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Summary of Contents for EWM Tetrix 351
- Page 1 Operating instructions Welding machines and accessories Tetrix 351 AC/DC AW FW Tetrix 451 AC/DC AW FW Tetrix 551 AC/DC AW FW 099-000115-EW501 Observe additional system documents! 17.06.2015 Register now and benefit! Jetzt Registrieren und Profitieren! www.ewm-group.com...
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Page 2: General Instructions
+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. -
Page 3: Table Of Contents
3.3.5 Calibration/Validation ....................18 4 Machine description – quick overview ....................19 System overview .......................... 19 Tetrix 351 AC/DC AW ........................20 Front view ............................ 20 Rear view ............................. 22 Tetrix 451, 551 AC/DC AW ......................24 Front view ............................ 24 Rear view ............................. - Page 4 Contents Notes on the use of these operating instructions 5.9.2 Legend .......................... 42 5.9.3 Installation ........................42 5.9.4 Intermediate hose package connection ................ 43 5.10 TIG hot wire welding ........................45 5.10.1 Connection plan ......................45 5.10.1.1 Legend......................46 5.10.2 Installation ........................
- Page 5 Contents Notes on the use of these operating instructions 5.13.16.2 TIG up/down torch (8-pole) ................84 5.13.16.3 Potentiometer torch (8-pole) ................. 86 5.13.16.4 Configuring the TIG potentiometer torch connection ........87 5.13.16.5 RETOX TIG torch (12-pole) ................88 5.13.16.6 Specifying max. no. of accessible JOBs ............89 5.13.16.7 Setting the first increment ................
- Page 6 9.2.1 Tetrix 351 AC/DC ......................132 9.2.2 Tetrix 451, 551 AC/DC ....................132 9.2.3 Tetrix 351, 451, 551 AC/DC ..................132 General accessories ........................133 Remote controls and accessories ....................133 Computer communication ......................133 10 Appendix A ............................134 10.1 JOB-List............................
- Page 7 Contents Notes on the use of these operating instructions 099-000115-EW501 17.06.2015...
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Page 8: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions 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. •... -
Page 9: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Special technical points which users must observe. Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER ENTER (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu) -
Page 10: General
Safety instructions General 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! •... - Page 11 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.
- Page 12 Safety instructions General 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.
- Page 13 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes - See 8 Technical data chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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Page 14: Transport And Installation
Safety instructions Transport and installation 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! •... -
Page 15: Lifting By Crane
Safety instructions Transport and installation 2.4.1 Lifting by crane DANGER Risk of injury due to lifting by crane! The hot wire welding system version (including machine carrier plate for wire feed unit and hot wire power source) may not be lifted by crane! •... -
Page 16: Ambient Conditions
Safety instructions Transport and installation 2.4.2 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. -
Page 17: Intended Use
3.1.1.3 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. -
Page 18: Use And Operation Solely With The Following Machines
3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 19: Machine Description - Quick Overview
Machine description – quick overview System overview Machine description – quick overview System overview The machine described in this manual is integrated into the welding system as shown in the diagram. Figure 4-1 Item Symbol Description Wire feed unit Power source (TIG) Observe additional system documents! Power source (TIG hot wire) Observe additional system documents! -
Page 20: Tetrix 351 Ac/Dc Aw
Machine description – quick overview Tetrix 351 AC/DC AW Tetrix 351 AC/DC AW Front view Figure 4-2 099-000115-EW501 17.06.2015... - Page 21 Machine description – quick overview Front view Item Symbol Description Lifting lug Main switch, machine on/off Machine control- See 4.8 Machine control – Operating elements chapter Carrying handle Automatic cut-out of coolant pump key button press to reset a triggered fuse Quick connect coupling (red) coolant return Quick connect coupling (blue)
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Page 22: Rear View
Machine description – quick overview Rear view Rear view Figure 4-3 099-000115-EW501 17.06.2015... - Page 23 Machine description – quick overview Rear view Item Symbol Description Intermediate hose package strain relief Securing elements for shielding gas cylinder (strap/chain) Mains connection cable - See 5.5 Mains connection chapter G¼” connecting nipple Shielding gas connection on the pressure regulator. Connector plug (TIG hot wire) Welding current, minus potential Connection socket for “+”...
