EWM Tetrix 351 AC/DC Synergic FW Operating Instructions Manual
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EWM Tetrix 351 AC/DC Synergic FW Operating Instructions Manual

EWM Tetrix 351 AC/DC Synergic FW Operating Instructions Manual

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Operating instructions
Welding machine
EN
Tetrix 351 AC/DC Synergic FW
Tetrix 451 AC/DC Synergic FW
Tetrix 501 AC/DC Synergic FW
Tetrix 551 AC/DC Synergic FW
099-000109-EW501
Observe additional system documents!
23.08.2018

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Summary of Contents for EWM Tetrix 351 AC/DC Synergic FW

  • Page 1 Operating instructions Welding machine Tetrix 351 AC/DC Synergic FW Tetrix 451 AC/DC Synergic FW Tetrix 501 AC/DC Synergic FW Tetrix 551 AC/DC Synergic FW 099-000109-EW501 Observe additional system documents! 23.08.2018...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. 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 ............................7 Notes on the use of these operating instructions ................7 Explanation of icons ........................8 Part of the complete documentation ....................9 Safety instructions ........................
  • Page 4 Contents Notes on the use of these operating instructions 5.3.7 Tungsten balling function ....................43 5.3.8 AC balance (optimise cleaning effect and penetration characteristics) ......44 5.3.9 AC amplitude balance ....................44 5.3.10 Arc ignition ........................45 5.3.10.1 HF ignition ..................... 45 5.3.10.2 Liftarc ......................
  • Page 5 Contents Notes on the use of these operating instructions 5.7.8.1 RTF start ramp ....................78 5.7.8.2 RTF response ....................79 Welding torch (operating variants) ....................79 5.8.1 Tapping function (tap torch trigger) ................79 5.8.2 Torch mode setting ....................... 79 5.8.3 Up/down speed ......................
  • Page 6 Contents Notes on the use of these operating instructions 11 Appendix B ............................116 11.1 Parameter overview – setting ranges ..................116 11.1.1 TIG welding ......................... 116 11.1.2 MMA welding ......................116 12 Appendix C ............................117 12.1 Searching for a dealer ........................ 117 099-000109-EW501 23.08.2018...

  • Page 7: 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 8: 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 hold Switch Incorrect / Invalid Turn Numerical value –...

  • Page 9: 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 10: Safety Instructions

    For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
  • Page 11 For your safety Safety instructions WARNING Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure when heated. • Move containers with inflammable or explosive liquids away from the working area! • Never heat explosive liquids, dusts or gases by welding or cutting! Fire hazard! Due to the high temperatures, sparks, glowing parts and hot slag that occur during welding, there is a risk of flames.
  • Page 12 For your safety Safety instructions CAUTION According to IEC 60974-10, welding machines are divided into two classes of electromagnetic compatibility (the EMC class can be found in the Technical da- ta) > see 8 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 13: Transport And Installation

    For your safety Transport and installation The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode hold- ers, remote controls, spare parts and replacement parts, etc.) from our range of products! •...
  • Page 14 For your safety Transport and installation The units are designed for operation in an upright position! Operation in non-permissible positions can cause equipment damage. • Only transport and operate in an upright position! Accessory components and the power source itself can be damaged by incorrect connection! •...

  • Page 15: Intended Use

    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 labelled product complies with the following EC directives in terms of its design and construction: •...

  • Page 16: Machine Description - Quick Overview

    Machine description – quick overview Tetrix 351 AC/DC Machine description – quick overview Tetrix 351 AC/DC 4.1.1 Front view Figure 4-1 099-000109-EW501 23.08.2018...
  • Page 17 Machine description – quick overview Tetrix 351 AC/DC Item Symbol Description Lifting lug > see 5.1.1 chapter Main switch, machine on/off Machine control > see 4.3 chapter Carrying handle Automatic cut-out of coolant pump key button press to reset a triggered fuse Quick connect coupling (red) Coolant return from welding torch Quick connect coupling (blue)

  • Page 18: Rear View

    Machine description – quick overview Tetrix 351 AC/DC 4.1.2 Rear view Figure 4-2 099-000109-EW501 23.08.2018...
  • Page 19 Machine description – quick overview Tetrix 351 AC/DC Item Symbol Description Connection socket, 7-pole (digital) To connect digital accessories Retrofitting option > see 9 chapter PC interface, serial (D-Sub connection socket, 9-pole) Automation interface 19-pin (analogue) Option for retrofitting > see 5.9.1 chapter Ignition type changeover switch >...

