099 000140 EW501
Operating instructions
Power sources for automated applications
GB
Tetrix 352 AC/DC Synergic
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08.07.2011
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099-000140-EW501
General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
NOTE
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our
customer service department on +49 2680 181-0.
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other
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 whether or not these instructions or the conditions and methods are
observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this reason,
we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation,
improper operation or incorrect usage and maintenance or any actions connected to this in any way.
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
Subject to technical amendments.
Contents
Notes on the use of these operating instructions
1
Contents
1 Contents.................................................................................................................................................. 3
2 Safety instructions................................................................................................................................. 6
2.1 Notes on the use of these operating instructions .......................................................................... 6
2.2 Explanation of icons....................................................................................................................... 7
2.3 General .......................................................................................................................................... 8
2.4 Transport and installation ............................................................................................................ 12
2.4.1
Lifting by crane .............................................................................................................13
2.5 Ambient conditions....................................................................................................................... 14
2.5.1
In operation................................................................................................................... 14
2.5.2
Transport and storage ..................................................................................................14
3 Intended use ......................................................................................................................................... 15
3.1 Applications.................................................................................................................................. 15
3.1.1
TIG welding .................................................................................................................. 15
3.1.2
TIG activArc welding..................................................................................................... 15
3.2 Use and operation solely with the following machines ................................................................15
3.3 Documents which also apply ....................................................................................................... 16
3.3.1
Warranty ....................................................................................................................... 16
3.3.2
Declaration of Conformity.............................................................................................16
3.3.3
Welding in environments with increased electrical hazards......................................... 16
3.3.4
Service documents (spare parts and circuit diagrams) ................................................ 16
4 Machine description – quick overview .............................................................................................. 17
4.1 Tetrix 352 AC/DC......................................................................................................................... 17
4.1.1
Front view ..................................................................................................................... 17
4.2 Tetrix 352 AC/DC......................................................................................................................... 18
4.2.1
Rear view...................................................................................................................... 18
4.3 Machine control – Operating elements ........................................................................................ 20
4.3.1
Function sequence ....................................................................................................... 22
5 Design and function............................................................................................................................. 24
5.1 General ........................................................................................................................................ 24
5.2 Installation.................................................................................................................................... 25
5.3 Machine cooling ........................................................................................................................... 25
5.4 Workpiece lead, general .............................................................................................................. 25
5.5 Welding torch cooling system ...................................................................................................... 26
5.5.1
General......................................................................................................................... 26
5.5.2
List of coolants.............................................................................................................. 26
5.6 Mains connection ......................................................................................................................... 27
5.6.1
Mains configuration ...................................................................................................... 27
5.7 Shielding gas supply .................................................................................................................... 28
5.7.1
Connecting the shielding gas supply............................................................................28
5.7.2
Shielding gas setting .................................................................................................... 29
5.7.2.1 Gas test......................................................................................................... 29
5.7.2.2 “Rinse tube package” function ...................................................................... 29
5.8 Connect the cooling module to the power source ....................................................................... 30
5.9 Welding torch connection ............................................................................................................ 31
5.10 Connection for workpiece lead .................................................................................................... 32
5.11 TIG Synergic operating principle ................................................................................................. 33
5.11.1 Synergic parameter setting in the functional sequence ............................................... 34
5.11.2 Conventional parameter setting in the functional sequence ........................................ 34
5.11.2.1 Set the operating principle (conventional/synergic) ...................................... 35
5.11.3 Select welding task....................................................................................................... 36
5.11.4 Select welding current ..................................................................................................36
5.11.5 Welding data display ....................................................................................................37
5.11.5.1 Welding parameter setting ............................................................................ 37
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Contents
Notes on the use of these operating instructions
5.12 Arc ignition ...................................................................................................................................38
5.12.1 HF ignition.....................................................................................................................38
5.12.2 Optimising the ignition characteristics for pure tungsten electrodes ............................38
5.12.3 TIG automatic cut-out ...................................................................................................38
5.13 TIG welding task definition ...........................................................................................................39
5.14 Protecting welding parameters from unauthorised access ..........................................................40
5.15 Welding programs ........................................................................................................................40
5.15.1 Selection and adjustment .............................................................................................41
5.15.2 Specifying max. no. of accessible programs ................................................................41
5.15.3 Example "Program with synergetic setting"..................................................................42
5.15.4 Example "Program with conventional setting" ..............................................................42
5.15.5 Accessories for switching over programs .....................................................................42
5.16 Organising welding tasks (Mode "JOB Manager").......................................................................43
5.16.1 Explanation of symbols on the display .........................................................................43
5.16.2 Creating a new JOB in the memory or copying a JOB.................................................44
5.16.3 Loading an existing JOB from the free memory ...........................................................45
5.16.4 Resetting an existing JOB to the factory setting (Reset JOB)......................................45
5.16.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs) .....................................46
5.16.6 Exit JOB Manager without changes .............................................................................46
5.16.7 Specifying max. no. of accessible JOBs.......................................................................47
5.17 Simultaneous welding on both sides, synchronisation types.......................................................48
5.17.1 Synchronisation via mains voltage (50Hz / 60Hz)........................................................48
5.17.2 Synchronisation via cable (frequency 50Hz to 200Hz).................................................49
5.18 Interfaces .....................................................................................................................................50
5.18.1 Connecting the robot interface / industrial bus interface ..............................................50
5.18.1.1 RINT X11 robot interface...............................................................................51
5.18.1.2 BUSINT X11 industrial bus interface.............................................................51
5.18.2 Connecting the PC 300.net welding parameterisation software...................................52
5.18.3 Connecting the Q-DOC 9000 welding data documentation software...........................53
5.18.4 Connecting the WELDQAS welding data monitoring and documentation system .......54
5.18.5 Automation interface.....................................................................................................55
5.18.6 Connection socket automation torch ............................................................................57
5.18.7 Sensor Voltage .............................................................................................................57
5.19 Advanced settings........................................................................................................................58
5.19.1 Setting slope times for secondary current AMP% or pulse edges ...............................58
5.19.2 TIG non-latched operating mode, C version.................................................................59
5.19.3 Welding current display (ignition, secondary, end and hotstart currents) ....................60
5.20 Menus and sub-menus on the machine control ...........................................................................61
5.20.1 Direct menus (direct access to parameters).................................................................61
5.20.2 Expert menu (TIG) ........................................................................................................61
5.20.3 Machine configuration menu ........................................................................................62
6 Maintenance, care and disposal .........................................................................................................65
6.1 General.........................................................................................................................................65
6.2 Maintenance work, intervals.........................................................................................................65
6.2.1
Daily maintenance tasks...............................................................................................65
6.2.2
Monthly maintenance tasks ..........................................................................................65
6.2.3
Annual test (inspection and testing during operation) ..................................................65
6.3 Maintenance work ........................................................................................................................66
6.4 Disposing of equipment................................................................................................................66
6.4.1
Manufacturer's declaration to the end user ..................................................................66
6.5 Meeting the requirements of RoHS..............................................................................................66
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Contents
Notes on the use of these operating instructions
7 Rectifying faults ................................................................................................................................... 67
7.1 Customer checklist....................................................................................................................... 67
7.2 Machine faults (error messages) ................................................................................................. 69
7.3 Resetting welding parameters to the factory settings.................................................................. 70
7.4 Display machine control software version ................................................................................... 71
7.5 General operating problems ........................................................................................................ 71
7.5.1
Interface for mechanised welding................................................................................. 71
8 Technical data ...................................................................................................................................... 72
8.1 Tetrix 352 AC/DC......................................................................................................................... 72
9 Accessories .......................................................................................................................................... 73
9.1 Connection cables, connection sockets....................................................................................... 73
9.2 General accessories .................................................................................................................... 73
9.3 Options......................................................................................................................................... 73
9.4 Transport systems ....................................................................................................................... 73
9.5 Interfaces ..................................................................................................................................... 73
9.6 Computer communication............................................................................................................ 73
9.7 Cooling units ................................................................................................................................ 74
9.8 Simultaneous welding on both sides, synchronisation types ...................................................... 74
9.8.1
Synchronisation via cable (frequency 50Hz to 200Hz) ................................................ 74
9.8.2
Synchronisation via mains voltage (50Hz / 60Hz)........................................................ 74
10 Circuit diagrams................................................................................................................................... 75
10.1 Tetrix 352 AC/DC......................................................................................................................... 75
11 Appendix A ........................................................................................................................................... 77
11.1 JOB-List ....................................................................................................................................... 77
12 Appendix B ........................................................................................................................................... 81
12.1 Overview of EWM branches ........................................................................................................ 81
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Safety instructions
Notes on the use of these operating instructions
2
Safety instructions
2.1
Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
• The 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 includes the "CAUTION" keyword in its heading with a general
warning symbol.
• The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at the edge of the page.
NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.
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Safety instructions
Explanation of icons
2.2
Explanation of icons
Symbol
Description
Press
Do not press
Turn
Switch
0
0
1
Switch off machine
1
Switch on machine
ENTER (enter the menu)
NAVIGATION (Navigating in the menu)
EXIT (Exit the menu)
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use
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Safety instructions
General
2.3
General
DANGER
Electric shock!
Welding machines use high voltages which can result in potentially fatal electric shocks
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!
• Switching off alone is not sufficient!
• Place welding torch and stick electrode holder on an insulated surface!
• The unit should only be opened by specialist staff after the mains plug has been unplugged!
• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
• Observe the maintenance instructions! (see Maintenance and Testing chapter)
• Unwind welding leads completely!
• Shield devices or equipment 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 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 only skilled persons for repair work (trained service personnel)!
WARNING
Risk of 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 prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
Risk of injury due to radiation or heat!
Arc radiation results in injury to skin and eyes.
Contact with hot workpieces and sparks results in burns.
• Use welding shield or welding helmet with the appropriate safety level (depending on the
application)!
• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
• Protect persons not involved in the work against arc beams and the risk of glare using
safety curtains!
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Safety instructions
General
WARNING
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!
Smoke and gases!
Smoke and gases can lead to breathing 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 fresh air!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
• Check for fire hazards in the working area!
• Do not carry any easily flammable objects such as matches or lighters.
• Keep appropriate fire extinguishing equipment to 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 allow to come into contact with flammable material!
• Connect welding leads correctly!
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
CAUTION
Obligations of the operator!
The respective national directives and laws must be observed for operation of the
machine!
• National implementation of the framework directive (89/391/EWG), as well as the
associated individual directives.
• In particular, directive (89/655/EWG), on the minimum regulations for safety and health
protection when staff members use equipment during work.
• The regulations regarding work safety and accident prevention for the respective country.
• Setting up and operating the machine according to IEC 60974-9.
• Check at regular intervals that users are working in a safety-conscious way.