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Page 24: Tetrix 451, 551 Ac/Dc Aw
Machine description – quick overview Tetrix 451, 551 AC/DC AW Tetrix 451, 551 AC/DC AW Front view Figure 4-4 099-000115-EW501 17.06.2015... - Page 25 Machine description – quick overview Front view Item Symbol Description Lifting lug Main switch, machine on/off Machine control- See 4.8 Machine control – Operating elements chapter Carrying handle Automatic cut-out of coolant pump key button press to reset a triggered fuse Quick connect coupling (red) coolant return Quick connect coupling (blue)
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Page 26: Rear View
Machine description – quick overview Rear view Rear view Figure 4-5 099-000115-EW501 17.06.2015... - Page 27 Machine description – quick overview Rear view Item Symbol Description Intermediate hose package strain relief Securing elements for shielding gas cylinder (strap/chain) Mains connection cable - See 5.5 Mains connection chapter G¼” connecting nipple Shielding gas connection on the pressure regulator. Connector plug (TIG hot wire) Welding current, minus potential Connection socket for “+”...
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Page 28: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-6 Item Symbol Description Polarity changeover (TIG manual) button Select material type (TIG Synergic) key button DC welding with positive polarity on the Chrome/nickel alloys / iron / electrode holder in relation to the steel alloys workpiece (pole reversing switch, MMA... - Page 29 Machine description – quick overview Machine control – Operating elements Item Symbol Description 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.
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Page 30: Function Sequence
Machine description – quick overview Machine control – Operating elements Item Symbol Description 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 simultaneously: Alternating current welding, AC special... - Page 31 Machine description – quick overview Machine control – Operating elements Item Symbol Description AMP% Secondary current (TIG) / pulse pause current Setting range 1 % to 100 % (1 % increments). Percentage of the main current. Pulse break time/slope time from AMP to AMP% •...
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Page 32: Design And Function
Design and function General Design and function 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! •... -
Page 33: Machine Cooling
Design and function Machine cooling 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. •... -
Page 34: Notes On The Installation Of Welding Current Leads
Design and function Notes on the installation of welding current leads Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc (flickering). Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel. - Page 35 Design and function Notes on the installation of welding current leads Use an individual welding lead to the workpiece for each welding machine! Figure 5-2 Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders.
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Page 36: Mains Connection
Design and function Mains connection 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! •... -
Page 37: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system 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). •... -
Page 38: Adding Coolant
Design and function Welding torch cooling system 5.6.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. Figure 5-5 Item Symbol Description Coolant tank cap Coolant filter sieve Coolant tank "Min" mark Minimum coolant level •... -
Page 39: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Shielding gas supply (shielding gas cylinder for welding machine) Shielding gas supply (shielding gas cylinder for welding machine) WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! •... -
Page 40: Tig Welding
Design and function TIG welding TIG welding • Fasten the gas hose to the shielding gas connecting nipple at the back of the machine using the crown nut. 5.8.1 TIG cold or hot wire welding • Screw the gas hose connection nipple (intermediate hose package) onto the output side of the pressure regulator. -
Page 41: Tig Cold Wire Welding
Design and function TIG cold wire welding TIG cold wire welding 5.9.1 Connection plan Tetrix drive 4L TIG 450W HW 12POL RT AW 1 hotwire Tetrix AW Figure 5-7 099-000115-EW501 17.06.2015... -
Page 42: Legend
Design and function TIG cold wire welding 5.9.2 Legend Shielding gas Welding current(minus potential) Coolant input (marked in colour) Coolant output (marked in colour) Control lead (28-pole) Hose package (TP = tube package) Welding current (minus potential, TIG hot wire) Welding current (plus potential, workpiece) Control lead, hot wire (signal input, 4-pole) hotwire... -
Page 43: Intermediate Hose Package Connection
Design and function TIG cold wire welding 5.9.4 Intermediate hose package connection Figure 5-8 Item Symbol Description Wire feed unit Intermediate hose package Intermediate hose package strain relief Connection socket (28-pole) Control lead Connecting thread (G¼") Shielding gas Connection socket (TIG) Welding current, minus potential Quick connect coupling (red) coolant return... - Page 44 Design and function TIG cold wire welding • Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right. • Push the cable plug for the welding current (TIG) onto the connection socket (TIG) and lock by turning to the right.
