EWM Tetrix 230 Comfort 2-0 puls Operating Instructions Manual
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EWM Tetrix 230 Comfort 2-0 puls Operating Instructions Manual

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Operating instructions

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T 4.03 - DC Comfort 2.0 (Tetrix 230)
099-00T403-EW501
Observe additional system documents!
04.09.2017

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Summary of Contents for EWM Tetrix 230 Comfort 2-0 puls

  • Page 1: Operating Instructions

    Operating instructions Control T 4.03 - DC Comfort 2.0 (Tetrix 230) 099-00T403-EW501 Observe additional system documents! 04.09.2017...

  • 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 For your safety ............................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 Part of the complete documentation ....................7 3 Machine control –...
  • Page 4 Display machine control software version ..................43 6 Appendix A ............................44 Parameter overview – setting ranges ..................44 6.1.1 TIG welding ........................44 6.1.2 MMA welding ........................ 45 7 Appendix B ............................46 Overview of EWM branches......................46 099-00T403-EW501 04.09.2017...

  • Page 5: For Your Safety

    For your safety Notes on the use of these operating instructions For your safety 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. •...

  • Page 6: Explanation Of Icons

    For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release/tap/tip user must observe. Switch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Correct Numerical value – adjustable Menu entry Signal light lights up in green Navigating the menu...

  • Page 7: Part Of The Complete Documentation

    For your safety Part of the complete documentation Part of the complete documentation These operating instructions are part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system.

  • Page 8: Machine Control - Operating Elements

    Machine control – Operating elements Overview of control sections Machine control – Operating elements Overview of control sections For description purposes, the machine control has been divided into two sections (A, B) to ensure maximum clarity. The setting ranges for the parameter values are summarised in the parameter overview section >...

  • Page 9: Control Section A

    Machine control – Operating elements Overview of control sections 3.1.1 Control section A Figure 3-2 Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values > see 3.2 chapter Gas test push-button > see 4.1.1 chapter Operating mode >...

  • Page 10: Control Section B

    Machine control – Operating elements Overview of control sections Item Symbol Description Coolant fault signal light Signals pressure loss or low coolant level in the coolant circuit. Voltage reduction device (VRD) signal light The VRD signal light is illuminated when the voltage reduction device is operating without fault and the output voltage is reduced to a value specified in the relevant standard (see technical data) >...
  • Page 11 Machine control – Operating elements Machine display Item Symbol Description Gas post-flow time End current signal light AMP% Down-slope time signal light AMP% Signal light, two colour Red: Secondary or pulse pause current (% of AMP) Green: Pulse pause time Signal light, two colour Red: Main current /pulse current...

  • Page 12: Machine Display

    Machine control – Operating elements Machine display Machine display The following welding parameters can be displayed before (nominal values), during (actual values) or after welding (hold values): "left display" Parameter Before welding During welding After welding (nominal values) (actual values) (hold values) Welding current ...

  • Page 13: Welding Parameter Setting In The Operation Sequence

    Machine control – Operating elements Operating the machine control 3.3.3 Welding parameter setting in the operation sequence A welding parameter can be set in two ways in the operation sequence. 1. Push the "left" or "right" arrow keys (flashing signal light will indicate your selection). Turn the control button to set the parameter value.

  • Page 14: Functional Characteristics

    Functional characteristics TIG welding Functional characteristics TIG welding 4.1.1 Gas test – setting the shielding gas volume • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. • Set the relevant gas quantity for the application on the pressure regulator.

  • Page 15: Welding Task Selection

    Functional characteristics TIG welding 4.1.2 Welding task selection The setting of the tungsten electrode diameter has a direct influence on the machine functionality, TIG ignition behaviour and minimum current limits. The ignition energy is controlled by the set electrode diameter. Smaller electrode diameters requires less ignition current and less ignition current time than greater electrode diameters.

