EWM TETRIX 1002 DC SYNERGIC User manual

EWM
HIGHTEC WELDING GmbH
Dr. Günter-Henle-Straße 8 • D-56271 Mündersbach
Fon [phone] • Fax [phone]
www.ewm.de • [e-mail]
GB
Operating instructions
Power sources for automated applications
TETRIX 1002 DC SYNERGIC
N. B. These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machines may only be operated by personnel who are familiar with the appropriate safety
regulations.
The machines bear the conformity mark and thus comply with the
• EC Low Voltage Directive (2006/95/ EG)
• EC EMC Directive (2004/108/ EG)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.
©The content of the operating instructions does not constitute grounds for any claims on the part
of the buyer.
The copyright to these operating instructions remains with the manufacturer.
Reprinting, including extracts, only with written approval.
© 2009 Subject to alteration. Item No.: 099-000155-EWM01 Revised: 22.07.2009

Mündersbach, 25 February 2009
Dear customer,
Thank you for your order.
Premium quality – made in Germany and with a three-year warranty.
The machines from EWM are impressive, with innovative technology, exceptional user-friendliness and
the most up to date inverter and control systems. This makes welding possible that is simple, efficient
and resource-saving as well as being highly economical!
Perfection doesn't happen by coincidence: Every single component is 100% tested and the machine is
“free welded” before it is delivered.
Our comprehensive service offer and the highly developed modern EWM quality management system
guarantee worldwide premium quality “Made in Germany” and a three-year warranty.
Continual further development and optimisation has made us Germany’s market leader in the
manufacture of light arc welding machines. We have manufacturing, training and service locations
throughout the world to advise you and provide you with a comprehensive range of services.
The accompanying operating instructions contain everything about commissioning the machine, notes
regarding safety, maintenance and care, technical data as well as information regarding the warranty. It
is very important to observe all our instructions in order to achieve optimal welding results with the
machine and to ensure many years of safe operation.
Thank you for the trust that you have placed in us. We look forward to a long-term and, above all,
successful partnership with you.
Yours faithfully
EWM HIGHTEC WELDING GmbH
Bernd Szczesny
Executive management

Machine and Company Data
Please enter the EWM machine data and your company’s data in the appropriate fields.
CE
EWM HIGHTEC WELDING GMBH
D-56271 MÜNDERSBACH
TYP:
ART:
SNR:
PROJ:
GEPRÜFT/CONTROL:
Name of Customer / company
Adress
Post code / Place
Country
Stamp / Signature of EWM-distibutor
Date of purchase
Name of Customer / company
Adress
Post code / Place
Country
Stamp / Signature of EWM-distibutor
Date of purchase
3