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Page 45: Tig Hot Wire Welding
Design and function TIG hot wire welding 5.10 TIG hot wire welding 5.10.1 Connection plan Tetrix drive 4L TIG 450W HW 12POL hotwire Tetrix Hotwire RT AW 1 hotwire Tetrix AW Figure 5-9 099-000115-EW501 17.06.2015... -
Page 46: Legend
Design and function TIG hot wire welding 5.10.1.1 Legend Shielding gas Welding current(minus potential) Coolant input (marked in colour) Coolant output (marked in colour) Control lead (28-pole) Hose package (TP = tube package) Welding current (minus potential, TIG hot wire) Welding current (plus potential, workpiece) Control lead, hot wire (signal input, 4-pole) hotwire... -
Page 47: Installation
Design and function TIG hot wire welding 5.10.2 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. -
Page 48: Power Source For Hot Wire Welding
Design and function TIG hot wire welding 5.10.2.2 Power source for hot wire welding CAUTION Hazards due to improper mounting! In this system, the hot wire power source is positioned on the carrier platform of the mobile power source (filler wire). •... - Page 49 Design and function TIG hot wire welding DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • For hot wire welding, this machine may only be connected to the primary power source (Tetrix series) via the connection intended for this power source.
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Page 50: Intermediate Hose Package Connection
Design and function TIG hot wire welding 5.10.3 Intermediate hose package connection Figure 5-13 Item Symbol Description Wire feed unit Intermediate hose package Intermediate hose package strain relief Connection socket (28-pole) Control lead Connecting thread (G¼") Shielding gas Connection socket (TIG) Welding current, minus potential Quick connect coupling (red) coolant return... - Page 51 Design and function TIG hot wire welding • Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right. • Push the cable plug for the welding current (TIG) onto the connection socket (TIG) and lock by turning to the right.
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Page 52: Configuring The Welding Machine For Mechanical Arc Fusion Welding
Design and function Configuring the welding machine for mechanical arc fusion welding 5.11 Configuring the welding machine for mechanical arc fusion welding Before the welding machine is commissioned it has to be configured for mechanical arc fusion welding (cold or hot wire welding). The following basic settings are made in the Expert menu: 1. -
Page 53: Selecting A Welding Task By Means Of The Job List
Design and function Configuring the welding machine for mechanical arc fusion welding Display Setting/selection Filler wire diameter (manual setting) Setting of the wire diameter from 0.6 mm to 1.6 mm. The character "d" preceding the wire diameter on the display (d0.8) indicates a pre- programmed characteristics (operating mode KORREKTUR). -
Page 54: Function Sequences/Operating Modes
Design and function Configuring the welding machine for mechanical arc fusion welding 5.11.4 Function sequences/operating modes The welding current operating mode must be set to latched on the welding machine. The welding current is infinitely adjustable by means of torch triggers 3 and 4 (BRT 3 and BRT 4). Torch trigger 2 (BRT 2) switches the welding current on or off. -
Page 55: Non-Latched Mode
Design and function Configuring the welding machine for mechanical arc fusion welding 5.11.4.2 Non-latched mode Figure 5-16 1st cycle (current) • Press torch trigger 2 (BRT 2), the gas pre-flow time elapses. • HF ignition pulses jump from the tungsten electrode to the workpiece. The arc ignites. •... -
Page 56: 3-Cycle Operation
Design and function Configuring the welding machine for mechanical arc fusion welding 5.11.4.3 3-cycle operation Figure 5-17 This operating mode differs from non-latched operation in the following ways: • Once the third cycle (current) has started, the wire electrode is fed, corresponding to the welding current, until the welding process ends. -
Page 57: Tig Welding
