EWM TETRIX 351 AC/DC COMFORT activArc Operating Instructions Manual

Welding machines for tig and mma welding

Hide thumbs Also See for TETRIX 351 AC/DC COMFORT activArc:

Operating instructions manual (117 pages)

Conversion instructions (15 pages)

Operating instructions manual (88 pages)

Table Of Contents

100

101

102

103

page of 103

/ 103
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

Need help?

Do you have a question about the TETRIX 351 AC/DC COMFORT activArc and is the answer not in the manual?

Questions and answers

Summary of Contents for EWM TETRIX 351 AC/DC COMFORT activArc

Page 1 HIGHTEC WELDING GmbH Dr. Günter-Henle-Straße 8 • D-56271 Mündersbach Fon +49 2680 181-0 • Fax +49 2680 181-244 www.ewm.de • info@ewm.de Operating instructions Welding machines for TIG and MMA welding TETRIX 351, 421, 521 AC/DC COMFORT activArc N. B. These operating instructions must be read before commissioning.
Page 2 Perfection doesn't happen by coincidence: Every single component is 100% tested and the machine is “free welded” before it is delivered. Our comprehensive service offer and the highly developed modern EWM quality management system guarantee worldwide premium quality “Made in Germany” and a three-year warranty.
Page 3 Machine and Company Data Please enter the EWM machine data and your company’s data in the appropriate fields. EWM HIGHTEC WELDING GMBH D-56271 MÜNDERSBACH TYP: SNR: ART: PROJ: GEPRÜFT/CONTROL: Name of Customer / company Name of Customer / company Adress...
Page 4: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................4 2 Safety instructions ..........................8 Notes on the use of these operating instructions................8 General............................10 Transport and installation......................12 2.3.1 Lifting by crane ......................13 Ambient conditions........................14 2.4.1 In operation........................14 2.4.2 Transport and storage ....................14 3 Technical data............................15 TETRIX 351, 421, 521 AC/DC .....................15...
Page 5 Contents Notes on the use of these operating instructions 5.2.8 TIG activArc welding..................... 44 5.2.9 Shielding gas setting ....................45 5.2.9.1 Gas test......................45 5.2.10 Welding torch (operating variants) ................45 5.2.10.1 Tap torch trigger (tapping function)............. 45 5.2.11 Torch mode and up/down speed setting ..............46 5.2.11.1 Standard TIG torch (5-pole) ................
Page 6 Contents Notes on the use of these operating instructions 6 Commissioning.............................69 General............................69 Workpiece lead, general ......................69 Area of application – proper usage ....................70 Installation ............................70 Machine cooling ...........................70 Welding torch cooling system ......................71 6.6.1 General .........................71 6.6.2 List of coolants......................71 6.6.3 Adding coolant ......................72 Mains connection .........................73...
Page 7 TETRIX 351, 421, 521 AC/DC ..................93 10.4 General accessories ........................93 10.5 Computer communication......................93 11 Circuit diagrams........................... 94 11.1 TETRIX 351 AC/DC COMFORT activArc..................94 11.2 TETRIX 421 AC/DC COMFORT activArc..................97 11.3 TETRIX 521 AC/DC COMFORT activArc.................. 100 12 Appendix A ............................103 12.1 Declaration of Conformity ......................103...
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 Safety instructions Notes on the use of these operating instructions 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. Symbol Description Press Do not press...
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 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 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: Lifting By Crane
Safety instructions Transport and installation 2.3.1 Lifting by crane DANGER Risk of injury during lifting by crane! When lifting the equipment by crane, serious injuries can be inflicted by falling equipment or add-on units. • Transport on all lifting lugs at the same time (see Fig.
Page 14: Ambient Conditions