Contents
Notes on the use of these operating instructions
4 Item No.: 099-000155-EWM01
1Contents
1Contents..................................................................................................................................................4
2Safety instructions.................................................................................................................................7
2.1 Notes on the use of these operating instructions...........................................................................7
2.2 General...........................................................................................................................................9
2.3 Transport and installation.............................................................................................................12
2.4 Ambient conditions.......................................................................................................................13
2.4.1 In operation...................................................................................................................13
2.4.2 Transport and storage ..................................................................................................13
3Technical data.......................................................................................................................................14
3.1 TETRIX 1002 DC SYNERGIC.....................................................................................................14
4Machine description.............................................................................................................................16
4.1 TETRIX 1002 DC SYNERGIC.....................................................................................................16
4.1.1 Front view.....................................................................................................................16
4.1.2 Rear view......................................................................................................................18
5Functional characteristics...................................................................................................................20
5.1 Machine control – Operating elements........................................................................................20
5.1.1.1 Function sequence........................................................................................22
5.2 TIG Synergic operating principle..................................................................................................23
5.2.1 Synergic parameter setting in the functional sequence................................................24
5.2.2 Conventional parameter setting in the functional sequence.........................................24
5.2.2.1 Change conventional setting / synergic parameter setting...........................25
5.2.3 Select welding task.......................................................................................................26
5.2.4 Select welding current ..................................................................................................27
5.2.5 Welding data display.....................................................................................................27
5.2.5.1 Welding parameter setting............................................................................28
5.3 TIG welding..................................................................................................................................28
5.3.1 Arc ignition....................................................................................................................28
5.3.1.1 HF ignition.....................................................................................................28
5.3.2 Optimising the ignition characteristics for pure tungsten electrodes............................29
5.3.3 TIG automatic cut-out...................................................................................................29
5.3.4 TIG welding task definition ...........................................................................................30
5.4 Key switch....................................................................................................................................31
5.5 Welding programs........................................................................................................................31
5.5.1 Specifying max. no. of accessible programs................................................................32
5.5.2 Example "Program with synergetic setting"..................................................................33
5.5.3 Example "Program with conventional setting"..............................................................33
5.5.4 Accessories for switching over programs.....................................................................33
5.6 Organising welding tasks (Mode "JOB Manager").......................................................................34
5.6.1 Explanation of symbols on the display .........................................................................34
5.6.2 Creating a new JOB in the memory or copying a JOB.................................................35
5.6.3 Loading an existing JOB from the free memory...........................................................36
5.6.4 Resetting an existing JOB to the factory setting (Reset JOB)......................................36
5.6.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs).....................................37
5.6.6 Exit JOB Manager without changes .............................................................................37
5.6.7 Specifying max. no. of accessible JOBs.......................................................................38
5.7 Interfaces .....................................................................................................................................40
5.7.1 Connecting the RINT X11 robot interface/BUSINT X11 industrial bus interface..........40
5.7.1.1 RINT X11 robot interface ..............................................................................40
5.7.1.2 BUSINT X11 industrial bus interface.............................................................40
5.7.2 Connecting the PC 300.net welding parameterisation software...................................42
5.7.3 Connecting the Q-DOC 9000 welding data documentation software...........................43
5.7.4 Connecting the WELDQAS welding data monitoring and documentation system.......44
5.7.5 Automation interface.....................................................................................................45
5.7.6 Connection socket automation torch............................................................................47
5.7.7 Sensor Voltage.............................................................................................................47

Contents
Notes on the use of these operating instructions
Item No.: 099-000155-EWM01 5
5.8 Menus and sub-menus on the machine control...........................................................................48
5.8.1 Direct menus (direct access to parameters) ................................................................48
5.8.2 Expert menu (TIG)........................................................................................................48
5.8.3 Machine configuration menu........................................................................................49
5.8.3.1 Display, explanation of symbols....................................................................50
6Commissioning ....................................................................................................................................51
6.1 General........................................................................................................................................51
6.2 Area of application – proper usage..............................................................................................51
6.3 Installation....................................................................................................................................52
6.4 Mains connection.........................................................................................................................52
6.5 Machine cooling...........................................................................................................................53
6.6 Workpiece lead, general..............................................................................................................53
6.6.1 Connection for workpiece lead.....................................................................................53
6.7 Connecting the welding torch and accessory components .........................................................54
6.7.1 Connecting the cooling module to the power source...................................................55
7Maintenance and testing.....................................................................................................................56
7.1 General........................................................................................................................................56
7.2 Cleaning.......................................................................................................................................56
7.3 Test..............................................................................................................................................57
7.3.1 Test equipment.............................................................................................................57
7.3.2 Scope of the test...........................................................................................................58
7.3.3 Visual inspection...........................................................................................................58
7.3.4 Measuring the open circuit voltage...............................................................................58
7.3.5 Measurement of insulation resistance..........................................................................58
7.3.6 Measuring the leakage current (protective conductor and contact current).................59
7.3.7 Measurement of protective conductor resistance ........................................................59
7.3.8 Functional test of the welding machine........................................................................59
7.3.9 Documentation of the test ............................................................................................59
7.4 Repair Work.................................................................................................................................60
7.5 Disposing of equipment ...............................................................................................................61
7.5.1 Manufacturer's declaration to the end user..................................................................61
7.6 Meeting the requirements of RoHS .............................................................................................61
8Warranty................................................................................................................................................62
8.1 General Validity............................................................................................................................62
8.2 Warranty Declaration...................................................................................................................63
9Operating problems, causes and remedies ......................................................................................64
9.1 Error messages (power source) ..................................................................................................64
9.2 Resetting welding parameters to the factory settings..................................................................65
9.3 Display machine control software version ...................................................................................66
10 Circuit diagrams...................................................................................................................................67
10.1 TETRIX 1002 DC SYNERGIC.....................................................................................................67
11 Appendix A ...........................................................................................................................................72
11.1 Declaration of Conformity ............................................................................................................72