Design and function TIG welding 5.12 TIG welding 5.12.1 Welding torch and workpiece line connection CAUTION Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •... -
Page 58: Torch Connection Options And Pin Assignments
Design and function TIG welding Item Symbol Description Connection socket, 8-pole/12-pole (depending on variant) 8-pole: Control cable TIG up/down or potentiometer torch 12-pole: Control cable TIG up/down torch with LED display (option) Connection socket, 5-pole Standard TIG torch control lead G¼”... -
Page 59: Tig Synergic Operating Principle
Design and function TIG Synergic operating principle 5.13 TIG Synergic operating principle Figure 5-21 The machine is operated according to the TIG Synergic operating principle: In a similar way to the MIG machines with Synergic operation, three basic parameters – •... -
Page 60: Synergic Parameter Setting In The Functional Sequence
Design and function TIG Synergic operating principle 5.13.1 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 4.8.1 Function sequence chapter with the exception of the gas pre-flow time. -
Page 61: Set The Operating Principle (Conventional/Synergic)
Design and function TIG Synergic operating principle 5.13.2.1 Set the operating principle (conventional/synergic) ENTER EXIT NAVIGATION Figure 5-24 Display Setting/selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display Operating principle • on = synergic parameter setting (factory setting) •... -
Page 62: Select Welding Task
Design and function TIG Synergic operating principle 5.13.3 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. 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”. -
Page 63: Select Welding Current
Design and function TIG Synergic operating principle 5.13.4 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. -
Page 64: Welding Current Display (Ignition, Secondary, End And Hotstart Currents)
Design and function TIG Synergic operating principle 5.13.5.1 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 (factory setting) or absolute values on the machine display. ENTER EXIT NAVIGATION... -
Page 65: Expert Menu (Tig)
Design and function TIG Synergic operating principle 5.13.6 Expert menu (TIG) ENTER (enter the menu) • Keep the "welding parameters" button pressed for 4 s. NAVIGATION (Navigating in the menu) • Parameters are selected by pressing the "welding parameters" button. •... -
Page 66: Arc Ignition
Design and function TIG Synergic operating principle 5.13.7 Arc ignition 5.13.7.1 HF ignition Figure 5-27 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. -
Page 67: Optimising The Ignition Characteristics For Pure Tungsten Electrodes
Design and function TIG Synergic operating principle 5.13.8 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 Result... -
Page 68: Function Sequences/Operating Modes
Design and function TIG Synergic operating principle 5.13.10 Function sequences/operating modes Figure 5-29 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. Welding parameter setting rotary transducer Setting of all parameters such as welding current, sheet metal thickness, gas pre-flow time, etc. -
Page 69: Non-Latched Mode
Design and function TIG Synergic operating principle 5.13.10.2 Non-latched mode Figure 5-30 1st cycle: • Press and hold torch trigger 1. • The gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece, the arc ignites. •... -
Page 70: Latched Mode
Design and function TIG Synergic operating principle 5.13.10.3 Latched mode Figure 5-31 Step 1 • Press torch trigger 1, the gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece, the arc ignites. • Welding current flows and immediately assumes the ignition current value set (search arc at minimum setting). -
Page 71: Spotarc
Design and function TIG Synergic operating principle 5.13.10.4 spotArc This process is suitable for tack welding or joint welding of metal sheets made from steel and CrNi alloys up to a thickness of approximately 2.5 mm. Metal sheets of different thicknesses can also be welded on top of one another. - Page 72 Design and function TIG Synergic operating principle Figure 5-32 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however- See 5.13.7 Arc ignition chapter. Sequence: • Press and hold torch trigger 1. •...
