EWM Tetrix DC Comfort 2.0 Operating Instructions Manual
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EWM Tetrix DC Comfort 2.0 Operating Instructions Manual

EWM Tetrix DC Comfort 2.0 Operating Instructions Manual

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Operating instructions
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T4.01 - Tetrix DC Comfort 2.0
EN
T4.09 - Tetrix DC Comfort 2.0
T4.12 - Tetrix DC Comfort 2.0
099-00T401-EW501
Observe additional system documents!
01.02.2022

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  • Page 1 Operating instructions Control T4.01 - Tetrix DC Comfort 2.0 T4.09 - Tetrix DC Comfort 2.0 T4.12 - Tetrix DC Comfort 2.0 099-00T401-EW501 Observe additional system documents! 01.02.2022...
  • 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. No other form of liability, regardless of type, shall be accepted.

  • Page 3: Table Of Contents

    Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use ..........................
  • Page 4 Contents Notes on using these operating instructions 5.1.9.10 Specifying max. no. of accessible JOBs ..........43 5.1.10 RTF 1 foot-operated remote control ..............44 5.1.10.1 RTF start ramp ..................44 5.1.10.2 RTF response ..................45 5.1.11 Expert menu (TIG) ....................46 5.1.12 Aligning the cable resistance ................

  • Page 5: For Your Safety

    For your safety Notes on using these operating instructions For your safety Notes on using these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •...

  • Page 6: Explanation Of Icons

    For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the u- Activate and release / Tap / Tip ser must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Correct / Valid...

  • Page 7: 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 8 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
  • Page 9 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...

  • Page 10: Transport And Installation

    For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.
  • Page 11 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.

  • Page 12: Intended Use

    Intended use Use and operation solely with the following machines Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and stand- ards applicable for use in industry and trade. It may only be used for the welding proce- dures indicated at the rating plate.

  • Page 13: Part Of The Complete Documentation

    Intended use Documents which also apply 3.3.1 Part of the complete documentation This document is 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 14: 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 15: 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 16 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 17: Control Section B

    Machine control – Operating elements Overview of control sections 4.1.2 Control section B Figure 4-3 Item Symbol Description Signal light, two colour AMP% Red: Secondary or pulse pause current (% of AMP) Green: Pulse pause time /slope time (Expert menu) Signal light, two colour Red: Main or pulse current...

  • Page 18: Machine Display

    Machine control – Operating elements Machine display Item Symbol Description Gas post-flow time Signal light, two colour AMP% Red: End current Green: End current time > see 5.1.11 chapter Down-slope time signal light Machine display The following welding parameters can be displayed before (nominal values), during (actual values) or af- ter welding (hold values): Parameter Before welding...

  • Page 19: 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 Set a welding parameter in the functional sequence by clicking (select) and turning the click wheel (navi- gate to the desired parameter). Press again to apply the selected parameter as the setting (corresponding parameter value and signal light flash).

  • Page 20: 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 21: 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 dia- meter.

  • Page 22: 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 23: 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 24: 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 Start current Start time Up-slope time Spot time Main current (minimum to maximum current) Secondary current AMP% Pulse time...

  • Page 25: 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 26: Latched Mode

    Functional characteristics TIG welding 5.1.4.3 Latched mode Selection Figure 5-7 Sequence Figure 5-8 099-00T401-EW501 01.02.2022...

  • Page 27: Spotarc

    Functional characteristics 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 start current (search arc at minimum set- ting).
  • Page 28 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, how- ever > see 5.1.3 chapter. Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. •...

  • Page 29: 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 30: 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, how- ever > 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 31: Tig Activarc Welding

    5.1.5 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 32: 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 ope- rating mode.

  • Page 33: Pulsed Welding In The Upslope And Downslope Phases

    Functional characteristics TIG welding Pulse time setting Figure 5-18 Pulse pause setting 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 34: 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 al- lows you to achieve a constricted arc with concentrated heat input. Unlike thermal pulsing, no times are set;...

  • Page 35: Average Value Pulse Welding

    Functional characteristics TIG welding Frequency setting Figure 5-24 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 36: Welding Torch (Operating Variants)

    Functional characteristics TIG welding 5.1.9 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 mo- dified individually via torch modes. Explanation of symbols for operating elements: Symbol Description Press torch trigger...

  • Page 37: 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 ele- Explanation of symbols ments BRT1 = torch trigger 1 (welding current on/off; secondary cur- rent via tapping function) Functions Mode Operating ele- ments Welding current on/off (ex works)
  • Page 38 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 39: 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 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 40 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 41: 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 ele- Explanation of symbols ments BRT 1 = torch trigger 1 Functions Mode Operating ele-...

