EWM T 4.06 - AC/DC Smart 2.0 Operating Instructions Manual
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EWM T 4.06 - AC/DC Smart 2.0 Operating Instructions Manual

EWM T 4.06 - AC/DC Smart 2.0 Operating Instructions Manual

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Operating instructions
Control
T 4.06 - AC/DC Smart 2.0 (Tetrix 230)
EN
099-00T406-EW501
Observe additional system documents!
13.07.2017

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Summary of Contents for EWM T 4.06 - AC/DC Smart 2.0

  • Page 1 Operating instructions Control T 4.06 - AC/DC Smart 2.0 (Tetrix 230) 099-00T406-EW501 Observe additional system documents! 13.07.2017...
  • Page 2 +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 ..................45 6 Appendix A ............................46 Parameter overview – setting ranges ..................46 6.1.1 TIG welding ........................46 6.1.2 MMA welding ........................ 47 7 Appendix B ............................48 Overview of EWM branches......................48 099-00T406-EW501 13.07.2017...

  • 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 Numerical value – adjustable Correct Menu entry Signal light lights up in green...

  • 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 combina- tion 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 en- sure maximum clarity. The setting ranges for the parameter values are summarised in the para- meter 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 Character function signal light Indicates that it is possible to weld in an environment with major electric hazards, such as in boilers. Service must be informed if this signal light is not on. Coolant fault signal light Signals pressure loss or low coolant level in the coolant circuit.

  • Page 11: Machine Display

    Machine control – Operating elements Machine display Item Symbol Description Electrode diameter signal light Ignition optimisation (TIG)/tungsten balling basic setting Gas post-flow time Down-slope time signal light Secondary current (TIG) AMP% Signal light • ----------- Main current • ----------- Pulse current Signal light Up-slope time (TIG)

  • Page 12: Welding Power Setting

    Machine control – Operating elements Operating the machine control 3.3.2 Welding power setting The welding power is set using the control button. You can also adjust the parameters in the operation sequence or settings in the different machine menus. 3.3.3 Welding parameter setting in the operation sequence A welding parameter can be set in two ways in the operation sequence.

  • Page 13: Functional Characteristics

    Functional characteristics TIG welding Functional characteristics TIG welding Gas test – setting the shielding gas volume 4.1.1 • 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 14: 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 ig- nition behaviour and minimum current limits. The ignition energy is controlled by the set electrode diame- ter.

  • Page 15: Ac Welding

    Functional characteristics TIG welding 4.1.3 AC welding 4.1.3.1 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 16: Alternating Current Waveforms

    Functional characteristics TIG welding 4.1.3.2 Alternating current waveforms Selection EXIT Figure 4-3 Display Setting/selection Alternating current waveforms Rectangular (ex works) Trapezoidal Sine AC welding with rectangular current waveform (ex works) Highest energy input Alternating current welding with trapezoidal current waveform An all-rounder, suitable for most applications Alternating current welding with sinusoidal current waveform Low noise level...

  • Page 17: Arc Ignition

    Functional characteristics TIG welding 4.1.4 Arc ignition To change the ignition type, use parameter to switch between HF start ( ) and lift arc ( ) in the Expert menu > see 4.1.10 chapter. 4.1.4.1 HF ignition Figure 4-4 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 18: Operating Modes (Functional Sequences)

    Functional characteristics TIG welding 4.1.5 Operating modes (functional sequences) 4.1.5.1 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 current Down-slope time...

  • Page 19: Non-Latched Mode

    Functional characteristics TIG welding 4.1.5.2 Non-latched mode Selection Figure 4-6 Figure 4-7 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 20: Latched Mode

    Functional characteristics TIG welding 4.1.5.3 Latched mode Selection Figure 4-8 Figure 4-9 099-00T406-EW501 13.07.2017...

  • Page 21: 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 22 Functional characteristics TIG welding Figure 4-11 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 4.1.4 chapter. Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. •...

  • Page 23: Spotmatic

    Functional characteristics TIG welding 4.1.5.5 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 24 Functional characteristics TIG welding Figure 4-13 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 4.1.4 chapter. Selecting the process activation type for the welding process > see 4.6 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 sec) only.

