EWM Tetrix 351 Synergic FW Operating Instructions Manual
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EWM Tetrix 351 Synergic FW Operating Instructions Manual

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Operating instructions
Welding machine
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Tetrix 351 Synergic FW
Tetrix 401 Synergic FW
Tetrix 451 Synergic FW
Tetrix 551 Synergic FW
099-000090-EW501
Observe additional system documents!
07.11.2017

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Summary of Contents for EWM Tetrix 351 Synergic FW

  • Page 1 Operating instructions Welding machine Tetrix 351 Synergic FW Tetrix 401 Synergic FW Tetrix 451 Synergic FW Tetrix 551 Synergic FW 099-000090-EW501 Observe additional system documents! 07.11.2017...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 Part of the complete documentation ....................8 Safety instructions ..........................
  • Page 4 Contents Notes on the use of these operating instructions 5.3.10.3 Automatic cut-out ..................37 5.3.11 Operating modes (functional sequences) ..............38 5.3.11.1 Explanation of symbols ................. 38 5.3.11.2 Non-latched mode ..................38 5.3.11.3 Latched mode ....................39 5.3.11.4 spotArc ......................41 5.3.11.5 spotmatic .......................
  • Page 5 10.1 JOB-List ............................. 100 11 Appendix B ............................104 11.1 Parameter overview – setting ranges ..................104 11.1.1 TIG welding ........................ 104 11.1.2 MMA welding ......................104 12 Appendix C ............................105 12.1 Overview of EWM branches ...................... 105 099-000090-EW501 07.11.2017...

  • Page 6: 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 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 keep pressed Switch Wrong Turn Numerical value – adjustable Correct Menu entry Signal light lights up in green...

  • Page 8: 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 9 For your safety Safety instructions WARNING Risk of injury from electrical voltage! Voltages can cause potentially fatal electric shocks and burns on contact. Even low voltages can cause a shock and lead to accidents. • Never touch live components such as welding current sockets or stick, tungsten or wire electrodes! •...
  • Page 10 For your safety Safety instructions WARNING Fire hazard! Due to the high temperatures, sparks, glowing parts and hot slag that occur during welding, there is a risk of flames. • Be watchful of potential sources of fire in the working area! •...
  • Page 11 For your safety Safety instructions CAUTION Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •...

  • Page 12: Transport And Installation

    For your safety Transport and installation Transport and installation WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! • Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air! •...

  • Page 13: Intended Use

    3.2.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.2.2 Declaration of Conformity The labelled machine complies with the following EC directives in terms of its design and construction: •...

  • Page 14: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-000090-EW501 07.11.2017...
  • Page 15 Machine description – quick overview Front view Item Symbol Description Lifting lug Main switch, machine on/off Machine control > see 4.3 chapter Carrying handle Automatic cut-out of coolant pump key button press to reset a triggered fuse Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply...

  • Page 16: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-000090-EW501 07.11.2017...
  • Page 17 Machine description – quick overview Rear view Item Symbol Description Connection socket, 7-pole (digital) To connect digital accessories Retrofitting option > see 9 chapter PC interface, serial (D-Sub connection socket, 9-pole) Automation interface 19-pin (analogue) Option for retrofitting > see 5.8.1 chapter Ignition type changeover switch >...

  • Page 18: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 Item Symbol Description "Welding process" button MMA welding, lights up in green / arcforce setting, lights up in red TIG synergic welding (synergic parameter setting) TIG manual welding (manual parameter setting) Electrode diameter push-button >...

  • Page 19: Function Sequence

    Machine description – quick overview Machine control – Operating elements Item Symbol Description Pulsing push-button -- TIG automated pulsing (frequency and balance) -------- Signal light lights up in green: Pulsing (thermal pulsing)/MMA pulse welding -------- Signal light lights up in red: kHz pulsing (metallurgical pulsing) Gas test/rinse hose package button >...
  • Page 20 Machine description – quick overview Machine control – Operating elements Item Symbol Description Gas pre-flow time signal light AMP% Signal light Ignition current (TIG)/hot start current (MMA) Signal light Up-slope time (TIG)/hot start time (MMA) Main current (TIG) / pulse current Main current (MMA) I min to I max (1 A increments) I min to I max (1 A increments)

  • Page 21: 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 22: Ambient Conditions

    Design and function Transport and installation 5.1.2 Ambient conditions T he machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work.

  • Page 23: Welding Torch Cooling System

    Design and function Transport and installation 5.1.5 Welding torch cooling system Insufficient frost protection in the welding torch coolant! Depending on the ambient conditions, different liquids are used for cooling the welding torch > see 5.1.5.1 chapter. Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components.