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Page 73: Spotmatic
Design and function TIG Synergic operating principle 5.13.10.5 Spotmatic This function must be enabled before use- See 5.22 Machine configuration menu chapter. In contrast to the spotarc operating mode, the arc ignites not by pressing the torch trigger as is usual, but by shortly touching the tungsten electrode against the workpiece. -
Page 74: Non-Latched Operation, Version C
Design and function TIG Synergic operating principle 5.13.10.6 Non-latched operation, version C Figure 5-34 1st cycle • Press torch trigger 1, the gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece, the arc ignites. •... -
Page 75: Pulses, Function Sequences
Design and function TIG Synergic operating principle 5.13.11 Pulses, function sequences The function sequences in pulses basically behave in the same way as in standard welding, but during the main current phase there is a continual switching back and forth between the pulse and pause currents at the relevant times. -
Page 76: Pulse Variants
Design and function TIG Synergic operating principle 5.13.12 Pulse variants The machines have an integrated pulse device. With pulses, the machine switches back and forth between the pulse current (main current) and pause current (secondary current). 5.13.12.1 Pulses (thermal pulses) With thermal pulses, the pulse and pause times (frequency up to 200 Hz) and the pulse edges (ts1 and ts2) are entered in seconds on the control. -
Page 77: Khz Pulses (Metallurgic Pulses)
Design and function TIG Synergic operating principle 5.13.12.2 KHz pulses (metallurgic pulses) The kHz pulses (metallurgic pulses) use the plasma pressure produced at high currents (arc pressure) which is used to achieve a constricted arc with concentrated heat feeding. The frequency can be infinitely adjusted from 50 Hz to 15 kHz and the pulse balance from 1-99 %. -
Page 78: Ac Pulses
Design and function TIG Synergic operating principle 5.13.12.4 AC pulses (AC pulse, max. 50Hz) Setting: = pulse current AMP% = pulse pause current / basic current tpuls = pulse time tpause = pulse pause time Figure 5-39 5.13.12.5 AC special Application: e.g. -
Page 79: Tig Activarc Welding
TIG Synergic operating principle 5.13.13 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. -
Page 80: Welding Torch (Operating Variants)
Design and function TIG Synergic operating principle 5.13.15 Welding torch (operating variants) Different torch versions can be used with this machine. Functions on the operating elements, such as torch triggers (TT), rockers or potentiometers, can be modified individually via torch modes. Explanation of symbols for operating elements: Symbol Description... -
Page 81: Torch Mode And Up/Down Speed Setting
Design and function TIG Synergic operating principle 5.13.16 Torch mode and up/down speed setting The user has the modes 1 to 6 and modes 11 to 16 available. Modes 11 to 16 include the same function options as 1 to 6, but without tapping function for the secondary current. The function options in the individual modes can be found in the tables for the corresponding torch types. -
Page 82: Standard Tig Torch (5-Pole)
Design and function TIG Synergic operating principle 5.13.16.1 Standard TIG torch (5-pole) Standard torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT1 = Torch trigger 1 (welding current on/off; secondary current via tapping function) Functions mode Operating elements Welding current On/Off (factory-set) - Page 83 Design and function TIG Synergic operating principle Standard torch with one rocker (MG rocker, two torch triggers) Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Functions mode Operating elements Welding current On/Off Secondary current (factory-set) Secondary current (tapping mode) / (latched mode)
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Page 84: Tig Up/Down Torch (8-Pole)
Design and function TIG Synergic operating principle 5.13.16.2 TIG up/down torch (8-pole) Up/down torch with one torch trigger Diagram Operating Explanation of symbols elements TT 1 = torch trigger 1 Functions Mode Operating elements Welding current on/off Secondary current (tapping mode) / (latched mode) (factory- set) Increase welding current, infinite adjustment (up function) - Page 85 Design and function TIG Synergic operating principle Up/down torch with two torch triggers Diagram Operating Explanation of symbols elements TT 1 = torch trigger 1 (left) TT 2 = torch trigger 2 (right) Functions Mode Operating elements Welding current on/off Secondary current Secondary current (tapping mode) / (latched mode) (factory-...
