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+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. No other form of liability, regardless of type, shall be accepted.
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................7 Notes on the use of these operating instructions ................7 Explanation of icons ........................8 General ............................9 Transport and installation ......................13 2.4.1 Lifting by crane ......................
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Contents Notes on the use of these operating instructions 5.8.5.4 TIG spotArc ....................41 5.8.5.5 Spotmatic ...................... 43 5.8.5.6 Non-latched operation, version C ..............45 5.8.5.7 Automated pulses ..................46 TIG pulses – non-latched operation .............. 46 5.8.5.8 5.8.5.9 TIG pulses - latched operation ..............46 5.8.6 TIG activArc welding .....................
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Notes on the use of these operating instructions Tetrix 551 FW ..........................82 8 Accessories ............................83 Remote controls and accessories ....................83 Options ............................83 General accessories ........................84 Computer communication ......................84 9 Appendix A ............................85 Overview of EWM branches ......................85 099-000128-EW501 16.07.2014...
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Contents Notes on the use of these operating instructions 099-000128-EW501 16.07.2014...
Safety instructions Notes on the use of these operating instructions Safety instructions 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. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •...
Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu) EXIT EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use...
Safety instructions General General DANGER Electric shock! Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents. • Do not touch any live parts in or on the machine! •...
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Safety instructions General WARNING Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure when heated. • Move containers with inflammable or explosive liquids away from the working area! • Never heat explosive liquids, dusts or gases by welding or cutting! Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning.
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Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
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Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •...
Safety instructions Transport and installation 2.4.1 Lifting by crane WARNING Risk of injury during lifting by crane When lifting the machine by crane, persons may be severely injured by falling machines or mount-on components. • Simultaneous lifting of system components such as power source wire feeder or cooling unit is not allowed.
Safety instructions Transport and installation 2.4.2 Ambient conditions CAUTION Installation site! The 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.
3.1.1.1 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. 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.
Intended use Documents which also apply Documents which also apply 3.2.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.2.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •...
Machine description – quick overview Front view Machine description – quick overview NOTE The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted (see "Accessories" chapter). Front view Figure 4-1 099-000128-EW501 16.07.2014...
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Machine description – quick overview Front view Item Symbol Description Lifting lug Main switch, machine on/off Machine control See Machine control – operating elements 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)
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Machine description – quick overview Rear view Item Symbol Description 7-pole connection socket (digital) For connecting digital accessory components PC interface, serial (D-Sub connection socket, 9-pole) 19-pole mechanised welding interface (analogue) (See chapter entitled "Design and function > interfaces".) Ignition type changeover switch Liftarc (contact ignition) HF ignition Securing elements for shielding gas cylinder (strap/chain)
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 Item Symbol Description Three-figure LED display Welding parameter display (see also chap. “Welding data display”). Error/status indicators Collective interference signal light Water deficiency signal light (welding torch cooling) Excess temperature signal light safety sign signal light Function sequence (see next chapter)
Machine description – quick overview Machine control – Operating elements 4.3.1 Function sequence Figure 4-4 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. Welding parameter setting rotary dial Setting currents, times and parameters.
Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •...
Design and function Installation Installation CAUTION Installation site! The 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.
Design and function Welding torch cooling system Welding torch cooling system CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! • Only use the coolant described in this manual (overview of coolants). •...
Design and function Welding torch cooling system 5.5.2 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 •...
Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations! •...
Design and function Notes on the installation of welding current leads Notes on the installation of welding current leads NOTE 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.
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Design and function Notes on the installation of welding current leads NOTE Use an individual welding lead to the workpiece for each welding machine! Figure 5-4 NOTE Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders.
Design and function TIG welding TIG welding 5.8.1 Welding torch and workpiece line connection CAUTION Equipment damage due to improperly connected coolant lines! If the coolant lines are not connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •...
Design and function TIG welding Item Symbol Description Welding torch Welding torch hose package Connection socket, 8-pole TIG Up/Down or potentiometer torch control lead Connection socket, 5-pole Standard TIG torch control lead G¼” connecting nipple, “-” welding current Shielding gas connection (with yellow insulating cap) for TIG welding torch Connection socket, “-”...
