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

EWM Tetrix AC/DC Comfort 2.0 Operating Instructions Manual

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Operating instructions
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T4.00 - Tetrix AC/DC Comfort 2.0
EN
T4.08 - Tetrix AC/DC Comfort 2.0
099-00T400-EW501
Observe additional system documents!
18.06.2020

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Summary of Contents for EWM Tetrix AC/DC Comfort 2.0

  • Page 1 Operating instructions Control T4.00 - Tetrix AC/DC Comfort 2.0 T4.08 - Tetrix AC/DC Comfort 2.0 099-00T400-EW501 Observe additional system documents! 18.06.2020...
  • 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 ........................5 Part of the complete documentation ....................7 3 Intended use ............................8 Use and operation solely with the following machines ..............
  • Page 4 Contents Notes on using these operating instructions 5.1.10.3 Up/down speed ..................... 36 5.1.10.4 Current jump ....................36 5.1.10.5 Standard TIG torch (5-pole) ................37 5.1.10.6 TIG up/down torch (8-pole) ................39 5.1.10.7 Potentiometer torch (8-pole) ................. 41 5.1.10.8 Configuring the TIG potentiometer torch connection ........42 5.1.10.9 RETOX TIG torch (12-pole)................

  • 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 For your safety Part of the complete documentation Symbol Description Symbol Description Output Signal light lights up in red Time representation (e.g.: wait 4 s / Signal light flashes red actuate) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use 099-00T400-EW501...

  • Page 7: Part Of The Complete Documentation

    For your safety Part of the complete documentation 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 8: 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 standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate.

  • 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 three sections (A, B, C) to ensure maximum clarity. The setting range 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 Display switching push-button kW ------- Welding power display V ---------- Welding voltage display JOB ------ Display and setting of the JOB number with the control button Welding data display (3-digit) Displays the welding parameters and the corresponding values >...

  • 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 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 13: Control Section C

    Machine control – Operating elements Machine display Item Symbol Description Electrode diameter signal light Ignition optimisation (TIG)/tungsten balling basic setting (JOB 1-100) Gas post-flow time Signal light, two colour AMP% Red: End current Green: End current time > see 5.1.13 chapter Down-slope time signal light 4.1.3...

  • Page 14: Machine Display

    Machine control – Operating elements Machine display Machine display The following welding parameters can be displayed before (nominal values), during (actual values) or af- ter welding (hold values): Parameter Before welding During welding After welding (nominal values) (actual values) (hold values) Welding current Parameter times Parameter currents...

  • Page 15: Setting Advanced Welding Parameters (Expert Menu)

    Machine control – Operating elements Operating the machine control 4.3.4 Setting advanced welding parameters (Expert menu) The Expert menu contains functions and parameters which cannot be set directly in the machine control or which do not need to be et on a regular basis. The number and display of these parameters depends on the previously selected welding procedure or the functions.

  • Page 16: 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 17: 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 ig- nition behaviour and minimum current limits. The ignition energy is controlled by the set electrode diame- ter.

  • Page 18: 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 19: Tungsten Balling Function

    Functional characteristics TIG welding 5.1.3.2 Tungsten balling function The tungsten balling function provides optimum tungsten balling, ensuring that the best ignition and welding results are achieved during AC welding. Optimum tungsten balling requires a sharpened electrode (about 15–25°) and the set electrode diameter on the machine control.

  • Page 20: Alternating Current Waveforms

    Functional characteristics TIG welding 5.1.3.4 Alternating current waveforms Selection EXIT Figure 5-6 Display Setting/selection Alternating current waveforms ------ Rectangular - Highest energy input (ex works) ------ Trapezoidal - An all-rounder, suitable for most applications ------ Sine - Low noise level 5.1.3.5 Automatic AC frequency Selecting the function AC frequency automatic is only possible in the JOB area 1-100.

  • Page 21: Ac Commutation Optimisation

    Functional characteristics TIG welding Selection < Figure 5-8 5.1.3.6 AC commutation optimisation The AC commutation assistance function can help to increase process stability when welding materials such as pure aluminium. If half-wave failures should occur during the welding process, the parameter can be increased, counteracting half-wave failures.

  • Page 22: Arc Ignition

    Functional characteristics TIG welding 5.1.4 Arc ignition To change the ignition type, use parameter to switch between HF start ( ) and lift arc ( ) in the Expert menu > see 5.1.13 chapter. 5.1.4.1 HF ignition Figure 5-9 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 23 Functional characteristics TIG welding Symbol Meaning 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 Pulse pause time Pulse current Pulsed TIG welding: Slope time from main current (AMP) to secondary current (AMP%) Pulsed TIG welding: Slope time from secondary current (AMP%) to main current (AMP) Down-slope time End-crater current...