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Page 86: Potentiometer Torch (8-Pole)
Design and function TIG Synergic operating principle 5.13.16.3 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch- See 5.13.16.4 Configuring the TIG potentiometer torch connection chapter. Potentiometer torch with one torch trigger: Diagram Operating Explanation of symbols elements... -
Page 87: Configuring The Tig Potentiometer Torch Connection
Design and function TIG Synergic operating principle 5.13.16.4 Configuring the TIG potentiometer torch connection DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed. -
Page 88: Retox Tig Torch (12-Pole)
Design and function TIG Synergic operating principle 5.13.16.5 RETOX TIG torch (12-pole) For operation with this welding torch, the welding machine must be equipped with the retrofit option "ON 12POL RETOX TIG" (12-pole torch connection socket)! Diagram Operating elements Explanation of symbols TT= torch trigger Functions Mode... -
Page 89: Specifying Max. No. Of Accessible Jobs
Design and function TIG Synergic operating principle 5.13.16.6 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. -
Page 90: Setting The First Increment
Design and function TIG Synergic operating principle 5.13.16.7 Setting the first increment Figure 5-46 ENTER EXIT NAVIGATION Figure 5-47 Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Setting the first increment Setting: 1 to 20 (factory setting 1) This function is only available when using up/down torches in modes 4 and 14! 099-000115-EW501 17.06.2015... -
Page 91: Mma Welding
Design and function MMA welding 5.14 MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •... -
Page 92: Select Welding Task
Design and function MMA welding Item Symbol Description Connection socket, “+” welding current Connection for workpiece lead • Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right. •... -
Page 93: Frequency And Balance Setting
Design and function MMA welding 5.14.5 Frequency and balance setting Operating Action Result Displays element Switch on welding current polarity "AC" - See 5.14.3 Welding current polarity reversal (polarity reversal) chapter Select the welding parameter alternating current frequency. Press until signal light comes on. -
Page 94: Hotstart Time
Design and function MMA welding 5.14.6.2 Hotstart time Control element Action Result Displays Select hotstart time welding parameter: Press until the hotstart time signal light sec comes Set hotstart time. 5.14.7 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current. -
Page 95: Mma Pulse Welding In The Vertical Up Position (Pf)
Design and function MMA welding 5.14.9 MMA pulse welding in the vertical up position (PF) Welding characteristics: • Especially suitable for root welding • Fine-flaked weld surface with a TIG look for final passes • Less finishing work thanks to less spatter •... -
Page 96: Welding Programs
Design and function Welding programs 5.15 Welding programs Changes made to the other welding parameters during the course of the program have the equivalent effect on all programs. The change to the welding parameters is saved immediately in the JOB. The welding machine has 16 programs, which you can change during welding. -
Page 97: Selection And Adjustment
Design and function Welding programs 5.15.1 Selection and adjustment Setting welding programs using the welding machine control Operating Action Result Display element Press button until signal light PROG comes on. Welding current (left) and program no. (right) Select or retrieve program no., e.g. no. 1 Set operating mode (can be specified separately for each No change program). -
Page 98: Example "Program With Synergetic Setting
Design and function Welding programs 5.15.3 Example "Program with synergetic setting" Figure 5-50 5.15.4 Example "Program with conventional setting" Figure 5-51 5.15.5 Accessories for switching over programs The user can change, retrieve and save programs using the following components. Programs Component Create and change Retrieve... -
Page 99: Organising Welding Tasks (Mode "Job Manager")
Design and function Organising welding tasks (Mode "JOB Manager") 5.16 Organising welding tasks (Mode "JOB Manager") 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. -
Page 100: Creating A New Job In The Memory Or Copying A Job
Design and function Organising welding tasks (Mode "JOB Manager") 5.16.2 Creating a new JOB in the memory or copying a JOB Copying a pre-defined welding task from the fixed memory (JOBs 1 to 128) to the free memory (JOBs 129-256): It is normally possible to adjust all 256 JOBs individually. -
Page 101: Loading An Existing Job From The Free Memory
Design and function Organising welding tasks (Mode "JOB Manager") 5.16.3 Loading an existing JOB from the free memory Operating Action Result Display element Press until the “VOLT” Select JOB Manager mode signal light is on Select JOB Manager mode 2 sec. Select the required JOB number using the rotary transducer (e.g. -
Page 102: Resetting Jobs 1-128 To The Factory Setting (Reset All Jobs)
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 Result Display element Press until the “VOLT” Select JOB Manager mode signal light is on Select JOB Manager mode 2 sec. -
Page 103: Remote Control
Design and function Remote control 5.17 Remote control The remote controls are operated on the 19-pole remote control connection socket (analogue). 5.17.1 Manual remote control RT1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. -