  • Page 24: Adding Coolant

    Design and function Transport and installation 5.1.5.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. Figure 5-1 Item Symbol Description Coolant tank cap Coolant filter sieve Coolant tank "Min" mark Minimum coolant level • Unscrew and remove the coolant tank sealing cover.

  • Page 25: 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 26: Stray Welding Currents

    Design and function Transport and installation 5.1.6.1 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 27: Mains Configuration

    Design and function Welding data display 5.1.7.1 Mains configuration The machine may be connected to: • a three-phase system with four conductors and an earthed neutral conductor • a three-phase system with three conductors of which any one can be earthed, e.g.

  • Page 28: Welding Parameter Setting

    Design and function Welding data display 5.2.1 Welding parameter setting During the welding parameter setting process, the parameter value being set is displayed on the left-hand display. The right-hand display shows the “Factory setting” or a variation of it upwards or downwards. Displays, e.g.

  • Page 29: Tig Welding

    Design and function TIG welding TIG welding 5.3.1 Welding torch and workpiece line connection Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur.

  • Page 30: Connection Assignment, Welding Torch Control Cable

    Design and function TIG welding Item Symbol Description Connection socket, “-” welding current TIG welding torch connection Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply Workpiece Connection socket, “+” welding current Connection for workpiece lead • Insert the welding current plug on the welding torch into the welding current connection socket and lock by turning to the right.

  • Page 31: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function TIG welding 5.3.2 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 serious injuries! •...

  • Page 32: Tig Synergic Operating Principle

    Design and function TIG welding 5.3.3 TIG Synergic operating principle Figure 5-10 The machine is operated according to the TIG Synergic operating principle: In a similar way to the MIG machines with Synergic operation, three basic parameters – • Tungsten electrode diameter (A), •...

  • Page 33: Synergic Parameter Setting In The Functional Sequence

    Design and function TIG welding 5.3.4 Synergic parameter setting in the functional sequence When setting the welding current, all the necessary welding parameters are adjusted automatically during the functional sequence > see 4.3.1 chapter with the exception of the gas pre-flow time. These welding parameters can also be set in the conventional way if required (regardless of the welding current) >...

  • Page 34: Welding Task Selection

    Design and function TIG welding 5.3.6 Welding task selection The following 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 5-13 5.3.7 Select welding current Figure 5-14...

  • Page 35: Gas Test

    Design and function TIG welding 5.3.8.1 Gas test EXIT Figure 5-15 • Set the required shielding gas quantity at the pressure regulator. “Purge hose package” function 5.3.8.2 EXIT Figure 5-16 If the "Rinse hose package" function is not ended by pressing the "Gas and current parameters" button again, shielding gas will flow until the gas cylinder is empty! 099-000090-EW501 07.11.2017...

  • Page 36: Optimising The Ignition Characteristics For Pure Tungsten Electrodes

    Design and function TIG welding 5.3.9 Optimising the ignition characteristics for pure tungsten electrodes The best ignition and stabilisation of the arc (DC, AC) and optimum spherical cup formation in the tungsten electrode depend on the electrode diameter being used. The set value should correspond to the diameter of the tungsten electrode.

  • Page 37: Arc Ignition

    Design and function TIG welding 5.3.10 Arc ignition 5.3.10.1 HF ignition Figure 5-19 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. 2-3mm). b) Press the torch trigger (high voltage ignition pulses ignite the arc).

  • Page 38: Operating Modes (Functional Sequences)

    Design and function TIG welding 5.3.11 Operating modes (functional sequences) The parameters that can be set in the function sequence of the machine control depend on the selected welding task. This means that if for example you have not selected a pulse variant, then you cannot set any pulse times in the function sequence.

  • Page 39: Latched Mode

    Design and function TIG welding Sequence Figure 5-22 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. • The welding current flows and immediately assumes the value of the ignition current •...
  • Page 40 Design and function TIG welding Sequence Figure 5-24 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 41: Spotarc

    Design and function TIG welding 5.3.11.4 spotArc This process is suitable for tack welding or joint welding of metal sheets made from steel and CrNi alloys up to a thickness of approximately 2.5 mm. Metal sheets of different thicknesses can also be welded on top of one another.

  • Page 42: Spotmatic

    Design and function TIG welding Figure 5-26 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 5.3.10.2 chapter. Sequence: • Press and hold torch trigger 1. • The gas pre-flow time elapses. •...
  • Page 43 Design and function TIG welding Figure 5-27 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 5.3.10.2 chapter. Selecting the process activation type for the welding process > see 5.12 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) only.

