EWM Tetrix 352 AC/DC SYNERGIC PL. AW GR User manual

Operating instructions
Power sources for automated applications
Tetrix 352 AC/DC SYNERGIC PL. AW GR
(SCO 3133)
099-003133-SCO01 Observe additional system documents! 07.04.2014

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 [phone].
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 AG · 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
099-003133-SCO01
07.04.2014
3
1 Contents
1Contents..................................................................................................................................................3
2Safety 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 Ambient conditions.......................................................................................................13
2.4.1.1 In operation ...................................................................................................13
2.4.1.2 Transport and storage...................................................................................13
3Intended use.........................................................................................................................................14
3.1 Applications..................................................................................................................................14
3.2 Plasma welding............................................................................................................................14
3.3 TIG welding..................................................................................................................................14
3.3.1 TIG activArc welding.....................................................................................................14
3.3.2 spotArc .........................................................................................................................14
3.3.3 TIG hot wire welding.....................................................................................................14
3.3.4 TIG cold wire welding...................................................................................................14
3.4 Use and operation solely with the following machines ................................................................15
3.5 Documents which also apply .......................................................................................................15
3.5.1 Warranty.......................................................................................................................15
3.5.2 Declaration of Conformity.............................................................................................15
3.5.3 Welding in environments with increased electrical hazards.........................................15
3.5.4 Service documents (spare parts and circuit diagrams)................................................15
3.5.5 Calibration/Validation....................................................................................................15
4Machine description – quick overview ..............................................................................................16
4.1 Front view ....................................................................................................................................16
4.2 Rear view.....................................................................................................................................18
4.3 Machine control (Mode RC - on)..................................................................................................20
4.3.1 Function sequence.......................................................................................................22
4.4 Machine control (Mode RC - off)..................................................................................................24
4.4.1 Function sequence.......................................................................................................27
4.5 Plasmadrive .................................................................................................................................29
4.6 "Insufficient wire" sensor..............................................................................................................30
5Design and function.............................................................................................................................31
5.1 General ........................................................................................................................................31
5.2 System integration.......................................................................................................................33
5.2.1 Plasma application with hot wire ..................................................................................33
5.2.1.1 Legend ..........................................................................................................34
5.3 Transport and installation ............................................................................................................35
5.3.1 Power source for hot wire welding ...............................................................................36
5.4 Machine cooling...........................................................................................................................36
5.5 Workpiece lead, general..............................................................................................................37
5.6 Notes on the installation of welding current leads .......................................................................38
5.7 Welding torch cooling system......................................................................................................40
5.7.1 General.........................................................................................................................40
5.7.1.1 List of coolants ..............................................................................................40
5.8 Mains connection.........................................................................................................................41
5.8.1 Mains configuration ......................................................................................................41
5.9 System gas connection................................................................................................................42
5.9.1 Connecting the shielding gas supply............................................................................44
5.9.1.1 Gas test.........................................................................................................44
5.9.1.2 “Purge hose package” function.....................................................................44

Contents
Notes on the use of these operating instructions
4 099-003133-SCO01
07.04.2014
5.10 Welding torch connection.............................................................................................................45
5.11 "Insufficient wire" sensor connection ...........................................................................................47
5.12 Connecting the wire feed unit.......................................................................................................48
5.13 Hot wire power source connection...............................................................................................49
5.14 Cooling unit connection................................................................................................................50
5.15 Connection for workpiece lead.....................................................................................................52
5.16 TIG Synergic operating principle..................................................................................................53
5.16.1 Synergic parameter setting in the functional sequence................................................54
5.16.2 Conventional parameter setting in the functional sequence.........................................54
5.16.2.1 Set the operating principle (conventional/synergic) ......................................55
5.16.3 Select welding task.......................................................................................................56
5.16.4 Select welding current ..................................................................................................56
5.16.5 Welding data display.....................................................................................................57
5.16.5.1 Welding parameter setting ............................................................................57
5.16.6 Arc ignition....................................................................................................................58
5.16.7 Optimising the ignition characteristics for pure tungsten electrodes ............................58
5.16.8 TIG automatic cut-out...................................................................................................58
5.16.9 Optimal and fast spherical cup formation .....................................................................59
5.17 Welding task definition .................................................................................................................60
5.18 Protecting welding parameters from unauthorised access..........................................................61
5.19 Welding programs........................................................................................................................61
5.19.1 Selection and adjustment .............................................................................................62
5.19.2 Specifying max. no. of accessible programs ................................................................62
5.19.3 Example "Program with synergetic setting"..................................................................63
5.19.4 Example "Program with conventional setting"..............................................................63
5.19.5 Accessories for switching over programs.....................................................................63
5.20 Organising welding tasks (Mode "JOB Manager").......................................................................64
5.20.1 Explanation of symbols on the display .........................................................................64
5.20.2 Creating a new JOB in the memory or copying a JOB.................................................65
5.20.3 Loading an existing JOB from the free memory ...........................................................66
5.20.4 Resetting an existing JOB to the factory setting (Reset JOB)......................................66
5.20.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs).....................................67
5.20.6 Exit JOB Manager without changes .............................................................................67
5.21 Interfaces......................................................................................................................................68
5.21.1 Connecting the robot interface / industrial bus interface ..............................................68
5.21.1.1 RINT X12 robot interface...............................................................................69
5.21.1.2 BUSINT X11 industrial bus interface.............................................................69
5.21.2 Connecting the PC 300.net welding parameterisation software...................................70
5.21.3 Connecting the Q-DOC 9000 V2.0 welding data documentation software ..................71
5.21.4 Connecting the WELDQAS welding data monitoring and documentation system.......72
5.21.5 Automation interface.....................................................................................................73
5.21.6 Connection socket automation torch ............................................................................75
5.21.7 Sensor current ..............................................................................................................76
5.22 Advanced settings........................................................................................................................77
5.22.1 Setting slope times for secondary current AMP% or pulse edges ...............................77
5.22.2 Welding current display (ignition, secondary, end and hotstart currents) ....................78
5.23 Menus and sub-menus on the machine control...........................................................................79
5.23.1 Direct menus (direct access to parameters).................................................................79
5.23.2 Expert menu (TIG)........................................................................................................79
5.23.3 Machine configuration menu.........................................................................................81