Safety instructions Ambient conditions Ambient conditions CAUTION Equipment damage due to dirt accumulation! Unusually high quantities of dust, acid, corrosive gases or substances may damage the equipment. • Avoid high volumes of smoke, vapour, oil vapour and grinding dust! • Avoid ambient air containing salt (sea air)! Non-permissible ambient conditions! Insufficient ventilation results in a reduction in performance and equipment damage.
Page 15: Technical Data
Technical data TETRIX 351, 421, 521 AC/DC Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! TETRIX 351, 421, 521 AC/DC TETRIX Setting ranges Welding current 5 A to 350 A 5 A to 420 A 5 A to 520 A Welding voltage (TIG) 10.2 V to 24 V...
Page 16: Machine Description
Machine description TETRIX 351 AC/DC Machine description TETRIX 351 AC/DC NOTE The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted (see "Accessories" chapter). 4.1.1 Front view Figure 4-1 Item No.: 099-000108-EWM01...
Page 17 Machine description TETRIX 351 AC/DC Item Symbol Description Lifting lug Main switch, machine on/off Machine control See Machine control – operating elements chapter Carrying handle Connection socket, 8-pole / 12-pole 8-pole: TIG Up/Down or potentiometer torch control lead 12-pole: Control lead for TIG up/down torch with LED display (option) Key switch for protection against unauthorised use Position “1”...
Page 18: Rear View
Machine description TETRIX 351 AC/DC 4.1.2 Rear view Figure 4-2 Item No.: 099-000108-EWM01...
Page 19 Machine description TETRIX 351 AC/DC Item Symbol Description 7-pole connection socket (digital) For connecting digital accessory components (documentation interface, robot interface digital or remote control, etc.). Connection socket, 28-pole (optional, factory-fitted) TIG cold wire feed unit connection Key button, automatic cutout Wire feed motor supply voltage fuse (press to reset a triggered fuse) 42V/4A...
Page 20: Tetrix 421, 521 Ac/Dc
Machine description TETRIX 421, 521 AC/DC TETRIX 421, 521 AC/DC NOTE The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted (see "Accessories" chapter). 4.2.1 Front view Figure 4-3 Item No.: 099-000108-EWM01...
Page 21 Machine description TETRIX 421, 521 AC/DC Item Symbol Description Lifting lug Main switch, machine on/off Machine control See Machine control – operating elements chapter Carrying handle Connection socket, 8-pole / 12-pole 8-pole: TIG Up/Down or potentiometer torch control lead 12-pole: Control lead for TIG up/down torch with LED display (option) Key switch for protection against unauthorised use Position “1”...
Page 22: Rear View
Machine description TETRIX 421, 521 AC/DC 4.2.2 Rear view Figure 4-4 Item No.: 099-000108-EWM01...
Page 23 Machine description TETRIX 421, 521 AC/DC Item Symbol Description 7-pole connection socket (digital) For connecting digital accessory components (documentation interface, robot interface digital or remote control, etc.). Connection socket, 28-pole (optional, factory-fitted) TIG cold wire feed unit connection Key button, automatic cutout Wire feed motor supply voltage fuse (press to reset a triggered fuse) 42V/4A...
Page 24: Machine Control - Operating Elements
Machine description Machine control – Operating elements Machine control – Operating elements NOTE Machine control provides the user with up to 8 welding tasks (JOBs). JOB 0 represents manual operating mode. This is where you can change/optimise all parameters directly in machine control (see chapter "Operating concepts"). COMFORT T 3.23 Puls...
Page 25 Machine description Machine control – Operating elements Item Symbol Description Welding current polarity button Direct current welding with positive polarity on the electrode holder in relation to the workpiece (pole reversal switch, MMA only). DC welding with negative polarity on the torch (or stick electrode holder) in relation to the workpiece.
Page 26: Function Sequence
Machine description Machine control – Operating elements 4.3.1.1 Function sequence Figure 4-6 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). Ignition current (TIG) Hotstart current (MMA) AMP%...
Page 27 Machine description Machine control – Operating elements Item Symbol Description Secondary current (TIG) / pulse pause current AMP% Setting range 1 % to 100 % (1 % increments). Percentage of the main current. Down-slope time (TIG) 0.00 sec to 20.0 sec (0.1 sec increments). The down-slope time can be set separately for non-latched and latched.
Page 28: Functional Characteristics