  • Page 44: Non-Latched Operation, Version C

    Design and function TIG welding 5.3.11.6 Non-latched operation, version C Figure 5-28 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 ignition current (search arc at minimum setting).

  • Page 45: Pulse Welding

    Design and function TIG welding 5.3.12 Pulse welding The following pulse types can be selected: • Automated pulsing • Thermal pulsing • Metallurgical pulsing 5.3.12.1 Automated pulses The automated pulses are used with tacking and spot welding of workpieces in particular. An oscillation in the molten pool is produced by the current-dependent pulse frequency and balance, which positively influences the ability to bridge the air gap.
  • Page 46 Design and function TIG welding The pulse function can also be deactivated if necessary during the up-slope and down-slope phases (parameter ) > see 5.12 chapter. Figure 5-31 Selection Figure 5-32 099-000090-EW501 07.11.2017...

  • Page 47: Metallurgical Pulsing (Khz Pulsing)

    Design and function TIG welding Pulse time setting Figure 5-33 Pulse pause setting Figure 5-34 Pulse edge setting pulse edges can be set in the Expert menu (TIG) > see 5.3.15 chapter. 5.3.12.3 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.
  • Page 48 Design and function TIG welding Selection Figure 5-36 Balance setting EXIT Figure 5-37 Frequency setting EXIT Figure 5-38 099-000090-EW501 07.11.2017...

  • Page 49: Tig Antistick

    ) > see 5.12 chapter. 5.3.14 activArc 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.

  • Page 50: Expert Menu (Tig)

    Design and function TIG welding 5.3.15 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 5-40 Display Setting/selection Expert menu Slope time (main current to secondary current)

  • Page 51: Mma Welding

    Design and function MMA welding Display Setting/selection Filler wire diameter (manual setting) Setting the wire diameter between 0.6 mm to 1.6 mm. The character "d" preceding the wire diameter on the display (d0.8) indicates a pre- programmed characteristics (correction operating mode "KORREKTUR”). If there is no characteristics for the selected wire diameter, the parameters have to be set manually (manual operating mode “MANUELL“).
  • Page 52 Design and function MMA welding Figure 5-41 Item Symbol Description Workpiece Connection socket, “+” welding current Connection for workpiece lead Electrode holder Connection socket, “-” welding current Electrode holder connection G¼" connecting nipple Shielding gas connection (with yellow insulating cap) for TIG welding torch Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

  • Page 53: Welding Task Selection

    Design and function MMA welding 5.4.2 Welding task selection The following 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 5-42 5.4.3 Hotstart The hot start function improves the arc striking.

  • Page 54: Hotstart Time

    Design and function MMA welding 5.4.3.2 Hotstart time EXIT Figure 5-45 5.4.4 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.

  • Page 55: Average Value Pulsing In The Vertical-Up Position (Pf)

    Design and function MMA welding 5.4.6 Average value pulsing in the vertical-up position (PF) Welding characteristics: • Especially suitable for root welding • Fine-flaked weld surface with a TIG look for final passes • Less finishing work thanks to less spatter •...
  • Page 56 Design and function Organising welding tasks (Mode "JOB Manager") Pulse pause current setting Figure 5-51 Balance setting Figure 5-52 Frequency setting Figure 5-53 The default pulse parameters are pre-set in such a way that the welding current average value corresponds to the pre-selected main current AMP. Changes in the pulse parameters result in changes to welding current average value AMP.

  • Page 57: Organising Welding Tasks (Mode "Job Manager")

    Design and function Organising welding tasks (Mode "JOB Manager") Organising welding tasks (Mode "JOB Manager") After carrying out any of the actions described, the machine switches back to the default parameters such as current and voltage. To ensure that all the changes are active, the welding machine should only be switched off after 5 seconds have elapsed.

  • Page 58: Creating A New Job In The Memory Or Copying A Job

    Design and function Organising welding tasks (Mode "JOB Manager") 5.5.2 Creating a new JOB in the memory or copying a JOB Copying a pre-defined welding task from the fixed memory (JOBs 1 to 128) to the free memory (JOBs 129-256): It is normally possible to adjust all 256 JOBs individually.

  • Page 59: Loading An Existing Job From The Free Memory

    Design and function Organising welding tasks (Mode "JOB Manager") 5.5.3 Loading an existing JOB from the free memory EXIT Figure 5-55 5.5.4 Resetting an existing JOB to the factory setting (Reset JOB) Figure 5-56 099-000090-EW501 07.11.2017...