Contents
Notes on the use of these operating instructions
099-003133-SCO01
07.04.2014
5
6Maintenance, care and disposal.........................................................................................................86
6.1 General ........................................................................................................................................86
6.2 Maintenance work, intervals ........................................................................................................86
6.2.1 Daily maintenance tasks...............................................................................................86
6.2.1.1 Visual inspection ...........................................................................................86
6.2.1.2 Functional test...............................................................................................86
6.2.2 Monthly maintenance tasks..........................................................................................86
6.2.2.1 Visual inspection ...........................................................................................86
6.2.2.2 Functional test...............................................................................................86
6.2.3 Annual test (inspection and testing during operation)..................................................87
6.3 Maintenance work........................................................................................................................87
6.4 Disposing of equipment ...............................................................................................................88
6.4.1 Manufacturer's declaration to the end user..................................................................88
6.5 Meeting the requirements of RoHS .............................................................................................88
7Rectifying faults ...................................................................................................................................89
7.1 Checklist for rectifying faults........................................................................................................89
7.2 Machine faults (error messages) .................................................................................................91
7.3 Resetting welding parameters to the factory settings..................................................................93
7.4 Display machine control software version ...................................................................................94
7.5 General operating problems ........................................................................................................94
7.5.1 Interface for automated welding...................................................................................94
7.6 Vent coolant circuit.......................................................................................................................95
8Technical data ......................................................................................................................................96
8.1 Tetrix 352 AC/DC SYNERGIC PL. AW GR.................................................................................96
9Accessories..........................................................................................................................................97
9.1 Welding torch cooling system......................................................................................................97
9.2 Wire feed units.............................................................................................................................97
9.3 General accessories....................................................................................................................97
9.4 Connection cables, connection sockets.......................................................................................97
9.5 Options.........................................................................................................................................97
9.6 Computer communication............................................................................................................97
9.7 Interfaces .....................................................................................................................................98
9.8 Connection and extension cables................................................................................................98
10 Circuit diagrams...................................................................................................................................99
10.1 Tetrix 352 AC/DC SYNERGIC PL. AW GR.................................................................................99
11 Appendix A .........................................................................................................................................105
11.1 JOB-List .....................................................................................................................................105
12 Appendix B .........................................................................................................................................109
12.1 Overview of EWM branches ......................................................................................................109

Safety instructions
Notes on the use of these operating instructions
6 099-003133-SCO01
07.04.2014
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.

Safety instructions
Explanation of icons
099-003133-SCO01
07.04.2014
7
2.2 Explanation of icons
Symbol
Description
Press
Do not press
Turn
Switch
Switch off machine
Switch on machine
ENTERENTER
ENTER (enter the menu)
NAVIGATION
NAVIGATION (Navigating in the menu)
EXIT
EXIT (Exit the menu)
4 s
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use

Safety instructions
General
8 099-003133-SCO01
07.04.2014
2.3 General
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 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)!
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!
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.
•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!
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!

Safety instructions
General
099-003133-SCO01
07.04.2014
9
WARNING
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!
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!
Danger when coupling multiple power sources
!
Coupling multiple power sources in parallel or in series has to be carried out by
qualified personnel and in accordance with the manufacturer's guidelines. Before
bringing the power sources into service for arc welding operations, a test has to verify
that they cannot exceed the maximum allowed open circuit voltage.
•Connection of the machine may be carried out by qualified personnel only!
•When decommissioning individual power sources, all mains and welding current leads have
to be safely disconnected from the welding system as a whole. (Danger due to inverse
voltages!)
•Do not couple welding machines with pole reversing switch (PWS series) or machines for
AC welding, as a minor error in operation can cause the welding voltages to be combined.
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
10 099-003133-SCO01
07.04.2014
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.
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.