Functional characteristics Operating concepts Functional characteristics Operating concepts The welding task (JOB) can be selected in two ways: • Manual, standard operation (JOB "0") • JOB operation, saved welding tasks (JOB 1 to 7) 5.1.1 Manual, standard operation (JOB 0) "Manual, standard operation (JOB 0)"...
Page 29: Save Welding Tasks (Jobs)
Functional characteristics Operating concepts Operating Action Result element Set alternating current balance (TIG AC only) Select welding parameter in the functional sequence Set welding parameters 5.1.2 Save welding tasks (JOBs) You can select, change and save the required welding parameters for recurring welding tasks (JOBs) in up to 7 JOBs (JOB 1 to JOB 7).
Page 30: Welding Data Display
Functional characteristics Operating concepts 5.1.3 Welding data display The following welding parameters can be displayed before (nominal values) or during (actual values) welding. Parameter Before welding During welding (nominal values) (actual values) Welding current Welding voltage JOB number Parameter times Frequency, balance Parameter currents 5.1.3.1...
Page 31: Tig Welding
Functional characteristics TIG welding TIG welding 5.2.1 Arc ignition 5.2.1.1 HF ignition Figure 5-1 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 32: Optimising The Ignition Characteristics For Pure Tungsten Electrodes
Functional characteristics TIG welding 5.2.2 Optimising the ignition characteristics for pure tungsten electrodes The best ignition and stabilisation of the arc (DC, AC) and optimum spherical cup formation in the tungsten electrode depend on the electrode diameter being used. The set value should correspond to the diameter of the tungsten electrode. The value can of course be adjusted in line with different requirements.
Page 33: Optimal And Fast Spherical Cup Formation
Functional characteristics TIG welding 5.2.4 Optimal and fast spherical cup formation NOTE A conically ground tungsten electrode (approx. 35°) is generally required to form an ideal spherical cup. Spherical cup formation preset Operating Action Result Display element spotArc operating mode Switch off pulse welding Set spotArc time in line with the electrode diameter in use (refer to the table of guideline values for spherical cup...
Page 34: Function Sequences/Operating Modes
Functional characteristics TIG welding 5.2.5 Function sequences/operating modes The "Select welding parameter" button and the "Welding parameter setting" rotary transducer can be used to control all the parameters for the TIG process: COMFORT T 3.23 Puls Automatic VOLT special DC + DC - AMP% AMP%...
Page 35: Non-Latched Mode
Functional characteristics TIG welding 5.2.5.2 Non-latched mode Figure 5-4 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. • The welding current flows and immediately assumes the value set for the ignition current I start •...
Page 36: Latched Mode
Functional characteristics TIG welding 5.2.5.3 Latched mode AMP% start Down Figure 5-5 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 37: Spotarc
Functional characteristics TIG welding 5.2.5.4 SpotArc The TIG SpotArc function is activated with the pulse variant automated frequencies by default, because this combination produces the most effective results. The user can of course combine the function with other pulse variants depending on the selected welding process. Pulse time (t1) and pulse break time (t2) can be set independently, but the spot time (tP) should be much greater than the pulse time in order to achieve an appropriate result.
Page 38 Functional characteristics TIG welding NOTE The process ends when the set spotArc time elapses or if the torch trigger is released prematurely. spotArc/pulse variants table: Process Pulse variants TIG DC Automated pulses (factory setting) (lights up in green) Pulses (thermal pulses) (lights up in red) kHz pulse (metallurgic pulses) No pulses...
Page 39: Non-Latched Operation, Version C
Functional characteristics TIG welding 5.2.5.5 Non-latched operation, version C Figure 5-7 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. • Welding current flows and immediately adopts the ignition current value set (search arc at minimum setting).
Page 40: Pulses, Function Sequences
Functional characteristics TIG welding 5.2.6 Pulses, function sequences NOTE 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. 5.2.6.1 TIG pulses –...
Page 41: Pulse Variants