  • Page 20: Tetrix 451-551 Ac/Dc

    Machine description – quick overview Tetrix 451-551 AC/DC Tetrix 451-551 AC/DC 4.2.1 Front view Figure 4-3 099-000109-EW501 23.08.2018...
  • Page 21 Machine description – quick overview Tetrix 451-551 AC/DC Item Symbol Description Lifting lug > see 5.1.1 chapter Main switch, machine on/off Machine control > see 4.3 chapter Carrying handle Automatic cut-out of coolant pump key button press to reset a triggered fuse Quick connect coupling (red) Coolant return from welding torch Quick connect coupling (blue)

  • Page 22: Rear View

    Machine description – quick overview Tetrix 451-551 AC/DC 4.2.2 Rear view Figure 4-4 099-000109-EW501 23.08.2018...
  • Page 23 Machine description – quick overview Tetrix 451-551 AC/DC Item Symbol Description Connection socket, 7-pole (digital) To connect digital accessories Retrofitting option > see 9 chapter PC interface, serial (D-Sub connection socket, 9-pole) Automation interface 19-pin (analogue) Option for retrofitting > see 5.9.1 chapter Ignition type changeover switch >...

  • Page 24: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-5 Item Symbol Description Polarity changeover (TIG manual) button Select material type (TIG Synergic) key button DC welding with positive polarity on the Chrome/nickel alloys / iron / electrode holder in relation to the work- steel alloys piece (pole reversing switch, MMA only).
  • Page 25 Machine description – quick overview Machine control – Operating elements Item Symbol Description Select seam type button ------- Fillet weld -------- Butt joint ------- Fillet weld - lap joint --------- Vertical-down 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.

  • Page 26: Function Sequence

    Machine description – quick overview Machine control – Operating elements 4.3.1 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 signal light AMP% Signal light...
  • Page 27 Machine description – quick overview Machine control – Operating elements Item Symbol Description Frequency signal light AC frequency (TIG)/pulse frequency (TIG DC – kHz pulses)/pulse frequency (MMA) Welding current polarity, MMA AC/DC > see 5.4.3 chapter Signal light activArc > see 5.3.15 chapter 099-000109-EW501 23.08.2018...

  • Page 28: Design And Function

    Design and function Transport and installation Design and function WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •...

  • Page 29: In Operation

    Design and function Transport and installation Equipment damage due to contamination! Unusually high amounts of dust, acids, corrosive gases or substances can damage the machine (observe maintenance intervals > see 6.3 chapter). • Avoid large amounts of smoke, steam, oily fumes, grinding dust and corrosive ambient air! 5.1.2.1 In operation Temperature range of the ambient air:...

  • Page 30: Approved Coolants Overview

    All information relates to the total hose package length of the complete welding system and presents exemplary configurations (of components of the EWM product portfolio with standard lengths). A straight kink-free installation is to be ensured, taking into account the max. delivery height.

  • Page 31: Notes On The Installation Of Welding Current Leads

    Design and function Transport and installation Item Symbol Description Coolant filter sieve Coolant tank > see 5.1.5 chapter "Min" mark Minimum coolant level • Unscrew and remove the coolant tank sealing cover. • Check filter sieve insert for dirt, clean if necessary and reinsert into position. •...

  • Page 32: Stray Welding Currents

    Design and function Transport and installation Use an individual welding lead to the workpiece for each welding machine! Figure 5-3 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 33: Mains Connection

    Design and function Transport and installation Figure 5-5 5.1.8 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • The connection (mains plug or cable), the repair or voltage adjustment of the device must be carried out by a qualified electrician in accordance with the respective local laws or nati- onal regulations! •...

  • Page 34: Mains Configuration

    Design and function Welding data display 5.1.8.1 Mains configuration The machine may be connected to: • a three-phase system with four conductors and an earthed neutral conductor • a three-phase system with three conductors of which any one can be earthed, e.g.

