EWM Tetrix 300 Smart TM Operating Instructions Manual
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EWM Tetrix 300 Smart TM Operating Instructions Manual

EWM Tetrix 300 Smart TM Operating Instructions Manual

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Operating instructions
Welding machine
Tetrix 300 Smart TM
EN
099-000125-EW501
Observe additional system documents!
29.9.2022

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Summary of Contents for EWM Tetrix 300 Smart TM

  • Page 1 Operating instructions Welding machine Tetrix 300 Smart TM 099-000125-EW501 Observe additional system documents! 29.9.2022...
  • 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 f orm 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......................6 Notes on using these operating instructions ............... 6 Explanation of icons ....................7 Saf ety instructions ....................8 Transport and installation ..................11 3 Intended use ........................13 Applications......................13 Software version ....................13 Documents which also apply ...................13...
  • Page 4 Contents Notes on using these operating instructions 5.2.7.8 Up/down speed ................37 5.2.8 Operating modes (f unctional sequences).............37 5.2.8.1 Explanation of symbols ...............37 5.2.8.2 Non-latched mode ..............38 5.2.8.3 Latched mode ................39 5.2.8.4 spotArc ..................40 5.2.8.5 spotmatic ..................41 5.2.8.6 Non-latched operation, version C ..........43 5.2.9 Expert menu (TIG) ...................44 MMA welding......................45...
  • Page 5 Contents Notes on using these operating instructions Welding torch cooling system..................71 9.2.1 Coolant - type blueCool ................71 9.2.2 Coolant - type KF..................71 Remote controls and accessories ................71 Options........................71 Transport system ....................72 Computer communication ..................72 10 Appendix ........................73 10.1 Searching for a dealer....................73 099-000125-EW501 29.9.2022...

  • Page 6: 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. • Saf ety notes include the "DANGER" keyword in the heading with a general warning symbol. •...

  • Page 7: 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 Incorrect / Invalid Switch Correct / Valid Turn...

  • Page 8: Safety Instructions

    For your safety Saf ety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Caref ully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
  • Page 9 For your safety Saf ety 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 10 For your safety Saf ety 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! •...

  • Page 11: 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 12 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 13: Intended Use

    3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration.

  • Page 14: Machine Description - Quick Overview

    Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-000125-EW501 29.9.2022...
  • Page 15 Machine description – quick overview Front view / rear view Item Symbol Description Carrying handle Machine control > see 4.2 chapter Cooling air inlet Connection socket, 19-pole Remote control connection Connection socket (welding torch control cable) > see 5.2.1.1 chapter G¼“...

  • Page 16: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-2 Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values > see 4.2.2 chapter Error/status indicators ------ Collective interference signal light ---------- Water def iciency signal light (welding torch cooling) ---------- Excess temperature signal light ---------- S saf ety sign signal light...

  • Page 17: Function Sequence

    Machine description – quick overview Machine control – Operating elements 4.2.1 Function sequence Figure 4-3 Item Symbol Description Main current (TIG) / pulse current Main current (MMA) I min to I max (1 A increments) I min to I max (1 A increments) Signal light activArc >...

  • Page 18: 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 19: Machine Cooling

    Design and function Transport and installation 5.1.2 Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage. • Observe the ambient conditions! • Keep the cooling air inlet and outlet clear! • Observe the minimum distance of 0.5 m from obstacles! 5.1.3 Workpiece lead, general CAUTION...

  • Page 20: Welding Torch Cooling System

    Design and function Transport and installation 5.1.5 Welding torch cooling system 5.1.5.1 Cooling unit connection Read and observe the documentation to all system and accessory components! Figure 5-2 Item Symbol Description 8-pole connection socket Cooling unit control lead 4-pole connection socket Cooling unit voltage supply Cooling module •...

  • Page 21: Notes On The Installation Of Welding Current Leads

    Design and function Transport and installation 5.1.6 Notes on the installation of welding current leads • Incorrectly installed welding current leads can cause faults in the arc (flickering). • Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel.