• Regular checks of the machine according to IEC 60974-4.
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Safety instructions
General
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, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of
products!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Damage to the machine due to stray welding 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 securely connected and check regularly.
• Always ensure a proper and secure electrical connection to the workpiece!
• Set up, attach or 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 the
power source, transport vehicle or crane frames unless they are insulated!
• Always put welding torches and electrode holders on an insulated surface when they are
not in use!
Mains connection
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of
the operator, where necessary in consultation with the mains network operator, to ensure that
the machine can be connected.
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Safety instructions
General
CAUTION
EMC Machine Classification
In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic
compatibility classes (see technical data):
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas,
including residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
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 following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding equipment
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
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Safety instructions
Transport and installation
2.4
Transport and installation
WARNING
Incorrect handling of shielding gas cylinders!
Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.
• Observe the instructions from 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 the shielding gas cylinder!
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 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 equipment!
• Replace damaged wheels and their fixing elements!
• Fix external wire feed units during transport (avoid uncontrolled rotation)!
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
• Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
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Safety instructions
Transport and installation
2.4.1
Lifting by crane
DANGER
min
.1
m
Risk of injury during lifting by crane!
When lifting the equipment by crane, serious injuries can be inflicted by falling
equipment or add-on units.
• Transport on all lifting lugs at the same time
(see Fig. Lifting principle)!
• Ensure that there is an even load distribution! Only
use ring chains or suspension ropes of the same
°
75
length!
• Observe the lifting principle (see Fig.)!
• Remove all accessory components before lifting
(e.g. shielding gas cylinders, tool boxes, wire feed
Fig. Lifting principle
units, etc.)!
• Avoid jerky movements when raising or lowering!
• Use shackles and load hooks of the appropriate size!
Risk of injury due to unsuitable ring screws!
In case of improper use of ring screws or the use of unsuitable ring screws, persons
can be seriously damaged by falling equipment or add-on components!
• The ring screw must be completely screwed in!
• The ring screw must be positioned flat onto and in full contact with the supporting surfaces!
• Check that the ring screws are securely fastened before use and check for any damage
(corrosion, deformation)!
• Do not use or screw in damaged ring screws!
• Avoid lateral loading of the ring screws!
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Safety instructions
Ambient conditions
2.5
Ambient conditions
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
Equipment damage due to dirt accumulation!
Unusually high quantities 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 ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!
2.5.1
In operation
Temperature range of the ambient air:
• -20 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.5.2
Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -25 °C to +55 °C
Relative air humidity
• Up to 90% at 20 °C
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Intended use
Applications
3
Intended use
This machine has been manufactured according to the latest developments in technology and current
regulations and standards. It must only be operated in line with the instructions on correct usage.
WARNING
Hazards due to improper usage!
Hazards may arise for persons, animals and material objects if the equipment is not
used correctly. No liability is accepted for any damages arising from improper 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!
3.1
Applications
3.1.1
TIG welding
TIG welding with alternating or direct current. Arc ignition optionally by means of non-contact HF ignition
or contact ignition with Liftarc.
3.1.2
TIG activArc welding
The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power
supplied is kept virtually constant in the event of changes in the distance 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 (ampere per volt - A/V), and vice
versa. This 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.
3.2
Use and operation solely with the following machines
•
•
•
•
•
BUSINT X11
RINT X12
cool82 U44
cool82 U45
cool82 U45 2Rob
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Intended use
Documents which also apply
3.3
Documents which also apply
3.3.1
Warranty
NOTE
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
3.3.2
Declaration of Conformity
The designated machine conforms to EC Directives and standards in terms of its design
and construction:
• EC Low Voltage Directive (2006/95/EC),
• EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, 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 declaration of conformity is enclosed with the unit.
3.3.3
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 hazard.
3.3.4
Service documents (spare parts and circuit diagrams)
DANGER
Do not carry out any unauthorised repairs or modifications!
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 only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
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Machine description – quick overview
Tetrix 352 AC/DC
4
Machine description – quick overview
4.1
Tetrix 352 AC/DC
4.1.1
Front view
NOTE
The maximum possible machine configuration is given in the text description.
If necessary, the optional connection may need to be retrofitted (see "Accessories"
chapter).
1
3
2
4
5
6
7
Figure 4-1
Item
Symbol Description 0
1
Lifting lug
2
Machine control
See Machine control – operating elements chapter
PC interface, serial (D-Sub connection socket, 9-pole)
3
COM
4
0
1
5
Main switch, machine on/off
6
Cooling air inlet
7
Machine feet
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Key switch for protection against unauthorised use
Position “1” > changes possible,
Position “0” > changes not possible.
Please take note of chapter “Protecting welding parameters from unauthorised access”
17
Machine description – quick overview
Tetrix 352 AC/DC
4.2
Tetrix 352 AC/DC
4.2.1
Rear view
Figure 4-2
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Machine description – quick overview
Tetrix 352 AC/DC
Item
Symbol Description 0
1
digital
2
analog
3
8-pole connection socket
Cooling unit control lead
4
19-pole connection socket (analogue)
Mechanised welding torch connection
5
7-pole connection socket (digital)
For connecting digital accessory components
Connecting nipple G¼, shielding gas connection
6
Connection socket, welding current Welding torch connection
Connection socket, welding current +
Workpiece connection
7
8
9
10
Key button, automatic cutout
Wire feed motor supply voltage fuse
press to reset a triggered fuse
Connecting nipple G¼, shielding gas connection
11
Cooling air outlet
12
Mains connection cable
13
Connection socket, 5-pole
Cooling unit voltage supply
14
Intermediate tube package strain relief
15
Machine feet
42V/4A
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Interfaces
Optional interface in the extension casing for assembly onto the power source
• RINTX11 robot interface
• BUSINTX10 industrial bus interface
19-pole mechanised welding interface (analogue)
(See chapter entitled "Design and function > interfaces".)
19
Machine description – quick overview
Machine control – Operating elements
4.3
Machine control – Operating elements
Figure 4-3
Item
1
2
20
Symbol Description 0
Polarity changeover (TIG manual) button
Select material type (TIG
Synergic) key button
CrNi Chrome/nickel alloys / iron /
DC welding with positive polarity on the DC
Fe/St
steel alloys
electrode holder in relation to the
workpiece (pole reversing switch, MMA
only).
Cu
DC welding with negative polarity at the DC
Copper / copper alloys
CuZn
torch (or electrode holder) with respect
(bronzes) / copper/zinc alloys
to the workpiece.
(brass)
AC
AC welding with rectangular current
AlMg Aluminium/magnesium alloys
output wave form. Maximum power
loading and safe welding.
AC welding with trapezoidal current
AC
AlSi Aluminium/silicon alloys
output wave form. An all-rounder,
suitable for most applications.
AC
AC welding with sinusoidal current
Al99 99% aluminium
output wave form. Low noise level.
"Welding 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)
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Machine description – quick overview
Machine control – Operating elements
Item
Symbol Description 0
Tungsten electrode diameter / Ignition optimisation / Spherical cap formation button
∅ 1.0mm, ∅ 1.6mm, ∅ 2.0mm, ∅ 2.4mm, ∅ 3.2mm, ∅ 4.0mm or greater
Best ignition and stabilisation of the arc (DC, AC) and optimum spherical cup formation
in the tungsten electrode according to the electrode diameter being used. The
adjustable welding current is limited to the maximum permissible welding current of the
tungsten electrode.
Select seam type button
Fillet weld
Butt joint
Fillet weld - lap joint
Vertical-down
Operating mode button
3
4
5
spotArc (spot time setting range 0.01 sec. to 20.0 sec.)
Non-latched
Latched
TIG pulse welding
TIG automated pulses (frequency and balance)
TIG pulses with times, green light /
Fast TIG DC pulses with frequency and balance, red light
TIG AC special
6
7
Synchronisation types key button (two-sided, simultaneous welding)
Synchronisation via mains voltage
Synchronisation via cable
8
Gas test/rinse tube package button
see "Shielding gas setting" chapter
9
Error/status indicators
Collective interference signal light
Water deficiency signal light (welding torch cooling)
S
Excess temperature signal light
S
10
safety sign signal light
Display switching button
VOLT
JOB
PROG
11
Welding parameter setting rotary transducer
Setting of all parameters such as welding current, sheet metal thickness, gas pre-flow
time, etc.
12
Three-figure LED display
Welding parameter display (see also chap. “Welding data display”).
13
Status displays
After each completed welding task, the last values used in the welding
process for the welding current and welding voltage are shown on the
displays, and the signal light will be on
Direct current welding
Alternating current welding
and
simultaneously: Alternating current welding, AC special
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Material thickness display
Welding voltage display
JOB number display
Program number display
21
Machine description – quick overview
Machine control – Operating elements
Item
Symbol Description 0
Function sequence (see next chapter)
14
4.3.1
Function sequence
Figure 4-4
Item
Symbol Description 0
1
22
2
sec
3
AMP%
4
sec
5
AMP
6
sec
7
AMP%
Select welding parameters button
This button is used to select the welding parameters depending on the welding process
and operating mode used.
Gas pre-flow time (TIG)
absolute setting range 0.0 sec to 20.0 sec (0.1s increments).
Ignition current (TIG)
Hotstart current (MMA)
Percentage of the main current.
Percentage of the main current. Setting
Setting range 1 % to 200 %
range 1 % to 200 %
(1 % increments). There are no pulses
(1 % increments).
during the ignition current phase.
Up-slope time (TIG)
Hotstart time (MMA)
Setting ranges: 0.00 s to 20.0 s
Setting ranges: 0.00 s to 20.0 s
(0.1 s increments).
(0.1 s increments).
The up-slope time can be set separately
for non-latched and latched.
Main current (TIG) / pulse current
Main current (MMA)
I min to I max (1 A increments)
I min to I max (1 A increments)
Pulse time / slope time from AMP% to AMP
• Pulse time setting range: 0.01 s to 20.0 s
(0.01 s increments < 0.5 s; 0.1 s increments > 0.5 s)
• Slope time (tS2) setting range: 0.0 s to 20.0 s
(see chapter "Advanced settings")
TIG pulses
TIG AC Special
The pulse time applies to the main current The pulse time applies to the AC phase for
phase (AMP) for pulses.
AC special.
Secondary current (TIG) / pulse pause current
Setting range 1 % to 100 % (1 % increments). Percentage of the main current.
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Machine control – Operating elements
Item
Symbol Description 0
8
sec
9
sec
10
AMP%
11
sec
12
13
14
AC/DC
15
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Pulse break time/slope time from AMP to AMP%
• Pulse break setting range: 0.01 sec to 20.0 sec
(0.01 sec increments < 0.5 sec; 0.1 sec increments > 0.5 sec)
• Slope time (tS1) setting range: 0.0 sec to 20.0 sec
(see chapter "Advanced settings").