  • Page 42: Configuring The Tig Potentiometer Torch Connection

    Functional characteristics TIG welding 5.1.9.8 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 43: Retox Tig Torch (12-Pole)

    Functional characteristics TIG welding 5.1.9.9 RETOX TIG torch (12-pole) These accessory components can be retrofitted as an option . Figure Operating elements Explanation of symbols BRT = torch trigger Functions Mode Operating ele- ments Welding current on/off BRT 1 Secondary current BRT 2 Secondary current (tapping function) BRT 1 (tapping)

  • Page 44: 5.1.10 Rtf 1 Foot-Operated Remote Control

    Functional characteristics TIG welding Display Setting/selection Retrieval of JOB number Set maximum selectable JOBs (setting: 1 to 101, factory-set to 0). Added parameter after activating the function BLOCK-JOB. The settings are defined in the machine configuration menu > see 5.7 chapter. The setting of the max.

  • Page 45: 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 46: 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 pa- rameters shown may be limited, e.g. if a function is deactivated. Figure 5-30 Display Setting/selection Expert menu Start time (duration of start current) Slope time (main current to secondary current) Slope time (secondary current to main current)
  • Page 47 Functional characteristics TIG welding Display Setting/selection Parameter activArc > see 5.1.5 chapter Setting the intensity Filler wire process (cold/hot wire) filler wire activated ------ filler wire deactivated (factory setting) ------ Hot wire process (start signal for hot wire power source) -------Function enabled -------Function disabled (ex works) Wire/pulse function (wire feeding behaviour when using pulsed TIG welding)

  • Page 48: 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 chan- ged.

  • Page 49: 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 50: 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 51: 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. Figure 5-36 5.2.4 Antistick...

  • Page 52: 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 (I- puls), a pulse pause current (IPP), a balance ( ) and a frequency ( ) having been defined first. Figure 5-38 AMP = main current, e.g.

  • Page 53: 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 54: 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 55: 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 56: Non-Latched Mode

    Functional characteristics Filler wire welding 5.3.5.2 Non-latched mode Figure 5-43 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 57: 3-Cycle Operation

    Functional characteristics Power-saving mode (Standby) 5.3.5.3 3-cycle operation Figure 5-44 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 cur- rent, until the welding process ends. 5.3.5.4 Latched mode Figure 5-45...

  • Page 58: 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 se- quence can only be viewed but not changed.

  • Page 59: 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 Figure 5-46 Display Setting/selection Exit the menu Exit 099-00T401-EW501 01.02.2022...
  • Page 60 Functional characteristics Machine configuration menu Display Setting/selection Torch configuration menu Set welding torch functions 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 61 Functional characteristics Machine configuration menu Display Setting/selection TIG antistick > see 5.1.6 chapter -------function active (factory setting). -------function inactive. 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...
  • Page 62 Functional characteristics Machine configuration menu Display Setting/selection 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 63 Functional characteristics Machine configuration menu Display Setting/selection Orbital welding Correction value for orbital current Service menu Any changes to the service menu should be agreed with the authorised service person- nel. 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 64: 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 dea- ler.

  • Page 65: Error Messages

    Rectifying faults Error messages Error messages Depending on the options of the machine display, a fault is shown as follows: Display type - machine control Display Graphic display two 7-segment displays one 7-segment display The possible cause of the fault is signalled by a corresponding fault number (see table). In the case of an error, the power unit shuts down.

  • Page 66: Resetting Welding Parameters To The Factory Settings

    Rectifying faults Resetting welding parameters to the factory settings Error Possible cause Remedy Electronics error (I>0 error) Electronics error (Uact error) Switch the machine off and on. If the error persists, no- Electronics error (A/D channel error) tify Service. Electronics error (slope error) Electronics error (S sign) Electronics error (temperature error) Allow the machine to cool.

  • Page 67: 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 68: Disposing Of Equipment

    Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html.

  • Page 69: Appendix

    Appendix Parameter overview – setting ranges Appendix Parameter overview – setting ranges 8.1.1 TIG welding Name Display Setting range Main current AMP, depending on power source Gas pre-flow time Start current, percentage of AMP Start current, absolute, depending on power source Start time 0,01 0,01...

  • Page 70: Mma Welding

    Appendix Parameter overview – setting ranges Name Display Setting range Amplitude balance [1], [2], [3] Dynamic power adjustment Machines with control Comfort 2.0. Machines for AC welding (AC). Machine series Tetrix 300. Machine series Tetrix 230. 8.1.2 MMA welding Name Display Setting range Main current AMP, depending on power source...

  • Page 71: Searching For A Dealer

    Appendix Searching for a dealer Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-00T401-EW501 01.02.2022...

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