  • Page 22: Stray Welding Currents

    Design and function Transport and installation 5.1.7 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. •...

  • Page 23: Mains Connection

    Design and function Transport and installation 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 24: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Transport and installation 5.1.9 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 seri- ous injuries! •...

  • Page 25: 5.1.10.1 Shielding Gas Hose Connection

    Design and function Transport and installation 5.1.10.1 Shielding gas hose connection Figure 5-9 Item Symbol Description Connection thread - G¼" Shielding gas connection (inlet) • Screw the gas hose connection to the shielding gas connection (inlet) on the machine gas-tight. 5.1.11 Gas test –...

  • Page 26: Tig Welding

    Design and function TIG welding TIG welding 5.2.1 Welding torch and workpiece line connection Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-10 Item Symbol Description Welding torch Welding torch hose package Connection socket (welding torch control cable) >...

  • Page 27: Welding Task Selection

    Design and function TIG welding 5.2.2 Welding task selection The f ollowing 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 5-12 099-000125-EW501 29.9.2022...

  • Page 28: Arc Ignition

    Design and function TIG welding 5.2.3 Arc ignition 5.2.3.1 HF ignition Figure 5-13 The arc is started without contact using high-voltage ignition pulses: a) Position the welding torch in the welding position above the workpiece (distance between the electrode tip and the workpiece approx. 2-3 mm). b) Press the torch trigger (high-voltage ignition pulses start the arc).

  • Page 29: Pulse Welding

    5.2.6 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 30: Welding Torch (Operating Variants)

    Design and function TIG welding 5.2.7 Welding torch (operating variants) Dif ferent torch versions can be used with this machine. Functions on the operating elements, such as torch triggers (BRT), rockers or potentiometers, can be mo- dif ied individually via torch modes. Explanation of symbols for operating elements: Symbol Description...

  • Page 31: Standard Tig Torch (5-Pole)

    Design and function TIG welding 5.2.7.2 Standard TIG torch (5-pole) Standard torch with one torch trigger Operating ele- Figure Explanation of symbols ments BRT1 = torch trigger 1 (welding current on/off; secondary cur- rent via tapping function) Operating ele- Functions Mode ments Welding current on/off...
  • Page 32 Design and function TIG welding Standard torch with one rocker (rocker, two torch triggers) Operating ele- Figure Explanation of symbols ments BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Operating ele- Functions Mode ments Welding current on/off Secondary current (ex works) Secondary current (tapping function)

  • Page 33: Tig Up/Down Torch (8-Pole)

    Design and function TIG welding 5.2.7.3 TIG up/down torch (8-pole) Up/down torch with one torch trigger Operating ele- Figure Explanation of symbols ments BRT 1 = torch trigger 1 Operating ele- Functions Mode ments Welding current on/off Secondary current (tapping function) )/(latched operating mode) (ex works) Increase welding current (up function...
  • Page 34 Design and function TIG welding Up/down torch with two torch triggers Operating ele- Figure Explanation of symbols ments BRT 1 = torch trigger 1 (lef t) BRT 2 = torch trigger 2 (right) Operating ele- Functions Mode ments Welding current on/off Secondary current Secondary current (tapping function) )/(latched operating mode)

  • Page 35: Potentiometer Torch (8-Pole)

    Design and function TIG welding 5.2.7.4 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch > see 5.2.7.5 chapter. Potentiometer torch with one torch trigger Operating ele- Figure Explanation of symbols ments BRT 1 = torch trigger 1 Operating ele- Functions Mode...

  • Page 36: Configuring The Tig Potentiometer Torch Connection

    Design and function TIG welding 5.2.7.5 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 37: Up/Down Speed

    Design and function TIG welding 5.2.7.8 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 38: Non-Latched Mode

    Design and function TIG welding 5.2.8.2 Non-latched mode Selection Figure 5-18 Sequence Figure 5-19 1st cycle: • Press torch trigger 1 and hold down. • Gas pre-f low time elapses. • HF ignition pulses jump from the electrode to the workpiece. The arc ignites. •...