Functional characteristics TIG welding 5.2.7 Pulse variants NOTE 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). 5.2.7.1 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 42: Khz Pulses (Metallurgic Pulses)
Functional characteristics TIG welding 5.2.7.2 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 43: Ac Pulses
Functional characteristics TIG welding 5.2.7.4 AC pulses (AC pulse, max. 50Hz) Setting: special = pulse current AMP% = pulse pause current / basic current AMP% tpuls = pulse time tpause = pulse pause time pause puls 5.2.7.5 AC special Application: e.g. for welding thick metal sheets onto thin metal sheets. Operating Action Result...
Page 44: Tig Activarc Welding
5.2.8 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 45: Shielding Gas Setting
Functional characteristics TIG welding 5.2.9 Shielding gas setting 5.2.9.1 Gas test Operating Action Result element Press the "Select welding parameter" button until the "activArc" LED flashes. Press the "Select welding parameter" button and hold for approx. 5 sec. 5 sec. The gas pre-flow time LED (TIG) will come on, shielding gas flows for approx.
Page 46: 5.2.11 Torch Mode And Up/Down Speed Setting
Functional characteristics TIG welding 5.2.11 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 47: Standard Tig Torch (5-Pole)
Functional characteristics TIG welding 5.2.11.1 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 BRT 1 Welding current On/Off (factory-set) BRT 1...
Page 48 Functional characteristics TIG welding 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 BRT 1 Welding current On/Off Secondary current BRT 2 (factory-set)
Page 49: Tig Up/Down Torch (8-Pole)
Functional characteristics TIG welding 5.2.11.2 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 BRT 1 Welding current on/off BRT 1 Secondary current (tapping mode) / (Latched mode) (factory- set) Increase welding current, infinite adjustment (up function)
Page 50 Functional characteristics TIG welding 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 BRT 1 Welding current on/off BRT 2 Secondary current BRT 1 (factory-...
Page 51: Potentiometer Torch (8-Pole)
Functional characteristics TIG welding 5.2.11.3 Potentiometer torch (8-pole) NOTE The welding machine needs to be configured for operation with a potentiometer torch (see chap. "Configuring TIG potentiometer torch") Potentiometer torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions Mode...
Page 52: Retox Tig Torch (12-Pole)
Functional characteristics TIG welding 5.2.11.4 RETOX TIG torch (12-pole) NOTE 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 BRT 1 BRT 3...
Page 53: 5.2.12 Setting The First Increment
Functional characteristics TIG welding 5.2.12 Setting the first increment Figure 5-13 Figure 5-14 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) NOTE This function is only available when using up/down torches in modes 4 and 14! Item No.: 099-000108-EWM01...
Page 54: Mma Welding
Functional characteristics MMA welding MMA welding 5.3.1 Selection and adjustment Operating Action Result Displays element Select MMA welding process Display shows the last current value signal light lights up in green used for welding. Set welding current Welding current is displayed.
Page 55: Hotstart Time
Functional characteristics Key switch 5.3.2.2 Hotstart time Operating Action Result Displays element Select hotstart time welding parameter Press until hotstart time light comes on Set hotstart time 5.3.3 Arcforce Shortly before the electrode threatens to stick, the arcforcing device sets an increased current designed to prevent the electrode sticking.
Page 56: Remote Control
Functional characteristics Remote control Remote control NOTE The remote control is operated on the 19-pole remote control connection socket. • If required, extension cables are available in different lengths (see chapter Accessories). • Plug the remote control unit into the remote control connection socket on the welding machine or wire feed unit and lock it only when the machine is switched off.
Page 57: Manual Remote Control Rt Pws 1
Functional characteristics Remote control 5.5.6 Manual remote control RT PWS 1 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 5.5.7 Foot-operated remote control RTF 1 Functions...
Page 58: Interfaces For Automation
Functional characteristics Interfaces for automation 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 59: Remote Control Connection Socket, 19-Pole