Page 104: Manual Remote Control Rt Pws 1 19Pol
Design and function Remote control 5.17.7 Manual remote control RT PWS 1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current at the welding machine • Pole reversing switch, suitable for machines with PWS function 5.17.8 Foot-operated remote control RTF1 19POL 5 M / RTF2 19POL 5 M Functions •... -
Page 105: Ramp Function Foot-Operated Remote Control Rtf 1 / Rtf 2
Design and function Remote control 5.17.8.1 Ramp function foot-operated remote control RTF 1 / RTF 2 ENTER EXIT NAVIGATION Figure 5-53 Display Setting/selection Exit the menu Exit Machine configuration (part two) Settings for machine functions and parameter display Ramp function Remote control RTF 1 The ramp function can be switched on and off Switch on Switching on machine function... -
Page 106: Simultaneous Welding On Both Sides, Synchronisation Types
Design and function Simultaneous welding on both sides, synchronisation types 5.18 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. -
Page 107: Synchronisation Via Cable (Frequency 50Hz To 200Hz)
Design and function Simultaneous welding on both sides, synchronisation types 5.18.2 Synchronisation via cable (frequency 50Hz to 200Hz) This application describes synchronisation (master/slave operation) with two machines in the Tetrix series. The following components are required: • The synchronisation interface SYNINT X10 •... -
Page 108: Interfaces For Automation
Design and function Interfaces for automation 5.19 Interfaces for automation CAUTION Damage to the machine due to improper connection! Unsuitable control leads or incorrect connection of input and output signals can cause damage to the machine. • Only use shielded control leads! •... -
Page 109: Remote Control Connection Socket, 19-Pole
Design and function Interfaces for automation 5.19.2 Remote control connection socket, 19-pole Figure 5-54 Pos. Signal shape Designation Output Connection for cable screen (PE) Output Current flows signal I>0, galvanically isolated (max. +- 15V/100mA) Output Reference voltage for potentiometer 10V (max. 10mA) Input Control value specification for main current, 0-10V (0V = I , 10V =... -
Page 110: Protecting Welding Parameters From Unauthorised Access
Design and function Protecting welding parameters from unauthorised access 5.20 Protecting welding parameters from unauthorised access These accessory components can be retrofitted as an option - See 9 Accessories chapter. 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. - Page 111 Design and function Machine configuration menu ENTER EXIT NAVIGATION Figure 5-55 099-000115-EW501 17.06.2015...
- Page 112 Design and function Machine configuration menu Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (factory setting 1) Up-/Down speed Increase value = rapid current change (factory setting 10) Reduce value = slow current change Setting the first increment Setting: 1 to 20 (factory setting 1) Get JOB number...
- Page 113 Design and function Machine configuration menu Display Setting/selection Warnings Warnings can be issued prior to a machine failure. Warnings disabled (ex works) Warnings enabled Machine configuration (part two) Settings for machine functions and parameter display Ramp function Remote control RTF 1 The ramp function can be switched on and off Tungsten balling with RT AC remote control Function switched off (factory setting)
- Page 114 Design and function Machine configuration menu Display Setting/selection 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 AC synchronisation or hot wire (factory setting) Error signal, negative logic...
- Page 115 Design and function Machine configuration menu Display Setting/selection Ignition pulse limit Setting 0 ms–15 ms (increments of 1 ms) 099-000115-EW501 17.06.2015...
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Page 116: Aligning The Cable Resistance
Design and function Machine configuration menu 5.22.2 Aligning the cable resistance To ensure optimum welding properties, the electric cable resistance should be aligned again whenever an accessory component such as the welding torch or the intermediate hose package (AW) has been changed. -
Page 117: Power-Saving Mode (Standby)
Design and function Machine configuration menu 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Unfasten the tungsten electrode and extract. 2 Configuration • Press the (Tetrix Classic) push-button while simultaneously switching on the welding machine. -
Page 118: Maintenance, Care And Disposal
Maintenance, care and disposal Maintenance work Maintenance, care and disposal 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. •... -
Page 119: Monthly Maintenance Tasks
For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 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. -
Page 120: Disposing Of Equipment
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU). -
Page 121: Rectifying Faults
Rectifying faults Checklist for rectifying faults 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. - Page 122 Rectifying faults Checklist for rectifying faults Wire feed problems Unsuitable or worn welding torch equipment Adjust contact tip (cold wire/hot wire) to wire diameter, blow through and replace if necessary Adjust wire guide to material in use, blow through and replace if necessary ...