TIG pulses: The pulse break time applies to the secondary current phase (AMP%)
TIG AC Special: The pulse break time applies to the DC phase with AC special.
Down-slope time (TIG)
0.00 s to 20.0 s (0.1 s increments).
The down-slope time can be set separately for non-latched and latched.
End-crater current (TIG)
Setting range 1 % to 200 % (1 % increments). Percentage of the main current.
Gas post-flow time (TIG)
Setting ranges: 0.00 sec to 40.0 sec (0.1 sec increments).
Alternating current balance (TIG AC)
Max. setting range: -30 % to +30 % (1 % increments). The setting range may also be
lower depending on the factory setting.
Optimisation of cleaning effect and fusion penetration characteristics.
Balance fast TIG DC pulses
Setting range: 1 % to +99 % (1 % increments)
Alternating current frequency (TIG AC)
50 Hz to 200 Hz (1 Hz increments).
Constriction and stabilisation of the arc:
The cleaning effect increases with a greater frequency. Particularly thin panels (welding
with a low current), anodised sheet aluminium or highly contaminated articles for
welding can be welded and cleaned perfectly at a higher frequency.
Frequency fast TIG DC pulses
Setting range: 50 Hz to 15 kHz
Welding current polarity, MMA
(see chap. "Switching the welding current polarity")
activArc TIG welding process
• Switch activArc on or off
• Correct the activArc characteristic (setting range: 0 to 100)
23
Design and function
General
5
Design and function
NOTE
Observe documentation of other system components when connecting!
5.1
General
WARNING
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
• Follow safety instructions on the opening pages of the operating instructions.
• Commissioning may only be carried out by persons who have the relevant expertise of
working with arc welding machines!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
CAUTION
Risk of burns on the 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 turning in clockwise direction,
if necessary.
Risk of injury 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 components!
• Keep casing covers closed during operation!
Risk of injury due to welding wire escaping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may
escape in an uncontrolled manner and injure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the
welding torch!
• Remove the pressure rollers from the wire feed unit if no welding torch is fitted!
• Check wire guide at regular intervals!
• Keep all casing covers closed during operation!
Risk from electrical current!
If welding is carried out alternately using different methods and if a welding torch and
an electrode holder remain connected to the machine, the open-circuit/welding voltage
is applied simultaneously on all cables.
• The torch and the electrode holder should therefore always be placed on an insulated
surface before starting work and during breaks.
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Design and function
Installation
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.
Using protective dust caps!
Protective dust caps protect the connection sockets and therefore the machine against
dirt and damage.
• The protective dust cap must be fitted if there is no accessory component being operated
on that connection.
• The cap must be replaced if faulty or if lost!
5.2
Installation
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.
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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25
Design and function
Welding torch cooling system
5.5
Welding torch cooling system
5.5.1
General
CAUTION
Coolant mixtures!
Mixtures with other liquids or the use of unsuitable coolants result in material damage
and renders the manufacturer's warranty void!
• Only use the coolant described in this manual (overview of coolants).
• Do not mix different coolants.
• When changing the coolant, the entire volume of liquid must be changed.
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch (see overview of coolants).
Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure
that the frost protection is adequate to prevent damage to the machine or the accessory
components.
• The coolant must be checked for adequate frost protection with the TYP 1 frost protection
tester (see accessories).
• Replace coolant as necessary if frost protection is inadequate!
NOTE
The disposal of coolant must be carried out according to official regulations and
observing the relevant safety data sheets (German waste code number: 70104)!
• Coolant must not be disposed of together with household waste.
• Coolant must not be discharged into the sewerage system.
• Recommended cleaning agent: water, if necessary with cleaning agent added.
5.5.2
List of coolants
The following coolants may be used (for item nos., please see the Accessories chapter):
Coolant
Temperature range
KF 23E (Standard)
-10 °C to +40 °C
KF 37E
-20 °C to +10 °C
DKF 23E (for plasma machines)
0 °C to +40 °C
26
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Design and function
Mains connection
5.6
Mains connection
DANGER
Hazard caused by improper mains connection!
An improper mains connection 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 electrician in accordance
with the relevant national provisions or regulations (any phase sequence for three-phase
machines)!
• Mains plug, socket and lead must be checked regularly by an electrician!
• When operating the generator always ensure 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 be connected to:
• a three-phase system with four conductors and an earthed neutral conductor
• a three-phase system with three conductors of which any one can be earthed,
e.g. the outer conductor
Figure 5-1
Legend
Item
L1
L2
L3
N
PE
Designation
Outer conductor 1
Outer conductor 2
Outer conductor 3
Neutral conductor
Protective conductor
Colour code
black
brown
grey
blue
green-yellow
CAUTION
Operating voltage - mains voltage!
The operating voltage shown on the rating plate must be consistent with the mains
voltage, in order to avoid damage to the machine!
• For mains fuse protection, please refer to the “Technical data” chapter!
•
Insert mains plug of the switched-off machine into the appropriate socket.
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Design and function
Shielding gas supply
5.7
Shielding gas supply
WARNING
Incorrect handling of shielding gas cylinders!
Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.
• Observe the instructions from 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 the shielding gas cylinder!
CAUTION
Faults in the shielding gas supply.
An unhindered shielding 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 being destroyed.
• Always re-fit the yellow protective cap when not using the shielding gas connection.
• All shielding gas connections must be gas tight.
NOTE
Before connecting the pressure regulator to the gas cylinder, open the cylinder valve
briefly to expel any dirt.
5.7.1
Connecting the shielding gas supply
Figure 5-2
Item
1
Pressure regulator
2
Shielding gas cylinder
3
Output side of the pressure regulator
4
Cylinder valve
•
•
•
•
•
28
Symbol Description 0
Place the shielding gas cylinder into the relevant cylinder bracket.
Secure the shielding gas cylinder using a securing chain.
Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.
Screw gas hose connection crown nut onto the output side of the 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).
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Design and function
Shielding gas supply
5.7.2
Shielding gas setting
NOTE
Rule of thumb for the gas flow rate:
Diameter of gas nozzle in mm corresponds to gas flow in l/min.
Example: 7mm gas nozzle corresponds to 7l/min gas flow.
Incorrect shielding gas setting!
If the shielding gas setting is too low or too high, this can introduce air to the weld pool
and may cause pores to form.
• Adjust the shielding gas quantity to suit the welding task!
•
•
5.7.2.1
Slowly open the gas cylinder valve. Conduct a gas test (see chapter "gas test")
Set the required amount of shielding gas on the pressure reducer, about 4 - 15 l/min depending on the
current strength and the material.
Gas test
Operating
element
Action
1x
5.7.2.2
Result
Select gas test
"Gas pre-flow time (TIG)" signal light is on. Shielding gas flows for
approx. 20 seconds. The gas test can be ended immediately by
pressing it once more.
“Rinse tube package” function
Operating
Action
Result
element
Select tube package rinsing
5s
"Gas pre-flow time (TIG)" signal light flashes.
The function is ended by pressing the button again.
NOTE
If the "Rinse tube package" function is not ended by pressing the "Gas and current
parameters" button again, shielding gas will flow until the gas cylinder is empty!
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Design and function
Connect the cooling module to the power source
5.8
Connect the cooling module to the power source
NOTE
Observe the fitting and connection instructions given in the relevant operating
instructions for the cooling unit.
Figure 5-3
Item
1
Connection socket, 5-pole
Cooling unit voltage supply
2
8-pole connection socket
Cooling unit control lead
3
Cooling module
•
•
30
Symbol Description 0
Insert and lock the 8-pole control lead plug on the cooling unit into the 8-pole connection socket on the
welding machine.
Insert and lock the 5-pole supply plug on the cooling unit into the 5-pole connection socket on the
welding machine.
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Design and function
Welding torch connection
5.9
Welding torch connection
5
1
4
2
3
Figure 5-4
Item
Symbol Description 0
1
19-pole (analogue) connection socket
Collision protection / sensor voltage control signals
2
Connection nipple for rapid-action closure coupling, shielding gas supply, G¼"
3
4
Connection socket, welding current Welding torch connection
Welding torch hose package
5
Welding torch
•
•
•
Insert the welding current plug on the welding torch into the welding current connection socket and
lock by turning to the right.
Screw the crown nut on the shielding gas lead gastight to the connecting thread (G¼").
Insert the 19-pole control lead plug into the 19-pole connection socket (analogue) and lock.
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Design and function
Connection for workpiece lead
5.10
Connection for workpiece lead
1
2
Figure 5-5
Item
1
2
•
32
Symbol Description 0
Workpiece
Connection socket, “+” welding current
Workpiece connection
Insert cable plug on the workpiece lead into the connection socket for workpiece lead and lock by
turning to the right.
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Design and function
TIG Synergic operating principle
5.11
TIG Synergic operating principle
Figure 5-6
The machine is operated according to the TIG Synergic operating principle:
The three basic parameters
• 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 applications, but they can
also be modified individually.
The required welding current can be set as the sheet metal thickness or conventionally as the welding
current (D).
The parameters and functions described here can also be programmed by PC using the Tetrix PCT 300
welding parameter software.
The Tetrix machine range has been designed to be very easy and quick to operate, whilst still providing
all the functions one could ever need.
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Design and function
TIG Synergic operating principle
5.11.1 Synergic parameter setting in the functional sequence
When setting the welding current, all the necessary welding parameters are adjusted automatically during
the functional sequence (see chap. “TIG functional sequences”) with the exception of the gas pre-flow
time. These welding parameters can also be set in the conventional way if required (regardless of the
welding current) (see chap. “Conventional parameter setting in the functional sequence”).
Figure 5-7
5.11.2 Conventional parameter setting in the functional sequence
All welding parameters in the functional sequence can also be adjusted, regardless of the welding current
set. This means that if the welding current is changed, the values for the down slope time or gas post-flow
time remain unchanged, for example. The welding task still needs to be selected as before using the
three basic parameters of tungsten electrode diameter, material type and seam type.
NOTE
The parameters for the ignition, secondary and end currents can be set and displayed
as percentage values or absolute values (see chapter “Welding current display”).
Figure 5-8
34
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Design and function
TIG Synergic operating principle
5.11.2.1 Set the operating principle (conventional/synergic)
0
0
1
1
Figure 5-9
Display
Setting/selection
Exit the menu
Exit
Machine configuration
Settings for machine functions and parameter display
Operating principle
• on = synergic parameter setting (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
same time.
NAVIGATION (navigating in the menu)
• Parameters are selected by pressing the "welding parameters" button.
• Set or change the parameters by turning the "welding parameter setting" rotary dial.
EXIT (leave the menu)
• Select the "Elt" menu item.