Functional characteristics Interfaces for automation 5.6.2 Remote control connection socket, 19-pole I>0 0-10V 10-100K 10-100K 0-10V +15V (max. 75mA) -15V (max. 25mA) START / STOP AMP / AMP% (PULS) (1V=100A) SOLL Figure 5-16 Pos. Signal shape Designation Output Connection for cable screen (PE) Output Current flows signal I>0, galvanically isolated (max.
Page 60: Advanced Settings
Functional characteristics Advanced settings Advanced settings 5.7.1 Setting slope times for secondary current AMP% or pulse edges Figure 5-17 Figure 5-18 Display Setting/selection Expert menu Slope time tS1 (main current to secondary current) Setting: 0.00 s to 20.0 s (factory setting 0.01 s) Slope time tS2 (secondary current to main current) Setting: 0.00 s to 20.0 s (factory setting 0.01 s) Item No.: 099-000108-EWM01...
Page 61: Tig Non-Latched Operating Mode, C Version
Functional characteristics Advanced settings 5.7.2 TIG non-latched operating mode, C version Figure 5-19 Display Setting/selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display Non-latched operation (C version) • on = on • off = off (factory setting) Item No.: 099-000108-EWM01...
Page 62: Configuring The Tig Potentiometer Torch Connection
Functional characteristics Advanced settings 5.7.3 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 two minutes after the mains plug is removed.
Page 63: Welding Current Display (Ignition, Secondary, End And Hotstart Currents)
Functional characteristics Advanced settings 5.7.4 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. Figure 5-21 Display Setting/selection...
Page 64: Ramp Function Foot-Operated Remote Control Rtf 1
Functional characteristics Advanced settings 5.7.5 Ramp function foot-operated remote control RTF 1 Figure 5-22 Display Setting/selection Exit the menu Exit Machine configuration 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 Switch off...
Page 65: Menus And Sub-Menus On The Machine Control
Functional characteristics Menus and sub-menus on the machine control Menus and sub-menus on the machine control 5.8.1 Direct menus (direct access to parameters) Functions, parameters and their values can be accessed directly, e.g. can be selected by pressing a button once. 5.8.2 Expert menu (TIG) The expert menu includes functions and parameters which are either not set on the machine control, or...
Page 66: Machine Configuration Menu
Functional characteristics Menus and sub-menus on the machine control 5.8.3 Machine configuration menu Figure 5-24 NOTE ENTER (enter the menu) • Switch off machine at the main switch • Press and hold the "welding parameters" button and switch the machine on again at the same time.
Page 67 Functional characteristics Menus and sub-menus on the machine control Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode • Modes 1-6: with tapping function (factory setting 1) • Modes 11-16: without tapping function Setting the first increment Setting: 1 to 20 (factory setting 1) Up-/Down speed (not available in modes 4 and 14) Increase value...
Page 68 Functional characteristics Menus and sub-menus on the machine control Display Setting/selection Welding current polarity during the ignition phase (AC series) • on = positive welding current polarity • off = negative welding current polarity (factory setting) Reconditioning pulse (spherical cup stability) •...
Page 69: Commissioning
Commissioning General Commissioning General DANGER 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 70: Area Of Application - Proper Usage
Commissioning Area of application – proper usage Area of application – proper usage WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! •...
Page 71: Welding Torch Cooling System
Commissioning Welding torch cooling system Welding torch cooling system 6.6.1 General CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! • Only use the coolant described in this manual (overview of coolants). •...
Page 72: Adding Coolant
Commissioning Welding torch cooling system 6.6.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. NOTE After the initial filling, wait for at least one minute when the machine is switched on so that the tube package is filled with coolant completely and without bubbles. With frequent changes of torch and during the initial filling process, the cooling unit tank should be topped up as necessary.
Page 73: Mains Connection
Commissioning 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 (any phase sequence for three-phase machines)! •...