  • Page 35: Welding Parameter Setting

    Design and function TIG welding 5.2.1 Welding parameter setting During the welding parameter setting process, the parameter value being set is displayed on the left-hand display. The right-hand display shows the “Factory setting” or a variation of it upwards or downwards. Displays, e.g.

  • Page 36: Tig Welding

    Design and function TIG welding TIG welding 5.3.1 Welding torch and workpiece line connection Prepare welding torch according to the welding task in hand (see operating instructions for the torch). 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 37: Connection Assignment, Welding Torch Control Cable

    Design and function TIG welding Item Symbol Description Connection socket, “-” welding current TIG welding torch connection Quick connect coupling (red) Coolant return from welding torch Quick connect coupling (blue) Coolant forward flow to the welding torch Workpiece Connection socket, “+” welding current Connection for workpiece lead •...

  • Page 38: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function TIG welding 5.3.2 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 39: Tig Synergic Operating Principle

    Design and function TIG welding 5.3.3 TIG Synergic operating principle Figure 5-10 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 – • Tungsten electrode diameter (A), •...

  • Page 40: Synergic Parameter Setting In The Functional Sequence

    Design and function TIG welding 5.3.3.1 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 chapter with the exception of the gas pre-flow time. These welding parameters can also be set in the conventional way if required (regardless of the welding rent) >...

  • Page 41: Welding Task Selection

    Design and function TIG welding 5.3.4 Welding task selection The following welding task selection is an example of use. In general, the selection process always has the same sequence. Signal lights (LED) will show the selected combination. inch EXIT Figure 5-13 5.3.5 Gas test or "rinse hose package"...

  • Page 42: Gas Test

    Design and function TIG welding 5.3.5.1 Gas test EXIT Figure 5-14 • Set the required shielding gas quantity at the pressure regulator. “Purge hose package” function 5.3.5.2 EXIT Figure 5-15 If the "Rinse hose package" function is not ended by pressing the "Gas and current parameters" button again, shielding gas will flow until the gas cylinder is empty! 5.3.5.3 Automatic gas post-flow...

  • Page 43: Optimising The Ignition Characteristics For Pure Tungsten Electrodes

    Design and function TIG welding 5.3.6 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 tung- sten electrode depend on the electrode diameter being used. The set value should correspond to the diameter of the tungsten electrode.

  • Page 44: Ac Balance (Optimise Cleaning Effect And Penetration Characteristics)

    Design and function TIG welding 5.3.8 AC balance (optimise cleaning effect and penetration characteristics) To weld aluminium and aluminium alloys, AC welding is used in combination with a continuous change in polarity of the tungsten electrode. The process encompasses two phases (half-waves): a positive and a negative one.

  • Page 45: Arc Ignition

    Design and function TIG welding 5.3.10 Arc ignition 5.3.10.1 HF ignition Figure 5-20 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. 2-3mm). b) Press the torch trigger (high voltage ignition pulses ignite the arc).

  • Page 46: Operating Modes (Functional Sequences)

    Design and function TIG welding 5.3.11 Operating modes (functional sequences) The parameters that can be set in the function sequence of the machine control depend on the selected welding task. This means that if for example you have not selected a pulse variant, then you cannot set any pulse times in the function sequence.

  • Page 47: Non-Latched Mode

    Design and function TIG welding 5.3.11.2 Non-latched mode Selection Figure 5-22 Sequence Figure 5-23 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 48: Latched Mode

    Design and function TIG welding 5.3.11.3 Latched mode Selection Figure 5-24 Sequence Figure 5-25 099-000109-EW501 23.08.2018...
  • Page 49 Design and function TIG welding 1st cycle • Press torch trigger 1 , the gas pre-flow time elapses. • HF start 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 50: Spotarc

    Design and function TIG welding 5.3.11.4 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 51: Spotmatic

    Design and function TIG welding The up-slope and down-slope times should be set to “0” to achieve an effective result. Figure 5-27 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever >...
  • Page 52 Design and function TIG welding Figure 5-28 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.3.10.2 chapter. Selecting the process activation type for the welding process > see 5.13 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) only.

  • Page 53: Non-Latched Operation, Version C

    Design and function TIG welding 5.3.11.6 Non-latched operation, version C Figure 5-29 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 assumes the set ignition current (search arc at minimum setting).

