EWM Tetrix 150 Synergic Plasma Operating Instructions Manual
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EWM Tetrix 150 Synergic Plasma Operating Instructions Manual

EWM Tetrix 150 Synergic Plasma Operating Instructions Manual

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Operating instructions
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099-007021-EW501
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Welding machine
Tetrix 150 Synergic Plasma
29.07.2015
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Summary of Contents for EWM Tetrix 150 Synergic Plasma

  • Page 1 Operating instructions Welding machine Tetrix 150 Synergic Plasma 099-007021-EW501 29.07.2015 Register now and benefit! Jetzt Registrieren und Profitieren! www.ewm-group.com...

  • 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

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 General ............................8 Transport and installation ......................12 2.4.1 Ambient conditions .......................
  • Page 4 Contents Notes on the use of these operating instructions 5.10.2.4 “Purge hose package” function ..............41 5.11 TIG Synergic operating principle ....................42 5.11.1 Synergic parameter setting in the functional sequence ..........43 5.11.2 Conventional parameter setting in the functional sequence ......... 43 5.11.3 Set the operating principle (conventional/synergic) ............
  • Page 5 General accessories ........................103 Remote controls and accessories ....................103 Options ............................104 Computer communication ......................104 10 Appendix A ............................105 10.1 JOB-List ............................. 105 11 Appendix B ............................109 11.1 Overview of EWM branches ...................... 109 099-007021-EW501 29.07.2015...

  • Page 6: 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 7: 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 8: General

    Safety instructions General 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. •...
  • Page 9 Safety instructions General 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! •...
  • Page 10 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 11 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.

  • Page 12: 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 13: Ambient Conditions

    Safety instructions Transport and installation 2.4.1 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 14: Intended Use

    3.1.2.1 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 15: Documents Which Also Apply

    3.2.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.2.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •...

  • Page 16: Machine Description

    Machine description Front view Machine description Front view Figure 4-1 099-007021-EW501 29.07.2015...
  • Page 17 Machine description Front view Item Symbol Description Carrying handle Fixing screws for gas metering unit ▼ Retrofitting option ▼ Key switch for protection against unauthorised use Position “1” > changes possible, Position “0” > changes not possible. - See 5.17 Protecting welding parameters from unauthorised access chapter ▲...

  • Page 18: Rear View

    Machine description Rear view Rear view Figure 4-2 099-007021-EW501 29.07.2015...
  • Page 19 Machine description Rear view Item Symbol Description 7-pole connection socket (digital) For connecting digital accessory components (documentation interface, robot interface or remote control, etc.). 7-pole connection socket (digital) For connecting digital accessory components (documentation interface, robot interface or remote control, etc.). "Automatic circuit-breaker"...

  • Page 20: Machine Control - Operating Elements

    Machine description Machine control – Operating elements Machine control – Operating elements As the plasma welding process is based directly on the TIG welding process, the TIG descriptions are used for plasma welding, with just a few differences. Figure 4-3 Item Symbol Description "Welding process"...
  • Page 21 Machine description Machine control – Operating elements Item Symbol Description Operating mode / Power-saving mode button spotArc / Spotmatic (spot time setting range) Non-latched Latched Press for 3 s to put machine into power-saving mode. To reactivate, activate one of the operating elements- See 5.19.2 Power-saving mode (Standby) chapter.

  • Page 22: Function Sequence

    Machine description Machine control – Operating elements 4.3.1 Function sequence Figure 4-4 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. Gas pre-flow time (TIG) absolute setting range 0.0 sec to 20.0 sec (0.1s increments).
  • Page 23 Machine description Machine control – Operating elements Item Symbol Description AMP% End-crater current (TIG) Setting range 1 % to 200 % (1 % increments). Percentage of the main current. Gas post-flow time (TIG) Setting ranges: 0.00 sec to 40.0 sec (0.1 sec increments). Balance TIG kHz-pulsing (metallurgical pulsing) Setting range: 1% to +99% (increments of 1%)

  • Page 24: 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 25: Machine Cooling

    Design and function Machine cooling Machine cooling To obtain an optimal duty cycle from the power components, the following precautions should be observed: • Ensure that the working area is adequately ventilated. • Do not obstruct the air inlets and outlets of the machine. •...

  • Page 26: 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 27 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.

