EWM T 4.01 Operating Instructions Manual
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EWM T 4.01 Operating Instructions Manual

EWM T 4.01 Operating Instructions Manual

Dc comfort 2.0
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Operating instructions
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T 4.01, 4.09, 4.12 - DC Comfort 2.0
099-00T401-EW501
Observe additional system documents!
21.06.2018

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Summary of Contents for EWM T 4.01

  • Page 1 Operating instructions Control T 4.01, 4.09, 4.12 - DC Comfort 2.0 099-00T401-EW501 Observe additional system documents! 21.06.2018...
  • 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 ............................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 Part of the complete documentation ....................7 3 Intended use ............................
  • Page 4 Contents Notes on the use of these operating instructions 5.1.10.2 RTF response ....................40 5.1.11 Expert menu (TIG) ......................41 5.1.12 Aligning the cable resistance ..................43 MMA welding ..........................44 5.2.1 Welding task selection ....................44 5.2.2 Hotstart ......................... 45 5.2.2.1 Hotstart current ....................

  • 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 hold Switch Incorrect / Invalid Turn Numerical value –...

  • 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: Intended Use

    The equipment must only be used in line with its designated purpose and by trained or expert personnel! • Do not improperly modify or convert the equipment! Use and operation solely with the following machines Machine control T 4.01 T 4.09 T 4.12 Product series Tetrix 300 Tetrix 351-551...

  • Page 9: 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 10: Control Section A

    Machine control – Operating elements Overview of control sections 4.1.1 Control section A Figure 4-2 Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values > see 4.2 chapter Push-button gas test / rinse hose package > see 5.1.1 chapter Operating mode >...
  • Page 11 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 12: Control Section B

    Machine control – Operating elements Overview of control sections 4.1.2 Control section B Figure 4-3 Item Symbol Description Parameter selection push-button, left The welding sequence parameters are selected one after another in an anti-clockwise direction. For control systems without this button settings are done exclusively via the control button.

  • Page 13: Machine Display

    Machine control – Operating elements Machine display Item Symbol Description Signal light activArc > see 5.1.5 chapter Signal light, two colour Green: Pulse frequency (MMA) Red: Pulse frequency (TIG, average value pulsing) Machine display The following welding parameters can be displayed before (nominal values), during (actual values) or after welding (hold values): Parameter Before welding...

  • Page 14: Welding Parameter Setting In The Operation Sequence

    Machine control – Operating elements Operating the machine control 4.3.3 Welding parameter setting in the operation sequence Welding parameters are set by briefly pressing the control knob (selecting the function sequence) and then turning the knob (navigation to the desired parameter). Press again to apply the selected parameter as the setting (corresponding parameter value and signal light flash).

  • Page 15: Functional Characteristics

    Functional characteristics TIG welding Functional characteristics TIG welding 5.1.1 Setting the shielding gas volume (gas test)/rinse hose package • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. •...

  • Page 16: Welding Task Selection

    Functional characteristics TIG welding 5.1.2 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 17: Recurring Welding Tasks (Job 1-100)

    Functional characteristics TIG welding 5.1.2.1 Recurring welding tasks (JOB 1-100) The user has 100 additional memory locations at their disposal to save recurring or different welding tasks on a permanent basis. To do so, simply select the required memory location (JOB 1-100) and set the welding task as described previously.

  • Page 18: Liftarc

    Functional characteristics TIG welding 5.1.3.2 Liftarc Figure 5-4 The arc is ignited on contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger (liftarc current flowing, regardless of the main current set). b) Incline the torch over the torch gas nozzle to produce a gap of approx.

  • Page 19: Operating Modes (Functional Sequences)

    Functional characteristics TIG welding 5.1.4 Operating modes (functional sequences) 5.1.4.1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 Current Time Gas pre-flow Ignition current Start time Up-slope time Spot time Main current (minimum to maximum current) Secondary current AMP% Pulse time...

  • Page 20: Non-Latched Mode

    Functional characteristics TIG welding 5.1.4.2 Non-latched mode Selection Figure 5-5 Sequence Figure 5-6 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 21: Latched Mode

    Functional characteristics TIG welding 5.1.4.3 Latched mode Selection Figure 5-7 Sequence Figure 5-8 099-00T401-EW501 21.06.2018...

  • Page 22: Spotarc

    Functional characteristics TIG welding 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 23 Functional characteristics TIG welding Figure 5-10 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 5.1.3 chapter. Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. •...