• Press the "welding parameters" button (settings will be applied, machine changes to the
ready-to-operate status).
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Design and function
TIG Synergic operating principle
5.11.3 Select welding task
The welding task is selected using the buttons on the machine control on the welding machine.
Signal lights (LED) display the welding parameter selection.
NOTE
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
element
Action
Result
Select and display welding process.
Select and display electrode diameter / ignition optimisation.
•
TIG - Synergic:
Select electrode diameter (ignition
optimisation is determined automatically).
•
TIG - 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:
Select welding current polarity.
Select and display seam type.
Select and display operating mode.
5.11.4 Select welding current
The user has two options for setting the required welding current:
• Using the sheet metal thickness
• Directly as welding current
The welding current is displayed in the left-hand display. The “Material thickness” parameter can
be selected in the right-hand display.
Control element Action
Result
Display (right)
Press button until signal light
Material thickness in
mm is displayed.
Xx
Material Thickness comes on.
Set welding current or sheet metal thickness.
36
Welding current and
sheet metal thickness
are displayed
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Design and function
TIG Synergic operating principle
5.11.5 Welding data display
The following welding parameters can be displayed before (nominal values), during (actual values) or
after welding (hold values):
“Left-hand display”
Parameter
Before welding
During welding
After welding
(nominal values)
(actual values)
(hold values)
Welding current
z
z
z
Parameter times
z
Frequency, balance
z
Parameter currents
z
“Right-hand display”
Material thickness
z
Welding voltage
z
z
z
JOB number
z
Program number
z
After welding the hold values are displayed. When changes are made to the settings (e.g. welding
current) after welding, the display switches to the relevant nominal values.
The right-hand display automatically switches over to the material 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”).
If the “JOB number” signal light is on in addition to the “Material thickness” light, the user is in a JOB in
the free memory (JOBs 128 to 256, see chap. “Creating a new JOB in the free memory”).
5.11.5.1 Welding parameter setting
During the welding parameter setting process, the parameter value being set is displayed on the left-hand
display. The right-hand display shows the “Factory setting” or a variation of it upwards or downwards.
Displays, e.g. when setting the ignition current, and their meanings:
Display
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Meaning of the symbols shown in the right-hand display
Increase parameter value To restore the factory settings.
Factory setting
Parameter value is on the optimum setting
Reduce parameter value
To restore the factory settings.
37
Design and function
Arc ignition
5.12
Arc ignition
5.12.1 HF ignition
Figure 5-10
The arc is started without contact from high-voltage ignition pulses.
a) Position the welding torch in welding position over the workpiece (distance between the electrode tip
and workpiece should be approx. 2-3 mm).
b) Robot start signal (high voltage ignition pulses ignite the arc).
c) Ignition current flows. The welding process is continued according to the operating mode selected.
End the welding process: Robot stop signal or other signals depending on the operating mode
selected.
5.12.2 Optimising the ignition characteristics for pure tungsten electrodes
This parameter can be used to improve the ignition characteristics of “pure tungsten electrodes”, for
example. The parameter is a %-value (factory-set to 20) and is changed across all JOBs.
Control element
Action
1x
Result
Display
Select 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 transducer during
this time.
Set parameter value
Increase parameter value:
more ignition power
Reduce parameter value:
less ignition power
5.12.3 TIG automatic cut-out
NOTE
If the arc does not ignite after starting or if the arc is interrupted when the torch is
moved away, an automatic cut-out occurs after 5 sec.
• The HF, gas and open circuit voltage (power unit) are switched off.
• If RINTX1x or BUSINTX1x are in use the automatic cut-out is regulated by the settings
made with the software PC300.net.
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Design and function
TIG welding task definition
5.13
TIG welding task definition
The user defines the welding tasks using JOB numbers.
Each JOB number stores all the parameters relating to the welding task.
The user can either load an existing JOB, load an existing JOB and change it, or define a completely new
JOB via the various interfaces.
The welding task or JOB is defined using the following parameters:
Basic parameters
The JOB number is defined using the four basic welding parameters:
welding process, material type, wire diameter and seam type.
Program sequence
Other welding parameters, such as parameters for the start program, secondary program or end program
and the gas pre-flow time, slope times and many more are preset for a variety of applications, but can be
modified where required. On the various interfaces, the most important 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 interface (RINT X12/BUSINT X11), for example.
• The welding current, operating mode and pulse function are stored in each program. These program
parameters can be set on a PC or the tablet PC RC 300 using the PC 300 welding parameter
software. The program number is selected by the robot control.
The digital system calculates the process parameters required, such as the welding current, welding
voltage and pulse current according to the operating point specified.
Operating mode
Non-latched or special non-latched (start, main and end program).
These parameters are predefined by the robot control via robot interface RINT X12 or BUSINT X11 (see
the relevant interface documentation).
Welding type
Pulse or standard welding.
This parameter setting is specified by the robot control via the RINT X12 or BUSINT X11 robot interface
(see documentation in the relevant interface description).
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Design and function
Protecting welding parameters from unauthorised access
5.14
Protecting welding parameters from unauthorised access
To protect against unauthorised or unintentional adjustment of the welding parameters on the machine,
the control input can be locked with the aid of a key switch.
5.15
Key position 1 =
All parameters can be set
Key position 0 =
Only the following operating elements are functional:
• “Operating mode” button
• “Welding parameter setting” rotary transducer
• “Display switching” button
• “TIG pulse welding”/“Select activArc” button
• “Select welding parameters” button
• “Gas test” button
Welding programs
The welding machine has 16 programs, which can be accessed during the welding process, e.g. using an
up/down torch.
In each selected welding task (JOB), see the "Selecting the welding task" chapter, 16 programs can be
set, saved and accessed. In program "0" (default setting), the welding current can be set infinitely across
the whole range. In programs 1–15, 15 different welding currents can be defined.
Operating mode and pulse function can also be defined for programs 1–15, if the connected RINT X12 or
BUSINT X11 interface is in JOB mode. If the interfaces are not in JOB mode, operating mode and pulse
function are predefined by the interfaces.
Example:
Welding current
Program number
Operating mode
Pulse function
1
80 A
Non-latched
Pulses on
2
70 A
Latched
Pulses off
The operating mode cannot be changed during the welding process. If the process is started with
program 1 (non-latched operating mode), program 2, despite being set to latched operating mode, will
apply the setting of start program 1 until the end of the welding process.
Pulse function (pulses off, pulses on) and welding currents will be applied from the relevant programs.
NOTE
Changes made to the other welding parameters during the course of the program have
the equivalent effect on all programs.
Any change to the welding parameters is saved immediately in the JOB!
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Design and function
Welding programs
5.15.1 Selection and adjustment
Setting welding programs using the welding machine control
Operatin Action
Result
g
element
Press button until signal light
VOLT
PROG comes on.
Display
Welding current
(left) and program
no. (right)
JOB
PROG
Select or retrieve program no., e.g. no. 1
Set operating mode (can be specified separately for each
program).
No change
Press until a "P" for program no. is displayed in the lefthand section of the right-hand display.
Any parameter can be selected and changed in the
function sequence. The changes are transferred to all
other programs in the same 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 changeover to the welding machine control is blocked!
5.15.2 Specifying max. no. of accessible programs
NOTE
This function can be used to specify the maximum number of programs which can be
called up (only applies to the welding torch). According to the factory setting, all 16
programs can be called up. If necessary these can be limited to a specific number.
To limit the number of programs, the welding current needs to be set to 0A for the next,
unused program. For example, if only programs 0 to 3 are being used, the welding
current is set to 0A in program 4. A maximum of programs 0 to 3 can then be called up
on the welding torch.
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Design and function
Welding programs
5.15.3 Example "Program with synergetic setting"
Figure 5-11
5.15.4 Example "Program with conventional setting"
Figure 5-12
5.15.5 Accessories for switching over programs
The user can change, retrieve and save programs using the following components.
Programs
Component
42
create and change
call up
Welding machine control
16
16
PC with PC 300 welding parameter
software
16
16
Tablet PC RC 300 with PC 300 welding
parameters
16
16
Tetrix RINT robot interface
-
16
BUSINT X10 industrial bus interface
-
16
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Design and function
Organising welding tasks (Mode "JOB Manager")
5.16
Organising welding tasks (Mode "JOB Manager")
NOTE
After carrying out any of the actions described, the machine switches back to the
default parameters such as current and voltage.
To ensure that all the changes are active, the welding machine should only be switched
off after 5 seconds have elapsed.
The JOB Manager can be used to load, copy or save JOBs.
A JOB is a welding task defined 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 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 distinction is made between two memory sectors:
• 121 factory-set, pre-programmed, permanent JOBs. Permanent JOBs are not loaded but are defined
by the welding task (each welding task is permanently assigned a JOB number).
• 128 freely definable JOBs (JOBs 129 to 256)
5.16.1 Explanation of symbols on the display
Display
Meaning
Load JOB
Copy JOB
Reset JOB
Reset all JOBs
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Design and function
Organising welding tasks (Mode "JOB Manager")
5.16.2 Creating a new JOB in the memory or copying a JOB
NOTE
It is normally possible to adjust all 256 JOBs individually. However, it is a good idea to
assign specific JOB numbers in the free memory (JOB 128 to 256) for specific welding
tasks.
Copying a pre-defined welding task from the fixed memory (JOBs 1 to 128) to the free memory
(JOBs 129-256):
NOTE
Define welding task which most closely matches the required application.
Operating Action
element
Result
Display
Select JOB Manager mode
Press until the “VOLT”
signal light is on
xx
Select JOB Manager mode
2 sec.
Switch from “Load JOB” to “Copy JOB”
1x
Select the required JOB number using the rotary
transducer (e.g. 150)
1x
44
JOB has been copied to the free memory, machine Current value and JOB
switches back to Display mode. The JOB can be
number displayed
modified individually.
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Design and function
Organising welding tasks (Mode "JOB Manager")
5.16.3 Loading an existing JOB from the free memory
Operating Action
element
Result
Display
Select JOB Manager mode
Press until the “VOLT”
signal light is on
xx
Select JOB Manager mode
2 sec.
Select the required JOB number using the rotary
transducer (e.g. 150)
1x
JOB loaded, machine switches back to Display
mode.
The JOB can be customised as required.
Current value and JOB
number displayed
5.16.4 Resetting an existing JOB to the factory setting (Reset JOB)
Operating Action
element
Result
Display
Select JOB Manager mode
Press until the “VOLT”
signal light is on
xx
Select JOB Manager mode
2 sec.
Switch from “Load JOB” to “Reset JOB”
2x
Select the required JOB number using the rotary
transducer (e.g. 150)
1x
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JOB reset to factory settings, machine switches
back to Display mode.