  • Page 24: Non-Latched Mode

    Functional characteristics TIG welding 5.1.5.2 Non-latched mode Selection Figure 5-11 Sequence Figure 5-12 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 25: Latched Mode

    Functional characteristics TIG welding 5.1.5.3 Latched mode Selection Figure 5-13 Sequence Figure 5-14 099-00T400-EW501 18.06.2020...

  • Page 26: 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 ignition current (search arc at minimum setting).
  • Page 27 Functional characteristics TIG welding Figure 5-16 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.1.4 chapter. Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. •...

  • Page 28: Spotmatic

    Functional characteristics TIG welding 5.1.5.5 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 29: 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 5.1.4 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 30: Tig Activarc Welding

    5.1.6 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 31: Thermal Pulsing

    Functional characteristics TIG welding 5.1.8.2 Thermal pulsing The operation sequences basically match the standard welding sequences, but there is an additional switching back and forth between the main current AMP (pulse current) and the secondary current AMP% (pulse pause current) at the set times. Pulse and pause times and the pulse edges ( ) are en- tered in seconds on the control.

  • Page 32: Pulsed Welding In The Upslope And Downslope Phases

    Functional characteristics TIG welding Pulse pause setting EXIT Figure 5-25 Pulse edge setting pulse edges can be set in the Expert menu (TIG) > see 5.1.13 chapter. 5.1.8.3 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 33 Functional characteristics TIG welding Selection Figure 5-28 Balance setting EXIT Figure 5-29 Frequency setting EXIT Figure 5-30 099-00T400-EW501 18.06.2020...

  • Page 34: Average Value Pulse Welding

    Functional characteristics TIG welding 5.1.9 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 35: Ac Special

    Functional characteristics TIG welding 5.1.9.1 AC special Is e.g. used to join metal sheets of different thickness. Figure 5-32 Figure 5-33 pulse edges can be set in the Expert menu (TIG) > see 5.1.13 chapter. 5.1.10 Welding torch (operating variants) Different torch versions can be used with this machine.

  • Page 36: 5.1.10.3 Up/Down Speed

    Functional characteristics TIG welding 5.1.10.3 Up/down speed Functionality Press and hold the up push-button: Increase current up to the maximum value (main current) set in the power source. Press and hold the down push-button: Decrease current to the minimum value. Use the machine configuration menu >...

  • Page 37: Standard Tig Torch (5-Pole)

    Functional characteristics TIG welding 5.1.10.5 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 5.1.10.6 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 5.1.10.7 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch > see 5.1.10.8 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: 5.1.10.8 Configuring The Tig Potentiometer Torch Connection

    Functional characteristics TIG welding 5.1.10.8 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 5.1.10.9 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: 5.1.11 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: 5.1.11.2 Rtf Response

    Functional characteristics TIG welding 5.1.11.2 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 5.1.13 Expert menu (TIG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa- rameters shown may be limited, e.g. if a function is deactivated. ENTER EXIT Figure 5-38 Display Setting/selection Expert menu Slope time (main current to secondary current)
  • Page 47 Functional characteristics TIG welding Display Setting/selection Slope time (main current to secondary current) Slope time (main current to secondary current) Slope time (main current to secondary current) Amplitude balance > see 5.1.3.3 chapter activArc parameter Parameter also adjustable after TIG activArc welding is activated. AC commutation optimisation >...

  • Page 48: 5.1.14 Aligning The Cable Resistance

    Functional characteristics TIG welding 5.1.14 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. EXIT Figure 5-44 5.2.4...

  • Page 52: Pulse Welding

    Functional characteristics MMA welding 5.2.6 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 5-47 AMP = main current, e.g.

  • Page 53: Average Value Pulse Welding

    Functional characteristics Filler wire welding 5.2.6.1 Average value pulse welding parameter in the machine configuration menu must be switched to to enable average value pulses. Average value pulse welding means that two currents are switched periodically, a current average value (AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first.

  • 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 5-52 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 5-53 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 5-54...

  • 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 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 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 ENTER EXIT NAVIGATION Figure 5-55 Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions 099-00T400-EW501 18.06.2020...
  • Page 60 Functional characteristics Machine configuration menu Display Setting/selection Torch mode (ex works 1) > see 5.1.10.2 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 5.1.7 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.
  • 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, Electronics error (A/D channel error) notify the service department. Electronics error (slope error) Electronics error (S sign) Electronics error (temperature error) Allow the machine to cool down.

  • Page 67: Appendix

    Appendix Parameter overview – setting ranges Appendix 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 68: Mma Welding

    Appendix Parameter overview – setting ranges Dynamic power adjustment Machines with control Comfort 2.0. Machines for AC welding (AC). Machine series Tetrix 300. Machine series Tetrix 230. 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, percentage of AMP Hot start current, absolute, depending on power source...

  • Page 69: 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" 099-00T400-EW501 18.06.2020...

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