  • Page 24: Spotmatic

    Functional characteristics TIG welding 5.1.4.5 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 25: Non-Latched Operation, Version C

    Functional characteristics TIG welding As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 5.1.3 chapter. Selecting the process activation type for the welding process > see 5.7 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) only.

  • Page 26: Tig Activarc Welding

    5.1.5 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 27: Pulse Welding

    Functional characteristics TIG welding 5.1.7 Pulse welding The following pulse types can be selected: • Automated pulsing • Thermal pulsing • Metallurgical pulsing • Average value pulsing 5.1.7.1 Automated pulses The automated pulsing pulse variant is only activated for DC welding in combination with the spotArc operating mode.

  • Page 28: Pulsed Welding In The Upslope And Downslope Phases

    Functional characteristics TIG welding Pulse time setting EXIT Figure 5-18 Pulse pause setting EXIT Figure 5-19 Pulse edge setting pulse edges can be set in the Expert menu (TIG) > see 5.1.11 chapter. 5.1.7.3 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 29: Metallurgical Pulsing (Khz Pulsing)

    Functional characteristics TIG welding 5.1.7.4 Metallurgical pulsing (kHz pulsing) Metallurgical pulsing (kHz pulsing) uses the plasma force (arc force) occurring at high currents which allows you to achieve a constricted arc with concentrated heat input. Unlike thermal pulsing, no times are set;...

  • Page 30: Average Value Pulse Welding

    Functional characteristics TIG welding 5.1.8 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 31: Torch Mode Setting

    Functional characteristics TIG welding 5.1.9.2 Torch mode setting Modes 1 to 6 and 11 to 16 are available to the user. Modes 11 to 16 feature the same functionality as 1 to 6, but without the tapping function > see 5.1.9.1 chapter for the secondary current. The functionality of the individual modes can be found in the corresponding torch type tables.

  • Page 32: Standard Tig Torch (5-Pole)

    Functional characteristics TIG welding 5.1.9.5 Standard TIG torch (5-pole) Standard torch with one torch trigger Figure Operating Explanation of symbols elements BRT1 = torch trigger 1 (welding current on/off; secondary current via tapping function) Functions Mode Operating elements Welding current on/off (ex works) Secondary current (latched operation) Standard torch with two torch triggers...
  • Page 33 Functional characteristics TIG welding 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 Welding current on/off Secondary current (ex works) Secondary current (tapping function) )/(latched operating mode)

  • Page 34: Tig Up/Down Torch (8-Pole)

    Functional characteristics TIG welding 5.1.9.6 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 35 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 36: Potentiometer Torch (8-Pole)

    Functional characteristics TIG welding 5.1.9.7 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch > see 5.1.9.8 chapter. Potentiometer torch with one torch trigger Figure Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions Mode Operating...
  • Page 37 Functional characteristics TIG welding 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 38: Retox Tig Torch (12-Pole)

    Functional characteristics TIG welding 5.1.9.9 RETOX TIG torch (12-pole) 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 Functions Mode Operating...

  • Page 39: 5.1.10 Rtf 1 Foot-Operated Remote Control

    Functional characteristics TIG welding 5.1.10 RTF 1 foot-operated remote control 5.1.10.1 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 40: 5.1.10.2 Rtf Response

    Functional characteristics TIG welding 5.1.10.2 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. for thin panels, as the logarithmic response enables a better control of the welding current. In the machine configuration menu, the RTF response function can be toggled between linear response...

  • Page 41: Expert Menu (Tig)

    Functional characteristics TIG welding 5.1.11 Expert menu (TIG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of parameters shown may be limited, e.g. if a function is deactivated. ENTER EXIT Figure 5-29 099-00T401-EW501 21.06.2018...
  • Page 42 Functional characteristics TIG welding Display Setting/selection Expert menu Slope time (main current to secondary current) Slope time (main current to secondary current) Slope time (main current to secondary current) Slope time (main current to secondary current) activArc parameter Parameter also adjustable after TIG activArc welding is activated. Filler wire process (cold/hot wire) ----- filler wire activated...

  • Page 43: 5.1.12 Aligning The Cable Resistance

    Functional characteristics TIG welding 5.1.12 Aligning the cable resistance To ensure optimum welding properties, the electric cable resistance should be aligned again whenever an accessory component such as the welding torch or the intermediate hose package (AW) has been changed. The resistance value of the cables can be set directly or can be aligned by the power source. In the delivery state the cable resistance is set to the optimum values.

  • Page 44: Mma Welding

    Functional characteristics MMA welding 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Unfasten the tungsten electrode and extract. 2 Configuration • Activate the rotary knob while switching on the welding machine at the same time. •...