  • Page 54: Alternating Current Waveforms

    Design and function TIG welding 5.3.12 Alternating current waveforms Figure 5-30 Waveform Description, areas of application Name Symbol Square Maximum energy input and safe welding (aluminium/magnesium alloys) Trapezoidal An all-rounder, suitable for most applications (aluminium/silicum alloys) Sine Low noise level (aluminium 99%) 099-000109-EW501 23.08.2018...

  • Page 55: Pulse Welding

    Design and function TIG welding 5.3.13 Pulse welding The following pulse types can be selected: • Automated pulsing (TIG DC) • Thermal pulsing (TIG AC or TIG DC) • Metallurgical pulsing (TIG DC) • AC special (TIG AC) 5.3.13.1 Automated pulses The automated pulses are used with tacking and spot welding of workpieces in particular.
  • Page 56 Design and function TIG welding The pulse function can also be deactivated if necessary during the up-slope and down-slope phases (parameter ) > see 5.13 chapter. Figure 5-33 Selection Figure 5-34 099-000109-EW501 23.08.2018...

  • Page 57: Metallurgical Pulsing (Khz Pulsing)

    Design and function TIG welding Pulse time setting Figure 5-35 Pulse pause setting Figure 5-36 Pulse edge setting pulse edges can be set in the Expert menu (TIG) > see 5.3.17 chapter. 5.3.13.3 Metallurgical pulsing (kHz pulsing) Metallurgical pulsing (kHz pulsing) uses the plasma force (arc force) occurring at high currents which al- lows you to achieve a constricted arc with concentrated heat input.
  • Page 58 Design and function TIG welding Selection Figure 5-38 Balance setting EXIT Figure 5-39 Frequency setting EXIT Figure 5-40 099-000109-EW501 23.08.2018...

  • Page 59: Ac Special

    Design and function TIG welding 5.3.13.4 AC special Is e.g. used to join metal sheets of different thickness. Figure 5-41 Selection Figure 5-42 pulse edges can be set in the Expert menu (TIG) > see 5.3.17 chapter. 5.3.14 TIG antistick The function prevents uncontrolled re-ignition following the sticking of the tungsten electrode in the weld pool by switching off the welding current.

  • Page 60: Activarc

    TIG welding 5.3.15 activArc The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power sup- plied 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 61: Synchronisation Via Cable (Frequency 50Hz To 200Hz)

    Design and function TIG welding 5.3.16.2 Synchronisation via cable (frequency 50Hz to 200Hz) This application describes synchronisation (master/slave operation) with two machines in the Tetrix series. The following components are required: • The synchronisation interface SYNINT X10 • Control lead (connecting cable) of the relevant length •...

  • Page 62: Expert Menu (Tig)

    Design and function TIG welding 5.3.17 Expert menu (TIG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa- rameters shown may be limited, e.g. if a function is deactivated. ENTER EXIT Figure 5-46 Display Setting/selection Expert menu...

  • Page 63: Mma Welding

    Design and function MMA welding Display Setting/selection Filler wire diameter (manual setting) Setting the wire diameter between 0.6 mm to 1.6 mm. The character "d" preceding the wire diameter on the display (d0.8) indicates a pre- programmed characteristics (correction operating mode "KORREKTUR”). If there is no characteristics for the selected wire diameter, the parameters have to be set manually (manual operating mode “MANUELL“).
  • Page 64 Design and function MMA welding Figure 5-47 Item Symbol Description Workpiece Connection socket, “+” welding current Connection for workpiece lead Electrode holder Connection socket, “-” welding current Electrode holder connection G¼" connecting nipple Shielding gas connection (with yellow insulating cap) for TIG welding torch Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

  • Page 65: Welding Task Selection

    Design and function MMA welding 5.4.2 Welding task selection The following welding task selection is an example of use. In general, the selection process always has the same sequence. Signal lights (LED) will show the selected combination. EXIT Figure 5-48 5.4.3 Welding current polarity reversal (polarity reversal) This function can be used to reverse the welding current polarity electronically.

  • Page 66: Frequency And Balance Setting

    Design and function MMA welding 5.4.4 Frequency and balance setting Balance setting Figure 5-50 Frequency setting Figure 5-51 5.4.5 Hotstart The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent metal at the beginning of the welding process.