  • Page 60: Resetting Jobs 1-128 To The Factory Setting (Reset All Jobs)

    Design and function Welding programs 5.5.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs) Figure 5-57 5.5.6 Exit JOB Manager without changes EXIT Figure 5-58 Welding programs Changes made to the other welding parameters during the course of the program have the equivalent effect on all programs.

  • Page 61: Selection And Adjustment

    Design and function Welding programs The operating mode cannot be changed during the welding process. If welding is started with program 1 (non-latched operating mode), program 2 controls the setting of ignition program 1 despite the latched setting and is implemented to the end of the welding process. The pulse function (pulses off, pulses on) and the welding currents are transferred from the corresponding programs.

  • Page 62: Example "Program With Synergetic Setting

    Design and function Remote control 5.6.2 Example "Program with synergetic setting" Figure 5-60 5.6.3 Example "Program with conventional setting" Figure 5-61 5.6.4 Accessories for switching over programs The user can change, retrieve and save programs using the following components. Programs Component create and change call up...

  • Page 63: Rtp1 19Pol

    Design and function Remote control 5.7.3 RTP1 19POL Functions • TIG/MMA • Infinitely 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. 5.7.4 RTP2 19POL Functions...

  • Page 64: Rtf Start Ramp

    Design and function Remote control 5.7.6.1 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 65: Rtf Response

    Design and function Remote control 5.7.6.2 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 66: Up/Down Speed

    Design and function Remote control 5.7.7.3 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 67 Design and function Remote control Standard torch with two torch triggers Figure Operating Explanation of symbols elements BRT1 = torch trigger 1 BRT2 = torch trigger 2 Functions Mode Operating elements Welding current on/off Secondary current (ex works) Secondary current (tapping function) )/(latched operating mode) Welding current on/off Secondary current (tapping function)
  • Page 68 Design and function Remote control 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 69: Tig Up/Down Torch (8-Pole)

    Design and function Remote control 5.7.7.6 TIG up/down torch (8-pole) Up/down torch with one torch trigger Image 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 70 Design and function Remote control 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 operation) (ex works)

  • Page 71: Potentiometer Torch (8-Pole)

    Design and function Remote control 5.7.7.7 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch > see 5.7.7.8 chapter. Potentiometer torch with one torch trigger Figure Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions Mode Operating...

  • Page 72: Configuring The Tig Potentiometer Torch Connection

    Design and function Remote control 5.7.7.8 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 73: Retox Tig Torch (12-Pole)

    Design and function Remote control 5.7.7.9 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...

  • Page 74: Specifying Max. No. Of Accessible Jobs

    Design and function Interfaces for automation 5.7.7.10 Specifying max. no. of accessible JOBs This function can be used to specify the maximum number of JOBs which can be retrieved from the free memory. The factory setting is for 10 JOBs to be accessible on the welding machine, but this figure can be increased to up to 128 if required.

  • Page 75: Automation Interface

    Design and function Interfaces for automation 5.8.1 Automation interface 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 76: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.8.2 Remote control connection socket, 19-pole Figure 5-66 Pos. Signal shape Designation Output Connection for cable screen (PE) Output Current flows signal I>0, galvanically isolated (max. +- 15V/100mA) Output Reference voltage for potentiometer 10V (max. 10mA) Input Control value specification for main current, 0-10V (0V = I , 10V =...

  • Page 77: Pc Interface

    Design and function PC interface PC interface PC 300 welding parameter software Set all welding parameters on the PC and simply transfer to one or more welding machines (accessory, set consisting of software, interface, connection leads) • Manage up to 510 JOBs •...

  • Page 78: Access Control

    Design and function Access control 5.11 Access control These accessory components can be retrofitted as an option > see 9 chapter. To protect against unauthorised or unintentional adjustment of the welding parameters on the machine, the control input can be locked with the aid of a key switch. Key position 1 = All parameters can be set Key position 0 =...

  • Page 79: Machine Configuration Menu

    Design and function Machine configuration menu 5.12 Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.12.1 Selecting, changing and saving parameters ENTER EXIT NAVIGATION Figure 5-68 Display Setting/selection Exit the menu Exit 099-000090-EW501 07.11.2017...
  • Page 80 Design and function Machine configuration menu Display Setting/selection Torch configuration menu Set welding torch functions Torch mode (ex works 1) > see 5.7.7.2 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 81 Design and function Machine configuration menu Display Setting/selection Program 0 block With machines with access block, program 0 can be disabled. When the access block has been enabled, programs 1–x only can be switched. ------- All programs can be selected (ex works) ------- Programs 1–x can be selected (program 0 disabled) Show warnings >...
  • Page 82 Design and function Machine configuration menu Display Setting/selection Expert menu 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 83 Design and function Machine configuration menu Display Setting/selection Automated/Manual (rC on/off) operating mode Select machine/function control ------ with external control voltages/signals ------ with machine control Software version query (example) 07.= ------ system bus ID 03c0= ---- version number System bus ID and version number are separated by a dot. Cable resistance alignment >...