  • Page 39: Latched Mode

    Design and function TIG welding 5.2.8.3 Latched mode Selection Figure 5-20 Sequence Figure 5-21 cycle • Press the torch trigger 1 • The gas pre-flow time expires (shielding gas flows). • The arc is ignited (HF ignition). • The start current flows as long as the torch trigger is held, but at least for the start time (the HF ignition shuts down).

  • Page 40: Spotarc

    Design and function TIG welding cycle • Release torch trigger 1. • The arc extinguishes. • The gas post-flow time expires (the shielding gas is shut down). When the foot-operated remote control is connected, the machine switches automatically to non- latched operation.

  • Page 41: Spotmatic

    Design and function TIG welding The up-slope and down-slope times should be set to “0” to achieve an effective result. Figure 5-23 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever >...
  • Page 42 Design and function TIG welding Figure 5-24 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.2.3 chapter. Selecting the process activation type for the welding process > see 5.8 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) only.

  • Page 43: Non-Latched Operation, Version C

    Design and function TIG welding 5.2.8.6 Non-latched operation, version C Figure 5-25 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 start current (search arc at minimum set- ting).

  • Page 44: Expert Menu (Tig)

    Design and function TIG welding 5.2.9 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 f unction is deactivated. The setting ranges for the parameter values are summarised in the Parameter overview section. ENTER EXIT Figure 5-26...

  • Page 45: Mma Welding

    Design and function MMA welding MMA welding 5.3.1 Connecting the electrode holder and workpiece lead CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. •...

  • Page 46: Welding Task Selection

    Design and function MMA welding 5.3.2 Welding task selection The f ollowing 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 5-28 5.3.3 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in...

  • Page 47: Antistick

    Design and function MMA welding 5.3.5 Antistick The Antistick feature prevents the electrode from annealing. Should the electrode stick despite the Arcforce feature, the machine au- tomatically 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 48: Pulse Welding

    Design and function MMA welding 5.3.6 Pulse welding 5.3.7 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: Expert Menu (Mma)

    Design and function Remote control 5.3.8 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 f unction is deactivated. The setting ranges for the parameter values are summarised in the Parameter overview section. ENTER EXIT Figure 5-34...

  • Page 50: Rtp1 19Pol

    Design and function Remote control 5.4.3 RTP1 19POL Functions • TIG/MMA • Inf initely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. • Pulse/spot/normal • Pulse, spot and break times are infinitely adjustable. 5.4.4 RTP2 19POL Functions...

  • Page 51: Start Ramp

    Design and function Remote control 5.4.6.1 Start ramp The start ramp function prevents an energy input that is too fast or too high immediately after the start of welding when the user depresses the pedal of the remote control too fast and too far. Example: The user sets the main current at the welding machine to 200 A.

  • Page 52: Responsiveness

    Design and function PC interf ace 5.4.6.2 Responsiveness This f unction controls the responsiveness of the welding current during the main current phase. The user can choose between linear and logarithmic responsiveness. The logarithmic setting is particularly suitable f or welding with low current, e.g., for thin panels as the logarithmic responsiveness enables better control of the welding current.

  • Page 53: Interfaces For Automation

    Design and function Interf aces for automation Item Symbol Description USB connection Connecting a Windows PC to SECINT X10 USB Windows PC Interfaces for automation WARNING No improper repairs and modifications! To prevent injuries and damage to the machine, only competent personnel (authorised service personnel) are allowed to repair or modify the machine.

  • Page 54: Automation Interface

    Design and function Interf aces for automation 5.6.1 Automation interface These accessory components can be retrofitted as an option > see 9 chapter. WARNING No function of the external interrupt equipment (emergency stop switch)! If the emergency stop circuit has been set up using an external interrupt equipment connected to the interface for automated welding, the machine must be configured for this setup.