  • Page 28: Welding Torch Cooling System

    Design and function Welding torch cooling system Welding torch cooling system 5.6.1 Cooling module connection Please note the relevant documentation of the accessory components. Figure 5-4 Item Symbol Description 8-pole connection socket Cooling unit control lead 4-pole connection socket Cooling unit voltage supply Cooling module Control and supply lead to the welding machine The cooling module and welding machine are connected using two leads.

  • Page 29: 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 30: Welding Data Display

    Design and function Welding data display Welding data display The following welding parameters can be displayed before (nominal values), during (actual values) or after welding (hold values): left-hand display Parameter Before welding During welding After welding (nominal values) (actual values) (hold values) ...

  • Page 31: Welding Current Display (Ignition, Secondary, End And Hotstart Currents)

    Design and function Plasma welding 5.8.2 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 32 Design and function Plasma welding Figure 5-7 099-007021-EW501 29.07.2015...
  • Page 33 Design and function Plasma welding Item Symbol Description G1/4 gas connection line Connection of the welding gases between the gas metering unit (GMU) and welding machine G1/4" shielding gas connecting nipple, welding machine output Connection to the welding torch or gas metering unit (GMU) G1/4 shielding gas connecting nipple, gas metering unit input Connection to the welding machine G1/4"...

  • Page 34: Welding Torch Connection (No Gas Metering Unit Gmu)

    Design and function Plasma welding 5.9.2 Welding torch connection (no gas metering unit GMU) Before commissioning, the plasma welding torch must be equipped for the welding JOB and correspondingly set/adjusted! Figure 5-8 Item Symbol Description Connection socket, "-" welding current TIG/Plasma welding current connection Pilot current connection socket Plasma welding torch nozzle potential...

  • Page 35: Connection For Workpiece Lead

    Design and function Plasma welding 5.9.3 Connection for workpiece lead • Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by turning to the right. 5.9.4 Shielding and plasma gas supply Figure 5-9 Item Symbol Description...

  • Page 36: Select Welding Task

    Design and function Plasma welding 5.9.5 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. The following plasma JOBs are pre-defined and may be selected in JOB manager: •...

  • Page 37: Select Welding Current

    Design and function Plasma welding 5.9.6 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 38: Tig Welding

    Design and function TIG welding 5.10 TIG welding 5.10.1 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 39: Torch Connection Options And Pin Assignments

    Design and function TIG welding Item Symbol Description Connection socket, welding current “+” (with DC- polarity) Connection for workpiece lead Connection socket, welding current “-” (with DC- polarity) connection TIG welding torch G1/4" shielding gas connecting nipple, welding machine output Connection to the welding torch or gas metering unit (GMU) 5-pole connection socket, welding torch control lead Connection socket, 8-pole...

  • Page 40: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function TIG welding 5.10.2 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 41: Setting The Shielding Gas Quantity

    Design and function TIG welding 5.10.2.2 Setting the shielding gas quantity Rule of thumb for the gas flow rate: Diameter of gas nozzle in mm corresponds to gas flow in l/min. Example: 7mm gas nozzle corresponds to 7l/min gas flow. Incorrect shielding gas setting! •...

  • Page 42: Tig Synergic Operating Principle

    Design and function TIG Synergic operating principle 5.11 TIG Synergic operating principle Figure 5-13 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 43: Synergic Parameter Setting In The Functional Sequence

    Design and function TIG Synergic operating principle 5.11.1 Synergic parameter setting in the functional sequence When setting the welding current, all the necessary welding parameters are adjusted automatically during the functional sequence - See 4.3.1 Function sequence chapter with the exception of the gas pre-flow time.

  • Page 44: Set The Operating Principle (Conventional/Synergic)

    Design and function TIG Synergic operating principle 5.11.3 Set the operating principle (conventional/synergic) ENTER EXIT NAVIGATION Figure 5-16 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 45: Select Welding Task

    Design and function TIG Synergic operating principle 5.11.4 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 46: Select Welding Current

    Design and function TIG Synergic operating principle 5.11.5 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 47: Expert Menu (Tig)

    Design and function TIG Synergic operating principle 5.11.7 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 48: Arc Ignition

    Design and function TIG Synergic operating principle 5.11.8 Arc ignition 5.11.8.1 HF ignition Figure 5-18 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 49: Function Sequences/Operating Modes