  • Page 45: Hotstart

    Functional characteristics MMA welding 5.2.2 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. The ignition takes place here with increased current (hot start current) over a certain time (hot start time).

  • Page 46: Arcforce

    Functional characteristics MMA welding 5.2.3 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. EXIT Figure 5-35 5.2.4...

  • Page 47: Pulse Welding

    Functional characteristics MMA welding 5.2.5 Pulse welding Pulse welding means that the system switches between two currents periodically with a pulse current (Ipuls), a pulse pause current (IPP), a balance ( ) and a frequency ( ) having been defined first. Figure 5-37 AMP = main current, e.g.

  • Page 48: Average Value Pulse Welding

    Functional characteristics Filler wire welding 5.2.6 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 49: Select Wire Speed Operating Mode (Korrektur / Manuell)

    Functional characteristics Filler wire welding 5.3.3 Select wire speed operating mode (KORREKTUR / MANUELL) The wire speed can be set in two different operating modes: MANUAL: The wire speed can be selected on the wire feed unit as an absolute value across the entire setting range.

  • Page 50: Operating Modes (Functional Sequences)

    Functional characteristics Filler wire welding 5.3.5 Operating modes (functional sequences) The welding current operating mode must be set to latched on the welding machine. The welding current is infinitely adjustable by means of torch triggers 3 and 4 (BRT 3 and BRT 4). Torch trigger 2 (BRT 2) switches the welding current on or off.

  • Page 51: Non-Latched Mode

    Functional characteristics Filler wire welding 5.3.5.2 Non-latched mode Figure 5-42 1st cycle (current) • Press torch trigger 2 (BRT 2), the gas pre-flow time elapses. • HF ignition pulses jump from the tungsten electrode to the workpiece. The arc ignites. •...

  • Page 52: 3-Cycle Operation

    Functional characteristics Power-saving mode (Standby) 5.3.5.3 3-cycle operation Figure 5-43 This operating mode differs from non-latched operation in the following ways: • Once the third cycle (current) has started, the wire electrode is fed, corresponding to the welding current, until the welding process ends. 5.3.5.4 Latched mode Figure 5-44...

  • Page 53: 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 54: Machine Configuration Menu

    Functional characteristics Machine configuration menu Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.7.1 Selecting, changing and saving parameters ENTER EXIT NAVIGATION Figure 5-45 Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions 099-00T401-EW501 21.06.2018...
  • Page 55 Functional characteristics Machine configuration menu Display Setting/selection Torch mode (ex works 1) > see 5.1.9.2 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 56 Functional characteristics Machine configuration menu Display Setting/selection Show warnings > see 6.1 chapter ------- Function disabled (ex works) ------- Function enabled Setting the system of units ------- Units of length in mm, m/min. (metric system) ------- Unit of length in inches, ipm (imperial system) Machine configuration (second part) Settings for machine functions and parameter display RTF start ramp >...
  • Page 57 Functional characteristics Machine configuration menu Display Setting/selection 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. ------- Function enabled (ex works) ------- Function disabled Automatic gas post-flow function >...
  • Page 58 Functional characteristics Machine configuration menu Display Setting/selection Service menu Any changes to the service menu should be agreed with the authorised service personnel. Reset (to factory setting) ------- Disabled (ex works) ------- Reset the values in the machine configuration menu ------- Complete reset of all values and settings Resetting is performed when exiting the menu ( Automated/Manual (rC on/off) operating mode...

  • Page 59: Rectifying Faults

    Rectifying faults Warnings 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 60: 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 61: Resetting Welding Parameters To The Factory Settings

    Rectifying faults Resetting welding parameters to the factory settings Error message Possible cause Remedy Err 38 Switch the machine off and on again. Err 39 Electronics error (secondary If the error persists, contact service. overvoltage) Err 40 Electronics error (I>0 error) Inform service Err 48 Ignition error...

  • Page 62: Parameter Overview - Setting Ranges

    Appendix A Parameter overview – setting ranges Appendix A Parameter overview – setting ranges 7.1.1 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 Start time 0,01 0,01 -...

  • Page 63: Mma Welding

    Appendix A Parameter overview – setting ranges 7.1.2 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 Arcforce AC frequency AC balance Pulse current...

  • Page 64: Searching For A Dealer

    Appendix B Searching for a dealer Appendix B Searching for a dealer Sales & service parteners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-00T401-EW501 21.06.2018...

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T 4.09T 4.12

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