  • Page 25: Average Value Pulse Welding

    Functional characteristics TIG welding 4.1.6 Average value pulse welding Once the pulse function is activated, the red signal lights for the main current AMP and secondary current AMP% light up at the same time. Average value pulsing means that the system switches between two currents periodically, an average current value (AMP), a pulse current (Ipuls), a balance ( ) and a fre- quency (...

  • Page 26: Pulsed Welding In The Upslope And Downslope Phases

    Functional characteristics TIG welding Pulse balance Figure 4-17 Pulse frequency Figure 4-18 4.1.6.1 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 ) > see 4.6 chapter. Figure 4-19 4.1.6.2 Automated pulses...

  • Page 27: Tig Activarc Welding

    4.1.7 TIG activArc welding 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 28: Torch Mode Setting

    Functional characteristics TIG welding 4.1.9.2 Torch mode setting Modes 1 to 4 and 11 to 14 are available to the user. Modes 11 to 14 feature the same functionality as 1 to 4, but without the tapping function > see 4.1.9.1 chapter for the secondary current. The functionality of the individual modes can be found in the corresponding torch type tables.
  • Page 29 Functional characteristics TIG welding 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) Welding current on/off Secondary current (tapping function)
  • Page 30 Functional characteristics TIG welding 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) Secondary current (tapping function)

  • Page 31: Tig Up/Down Torch (8-Pole)

    Functional characteristics TIG welding 4.1.9.6 TIG up/down torch (8-pole) Up/down torch with one torch trigger Figure 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 32: Potentiometer Torch (8-Pole)

    Functional characteristics TIG welding 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 operating mode) (ex works)
  • Page 33 Functional characteristics TIG welding Potentiometer torch with one torch trigger Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 Functions Mode Operating ele- ments Welding current on/off Secondary current (tapping function Increase welding current Decrease welding current Potentiometer torch with two torch triggers Figure Operating ele-...

  • Page 34: Configuring The Tig Potentiometer Torch Connection

    Functional characteristics TIG welding 4.1.9.8 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 35: Expert Menu (Tig)

    Functional characteristics TIG welding 4.1.10 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 4-22 Display Setting/selection Expert menu Ignition type (TIG)

  • Page 36: 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 37: Antistick

    Functional characteristics MMA welding 4.2.1.2 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. Check the welding current setting and correct for the welding task in hand.
  • Page 38 Functional characteristics MMA welding Pulse current Figure 4-28 Pulse balance Figure 4-29 Pulse frequency Figure 4-30 099-00T406-EW501 13.07.2017...

  • Page 39: Expert Menu (Mma)

    Functional characteristics Power-saving mode (Standby) 4.2.3 Expert menu (MMA) 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. The setting ranges for the parameter values are summarised in the Parameter overview sec- tion >...

  • Page 40: Access Control

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

  • Page 41: 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 4-32 099-00T406-EW501 13.07.2017...
  • Page 42 Functional characteristics Machine configuration menu Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (ex works 1) > see 4.1.9.2 chapter Up/down speed > see 4.1.9.3 chapter Increase value > rapid current change Decrease value > slow current change Current jump >...
  • Page 43 Functional characteristics Machine configuration menu Access control – access code Setting: 000 to 999 (000 ex works) Machine code Querying the three-digit machine code (000 to 999), user input Error Error message after entering an incorrect machine code New machine code •...

  • Page 44: 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 dea- ler.

  • Page 45: Dynamic Power Adjustment

    Rectifying faults Dynamic power adjustment Dynamic power adjustment This requires use of the appropriate mains fuse. Observe mains fuse specification! This function enables aligning the machine to the mains connection fusing to avoid continuous tripping of the mains fuse. The maximum power input of the machine is limited by an exemplary value for the exis- ting mains fuse (several levels available).

  • Page 46: 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 47: 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 Pulse current Pulse frequency Pulse balance Dynamic power adjustment...

  • Page 48: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B Overview of EWM branches 099-00T406-EW501 13.07.2017...

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Tetrix 230

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