  • Page 67: Hotstart Current

    Design and function MMA welding 5.4.5.1 Hotstart current EXIT Figure 5-53 5.4.5.2 Hotstart time EXIT Figure 5-54 099-000109-EW501 23.08.2018...

  • Page 68: Arcforce

    Design and function MMA welding 5.4.6 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current. This makes it easier to weld large-drop melting electrode types at low current strengths with a short arc in particular.

  • Page 69: Average Value Pulsing In The Vertical-Up Position (Pf)

    Design and function MMA welding 5.4.8 Average value pulsing 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 70 Design and function MMA welding Pulse pause current setting Figure 5-60 Balance setting Figure 5-61 Frequency setting Figure 5-62 The default pulse parameters are pre-set in such a way that the welding current average value corresponds to the pre-selected main current AMP. Changes in the pulse parameters result in changes to welding current average value AMP.

  • Page 71: Organising Welding Tasks (Mode "Job Manager")

    Design and function Organising welding tasks (Mode "JOB Manager") 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 72: Creating A New Job In The Memory Or Copying A Job

    Design and function Organising welding tasks (Mode "JOB Manager") 5.5.2 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 73: Loading An Existing Job From The Free Memory

    Design and function Organising welding tasks (Mode "JOB Manager") 5.5.3 Loading an existing JOB from the free memory EXIT Figure 5-64 5.5.4 Resetting an existing JOB to the factory setting (Reset JOB) Figure 5-65 099-000109-EW501 23.08.2018...

  • Page 74: Resetting Jobs 1-128 To The Factory Setting (Reset All Jobs)

    Design and function Welding programs 5.5.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs) Figure 5-66 5.5.6 Exit JOB Manager without changes EXIT Figure 5-67 099-000109-EW501 23.08.2018...

  • Page 75: Welding Programs

    Design and function Welding programs 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. In each selected welding task (JOB), >...

  • Page 76: Specifying Max. No. Of Accessible Programs

    Design and function Remote control 5.6.2 Specifying max. no. of accessible programs This function can be used to specify the maximum number of programs which can be called up (only applies to the welding torch). According to the factory setting, all 16 programs can be called up.

  • Page 77: Rtg1 19Pol

    Design and function Remote control 5.7.2 RTG1 19POL Functions • Infinite setting of the welding current (0% to 100%) depending on the main current preselected at the welding machine 5.7.3 RTP1 19POL Functions • TIG/MMA • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine.

  • Page 78: Rtf Start Ramp

    Design and function Remote control 5.7.8.1 RTF start ramp The RTF start ramp function prevents the energy input at the start of welding from being too high and too fast should the user press the remote control pedal too fast and too strongly. Example: The user sets the main current at the welding machine to 200 A.

  • Page 79: Rtf Response

    Design and function Welding torch (operating variants) 5.7.8.2 RTF response This function controls the current response during the main current phase. The user can choose between linear and logarithmic response. The logarithmic setting is especially suited for welding with low currents, e.g.

  • Page 80: Up/Down Speed

    Design and function Welding torch (operating variants) 5.8.3 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 81 Design and function Welding torch (operating variants) Standard torch with two torch triggers Figure Operating ele- Explanation of symbols ments BRT1 = torch trigger 1 BRT2 = torch trigger 2 Functions Mode Operating ele- ments Welding current on/off Secondary current (ex works) Secondary current (tapping function) )/(latched operating mode)
  • Page 82 Design and function Welding torch (operating variants) Standard torch with one rocker (rocker, two torch triggers) Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Functions Mode Operating ele- ments Welding current on/off Secondary current (ex works)

  • Page 83: Tig Up/Down Torch (8-Pole)

    Design and function Welding torch (operating variants) 5.8.6 TIG up/down torch (8-pole) Up/down torch with one torch trigger Image Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 Functions Mode Operating ele- ments Welding current on/off Secondary current (tapping function) )/(latched operating mode) (ex works) Increase welding current (up function...
  • Page 84 Design and function Welding torch (operating variants) Up/down torch with two torch triggers Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 (left) BRT 2 = torch trigger 2 (right) Functions Mode Operating ele- ments Welding current on/off Secondary current Secondary current (tapping function) /(latched operation)

  • Page 85: Potentiometer Torch (8-Pole)

    Design and function Welding torch (operating variants) 5.8.7 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch > see 5.8.7.1 chapter. Potentiometer torch with one torch trigger Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 Functions...