    Design and function TIG Synergic operating principle 5.11.9 Function sequences/operating modes Figure 5-20 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 50: Non-Latched Mode

    Design and function TIG Synergic operating principle 5.11.9.2 Non-latched mode Figure 5-21 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 51: Latched Mode

    Design and function TIG Synergic operating principle 5.11.9.3 Latched mode Figure 5-22 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 52: Spotarc

    Design and function TIG Synergic operating principle 5.11.9.4 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 53 Design and function TIG Synergic operating principle Figure 5-23 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however- See 5.9.7 Arc ignition chapter. Sequence: • Press and hold torch trigger 1. •...

  • Page 54: Spotmatic

    Design and function TIG Synergic operating principle 5.11.9.5 Spotmatic This function must be enabled before use- See 5.19 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 55: Non-Latched Operation, Version C

    Design and function TIG Synergic operating principle 5.11.9.6 Non-latched operation, version C Figure 5-25 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 56: Pulses, Function Sequences

    Design and function TIG Synergic operating principle 5.11.10 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 57: Pulse Variants

    Design and function TIG Synergic operating principle 5.11.11 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). 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 58 Design and function TIG Synergic operating principle 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 59: Tig Activarc Welding

    TIG Synergic operating principle 5.11.12 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 60: Welding Torch (Operating Variants)

    Design and function TIG Synergic operating principle 5.11.14 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 61: Torch Mode And Up/Down Speed Setting

    Design and function TIG Synergic operating principle 5.11.15 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 62: Standard Tig Torch (5-Pole)

    Design and function TIG Synergic operating principle 5.11.15.1 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 63 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)

  • Page 64: Tig Up/Down Torch (8-Pole)

    Design and function TIG Synergic operating principle 5.11.15.2 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 65 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-...

  • Page 66: Potentiometer Torch (8-Pole)

    Design and function TIG Synergic operating principle 5.11.15.3 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch- See 5.11.15.4 Configuring the TIG potentiometer torch connection chapter. Potentiometer torch with one torch trigger: Diagram Operating Explanation of symbols elements...

  • Page 67: Configuring The Tig Potentiometer Torch Connection

    Design and function TIG Synergic operating principle 5.11.15.4 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 68: Setting The First Increment

    Design and function TIG Synergic operating principle 5.11.15.5 Setting the first increment Figure 5-33 ENTER EXIT NAVIGATION Figure 5-34 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! 099-007021-EW501 29.07.2015...

  • Page 69: Mma Welding

    Design and function MMA welding 5.12 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 70: Select Welding Task

    Design and function MMA welding Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging. 5.12.2 Select welding task Operating Action Result element MMA welding process selection. Signal light lights up in green. Set welding current. If necessary, the pulse function can be enabled as well.

  • Page 71: Hotstart Time

    Design and function MMA welding 5.12.3.2 Hotstart time Control element Action Result Displays Select hotstart time welding parameter: Press until the hotstart time signal light sec comes Set hotstart time. 5.12.4 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current.

  • Page 72: Mma Pulse Welding In The Vertical Up Position (Pf)

    Design and function MMA welding 5.12.6 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 73: Welding Programs

    Design and function Welding programs 5.13 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 74: Selection And Adjustment

    Design and function Welding programs 5.13.1 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 75: Example "Program With Synergetic Setting

    Design and function Welding programs 5.13.3 Example "Program with synergetic setting" Figure 5-37 5.13.4 Example "Program with conventional setting" Figure 5-38 5.13.5 Accessories for switching over programs The user can change, retrieve and save programs using the following components. Programs Component Create and change Retrieve...

  • Page 76: Organising Welding Tasks (Mode "Job Manager")

    Design and function Organising welding tasks (Mode "JOB Manager") 5.14 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 77: Creating A New Job In The Memory Or Copying A Job

    Design and function Organising welding tasks (Mode "JOB Manager") 5.14.2 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 78: Loading An Existing Job From The Free Memory

    Design and function Organising welding tasks (Mode "JOB Manager") 5.14.3 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 79: Resetting Jobs 1-128 To The Factory Setting (Reset All Jobs)

    Design and function Organising welding tasks (Mode "JOB Manager") 5.14.5 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 80: Remote Control

    Design and function Remote control 5.15 Remote control The remote controls are operated on the 19-pole remote control connection socket (analogue). 5.15.1 Manual remote control RT1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine.