Current value and JOB
number displayed
45
Design and function
Organising welding tasks (Mode "JOB Manager")
5.16.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs)
Operating Action
element
Result
Display
Select JOB Manager mode
Press until the “VOLT”
signal light is on
xx
Select JOB Manager mode
2 sec.
Switch from “Load JOB” to “Reset All JOBs”
3x
•
•
1x
ON = Reset all JOBs to factory settings
OFF = Do not reset JOBs
All JOBs reset to factory settings, machine
switches back to Display mode.
Current value and JOB
number displayed
5.16.6 Exit JOB Manager without changes
The user is in the JOB manager menu and wants to exit without making any changes:
Operating Action
Result
Display
element
2 sec.
46
Machine switches back to Display mode
The JOB can be adjusted individually.
Current value and JOB
number displayed
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Design and function
Organising welding tasks (Mode "JOB Manager")
5.16.7 Specifying max. no. of accessible JOBs
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 machine, but this figure can
be increased to up to 128 if required.
The first JOB in the free memory is JOB 129. With the factory setting of 10 JOBs, this equates to JOB
numbers 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 150.
Job 129...
...192...
145...
...256
...150
Figure 5-13
0
1
0
1
Figure 5-14
Display
Setting/selection
Exit the menu
Exit
Torch configuration menu
Set welding torch functions
Get JOB number
Set maximum selectable jobs (setting: 1 to 128, factory setting 10).
Additional parameter after activating the BLOCK JOB function.
Start JOB
Set first JOB to get (setting: 129 to 256, factory setting 129).
NOTE
The setting of the max. number of JOBs is intended solely for torch modes 4, 5 and 6 or
14, 15 and 16 (no tapping function).
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Design and function
Simultaneous welding on both sides, synchronisation types
5.17
Simultaneous welding on both sides, synchronisation types
This function is important, if two power sources are used to simultaneously weld on both sides, as is
sometimes required for welding thick aluminium materials in the PF position. This ensures that, with
alternating currents, the positive and negative pole phases are present on both power sources
simultaneously, thus avoiding the arcs negatively influencing each other.
5.17.1 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.
• Synchronisation between two Tetrix series machines.
Phase sequences and rotating fields of the supply voltages must be identical for both
welding machines.
If this is not the case, the energy input into the weld pool will be negatively affected.
Use the "Phase sequence changeover“ rotary switch to correct the phase difference in steps of
60° (0°, 60°, 120°, 180°, 240° and 300°).
An optimum phase correction will directly achieve better welding results.
Operating
element
Action
Result
Select "Synchronisation types" parameter:
Press until signal light
comes on.
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Simultaneous welding on both sides, synchronisation types
5.17.2 Synchronisation via cable (frequency 50Hz to 200Hz)
HINWEIS
This application describes synchronisation (master/slave operation) with two machines
in the TETRIX series. The following components are required:
• The synchronisation interface SYNINT X10
• Control lead (connecting cable) of the relevant length
• Both welding machines must be fitted with the 19-pole TIG interface for mechanised welding
(optional)
•
Connect the SYNINT X10 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 synchronisation interface using the short connection
cable is designated the "master" welding machine. The TIG AC frequencies are set on
this welding machine and transferred to the second welding machine (slave).
•
Connect the extension cable RA (5 m, 10 m or 20 m) between the interface and the 19-pole TIG
interface for mechanised welding on the second welding machine.
Operating
element
Action
Result
Switch on the welding machine.
Select "Synchronisation types" parameter:
Press until signal light
comes on.
This setting must be made on both machines.
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Design and function
Interfaces
5.18
Interfaces
5.18.1 Connecting the robot interface / industrial bus interface
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, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of
products!
• Only insert and lock accessory components 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
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.
The interfaces can be operated directly on the power source in a separate interface casing or externally,
e.g. in a robot control cabinet or via a data cable.
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Design and function
Interfaces
A
B
2
2
4
3
3
6
1
5
Figure 5-15
Item
Symbol Description 0
2
7-pole connection socket (digital)
For connecting digital accessory components
Switching cabinet
3
Robot interface / Industrial bus interface
4
Interface casing ATCASE
5
Connection cable, 7-pole
Connection between switching cabinet and power source
Connection cables, 12-, 19- and 23-pole
Connection between interface casing and switching cabinet
1
6
5.18.1.1 RINT X11 robot interface
The 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 program selection, inching, gas test
• Analogue inputs: control voltages, e.g. for welding performance, welding current, etc.
• Relay outputs: process signal, ready for welding, system composite fault, etc.
5.18.1.2 BUSINT X11 industrial bus interface
The solution for integration into mechanised production lines, with for example
• Profibus
• CAN-Open, CAN DeviceNet
• Interbus systems with copper and optical fibre connection (FSMA/Rugged Line)
NOTE
Only one variant can ever be operated at any one time.
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Design and function
Interfaces
5.18.2 Connecting the PC 300.net welding parameterisation software
Create all welding parameters quickly on the PC and easily transfer them to one or more welding
machines (accessories, set consisting of software, interface, connection leads)
1
4
3
2
5
6
Figure 5-16
Item
Symbol Description 0
PC interface, serial (D-Sub connection socket, 9-pole)
1
COM
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 incorrectly!
Not using the SECINT X10USB interface results 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 machine!
• The connection must only be made using the cables supplied (do not use any additional
extension cables)!
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Design and function
Interfaces
5.18.3 Connecting the Q-DOC 9000 welding data documentation software
(Accessories: Set consisting of software, interface, connection leads)
The ideal tool for welding data documentation of, for example:
welding voltage and current, wire speed and motor current.
1
2
3
4
7
6
5
Figure 5-17
Item
Symbol Description 0
2
7-pole connection socket (digital)
For connecting digital accessory components
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
1
CAUTION
Equipment damage or faults may occur if the PC is connected incorrectly!
Not using the SECINT X10USB interface results 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 machine!
• The connection must only be made using the cables supplied (do not use any additional
extension cables)!
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Design and function
Interfaces
5.18.4 Connecting the WELDQAS welding data monitoring and documentation system
Network-compatible welding data monitoring and documentation system for digital power sources.
2
6
1
5
3
4
Figure 5-18
Item
2
7-pole connection socket (digital)
For connecting digital accessory components
Windows PC
3
WELDQAS welding data monitoring and documentation system
4
Connection cable, 7-pole
Connection between switching cabinet and power source
Integration option of WELDQAS into existing network systems via network
cables
Connection cable included as standard with WELDQAS
1
5
6
54
Symbol Description 0
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Design and function
Interfaces
5.18.5 Automation interface
WARNING
No function of the external shut-down devices (emergency stop switch)!
If the emergency stop circuit has been realised using an external shut-down device via
the interface for mechanised welding, the device must be set for this setup. If this is not
observed, the power source will ignore the external shut-down devices and will not shut
down!
• Disconnect jumper 1 on PCB T320/1 (Tetrix) or M320/1 (Phoenix / alpha Q)!
CAUTION
Equipment damage due to unshielded control leads!
Unshielded control leads can cause damage to the power source and accessory
components.
• Use shielded control leads 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 equipment meets the same criteria, particularly with regard to isolation from the mains
supply.
This is guaranteed by the use of transformers conforming to VDE 0551.
The welding machines are equipped for mechanised operation as standard.
For the simplest possible mechanised applications, control inputs and galvanically isolated relay contacts
are available on the interface for mechanised welding.
A
B
C
D
P
T
S
F
L
U
V
R
E
M
N
G
K
J
H
Figure 5-19
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Design and function
Interfaces
19-pole connection assignments for mechanised welding interface (X6):
Pin
56
A
B
Signal
shape
Output
Input
Circuit diagram
signal name
PE
PULSEN EIN
C
D
Input
Input
SYN_E
IGRO RELAY
E
Input
NOT/AUS
F
Input
INOMINAL LOW
G
Output
IGRO RELAY
H
Output
UACTUAL
J
K
L
Output
Input
Input
SYN_AE
SYN_AC
START/STOP
M
Output
+15 V
N
Input
Isoll HIGH
P
Input
FREQUENZ
R
Input
Emergency stop
S
T
Output
Output
0V
Iist
U
V
Input
Output
BR. KOLL. 1
BR. KOLL. 2
Function
Connection for cable screen
Thermal pulse mode up to max. 50 Hz, fixed balance of
50%
Synchronisation for master/slave operation
Current flows signal
I>0
Contact closed = welding current flowing
(forms contact with signal G)
Emergency stop for higher level shut-down of the power
source.
To use this function, jumper 1 must be unplugged on PCB
T320/1 in the welding machine.
Contact open = welding current switched off
Control voltage specification for secondary current,
0-10 V (0 V = Imin/10 V = Imax)
Current flows signal
I>0
Contact closed = welding current flowing
(forms contact with signal D)
Actual welding voltage, measured on pin S,
0-10 V (0 V = 0 V, 10 V = 100 V)
Synchronisation for master/slave operation
Start/stop welding current, same as torch trigger.
Only available in non-latched operating mode.
+15 V = Start, 0 V = Stop
Power supply
+15 V, max. 75 mA
Control voltage specification for main current,
0-10 V (0 V = Imin/10 V = Imax)
Nominal frequency value
0-10 V (0 V= 50 Hz, 10 V = 0.1 Hz)
Emergency stop for higher level shut-down of the power
source.
To use this function, jumper 1 must be unplugged on PCB
T320/1 in the welding machine.
Contact open = welding current switched off
Reference potential
Welding current, measured on pin S,
0-10 V (0 V = 0 A, 10 V = 1000 A)
Emergency shut-down collision protection +24 V
Emergency shut-down collision protection
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Design and function
Interfaces
5.18.6 Connection socket automation torch
X22-
2n2F
PE
BR KOLL1
BR KOLL2
NC
NC
Fühlerspannung
NC
TETRIX
DRIVE 4 ROB
only!
A
B
C
D
T
S
E
F
G
NC
NC
U
V
R
NC
L
N
P
NC
M
K
J
H
Gastest
Einfädeln
0V
codiert
NC
NC
NC
NC
PE
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Figure 5-20
Connection socket19-pole Automation torch (X22):
Pin
Signal
shape
Output
Input
Input
Signal name
designation
A
PE
Connection for cable screen
B
BR. KOLL. 1
Emergency shut-down collision protection
C
BR. KOLL. 2
Emergency shut-down collision protection + 24 V
D
NC
not used
E
NC
not used
F
Output
Fühlerspannung
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*
Shielding gas runs 20 s
N
Input
Einfädeln*
Welding wire Inching
P
Output
0V
R
codiert
coded
S
NC
not used
T
NC
not used
U
NC
not used
V
NC
not used
*Feature only available for the cold wire versions.
5.18.7 Sensor Voltage
The sensor voltage is transmitted via PIN F of the mechanised welding torch connection socket (X22).