  • Page 55: Remote Control Connection Socket, 19-Pole

    Design and function Interf aces for automation 5.6.2 Remote control connection socket, 19-pole Figure 5-38 Pos. Pin Signal shape Designation Output Connection for cable screen (PE) Output Current f lows signal I>0, galvanically isolated (max. +- 15V/100mA) Output Ref erence voltage for potentiometer 10V (max. 10mA) Control value specification for main current, 0-10V (0V = I , 10V = Input...

  • Page 56: Busint X11 Industrial Bus Interface

    Design and function Interf aces for automation 5.6.4 BUSINT X11 industrial bus interface The solution for easy integration with automated production with e.g. • Prof inet/Profibus • EnthernetIP/DeviceNet • EtherCAT etc. 5.6.5 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 57: Power-Saving Mode (Standby)

    Design and function Power-saving mode (Standby) 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle f rom the welding torch. • Unf asten the tungsten electrode and extract. 2 Configuration • Press the (Tetrix Classic) push-button while simultaneously switching on the welding ma- chine.

  • Page 58: Machine Configuration Menu

    Design and function Machine configuration menu Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.8.1 Selecting, changing and saving parameters ENTER EXIT NAVIGATION Figure 5-40 Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (ex works 1) >...
  • Page 59 Design and function Machine configuration menu Display Setting/selection 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 > see 5.2.7.8 chapter Increase value > rapid current change Decrease value >...
  • Page 60 Design and function Machine configuration menu Display Setting/selection Welding torch cooling, post-flow time Setting 1–60 min. (ex works 5 min.) Time-based power-saving mode > see 5.7 chapter Time to activation of the power-saving mode in case of inactivity. Setting = disabled or numerical value 5-60 min.. Operating mode switching via interface for automated welding ------- Non-latched ------- Special non-latched...
  • Page 61 Design and function Machine configuration menu Display Setting/selection Software version query System bus ID and version number are separated by a dot. Example: 07.0040 = 07 (system bus ID) 0.0.4.0 (version number) Cable resistance alignment > see 5.6.5 chapter Only qualified service personnel may change the parameters! TIG HF start (soft/hard) switching -------- sof t ignition (factory setting).

  • Page 62: 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 63: 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! 099-000125-EW501 29.9.2022...

  • Page 64: Disposing Of Equipment

    Inf ormation 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 inf ormation 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 65: 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 66: 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 67: Error Messages

    Rectifying faults Error messages Warning code Possible cause Remedy Machine excess temperature Allow the machine to cool down Half -wave f ailures Check process parameters Welding torch cooling warning Check coolant level and refill if necessary Gas warning Check gas supply See warning number 3 Welding consumable (wire electrode) Check wire f eeding (with machines with filler...
  • Page 68 Rectifying faults Error messages Error Possible cause Remedy Error in the emergency stop circuit Check the external shutdown devices. Check the jum- (interf ace for automated welding) per JP 1 on PCB T320/1. Overvoltage Switch off the machine and check the mains voltage. Undervoltage Coolant error (with connected coo- Check coolant level and top up if necessary.

  • Page 69: Resetting Welding Parameters To The Factory Settings

    Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. To reset the welding parameters or machine settings to the factory settings, select parameter in the service menu >...

  • Page 70: Technical Data

    Technical data Tetrix 300 DC Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 300 DC Welding current (I 5 A to 300 A Welding voltage according to standard (U 10,2 V to 22,0 V 20,2 V to 32,0 V Duty cycle DC at 40°...

  • Page 71: Accessories

    Accessories General accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 DM AR D F1 Flowmeter pressure regulator 094-001980-00000 GH 2X1/4'' 2M...

  • Page 72: Transport System

    Accessories Transport system Transport system Type Designation Item no. Trolly 35.2-2 Transport vehicle 090-008296-00000 Trolly 38-2 E Transport vehicle, long wheelbase 090-008270-00000 Computer communication Type Designation Item no. PC300.Net welding parameter software kit incl. PC300 XQ Set 090-008777-00000 cable and SECINT X10 USB interface 099-000125-EW501 29.9.2022...

  • Page 73: Appendix

    Appendix Searching for a dealer Appendix 10.1 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-000125-EW501 29.9.2022...

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