Page 74: Tig Welding
Commissioning TIG welding TIG welding 6.8.1 Welding torch connection The TIG welding torch is to be equipped to suit the relevant welding task! • Fit suitable tungsten electrodes and • an appropriate shielding gas nozzle. • Observe the operating instructions for the TIG welding torch! Figure 6-3 Item Symbol Description...
Page 75: Torch Connection Options And Pin Assignments
Commissioning TIG welding • Insert the welding current plug on the welding torch into the welding current connection socket and lock by turning to the right. • Screw welding torch shielding gas connection tightly onto the G¼" connection nipple, welding current “-”.
Page 76 Commissioning TIG welding Figure 6-5 Item Symbol Description Pressure reducer Shielding gas cylinder Output side of the pressure reducer Cylinder valve • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. NOTE Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to expel any dirt.
Page 77: Setting The Shielding Gas Quantity
Commissioning MMA welding 6.8.4.2 Setting the shielding gas quantity CAUTION Electric shocks! When setting the shielding gas quantity, high voltage ignition pulses or open circuit voltage are applied at the welding torch; these can lead to electric shocks and burning on contact.
Page 78: Connecting The Electrode Holder And Workpiece Lead
Commissioning MMA welding 6.9.1 Connecting the electrode holder and workpiece lead Figure 6-6 Item Symbol Description G¼” connecting nipple, “-” welding current Shielding gas connection (with yellow insulating cap) for TIG welding torch Connection socket, “-” welding current Electrode holder connection Connection socket, “+”...
Page 79: Simultaneous Welding On Both Sides, Synchronisation Types
Commissioning Simultaneous welding on both sides, synchronisation types 6.10 Simultaneous welding on both sides, synchronisation types This function is important for carrying out welding on both sides simultaneously by two welders. This is sometimes the case with thick aluminium materials in the V-up position, for example. This ensures that when using alternating current the plus and minus pole phases occur simultaneously on both power sources ensuring that the arcs do not have a negative effect on one another.
Page 80: Maintenance And Testing
NOTE The maintenance, cleaning and testing work described below must be conducted correctly and on an annual basis in order qualify for claims under the EWM warranty. General When used in the specified environmental conditions and under normal operating conditions, this machine is largely maintenance-free and requires a minimum of care.
Page 81: Test
DIN EN 61010-1 Appendix A – Measuring Circuit A1. You as the user are tasked with ensuring that your EWM machines conform to the standard IEC/DIN EN 60974-4 and are tested with the relevant test equipment and measuring devices given above.
Page 82: Scope Of The Test
Maintenance and testing Test 7.3.2 Scope of the test a) Visual inspection b) Electrical test: measurement of • open circuit voltage • insulation resistance, or alternatively • leakage currents • protective conductor resistance c) Functional test d) Documentation 7.3.3 Visual inspection The key areas in the test are: 1.
Page 83: Measuring The Leakage Current (Protective Conductor And Contact Current)
Note: Even if the leakage current measurement according to the standard is only an alternative to the insulation resistance measurement, EWM recommends always performing both measurements, especially following repair work. The leakage current is based for the greater part on a physical effect other than the insulation resistance.
Page 84: Repair Work
Maintenance and testing Repair Work Repair Work Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine. Return deliveries of defective equipment subject to warranty may only be made through your dealer.
Page 85: Disposing Of Equipment
Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922. •...
Page 86: Warranty
• Wire feeds • Cooling units • Trolleys * If these are operated with genuine EWM accessories (such as intermediate tube package, remote control, remote control extension cable, coolant, etc.). 1-year warranty on: • Used EWM machines • Automation and mechanisation components •...
Page 87: Warranty Declaration