Contents
Notes on the use of these operating instructions
6 Item No.: 099-000155-EWM01

Safety instructions
Notes on the use of these operating instructions
Item No.: 099-000155-EWM01 7
2Safety instructions
2.1 Notes on the use of these operating instructions
NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
• Notes are highlighted using a "hand" symbol at 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.
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.
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 on the edge of the page.
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.

Safety instructions
Notes on the use of these operating instructions
8 Item No.: 099-000155-EWM01
Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet points,
e.g.:
• Insert the welding current lead socket into the relevant socket and lock.
Symbol Description
Press
Do not press
Turn
Switch

Safety instructions
General
Item No.: 099-000155-EWM01 9
2.2 General
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!
CAUTION
Obligations of the operator!
In the European Economic Area (EEA), the relevant national version of the basic
guidelines must be followed and observed!
• National version of the basic guidelines (89/391/EEC) as well as the relevant individual
guidelines.
• In particular the Directive (89/655/EEC) on the minimum regulations for safety and health
protection when staff members are using equipment during work.
• The accident prevention regulations of the relevant country (e.g. in Germany, BGV D 1).
• Check at regular intervals that users are working in a safety-conscious way!
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.
Electromagnetic interference!
The machines are intended to be used in industrial areas, according to IEC 60974-10. If
they are used in residential areas, for example, problems may occur with ensuring
electromagnetic compatibility.
• Check whether interference is caused to other machines!
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!

Safety instructions
General
10 Item No.: 099-000155-EWM01
WARNING
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.
• 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!
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!

Safety instructions
General
Item No.: 099-000155-EWM01 11
DANGER
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 lines 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)!
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! Wait for 2 minutes until the capacitors have discharged.
• 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!

Safety instructions
Transport and installation
12 Item No.: 099-000155-EWM01
2.3 Transport and installation
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!
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 IEC 60974-1, -3, -10).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
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!
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!

Safety instructions
Ambient conditions
Item No.: 099-000155-EWM01 13
2.4 Ambient conditions
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!
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.
2.4.1 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
2.4.2 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

Technical data
TETRIX 1002 DC SYNERGIC
14 Item No.: 099-000155-EWM01
3Technical data
3.1 TETRIX 1002 DC SYNERGIC
TETRIX 1002 DC SYNERGIC
Welding current setting range 10 – 1000 A
Welding voltage setting range 10,4 – 34 V
Duty cycle 20°C ambient temperature
60%DC -
80%DC 1000 A
100%DC 900 A
Duty cycle 40°C ambient temperature
60%DC 1000 A
80%DC -
100%DC 750 A
Load alternation 10min (60% DC ∧6 min welding, 4min break)
Open circuit voltage 79 V
3 x 400V (-25% to +20%)Mains voltage (tolerance) 3 x 415V (-25% to +15%)
Frequency 50/60Hz
Mains fuse 3 x 63 A
Mains connection lead H07RN-F4G10
Max. connected power 50,7 kVA
Recommended generator rating 68,4 kVA
Cosϕ/ efficiency 0.99%
Insulation class H / IP 23
Protection classification IP 23
Ambient temperature -20°C to +40°C
Machine cooling Fan
Workpiece lead 2 x 95 mm2
Dimensions L/W/H [mm] 660 x 380 x 1110
Weight 177 kg
Constructed to standards IEC 60974-1, -3, -10
/

Technical data
TETRIX 1002 DC SYNERGIC
Item No.: 099-000155-EWM01 15
785 mm
1310 mm
660 mm
380 mm
495 mm
1110 mm
Figure 3-1

Machine description
TETRIX 1002 DC SYNERGIC
16 Item No.: 099-000155-EWM01
4Machine description
4.1 TETRIX 1002 DC SYNERGIC
4.1.1 Front view
6
7
4
3
2
1
10
5
9
8
Figure 4-1