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Page 123: Warnings (Power Source)
Rectifying faults Warnings (power source) Warnings (power source) A warning is denoted by the letter A on the machine display, or Att in case of multiple machine displays. The possible cause of the warning is signalled by the respective error code (see table). The display of possible error numbers depends on the machine version (interfaces/functions). -
Page 124: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) 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. - Page 125 Rectifying faults Error messages (power source) Error message Possible cause Remedy Err 20 Coolant Check coolant level and refill if necessary • The flow quantity of the torch coolant Check coolant level in the reverse cooler • has fallen below the permissible Check coolant lines for leaks and kinks minimum ->...
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Page 126: Resetting Welding Parameters To The Factory Settings
Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. ENTER EXIT NAVIGATION Figure 7-1 Display Setting/selection Exit the menu Exit Service menu Modifications to the service menu may only be carried out by authorised maintenance... -
Page 127: Display Machine Control Software Version
Rectifying faults Display machine control software version Display machine control software version The query of the software versions only serves to inform the authorised service staff! ENTER EXIT NAVIGATION 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) System bus ID... -
Page 128: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-3 099-000115-EW501... -
Page 129: Technical Data
Technical data Tetrix 351 AC/DC AW Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 351 AC/DC AW Welding current 5 A–350 A Welding voltage (TIG) 10.2 V–24 V 20.2 V–34 V Duty cycle at 25 °C... -
Page 130: Tetrix 451 Ac/Dc Aw
Technical data Tetrix 451 AC/DC AW Tetrix 451 AC/DC AW Welding current 5 A–450 A Welding voltage 10.2 V–28.0 V 20.2 V–38.0 V Duty cycle at 25 °C 100% DC 450 A Duty cycle at 40 °C 80% DC 450 A 100% DC 420 A ... -
Page 131: Tetrix 551 Ac/Dc Aw
Technical data Tetrix 551 AC/DC AW Tetrix 551 AC/DC AW Welding current 5 A–550 A Welding voltage (TIG) 10.2 V–32.0 V 20.2 V–42.0 V Duty cycle at 25 °C 60% DC 550 A 80% DC 520 A 100% DC 450 A Duty cycle at 40 °C 550 A 60% DC... -
Page 132: Accessories
Retrofit option, dirt filter for air inlet 092-004999-00000 ON Holder Gas Bottle <50L Optional retrofit holding plate for gas cylinder <50l 092-002345-00000 TETRIX XL 9.2.3 Tetrix 351, 451, 551 AC/DC Type Designation Item no. ON 7pol Optional 7-pole retrofit connection socket 092-001826-00000... -
Page 133: General Accessories
Accessories General accessories General accessories Type Designation Item no. KF 23E-10 Coolant (-10 °C), 9.3 l 094-000530-00000 KF 23E-200 Coolant (-10 °C), 200 litres 094-000530-00001 KF 37E-10 Coolant (-20 °C), 9.3 l 094-006256-00000 KF 37E-200 Coolant (-20 °C), 200 l 094-006256-00001 TYP 1 Frost protection tester... -
Page 134: Job-List
Appendix A JOB-List Appendix A 10.1 JOB-List Process Material Wire Seam position Reserved CrNi/ Fe/ St CrNi/ Fe/ St CrNi/ Fe/ St CrNi/ Fe/ St ... - Page 135 Appendix A JOB-List Process Material Wire Seam position Cu/CuZn Cu/CuZn >3.2 Cu/CuZn Cu/CuZn Cu/CuZn Cu/CuZn Cu/CuZn Cu/CuZn >3.2 ...
- Page 136 Appendix A JOB-List Process Material Wire Seam position AlSi AlSi AlSi AlSi AlSi AlSi >3.2 AlSi AlSi ...
- Page 137 Appendix A JOB-List Process Material Wire Seam position Al99 Al99 Al99 Al99 >3.2 Al99 Al99 Al99 ...
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Page 138: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 11.1 Overview of EWM branches 099-000115-EW501 17.06.2015...
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