  • Page 81: Foot-Operated Remote Control Rtf1 19Pol 5 M / Rtf2 19Pol 5 M

    Design and function Remote control 5.15.6 Foot-operated remote control RTF1 19POL 5 M / RTF2 19POL 5 M Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. • Start/stop welding operation (TIG) ActivArc welding is not possible in combination with the foot-operated remote control.

  • Page 82: Ramp Function Foot-Operated Remote Control Rtf 1 / Rtf 2

    Design and function Remote control 5.15.6.1 Ramp function foot-operated remote control RTF 1 / RTF 2 ENTER EXIT NAVIGATION Figure 5-40 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 83: Interfaces For Automation

    Design and function Interfaces for automation 5.16 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 84: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.16.2 Remote control connection socket, 19-pole Figure 5-41 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 85: Protecting Welding Parameters From Unauthorised Access

    Design and function Protecting welding parameters from unauthorised access 5.17 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 86 Design and function Machine configuration menu ENTER EXIT NAVIGATION Figure 5-42 099-007021-EW501 29.07.2015...
  • Page 87 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 88 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 spotMatic Variation of operation mode spotArc, ignition with workpiece contact...

  • Page 89: Power-Saving Mode (Standby)

    Design and function Machine configuration menu Display Setting/selection Fast take-over of control voltage (automation) • on = function on • off = function off (factory setting) Orbital welding • off = off (ex works) • on = on Orbital welding Correction value for orbital current Service menu Modifications to the service menu may only be carried out by authorised maintenance...

  • Page 90: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.19.3 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 91 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 92: Maintenance, Care And Disposal

    Maintenance, care and disposal General 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 93: Annual Test (Inspection And Testing During Operation)

    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 94: 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 95 Rectifying faults Checklist for rectifying faults No arc ignition  Incorrect ignition type setting.  Set ignition type changeover switch to the HF ignition setting. Bad arc ignition  Material inclusions in the tungsten electrode due to contact with filler material or workpiece ...

  • Page 96: 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 97: Machine Faults (Error Messages)

    Rectifying faults Machine faults (error messages) Machine faults (error messages) 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 98 Rectifying faults Machine faults (error messages) 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 ->...

  • Page 99: 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 100: 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 101: 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 7-3 099-007021-EW501...

  • Page 102: Technical Data

    Technical data Tetrix 150 Plasma Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 150 Plasma Setting ranges Plasma/TIG Pilot arc current, pilot arc 5 A to 25 A (factory setting 10 A) (adjustable with PC 300 software) Welding current 5 A-150 A...

  • Page 103: Accessories

    Accessories Welding torch cooling system Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Welding torch cooling system Type Designation Item no. cool71 U43 Cooling unit with centrif. pump and reinforced 090-008220-00502 cooling DKF10...

  • Page 104: Options

    Accessories Options Options Type Designation Item no. ON 7pol Optional 7-pole retrofit connection socket 092-001826-00000 Accessory components and digital interfaces ON Key Switch Optional retrofit kit for key switch 092-001828-00000 Computer communication Type Designation Item no. PC300.Net PC300.Net welding parameter software kit incl. 090-008777-00000 cable and SECINT X10 USB interface 099-007021-EW501...

  • Page 105: Job-List

    Appendix A JOB-List Appendix A 10.1 JOB-List Process Material Wire Seam position  Reserved   CrNi   CrNi   CrNi       CrNi       CrNi      ...
  • Page 106 Appendix A JOB-List Process Material Wire Seam position        Fe/St       Fe/St >3.2   Fe/St   Fe/St   Fe/St       Fe/St ...
  • Page 107 Appendix A JOB-List Process Material Wire Seam position    CuZn   CuZn   CuZn     CuZn     CuZn   CuZn >3.2   CuZn   CuZn   CuZn ...
  • Page 108 Appendix A JOB-List Process Material Wire Seam position    Special   Special   Special   Special >3.2   Special   Special   Special   Special   Special   Special >3.2 TIG manual/TIG classic Classic electrode...

  • Page 109: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 11.1 Overview of EWM branches 099-007021-EW501 29.07.2015...

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