  • Page 86: Retox Tig Torch (12-Pole)

    Design and function Welding torch (operating variants) WARNING 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 87 Design and function Welding torch (operating variants) Functions Mode Operating ele- ments 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 Modes 2 and 3 are not used with this type of torch or, respectively, are not appropriate.

  • Page 88: Specifying Max. No. Of Accessible Jobs

    Design and function Interfaces for automation 5.8.8.1 Specifying max. no. of accessible JOBs This function can be used to specify the maximum number of JOBs which can be retrieved from the free memory. The factory setting is for 10 JOBs to be accessible on the welding machine, but this figure can be increased to up to 128 if required.
  • Page 89 Design and function Interfaces for automation These accessory components can be retrofitted as an option > see 9 chapter. Signal Designation Diagram shape Output Connection for cable screen Output REGaus For servicing purposes only Input SYN_E Synchronisation for master/slave operation Input IGRO Current flows signal I>0 (maximum load 20mA...

  • Page 90: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.9.2 Remote control connection socket, 19-pole Figure 5-75 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 91: Pc Interface

    Design and function PC interface 5.10 PC interface PC 300 welding parameter software Set all welding parameters on the PC and simply transfer to one or more welding machines (accessory, set consisting of software, interface, connection leads) • Manage up to 510 JOBs •...

  • Page 92: Machine Configuration Menu

    Design and function Machine configuration menu 5.13 Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.13.1 Selecting, changing and saving parameters ENTER EXIT NAVIGATION Figure 5-77 Display Setting/selection Exit the menu Exit 099-000109-EW501 23.08.2018...
  • Page 93 Design and function Machine configuration menu Display Setting/selection Torch configuration menu Set welding torch functions Torch mode (ex works 1) > see 5.8.2 chapter Alternative welding start – tapping start Available from torch mode 11 (welding stop by tapping remains active). ------- Function enabled (ex works) ------- Function disabled Up/down speed >...
  • Page 94 Design and function Machine configuration menu Display Setting/selection Program 0 block With machines with access block, program 0 can be disabled. When the access block has been enabled, programs 1–x only can be switched. ------- All programs can be selected (ex works) ------- Programs 1–x can be selected (program 0 disabled) Show warnings >...
  • Page 95 Design and function Machine configuration menu Display Setting/selection Expert menu AC average value controller ------- Function enabled (ex works) ------- Function disabled Welding current polarity switch (dc+) with TIG DC ------- Polarity switch released ------- Polarity switch blocked; protects the tungsten electrode from being permanently damaged (ex works). Reconditioning pulse (tungsten ball stability) Cleaning effect of the tungsten ball at the end of welding.
  • Page 96 Design and function Machine configuration menu Display Setting/selection Automated/Manual (rC on/off) operating mode Select machine/function control ------ with external control voltages/signals ------ with machine control Software version query (example) 07.= ------ system bus ID 03c0= --- version number System bus ID and version number are separated by a dot. Cable resistance alignment >...

  • Page 97: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.13.2 Aligning the cable resistance To ensure optimum welding properties, the electric cable resistance should be aligned again whenever an accessory component such as the welding torch or the intermediate hose package (AW) has been chan- ged.
  • Page 98 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 machi- •...

  • Page 99: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal General 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 100: Maintenance Work, Intervals

    A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-000109-EW501 23.08.2018...

  • Page 101: Disposing Of Equipment

    • Information about returning used equipment or about collections can be obtained from the respective municipal administration office. • In addition to this, returns are also possible throughout Europe via EWM sales partners. 099-000109-EW501 23.08.2018...

  • Page 102: 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 dea- ler.

  • Page 103: Warnings

    Rectifying faults Warnings Unstable arc  Material inclusions in the tungsten electrode due to contact with filler material or workpiece  Regrind or replace the tungsten electrode  Incompatible parameter settings  Check settings and correct if necessary Pore formation ...

