страница 81: ...tions and high alloy steels Unsuitable or worn welding torch equipment Check size of gas nozzle and replace if necessary Condensation hydrogen in the gas tube Purge hose package with gas or replace Ba...

Страница 82: ...el if required 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 coolan...

Страница 83: ...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...

Страница 84: ...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...

Страница 85: ...ervice menu Any changes to the service menu should be agreed with the authorised service personnel Reset reset to factory settings off aus factory setting CFG Reset the values in the machine configura...

Страница 86: ...ed service personnel Software version 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 auto...

Страница 87: ...upling 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 is located as deep as possible inside the sys...

Страница 88: ...A 80 DC 450 A 100 DC 350 A 420 A 420 A Load alternation 10 min 60 DC 6 min welding 4 min break Open circuit voltage 79 V Mains voltage tolerance 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety...

Страница 89: ...ype Designation Item no PALETTE ROB XX2 Transport pallet for use with robots 090 008275 00000 TROLLY ROB XX2 Transport vehicle for a power source with an add on module 090 008278 00000 9 5 Interfaces...

Страница 90: ...IG 1 2 230V 5 6 0V 8 9 42V 1 0 1 1 0V 2 0VAC 4 25VAC X2 1 X2 2 X2 3 X2 4 X2 X1 1 X1 2 X1 X4 1 X4 2 X4 3 X4 4 X3 1 X3 2 X4 X3 HF DC2 A5 1 15V 3 0V C 5 2 D 5 2 4 230V X17 2 3 1 X18 2 3 1 9 0V O 4 2 Ring...

Страница 91: ...11 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 20 X11 21 X11 22 X11 23 X11 24 X11 25 X11 26 X8 Systembus X11 Frontplatte X2 L fter Erdung A2 Ana A Ana...

Страница 92: ...0 X1 X3 X5 2 X5 3 X5 4 X5 5 X5 6 X5 7 X5 8 X5 9 X5 1 X5 10 X5 A1 L2 L1 L3 L4 L5 L6 L7 L8 L9 B T F 5 1 PE 1 BR KOLL2 2 BR KOLL13 BR KOLL1 4 BR KOLL2 L 16 2 M 16 2 8 0VB 9 Gastest 1 0 Gasmangel P 12 2 Q...

Страница 93: ...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 2...

Страница 94: ...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...

Страница 95: ...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...

Страница 96: ...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...

Страница 97: ...www ewm cn info ewm cn info ewm group cn EWM HIGHTEC WELDING GmbH Wiesenstra e 27b 4812 Pinsdorf Austria Tel 43 7612 778 02 0 Fax 20 www ewm austria at info ewm austria at EWM HIGHTEC WELDING UK Ltd...

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