Outside the welding process, there is a voltage 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 (BUSINT X11/RINT X12), the resultant signal can be used for various
functions (e.g. workpiece search). The output signal can be used to connect the cold wire component in
order to enable fusing detection at the end of the process.
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Design and function
Advanced settings
5.19
Advanced settings
5.19.1 Setting slope times for secondary current AMP% or pulse edges
Figure 5-21
Figure 5-22
Display
Setting/selection
Expert menu
Slope time tS1 (main current to secondary current)
Setting: 0.00 s to 20.0 s (factory setting 0.01 s)
Slope time tS2 (secondary current to main current)
Setting: 0.00 s to 20.0 s (factory setting 0.01 s)
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Advanced settings
5.19.2 TIG non-latched operating mode, C version
0
1
0
1
Figure 5-23
Display
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Setting/selection
Exit the menu
Exit
Machine configuration
Settings for machine functions and parameter display
Non-latched operation (C version)
• on = on
• off = off (factory setting)
59
Design and function
Advanced settings
5.19.3 Welding current display (ignition, secondary, end and hotstart currents)
The welding currents for secondary current, ignition current and end current (expert menu) can be
displayed as percentages or absolute values on the machine display.
0
1
0
1
Figure 5-24
Display
60
Setting/selection
Exit the menu
Exit
Machine configuration
Settings for machine functions and parameter display
Welding current display (ignition, secondary, end and hotstart currents)
• Pro = welding current display as a percentage of the main current
• Abs = absolute welding current display (factory setting)
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Design and function
Menus and sub-menus on the machine control
5.20
Menus and sub-menus on the machine control
5.20.1 Direct menus (direct access to parameters)
Functions, parameters and their values can be accessed directly, e.g. can be selected by pressing a
button once.
5.20.2 Expert menu (TIG)
The expert menu includes functions and parameters which are either not set on the machine control, or
which do not require regular setting.
Figure 5-25
Display
Setting/selection
Expert menu
Slope time tS1 (main current to secondary current)
Setting: 0.00 s to 20.0 s (factory setting 0.01 s)
Slope time tS2 (secondary current to main current)
Setting: 0.00 s to 20.0 s (factory setting 0.01 s)
Wire return
• Increase value = more wire return
• Reduce value = less wire return
Parameter can also be set after connecting a TIG cold wire feed unit. Setting: 0 to 255
(factory setting 50).
activArc parameter
Parameter can also be set after activating TIG activArc welding.
Display shown = factory setting.
NOTE
ENTER (enter the menu)
• Keep the "welding parameters" button pressed for 4 s.
Navigating in the menu
• Parameters are selected by pressing the "welding parameters" button.
• Set or change the parameters by turning the "welding parameter setting" rotary dial.
EXIT (leave the menu)
• After 4 s, the machine will return automatically to the ready-to-operate status.
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Design and function
Menus and sub-menus on the machine control
5.20.3 Machine configuration menu
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
same time.
NAVIGATION (navigating in the menu)
• Parameters are selected by pressing the "welding parameters" button.
• Set or change the parameters by turning the "welding parameter setting" rotary dial.
EXIT (leave the menu)
• Select the "Elt" menu item.
• Press the "welding parameters" button (settings will be applied, machine changes to the
ready-to-operate status).
0
1
0
1
Figure 5-26
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Menus and sub-menus on the machine control
Display
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Setting/selection
Exit the menu
Exit
Torch configuration menu
Set welding torch functions
Torch mode
• Modes 1-6: with tapping function (factory setting 1)
• Modes 11-16: without tapping function
Setting the first increment
Setting: 1 to 20 (factory setting 1)
Up-/Down speed (not available in modes 4 and 14)
Increase value
= rapid current change (factory setting 10)
Reduce value
= slow current change
Get JOB number
Set maximum selectable jobs (setting: 1 to 128, factory setting 10).
Additional parameter after activating the BLOCK JOB function.
Start JOB
Set first JOB to get (setting: 129 to 256, factory setting 129).
Machine configuration
Settings for machine functions and parameter display
Operating principle
• on = synergic parameter setting (factory setting)
• off = conventional parameter setting
Welding current display (ignition, secondary, end and hotstart 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 for the primary setpoint value display
Defines the priority display for setpoint values:
• bld = panel thickness
• vol = welding voltage (factory setting)
RINT X12, JOB control for automation solutions
• on = on
• off = off (factory setting)
Power display switching (MMA)
• on = actual value display
• off = setpoint value display (factory setting)
spotMatic
Variation of operation mode spotArc, ignition with workpiece contact
• on = on
• off = off (factory setting)
Ramp function Remote control RTF 1
The ramp function can be switched on and off
Pulses in the upslope and downslope phases
The function can be switched on or off
Torch cooling mode
• AUt = automatic operation (ex works)
• on = permanently switched on
• off = permanently switched off
Expert menu
63
Design and function
Menus and sub-menus on the machine control
Display
Setting/selection
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 protect the
tungsten electrode from being destroyed.
• on = Polarity can be selected freely
Reconditioning pulse (spherical cap stability)
• on = function on (factory setting)
• off = function off
activArc voltage measuring
• on = function on (factory setting)
• off = function off
Error output to automated welding interface, contact SYN_A
off
AC synchronisation or hot wire (factory setting)
FSn
Error signal, negative logic
FSP
Error signal, positive logic
AvC
AVC (Arc voltage control) connection
Automation menu
Fast take-over of control voltage (automation)
• on = function on
• off = function off (factory setting)
Orbital welding
• off = off (ex works)
• on = on
Orbital welding
Correction value for orbital current
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 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 machine/function control
on:
with external control voltages/signals
off:
with machine control
Software version query (example)
07=
System bus ID
02c0= Version number
System bus ID and version number are separated by a dot.
64
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Maintenance, care and disposal
General
6
Maintenance, care and disposal
DANGER
Risk of injury from electric shock!
Cleaning machines that are not disconnected from the mains can lead to serious
injuries!
• Disconnect the machine completely from the mains.
• Remove the mains plug!
• Wait for 4 minutes until the capacitors have discharged!
6.1
General
When used in the specified environmental conditions and under normal operating conditions, this
machine is largely maintenance-free and requires a minimum of care.
There are some points, which should be observed, to guarantee fault-free operation of your welding
machine. Among these are regular cleaning and checking as described below, depending on the pollution
level of the environment and the length of time the unit is in use.
6.2
Maintenance work, intervals
6.2.1
Daily maintenance tasks
•
•
•
•
•
•
•
6.2.2
Monthly maintenance tasks
•
•
•
•
•
•
6.2.3
Check correct mounting of the wire spool.
Mains supply lead and its strain relief
Welding current cables (check that they are fitted correctly and secured)
Gas tubes and their switching equipment (solenoid valve)
Gas cylinder securing elements
Operating, message, safety and adjustment devices (Functional test)
Other, general condition
Casing damage (front, rear and side walls)
Wheels and their securing elements
Transport elements (strap, lifting lugs, handle)
Selector switches, command devices, emergency stop devices, voltage reducing devices, message
and control lamps
Check coolant tubes and their connections for impurities
Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
Annual test (inspection and testing during operation)
NOTE
The welding machine may only be tested by competent, capable personsl.
A capable person is one who, because of his training, knowledge and experience, is
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.
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition
to the regulations on testing given here, the relevant local laws and regulations must also be observed.
099-000140-EW501
08.07.2011
65
Maintenance, care and disposal
Maintenance work
6.3
Maintenance work
DANGER
Do not carry out any unauthorised repairs or modifications!
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 only skilled persons for repair work (trained service personnel)!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service matters, always consult the dealer who supplied the
machine. Return deliveries of defective equipment subject to warranty may only be made through your
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 item
number of the spare part.
6.4
Disposing of equipment
NOTE
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and
electronic components, which must be disposed of.
• Do not dispose of in household waste!
• Observe the local regulations regarding disposal!
6.4.1
Manufacturer's declaration to the end user
•
•
•
•
•
6.5
According 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 waste. It must be collected separately. The symbol depicting a waste container on wheels
indicates that the equipment must be collected separately.
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 environmentally correct
disposal of electric and electronic equipment (ElektroG) from 16.03.2005), used machines are to be
placed in a collection system separate from unsorted municipal waste. The public waste management
utilities (communities) have created collection points at which used equipment from private households
can be disposed of free of charge.
Information about giving back used equipment or about collections can be obtained from the
respective municipal administration office.
EWM participates in an approved waste disposal and recycling system and is registered in the Used
Electrical Equipment Register (EAR) under number WEEE DE 57686922.
In addition to this, returns are also possible throughout Europe via EWM sales partners.
Meeting the requirements of RoHS
We, EWM HIGHTEC Welding GmbH Mündersbach, hereby confirm that all products supplied by us which
are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).
66
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Rectifying faults
Customer checklist
7
Rectifying faults
All products are subject to rigorous production checks and final checks. If, despite this, something fails to
work at any time, please check the product using the following flowchart. If none of the fault rectification
procedures described leads to the correct functioning of the product, please inform your authorised
dealer.
7.1
Customer checklist
Legend
a: Fault/Cause
#: Remedy
NOTE
The correct machine equipment for the material and process gas in use is a
fundamental requirement for perfect operation!
Functional 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)
a Various parameters cannot be set
#
Entry level is blocked, disable access lock (see chapter entitled "Lock welding parameters
against unauthorised access")
a Connection problems
#
Make control lead connections and check that they are fitted correctly.
No arc ignition
a Incorrect ignition type setting.
#
Set ignition type changeover switch to the HF ignition setting.
Bad arc ignition
a Material inclusions in the tungsten electrode due to contact with filler material or workpiece
#
Regrind or replace the tungsten electrode
a Bad current transfer on ignition
#
Check the setting on the "Tungsten electrode diameter/Ignition optimisation" rotary dial and
increase if necessary (higher ignition energy).
Welding torch overheated
a Loose welding current connections
#
Tighten power connections on the torch and/or on the workpiece
#
Tighten contact tip/collet correctly
a Overload
#
Check and correct welding current setting
#
Use a more powerful welding torch
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67
Rectifying faults
Customer checklist
Unstable arc
a Material inclusions in the tungsten electrode due to contact with filler material or workpiece
#
Regrind or replace the tungsten electrode
a Incompatible parameter settings
#
Check settings and correct if necessary
Pore formation
a Inadequate or missing gas shielding
#
Check shielding gas setting and replace shielding gas cylinder if necessary
#
Shield welding site with protective screens (draughts affect the welding result)
#
Use gas diffuser for aluminium applications and high-alloy steels
a Unsuitable or worn welding torch equipment
#
Check size of gas nozzle and replace if necessary
a Condensation (hydrogen) in the gas tube
#
Rinse hose package with gas or replace
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Rectifying faults
Machine faults (error messages)
7.2
Machine faults (error messages)
NOTE
A welding machine error is indicated by the collective fault signal lamp (A1) lighting up
and an error code (see table) being displayed in the machine control display. In the
event of a machine error, the power unit shuts down.