  • Page 104: Error Messages

    Rectifying faults Error messages Error messages A welding machine error will be signalled by an error code (see table) on the control display. In the event of an error, the power unit shuts down. The display of possible error numbers depends on the machine version (interfaces/functions). •...

  • Page 105: Resetting Welding Parameters To The Factory Settings

    Rectifying faults Resetting welding parameters to the factory settings Error message Possible cause Remedy If the error persists, contact service. Err 39 Electronics error (secondary overvolta- Err 40 Electronics error (I>0 error) Inform service Err 48 Ignition error Check welding process Err 49 Arc interruption Inform service...

  • Page 106: Technical Data

    Technical data Tetrix 351 AC/DC Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 351 AC/DC Welding current (I 5 A up to 350 A Welding voltage according to Standard (U 10,2 V up to 24 V 20,2 V up to 34 V Duty cycle at 40°...

  • Page 107: Tetrix 451 Ac/Dc

    Technical data Tetrix 451 AC/DC Tetrix 451 AC/DC Welding current (I 5 A up to 450 A Welding voltage according to Standard (U 10,2 V up to 28,0 V 20,2 V up to 38,0 V Duty cycle at 40° C 80 % 450 A 100 %...

  • Page 108: Tetrix 501 Ac/Dc

    Technical data Tetrix 501 AC/DC Tetrix 501 AC/DC Welding current (I 5 A up to 500 A Welding voltage according to Standard (U 10,2 V up to 30 V 20,2 V up to 40 V Duty cycle at 40° C 60 % 500 A 100 %...

  • Page 109: Tetrix 551 Ac/Dc

    Technical data Tetrix 551 AC/DC Tetrix 551 AC/DC Welding current (I 5 A up to 550 A Welding voltage according to Standard (U 10,2 V up to 32,0 V 20,2 V up to 42,0 V Duty cycle at 40° C 60 % 550 A 100 %...

  • Page 110: Accessories

    Accessories Remote controls and accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Remote controls and accessories Type Designation Item no. RTF1 19POL 5 M Foot-operated remote control current with connec- 094-006680-00000 tion cable RT1 19POL...

  • Page 111: Tetrix 451-551 Ac/Dc

    Accessories General accessories 9.3.2 Tetrix 451-551 AC/DC Type Designation Item no. ON Filter Tetrix XL Retrofit option, dirt filter for air inlet 092-004999-00000 ON Holder Gas Bottle <50L Optional retrofit holding plate for gas cylinder <50l 092-002345-00000 TETRIX XL General accessories Type Designation Item no.

  • Page 112: Job-List

    Appendix A JOB-List Appendix A 10.1 JOB-List Process Material Wire Seam position  Reserved   CrNi/ Fe/ St   CrNi/ Fe/ St   CrNi/ Fe/ St       CrNi/ Fe/ St   ...
  • Page 113 Appendix A JOB-List Process Material Wire Seam position    Cu/CuZn >3,2   Cu/CuZn   Cu/CuZn   Cu/CuZn     Cu/CuZn     Cu/CuZn   >3,2 Cu/CuZn   Cu/CuZn  ...
  • Page 114 Appendix A JOB-List Process Material Wire Seam position    AlSi     AlSi     AlSi     AlSi >3,2   AlSi   AlSi   AlSi    ...
  • Page 115 Appendix A JOB-List Process Material Wire Seam position      Al99 >3,2   Al99   Al99   Al99     Al99     Al99     Al99 >3,2 TIG manual/TIG classic Classic electrode Reserved...

  • Page 116: Appendix B

    Appendix B Parameter overview – setting ranges Appendix B Parameter overview – setting ranges 11.1 11.1.1 TIG welding Parameter Display Setting range Comment TIG/plasma Gas pre-flow time Ignition current AMP% % of main current AMP Up-slope time 20,0 Pulse time 0,01 0,00 - 20,0 Slope time...

  • Page 117: Appendix C

    Sales & service parteners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" This welding equipment does not comply with IEC 61000-3-12. When connecting a welding machine to a public low-voltage supply system, the manufacturer or operator has to consult the electricity utilities to make sure the welding machine may be connected.

This manual is also suitable for:

Tetrix 501 ac/dc synergic fwTetrix 551 ac/dc synergic fwTetrix 451 ac/dc synergic fw

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