  • Page 84: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.12.2 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.
  • Page 85 Design and function Machine configuration menu 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Unfasten the tungsten electrode and extract. 2 Configuration • Press the (Tetrix Classic) push-button while simultaneously switching on the welding machine.

  • Page 86: 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 87: 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! 099-000090-EW501 07.11.2017...

  • Page 88: Disposing Of Equipment

    • Information about returning used equipment or about collections can be obtained from the respective municipal administration office. • In addition to this, returns are also possible throughout Europe via EWM sales partners. 099-000090-EW501 07.11.2017...

  • Page 89: 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 dealer.

  • Page 90: 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 91: Error Messages

    Rectifying faults Error messages Error messages A welding machine error is indicated by an error code being displayed (see table) on the display on the machine control. In the event of a machine error, the power unit is shut down. The display of possible error numbers depends on the machine version (interfaces/functions).

  • Page 92: 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 93: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-1 099-000090-EW501...

  • Page 94: Technical Data

    Technical data Tetrix 351 FW Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 351 FW Welding current 5 A–350 A Welding voltage 10.2 V–24.0 V 20.2 V–34.0 V Duty cycle at 40 °C 350 A (100% DC) ...

  • Page 95: Tetrix 401 Fw

    Technical data Tetrix 401 FW Tetrix 401 FW Welding current 5 A–400 A Welding voltage 10.2 V–26.0 V 20.2 V–36.0 V Duty cycle at 40 °C 400 A (100% DC)  Load cycle 10 min. (60% DC 6 min. welding, 4 min. pause) Open circuit voltage 79 V Mains voltage (tolerances)

  • Page 96: Tetrix 451 Fw

    Technical data Tetrix 451 FW Tetrix 451 FW Welding current 5 A–450 A Welding voltage 10.2 V–28.0 V 20.2 V–38.0 V Duty cycle at 40 °C 450 A (80% DC) 420 A (100% DC)  Load cycle 10 min. (60% DC 6 min.

  • Page 97: Tetrix 551 Fw

    Technical data Tetrix 551 FW Tetrix 551 FW Welding current 5 A–550 A Welding voltage 10.2 V–32.0 V 20.2 V–42.0 V Duty cycle at 40 °C 550 A (60% DC) 420 A (100% DC)  Load cycle 10 min. (60% DC 6 min.

  • Page 98: Accessories

    Accessories Remote controls and accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Remote controls and accessories Type Designation Item no. RTF1 19POL 5 M Foot-operated remote control current with 094-006680-00000 connection cable RT1 19POL...

  • Page 99: Computer Communication

    Accessories Computer communication Computer communication Type Designation Item no. PC300.Net PC300.Net welding parameter software kit incl. 090-008777-00000 cable and SECINT X10 USB interface 099-000090-EW501 07.11.2017...

  • Page 100: Job-List

    Appendix A JOB-List Appendix A 10.1 JOB-List Process Material Wire Seam position  Reserved   CrNi   CrNi   CrNi       CrNi       CrNi      ...
  • Page 101 Appendix A JOB-List Process Material Wire Seam position        Fe/St       Fe/St >3.2   Fe/St   Fe/St   Fe/St       Fe/St ...
  • Page 102 Appendix A JOB-List Process Material Wire Seam position    CuZn   CuZn   CuZn     CuZn     CuZn   CuZn >3.2   CuZn   CuZn   CuZn ...
  • Page 103 Appendix A JOB-List Process Material Wire Seam position    Special   Special   Special   Special >3.2   Special   Special   Special   Special   Special   Special >3.2 TIG manual/TIG classic Classic electrode...

  • Page 104: Parameter Overview - Setting Ranges

    Appendix B Parameter overview – setting ranges Appendix B Parameter overview – setting ranges 11.1 11.1.1 TIG welding Parameter Display Setting range Comment TIG/plasma Gas pre-flow time Ignition current AMP% % of main current AMP Up-slope time 20,0 Pulse time 0,01 0,00 - 20,0...

  • Page 105: Overview Of Ewm Branches

    Appendix C Overview of EWM branches Appendix C 12.1 Overview of EWM branches 099-000090-EW501 07.11.2017...

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