•
•
If multiple errors occur, these are displayed in succession.
Document machine errors and inform service staff as necessary.
Error message
Err 3
Possible cause
Speedometer error
Wire feed unit not connected
Err 4
Temperature error
Error in emergency stop circuit
(interface for mechanised welding)
Err 5
Err 6
Err 7
Overvoltage
Undervoltage
Coolant error (only if cooling module
connected)
Gas error
Secondary overvoltage
PE error
FastStop position
Err 8
Err 9
Err 10
Err 11
Err 32
Err 33
Err 34
Err 35
Err 36
Err 37
Err 38
Err 39
Err 51
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Electronics error (I>0 error)
Electronics error (Uactual error)
Electronics error (A/D channel error)
Electronics error (edge error)
Electronics error (S sign)
Electronics error (temperature error)
--Electronics error (secondary
overvoltage)
Error in emergency stop circuit
(interface for mechanised welding)
Remedy
Check wire guide/tube package
• Switch off cold wire mode in the device
configuration menu (off status)
• Connect wire feed unit
Allow machine to cool down.
• Check the external shut-down equipment
• Check plug-in jumper JP 1 on
PCB T320/1
Switch off the machine and check mains
voltages
Check coolant level and refill if necessary
Check gas supply
Switch the machine off and on again.
If the error persists, inform the service dept.
Edge "Acknowledge error" signal (0 to 1) via
robot interface (if available)
Switch the machine off and on again.
If the error persists, inform the service dept.
Allow machine to cool down.
Switch the machine off and on again.
If the error persists, inform the service dept.
•
•
Check the external shut-down equipment
Check plug-in jumper JP 1 on PCB
T320/1
69
Rectifying faults
Resetting welding parameters to the factory settings
7.3
Resetting welding parameters to the factory settings
NOTE
All customised welding parameters that are stored will be replaced by the factory
settings.
0
1
0
1
Figure 7-1
Display
70
Setting/selection
Exit the 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 machine configuration menu
• CPL = Complete reset of all values and settings
The reset is performed when leaving the menu (EXIT).
Switch off
Switching off machine function
Reset machine configuration
Resetting the values in the machine configuration menu
Complete reset
Complete reset of all values and settings by the factory settings
099-000140-EW501
08.07.2011
Rectifying faults
Display machine control software version
7.4
Display machine control software version
NOTE
The query of the software versions only serves to inform the authorised service staff!
0
0
1
1
Figure 7-2
Display
Setting/selection
Exit the menu
Exit
Service menu
Modifications to the service menu may only be carried out by authorised maintenance
staff!
Software version query (example)
07=
System bus ID
02c0= Version number
System bus ID and version number are separated by a dot.
7.5
General operating problems
7.5.1
Interface for mechanised welding
WARNING
No function of the external shut-down devices (emergency stop switch)!
If the emergency stop circuit has been realised using an external shut-down device via
the interface for mechanised welding, the device must be set for this setup. If this is not
observed, the power source will ignore the external shut-down devices and will not shut
down!
• Disconnect jumper 1 on PCB T320/1 (Tetrix) or M320/1 (Phoenix / alpha Q)!
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71
Technical data
Tetrix 352 AC/DC
8
Technical data
8.1
Tetrix 352 AC/DC
NOTE
Performance specifications and guarantee only in connection with original spare and
replacement parts!
Welding current setting range
Welding voltage setting range
Duty cycle 25 °C ambient temperature
80%DC
100%DC
Duty cycle 40 °C ambient temperature
60%DC
100%DC
Load alternation
Open circuit voltage
Mains voltage (tolerance)
Frequency
Mains fuse
(safety fuse, slow-blow)
Mains connection lead
Max. connected power
Recommended generator rating
Insulation class
Protection classification
Ambient temperature
Machine cooling
Workpiece lead
Dimensions L/W/H [mm]
Weight
EMC class
Constructed to standards
5 A–350 A
10.2 V–24.0 V
350 A
320A
350 A
300A
∧
10min. (60% DC 6 min. welding, 4 min. break)
100 V
3 x 400 V (-25% to +20%)
50/60 Hz
3 x 25 A
H07RN-F4G4
10.6 kVA
23.9 kVA
H
IP 23
-20 °C to +40 °C
Fan
70 mm2
654 x 374 x 576
82,0 kg
A
IEC 60974-1, -3, -10
/
625
780
375
Figure 8-1
72
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08.07.2011
Accessories
Connection cables, connection sockets
9
Accessories
NOTE
Performance-dependent accessories like torches, workpiece leads, electrode holders or
intermediate hose packages are available from your authorised dealer.
9.1
Connection cables, connection sockets
Type
5POLE/CEE/32A/M
RA5 19POL 1x 5M
RA10 19POL 1x 10M
9.2
Item no.
094-012294-00001
092-001828-00000
Designation
Item no.
Transport pallet for use with robots
090-008275-00000
Transport vehicle for a power source with an add-on 090-008278-00000
module
Designation
Robot interface
Interbus industrial bus interface in casing
Item no.
090-008291-00000
090-008225-00000
Computer communication
Type
RC 300
PC300.NET
WELDQAS1 Station
QDOC9000 V2.0
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08.07.2011
Designation
Panel for stacking machines
Optional retrofit kit for key switch
Interfaces
Type
RINT X12 STANDARD
BUSINT X11 INTERBUS
ATCASE
9.6
Item no.
094-000009-00000
094-000010-00001
Transport systems
Type
PALETTE ROB XX2
TROLLY ROB XX2
9.5
Designation
Manometer pressure regulator
Gas hose
Options
Type
BGA364X51X47
ON KEY SWITCH
9.4
Item no.
094-000207-00000
092-001569-00005
092-001569-00010
General accessories
Type
DM1 32L/MIN
GH 2X1/4'' 2M
9.3
Designation
Machine plug
Connection cable, 19-pole, 5 m
Connection cable, 19-pole, 10 m
Designation
EWM tablet PC incl. software, adapter and interface
PC300.Net welding parameter software set incl.
cable and SECINT X10 USB interface
Stationary welding data monitoring and docu set for
one welding machine
Set consisting of interface, documentation software,
connection lead
Item no.
090-008238-00002
090-008265-00000
090-008215-00000
090-008713-00000
73
Accessories
Cooling units
9.7
Cooling units
Type
RK1
RK2
RK3
cool82 U44
cool82 U45
Designation
Reverse cooling unit
Reverse cooling unit
Reverse cooling unit
Cooling module for robot welding machines
Cooling module for robot welding machines
Item no.
094-002283-00000
094-002284-00000
094-002285-00000
090-008268-00502
090-008280-00502
9.8
Simultaneous welding on both sides, synchronisation types
9.8.1
Synchronisation via cable (frequency 50Hz to 200Hz)
NOTE
For simultaneous, 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 the machine type).
Type
SYNINT X10 19POL
RA10 19POL 10M
9.8.2
Item no.
090-008189-00000
092-001470-00010
Synchronisation via mains voltage (50Hz / 60Hz)
Type
ON NETSYNCHRON
74
Designation
Synchronisation set incl. interface and connector
cable
Remote control e.g. connection cable
Designation
Item no.
Optional retrofit set for phase sequence changeover 090-008212-00000
for synchronous welding
099-000140-EW501
08.07.2011
L3
PE
PE
L3
L2
PE
1
2
3
4
X3-
PE
L3
L2
1
PE
15
10
9
9
10
0V
2
4
6
11
Temp
105°C
8
14
15
T1-
16
20V
11
25V
14
0V
42V
n=3Wdg.
L3
L2
6
2
0V
4
230V
400V/415V
T3
T2
18
0VAC
15
230VAC
12
400/415VAC
9
0VAC
6
230VAC
L3
A1-
X7/18
X7/17
X7/16
X7/15
X7/14
X7/13
X7/12
X7/11
X7/10
X7/9
X7/8
X7/7
X7/6
X7/5
X7/4
X7/3
X7/2
X7/1
A1-
L3
L2
L2
X7
X5
1
A1-
2
L1
F1-
X13
4A
X5/1
1
L1
X5/2
0VAC
42VAC
2
T1
X13/1
Lüfter
2
1
?T
?T
2
1
2 7
A
L2
PE
Q1-
X13/2
Lüfter
2 7
B
L1
2 6
2 6
D
E
X2/2
X1/2
X9/2
X1/3
X1/4
4
3
0VAC
X1/2
X1/1
X3/2
0VAC
2
25VAC
1
25VAC
1
PE
X3/1
X9/1
2
Absicherung
X1/8
X1/7
X1/6
X1/5
X1/4
Absicherung
1
8
PE
2
X1/3
X1/1
0VAC
1
42VAC
X3/4
X3/3
X3/2
X3/1
X2/4
X2/3
X2/1
0VAC
2
42VAC
1
DC351
A1-
X1
X3
X9
X1
X3
X2
A10-
T1
LDC2
F1
4AT
A3-
X8
X2
12V
1
-18V
UD
X2/5
6
0V
5
4
3
0V
X2/4
X2/6
+8V
X2/3
2
+18V
X7
X6
X5
X4
X2/2
X2/1
WK-6
T2
DSB10
PE
1
PE
-
+
R330/20W 4u7F
I
H
L1-
2 12
2 8
n=?Wdg.
Ringkern
T3
Ringkern
E
A
?T
2 5
2 5
F
G
1
L1
Fühler-
X5
3
1
0V
+15V
A15-
T3
T2
X1/2
Blatt:
Datum:
01.02.2008
1/ 2
Freigabe:
Änderung-
Änderung-
Änderung-
Änderung-
gezeichnet:
X4/4
NIEDENTHAL
Name:
X3/2
X3/1
X4/3
X1/1
X4/2
X4/1
X2/4
X3
X4
X2/3
X1
X2
A5-
X8
HF-DC2
Ringkern
n=?Wdg.
X6
D-Sub.
15polig
X2/2
X2/1
PE
PE1-
X4
TRF6/-6M
T4
T1
X4/1
X5-
2 4
spannung
X8/1
X5/1
20VAC
2
Xe
2 4
J
1
K
2
X8/2
X5/2
0VAC
L1
D-Sub.
15polig
D-Sub.
15polig
D-Sub.
15polig
D-Sub.