  • Page 16: Arc Ignition

    Functional characteristics TIG welding 4.1.3 Arc ignition To change the ignition type, use parameter to switch between HF start ( ) and lift arc ( ) in the Expert menu > see 4.1.9 chapter. 4.1.3.1 HF ignition Figure 4-3 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 17: Operating Modes (Functional Sequences)

    Functional characteristics TIG welding 4.1.4 Operating modes (functional sequences) 4.1.4.1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 Current Time Gas pre-flow Ignition current Up-slope time Spot time Main current (minimum to maximum current) Secondary current AMP% Pulse time Pulse pause time...

  • Page 18: Non-Latched Mode

    Functional characteristics TIG welding 4.1.4.2 Non-latched mode Selection Figure 4-5 Sequence Figure 4-6 1st cycle: • Press torch trigger 1 and hold down. • Gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece. The arc ignites. •...

  • Page 19: Latched Mode

    Functional characteristics TIG welding 4.1.4.3 Latched mode Selection Figure 4-7 Sequence Figure 4-8 099-00T403-EW501 04.09.2017...

  • Page 20: Spotarc

    Functional characteristics TIG welding cycle • Press torch trigger 1; 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 set ignition current (search arc at minimum setting).
  • Page 21 Functional characteristics TIG welding Figure 4-10 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 4.1.3 chapter. Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. •...

  • Page 22: Spotmatic

    Functional characteristics TIG welding 4.1.4.5 spotmatic In contrast to the spotArc operating mode, the arc is not ignited by pressing the torch trigger as is usual, but by briefly touching the tungsten electrode against the workpiece. The torch trigger is used for welding process activation.

  • Page 23: Tig Activarc Welding

    4.1.5 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 24: Pulse Welding

    Functional characteristics TIG welding 4.1.7 Pulse welding The following pulse types can be selected: • Automated pulsing • Thermal pulsing • Metallurgical pulsing • Average value pulsing 4.1.7.1 Automated pulses The automated pulsing pulse variant is only activated for DC welding in combination with the spotArc operating mode.

  • Page 25: Pulsed Welding In The Upslope And Downslope Phases

    Functional characteristics TIG welding Pulse time setting EXIT Figure 4-17 Pulse pause setting EXIT Figure 4-18 Pulse edge setting 4.1.7.3 Pulsed welding in the upslope and downslope phases The pulse function can also be deactivated if necessary during the up-slope and down-slope phases (parameter ) >...

  • Page 26: Average Value Pulse Welding

    Functional characteristics TIG welding 4.1.7.4 Average value pulse welding A special feature with average value pulses is that the power source will always maintain the preset average value. This makes this method especially suitable for welding according to welding procedure specifications.

  • Page 27: Welding Torch (Operating Variants)

    Functional characteristics TIG welding Balance setting EXIT Figure 4-23 Frequency setting EXIT Figure 4-24 4.1.8 Welding torch (operating variants) Different torch versions can be used with this machine. Functions on the operating elements, such as torch triggers (BRT), rockers or potentiometers, can be modified individually via torch modes.

  • Page 28: Up/Down Speed

    Functional characteristics TIG welding 4.1.8.3 Up/down speed Functionality Press and hold the up push-button: Increase current up to the maximum value (main current) set in the power source. Press and hold the down push-button: Decrease current to the minimum value. Use the machine configuration menu >...
  • Page 29 Functional characteristics TIG welding > see 4.1.8.3 chapter > see 4.1.8.4 chapter Standard torch with one rocker (rocker, two torch triggers) Figure Operating Explanation of symbols elements BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Functions Mode Operating elements...

  • Page 30: Tig Up/Down Torch (8-Pole)

    Functional characteristics TIG welding 4.1.8.6 TIG up/down torch (8-pole) Up/down torch with one torch trigger Figure Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions Mode Operating elements Welding current on/off Secondary current (tapping function) )/(latched operating mode) (ex works) Increase welding current (up function Decrease welding current (down function...

  • Page 31: Potentiometer Torch (8-Pole)

    Functional characteristics TIG welding Up/down torch with two torch triggers Figure Operating Explanation of symbols elements BRT 1 = torch trigger 1 (left) BRT 2 = torch trigger 2 (right) Functions Mode Operating elements Welding current on/off Secondary current Secondary current (tapping function) )/(latched operating mode) (ex works) Increase welding current (up function...
  • Page 32 Functional characteristics TIG welding Potentiometer torch with one torch trigger Figure Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions Mode Operating elements Welding current on/off Secondary current (tapping function Increase welding current Decrease welding current Potentiometer torch with two torch triggers Figure Operating Explanation of symbols...