This limitation does not apply to personal injuries or damage to property caused by negligent behaviour on the part of EWM. In no way will EWM be responsible for lost profits, indirect or subsequent damage. EWM is not liable for damages based on the claims of third parties.
Page 88: Operating Problems, Causes And Remedies
Operating problems, causes and remedies Error messages (power source) Operating problems, causes and remedies All machines are subject to rigorous production checks and final checks. If despite this, anything fails to work at any time, please check the machine using the following chart. If none of the fault rectification procedures described leads to the correct functioning of the machine, please inform your authorised dealer.
Page 89: Resetting Welding Parameters To The Factory Settings
Operating problems, causes and remedies Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings. Figure 9-1 Display Setting/selection Exit the menu Exit Service menu Modifications to the service menu may only be carried out by authorised maintenance...
Page 90: Display Machine Control Software Version
Operating problems, causes and remedies Display machine control software version Display machine control software version NOTE The query of the software versions only serves to inform the authorised service staff! Figure 9-2 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)
Page 91: General Operating Problems
Operating problems, causes and remedies General operating problems General operating problems Problem Possible cause > remedy Machine control without displaying the signal • Phase failure > check mains connection (fuses) lights after switching on no welding performance • Phase failure > check mains connection (fuses) various parameters cannot be set •...
Page 92: Accessories, Options
Accessories, options Torches/electrode holders Accessories, options 10.1 Torches/electrode holders 10.1.1 TETRIX 351, 421 AC/DC Type Designation Item no. TIG 450 WD 4M 5P 2T TIG welding torch, 4 m, water-cooled, double 094-010994-00600 pressure TIG 450 WD 4M 8P 2T UD TIG welding torch, 4 m, water-cooled, double 094-010994-00200 pressure, U/D...
Page 93: Options
Accessories, options Options 10.3 Options 10.3.1 TETRIX 351 AC/DC Type Designation Item no. ON 19POL Optional 19-pole retrofit connection socket 092-001827-00000 Accessory components and analogue A interface ON FILTER T/P Retrofit option contamination filter for air inlet 092-002092-00000 ON HOLDER GAS BOTTLE Retrofit option holding plate for gas bottle <50 L 092-002151-00000 <50L...
Page 94: Circuit Diagrams
Circuit diagrams TETRIX 351 AC/DC COMFORT activArc Circuit diagrams NOTE Original format circuit diagrams are located inside the machine. 11.1 TETRIX 351 AC/DC COMFORT activArc Figure 11-1 Item No.: 099-000108-EWM01...
Page 95 Circuit diagrams TETRIX 351 AC/DC COMFORT activArc Figure 11-2 Item No.: 099-000108-EWM01...
Page 96 Circuit diagrams TETRIX 351 AC/DC COMFORT activArc Figure 11-3 Item No.: 099-000108-EWM01...
Page 97: Tetrix 421 Ac/Dc Comfort Activarc
Circuit diagrams TETRIX 421 AC/DC COMFORT activArc 11.2 TETRIX 421 AC/DC COMFORT activArc Figure 11-4 Item No.: 099-000108-EWM01...
Page 98 Circuit diagrams TETRIX 421 AC/DC COMFORT activArc Figure 11-5 Item No.: 099-000108-EWM01...
Page 99 Circuit diagrams TETRIX 421 AC/DC COMFORT activArc Figure 11-6 Item No.: 099-000108-EWM01...
Page 100: Tetrix 521 Ac/Dc Comfort Activarc
Circuit diagrams TETRIX 521 AC/DC COMFORT activArc 11.3 TETRIX 521 AC/DC COMFORT activArc Figure 11-7 Item No.: 099-000108-EWM01...
Page 101 Circuit diagrams TETRIX 521 AC/DC COMFORT activArc Figure 11-8 Item No.: 099-000108-EWM01...
Page 102 Circuit diagrams TETRIX 521 AC/DC COMFORT activArc Figure 11-9 Item No.: 099-000108-EWM01...
Page 103: Declaration Of Conformity
Umbauten, die nicht ausdrücklich von authorised by EWM. bées n’ayant pas été autorisés expressé- EWM autorisiert sind, verliert diese ment par EWM, cette déclaration devient Erklärung ihre Gültigkeit. caduque. Gerätebezeichnung: Description of the machine: Déscription de la machine: Gerätetyp:...

This manual is also suitable for:

Tetrix 521 ac/dc comfort activarc Tetrix 421 ac/dc comfort activarc

EWM TETRIX 351 AC/DC COMFORT activArc Operating Instructions Manual

1 Contents

2 Safety Instructions

3 Technical Data

4 Machine Description

5 Functional Characteristics

6 Commissioning

7 Maintenance and Testing

8 Warranty

9 Operating Problems, Causes and Remedies

10 Accessories, Options

11 Circuit Diagrams

12 Appendix A