Machine description
TETRIX 1002 DC SYNERGIC
Item No.: 099-000155-EWM01 17
Item Symbol Description 0
1 Machine control
See Machine control – operating elements chapter
2
0
1
Key switch for protection against unauthorised use
Position “1” > changes possible,
Position “0” > changes not possible.
Please take note of chapter “Key switch”
3
Main switch, machine on/off
4
"Operating state" display
Lights up when the machine is switched on and ready for operation
5
"Fault" display
"Collective interference" signal light
If the signal light is on, the power unit is automatically switched off. Because some
interference is short-term and one-off (e.g. excess mains voltage), the signal light will
go off again and the welding machine will be ready for welding. If the signal light is still
on after a reasonable amount of time, see the chapter on “Operating errors, causes
and remedies”.
6
Arc is burning (welding current flows)
7
COM
PC interface, serial (D-SUB connection socket, 9-pole)
8
7-pole connection socket (digital)
For connecting digital accessory components
9
19-pole connection socket (digital)
Operating panel connection lead connection
10 ROB XX2 pallet
Transport pallet (option)

Machine description
TETRIX 1002 DC SYNERGIC
18 Item No.: 099-000155-EWM01
4.1.2 Rear view
6
7
4
3
2
1
18
17
10
5
9
14
11 12
15
16
8
13
Figure 4-2

Machine description
TETRIX 1002 DC SYNERGIC
Item No.: 099-000155-EWM01 19
Item Symbol Description 0
1
digital
Interfaces (customised)
Optional interface in the extension casing for assembly onto the power source
• RINTX11 robot interface
• BUSINTX10 industrial bus interface
2
42V/4A
Key button, automatic cutout
Wire feed motor supply voltage fuse
(press to reset a triggered fuse)
3
analog
Automation interface, 19-pole (analogue)
(see Function Specification chapter)
4
Connecting nipple G¼, shielding gas connection, entry
5
19-pole connection socket (analogue)
Mechanised welding torch connection
6
12-pole connection socket
For connecting Wire feed unit
7
7-pole connection socket
For connecting Control lead, Welding torch
8
12-pole connection socket
For connecting Wire feed unit
9 Connection socket, welding current -
Welding torch connection
10 Cooling air outlet
11
8-pole connection socket
Cooling unit control lead
12
Connecting nipple G¼, shielding gas connection, exit
13
7-pole connection socket (digital)
For connecting digital accessory components
Connection socket, “+” welding current
• MMA welding: Workpiece or electrode holder connection
14 • TIG welding: Workpiece connection
15 ROB XX2 pallet
Transport pallet (option)
16 Mains connection cable
17
Connection socket, 5-pole
Cooling unit voltage supply
18 Cooling air outlet

Functional characteristics
Machine control – Operating elements
20 Item No.: 099-000155-EWM01
5Functional characteristics
5.1 Machine control – Operating elements
AMP%
AMP
sec
sec
sec
sec
sec
sec
AMP%
AMP%
HOLD
VOLT
JOB
S
kHz
AMP
sec
%
Automatic
PROG
1,0
1,6
2,0
2,4
3,2
4,0
>
SYNERGIC T 3.27
S
Puls
Manuell
Synergic
sec
kHz
kHz
Spez
Fe/St
CrNi
CuZn
Cu
%
000 000
activArc
6
7
43
2
1
10
5
9
11
11
12
8
13
Figure 5-1
Item Symbol Description 0
1
"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)
“Tungsten electrode diameter”/ “Ignition optimisation” key button
1,0
∅1.0mm
1,6
∅1.6mm
2,0
∅2.0mm
2,4
∅2.4mm
3,2
∅3.2mm
4,0
>
∅4.0mm or greater
2
Optimum ignition and stabilisation of the arc. The adjustable welding current is limited
to the maximum permissible welding current of the tungsten electrode.
3
“Select material type” button
Chrome nickel alloys
Iron and steel alloys
Copper or copper alloys (bronzes)
Copper zinc alloys (brass)
Special (for special custom-built tasks)