15polig
T1
X8/2
2
T1T3
X8/4
4
T2T4
X8/1
1
+15V
X8/3
3
TKom
08.07.2011
2 4
099-000140-EW501
C
2
2
1
geprüft:
-
+
0VAC
4
L2-
W
E
EL
PE
1
1
+
3
2
42V
1
TXD
X1/4
TXD
RXD
0V
Schirm
X2/7
W
WIG
Zeichnungsnummer:
5214-00
TETRIX 352 AC/DC ROB
WIG-GERAET, 3X400V SYNERGIC
This drawing is protected by copyright.
It may not be reproduced or utilised in any way
or communicated or forwarded to third parties
without our express permission!
2x2n2F
X2/6
X2/5 RS+12V
X2/4
X2/3
X2/2 RSGND
42V
X1/7
X2/1
0V
Schirm
X1/6
X1/5 RS+12V
RXD
X1/3
X1/2 RSGND
A6VP5/2D X1/1
-
PE
22nF
C1-
A4HF-DC2 Coil
HF-Drossel
25VAC
A
10.1
D-SUB
15polig
10
Stecker X3
L1
Circuit diagrams
Tetrix 352 AC/DC
Circuit diagrams
NOTE
Original format circuit diagrams are located inside the machine.
Tetrix 352 AC/DC
Figure 10-1
75
NC
1 10
1Wdg. durchgezogen
K
1 10
Wasserkühler
2
Fühlerspannung
1
Fühlerspannung
0V
4
Wassermangel
WKühler
3
WMangel
8 PC-RTS
9
J
+15V
+15V
2
6
Lüfter
Lüfter
1
5
Pumpe
PC-DTR
X12
Fernregler
X22
Brennertaster2
X4/1
2
1
+18V
X9/6
X9/5
X9/4
X9/3
X9/2
X9/1
X9
Wasserkühler
X10/2
X10/1
X10
Fühlerspannung
X7
Computer
X-PE
Erdung
PE6-
X13
Brennertaster1
T320/1
X5
Robo./Auto.
X2/5
X2/6
X2/7
X2/8
X1/5
X1/6
X1/7
X1/8
X1/9
X1/10
UP
Poti UD/ein
NC
NC
0V
0V
BTF1
X2/4
X1/4
X3/4
X3/3
X3/2
X3/1
X2/3
X1/3
A11-
X2/2
X1/2
PE
X2/1
X1/1
12
11
10
9
8
7
6
5
4
3
2
1
Not/Aus
X6/2
1
Not/Aus
X6/1
X5/18
X5/17
15
BRT2
7x2n2F
0V
X5/15
Sollwert
4M7
SYN_A E
X5/14
X5/16
Str./Stp.
11
SYN_A C
X5/13
12
10
I
6
1 11
Sollwert Frequenz
Prozeßspannung Uist
7
Uref+10V
BRT1
X6
Not/Aus
1
+15V
3
SYN_E
Prozeßstrom Iist
6
X5/12
X5/11
X5/10
X5/9
X5/8
X5/7
X5/6
X5/5
X5/4
X5/3
X5/2
0V
X4/6
5
UD
X4/5
4
3
-18V
X4/4
X5/1
D-Sub.
9polig
Pumpe
7
X4
Versorgung
X19/12
1
PC-TXD
X11
Frontplatte
X19/11
X19/10
X12/1
Relais IGRO
10
X12/2
Sollwert Grundstrom
T2T4
X19/9
X19/8
X19/7
X12/4
6
1 13
0V
X12/13
+8V
X12/5
NC
Ana. B
X4/3
X12/9
5
Ana. C
X4/2
X19/6
X12/11
NC
OE
X19/5
X12/12
4
0V-Ana.
X19/4
X-PE/1
PC-GND
X14/10
1 0
X12/10
IGR0
X12/3
3
Sollwert Absenkstrom
X-PE/2
PE
5
X13/1
BRT1
4
X13/2
BRT2
3
WR1
X13/3
Uref.10V
PC-RXD
CS1
X13/4
2
RD1
X13/5
IH-Up
Sollwert
Ringkern
CS2
X13/6
P. UD ein
NC
CLK1
X13/7
NC
1
B1
X13/8
NC
X2-
CLK1
X13/9
0V
NC
A1
X13/10
0V
NC
0V-Ana.
X22/1
WA2
0V
+10V Uref.
T1T3
A2-
+10V Uref.
X22/2
CS3
Ringkern
0V1
X22/3
CLK2
A
B
C
D
E
F
G
H
X8
Systembus
D-Sub.
15polig
+5V1
X22/4
RD2
X9-
X14/4
X19AC-Steuerung
X2
Lüfter
0V1
TKom
X19/3
X19/2
X19/1
1 13
0V
X14/2
F
1
G
X14/3
1 8
E
1 8
5
Ringkern
+5V1
X22/5
CS4
1 15
3
+15V
X14/5
42VAC
D
X14/6
X14
Peripherie
7
1 6
1
1 6
3
1 11
H
PE
A2
PE
9
+15V
X14/1
+15V
X22/6
+5V
PE
1 1
HF-Liftarc
X14/9
Gasrelais
X14/11
0VAC
6
X12/6
-15V
X22/7
NC
2
1 2
Gasrelais
X14/12
0V
X14/7
X12/7
+15V
X22/8
1
X12/14
1 4
Pulsen ein
X22/10
0V
C
Gas
X14/8
X12/8
Ana. A
A
X2/2
X12/16
B2
B
Lüfter
X2/3
X12/17
Lüfter
X2/1
X12/15
X2/4
X12/18
-15V
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
X11/20
X11/21
X11/22
X11/23
X11/24
X11/25
X11/26
X22/9
0V
NC
0V1
+10V Uref.
+10V Uref.
0V-Ana.
Ringkern
-15V
-15V
+15V
+15V
+5V1
+5V1
0V1
OE
0V-Ana.
B2
Ana. C
A1
Ana. B
B1
Ana. A
CLK1
CLK1
A2
CS2
CS1
RD1
WR1
X1
Frontplatte
Blatt:
2/ 2
gezeichnet:
Datum:
Name:
E
L
M
N
P
+15V
Sollwert Grundstrom
Sollwert Frequenz
T
Prozeßstrom Iist
Freigabe:
5214-00
PE
2n2F
Rückseite
Zeichnungsnummer:
V
U
S
0V
R
K
Str./Stp.
Not/Aus
J
SYN_A C
H
G
SYN_A E
Prozeßspannung Uist
F
D
IGRO Relais
Sollwert Absenkstrom
Not/Aus
C
B
A
X6-
2
IGR0 Relais
SYN_E
Pulsen ein
PE
This drawing is protected by copyright.
It may not be reproduced or utilised in any way
or communicated or forwarded to third parties
without our express permission!
Ringkern
1
S1-
Schlüsselschalter
2
1
WIG-GERAET, 3X400V SYNERGIC
geprüft:
1
TETRIX 352 AC/DC ROB
NIEDENTHAL
1
Änderung-
01.02.2008
2
X2/1
X2
Schlüsselschalter
X2/2
Änderung-
Änderung-
Änderung-
X13- 1
T322/2
A7-
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
X11/20
X11/21
X11/22
X11/23
X11/24
X11/25
X11/26
76
1
1
Y1-
Circuit diagrams
Tetrix 352 AC/DC
Figure 10-2
099-000140-EW501
08.07.2011
Appendix A
JOB-List
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
∅
Seam position
Tungsten electrode ∅
Wire
Vertical-down weld
Material
MMA
TIG cold wire
Reserved
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
099-000140-EW501
08.07.2011
TIG hot wire
TIG
JOB
Process
Fillet weld lap joint
JOB-List
Butt joint
11.1
Fillet weld
Appendix A
0,6
0,8
1,0
1,2
1,6
11
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
CrNi/ Fe/ St
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
; ; ;
; ; ;
; ; ;
;
;
;
;
;
;
;
;
;
;
;
;
; ; ;
; ; ;
; ; ;
;
;
;
;
;
;
; ; ;
; ; ;
; ; ;
;
;
;
;
;
;
; ; ;
; ; ;
; ; ;
;
;
;
;
;
;
;
;
;
;
;
;
;
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
77
Appendix A
JOB-List
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
78
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
Tungsten electrode ∅
0,6
0,8
1,0
1,2
1,6
Vertical-down weld
∅
Fillet weld lap joint
Seam position
Butt joint
Wire
Fillet weld
Material
MMA
TIG cold wire
TIG hot wire
TIG
JOB
Process
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
Cu/CuZn
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
AlMg
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
; ; ;
; ; ;
; ; ;
; ;
; ;
; ;
; ;
; ;
; ;
; ;
; ;
; ;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
099-000140-EW501
08.07.2011
Appendix A
JOB-List
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
099-000140-EW501
08.07.2011
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
Tungsten electrode ∅
0,6
0,8
1,0
1,2
1,6
Vertical-down weld
∅
Fillet weld lap joint
Seam position
Butt joint
Wire
Fillet weld
Material
MMA
TIG cold wire
TIG hot wire
TIG
JOB
Process
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
AlSi
Al99
Al99
Al99
Al99
Al99
Al99
Al99
Al99
Al99
Al99
Al99
Al99
Al99
Al99
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
2
2.4
3.2
>3.2
1
1.6
79
Appendix A
JOB-List
Tungsten electrode ∅
Vertical-down weld
Fillet weld lap joint
Butt joint
∅
Seam position
Fillet weld
Wire
0,6
0,8
1,0
1,2
1,6
Material
MMA
TIG cold wire
TIG hot wire
TIG
JOB
Process
Al99
2
;
;
Al99
2.4
;
;
;
;
Al99
3.2
;
;
;
;
Al99
>3.2
;
;
;
;
Al99
1
;
;
Al99
1.6
;
;
Al99
2
;
;
Al99
2.4
;
;
;
;
Al99
3.2
;
;
;
;
Al99
>3.2
;
;
;
;
TIG manual/TIG classic
Classic electrode
Reserved
Reserved
Reserved
Electrode JOB
Reserved
Free JOBs or SCO (e.g. plasma)
CrNi/FeSt
2.4
; ;
; ; ;
;
CrNi/FeSt
3.2
; ;
; ; ;
;
CrNi/FeSt
>3.2
; ;
; ; ;
;
CuSi
2.4
; ;
;
;
CuSi
3.2
; ;
;
;
Free JOBs or special customer order (SCO)/TIG Comfort (with Smart
200 only)
208-215 Free JOBs or special customer order (SCO)/electrode Comfort (with
Smart 208 only)
216-254 Free JOBs or special customer order (SCO)
255
DC- with DC+ ignition
256
Test job: 5 A to Imax
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129-179
180
181
182
183
184
185-207
† not possible
; possible
80
099-000140-EW501
08.07.2011
Appendix B
Overview of EWM branches
12
Appendix B
12.1
Overview of EWM branches
099-000140-EW501
08.07.2011
81
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