  • Page 33: Configuring The Tig Potentiometer Torch Connection

    Functional characteristics TIG welding 4.1.8.8 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 34: Expert Menu (Tig)

    Functional characteristics TIG welding Functions Mode Operating elements Welding current on/off TT 1 Secondary current TT 2 Secondary current (tapping function) TT 1 (tapping) (ex works) Increase welding current (up function) TT 3 Reduce welding current (down function) TT 4 Welding current on/off TT 1 Secondary current...

  • Page 35: Mma Welding

    Functional characteristics MMA welding MMA welding 4.2.1 Welding task selection It is only possible to change the basic parameters when no welding current is flowing and any possible access control is disabled > see 4.4 chapter. The following welding task selection is an example of use. In general, the selection process always has the same sequence.

  • Page 36: Hotstart Time

    Functional characteristics MMA welding 4.2.2.2 Hotstart time EXIT Figure 4-30 4.2.3 Antistick The Antistick feature prevents the electrode from annealing. Should the electrode stick, the machine automatically switches to the minimum current within approx. one second. This prevents the electrode from annealing.

  • Page 37: Average Value Pulse Welding

    Functional characteristics Power-saving mode (Standby) 4.2.4 Average value pulse welding With average value pulsing, two currents are periodically toggled. The user can adjust the welding current (average current value AMP), pulse current Ipuls (parameter ), balance and frequency to the welding task.

  • Page 38: Access Control

    Functional characteristics Access control Access control The machine control can be locked to secure it against unauthorised or unintentional adjustment. The access block has the following effect: • The parameters and their settings in the machine configuration menu, Expert menu and operation sequence can only be viewed but not changed.

  • Page 39: Machine Configuration Menu

    Functional characteristics Machine configuration menu Machine configuration menu Basic machine settings are defined in the machine configuration menu. 4.6.1 Selecting, changing and saving parameters ENTER EXIT NAVIGATION Figure 4-34 099-00T403-EW501 04.09.2017...
  • Page 40 Functional characteristics Machine configuration menu Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (ex works 1)<dg_ref_source_inline>Brennermodus</dg_ref_source_inline> Up/down speed<dg_ref_source_inline>Up-/Down- Geschwindigkeit</dg_ref_source_inline> Increase value > rapid current change Decrease value > slow current change Current jump<dg_ref_source_inline>Stromsprung</dg_ref_source_inline> Current jump setting in ampere Machine configuration Settings for machine functions and parameter display...
  • Page 41 Functional characteristics Machine configuration menu Display Setting/selection Machine code Querying the three-digit machine code (000 to 999), user input Switch off Switching off machine function Switch on Switching on machine function Error Error message after entering an incorrect machine code Access control –...

  • Page 42: Rectifying Faults

    Rectifying faults Error messages (power source) 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 43: 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. RESET Figure 5-1 Display Setting/selection Input confirmation User entries are applied, release button(s). Display machine control software version The query of the software versions only serves to inform the authorised service staff.

  • Page 44: Parameter Overview - Setting Ranges

    Appendix A Parameter overview – setting ranges Appendix A Parameter overview – setting ranges 6.1.1 TIG welding Name Display Setting range Main current AMP, depending on power source Gas pre-flow time Ignition current, percentage of AMP Ignition current, absolute, depending on power source Up-slope time 20,0 Pulse current...

  • Page 45: Mma Welding

    Appendix A Parameter overview – setting ranges 6.1.2 MMA welding Name Display Setting range Main current AMP, depending on power source Hot start current, percentage of AMP Hot start current, absolute, depending on power source Hot start time 10,0 Pulse current Pulse frequency Pulse balance Dynamic power adjustment...

  • Page 46: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B Overview of EWM branches 099-00T403-EW501 04.09.2017...

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T 4.03 - dc comfort 2.0

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