Design and function TIG welding 5.8.2 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! •...
Design and function TIG welding 5.8.2.1 Connecting the shielding gas supply • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. Figure 5-8 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve •...
Design and function TIG welding 5.8.3 Select welding task NOTE No changes can be made to the basic welding parameters during the welding process. The welding task is selected using the buttons on the machine control on the welding machine. Signal lights (LED) display the welding parameter selection.
Design and function TIG welding 5.8.3.2 Expert menu (TIG) The expert menu includes functions and parameters which are either not set on the machine control, or which do not require regular setting. ENTER EXIT NAVIGATION Figure 5-9 Display Setting/selection Expert menu Gas pre-flow time Setting range: 0.0 s to 20.0 s (0.1 s increments) Ignition current...
Design and function TIG welding 5.8.4 Arc ignition 5.8.4.1 HF ignition Figure 5-10 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).
Design and function TIG welding 5.8.5 Function sequences/operating modes The parameters for the function sequence are set using the “Select welding parameters” button and the “Welding parameter setting” rotary dial. Figure 5-12 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used.
Design and function TIG welding 5.8.5.2 Non-latched mode Figure 5-13 1st cycle: • Press and hold torch trigger 1. • The 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 set for the ignition current I start •...
Design and function TIG welding 5.8.5.3 Latched mode Figure 5-14 Step 1 • 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 ignition current value set (search arc at minimum setting).
Design and function TIG welding 5.8.5.4 TIG 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.
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Design and function TIG welding Figure 5-15 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however (see chapter "Arc ignition"). Sequence: • Press and hold torch trigger 1. • The gas pre-flow time elapses. •...
Design and function TIG welding 5.8.5.5 Spotmatic NOTE This function must be enabled before use, see "Advanced settings" chapter. In contrast to the spotarc operating mode, the arc ignites not by pressing the torch trigger as is usual, but by shortly touching the tungsten electrode against the workpiece. The torch trigger is used for process activation.
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Design and function TIG welding Figure 5-16 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however (see chapter "Arc ignition"). Select the process activation type (see chapter "Advanced settings"). Up- and down-slope times possible for long setting range of the spot time (0.01 s - 20.0 s) only. ...
Design and function TIG welding 5.8.5.6 Non-latched operation, version C Figure 5-17 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 adopts the ignition current value set (search arc at minimum setting).
Design and function TIG welding 5.8.5.7 Automated pulses NOTE The machines have an integrated pulse device. With pulses, the machine switches back and forth between the pulse current (main current) and pause current (secondary current). 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.
5.8.6 TIG activArc welding The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power supplied is kept virtually constant in the event of changes in the distance between the welding torch and the weld pool, e.g. during manual welding. Voltage losses as a result of a shortening of the distance between the torch and molten pool are compensated by a current rise (ampere per volt - A/V), and vice versa.
Design and function TIG welding 5.8.7 Welding torch (operating variants) Different torch versions can be used with this machine. Functions on the operating elements, such as torch triggers (TT), rockers or potentiometers, can be modified individually via torch modes. Explanation of symbols for operating elements: Symbol Description Press torch trigger...
Design and function TIG welding 5.8.7.2 Torch mode and up/down speed setting The user has the modes 1 to 6 and modes 11 to 16 available. Modes 11 to 16 include the same function options as 1 to 6, but without tapping function for the secondary current. The function options in the individual modes can be found in the tables for the corresponding torch types.
Design and function TIG welding 5.8.7.3 Standard TIG torch (5-pole) Standard torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT1 = Torch trigger 1 (welding current on/off; secondary current via tapping function) Functions mode Operating elements Welding current On/Off (factory-set) Secondary current (Latched mode) Standard torch with two torch triggers:...
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Design and function TIG welding Standard torch with one rocker (MG rocker, two torch triggers) Diagram 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 (factory-set) Secondary current (tapping mode) / (latched mode)
Design and function TIG welding 5.8.7.5 Potentiometer torch (8-pole) NOTE The welding machine needs to be configured for operation with a potentiometer torch (see chap. "Configuring TIG potentiometer torch") Potentiometer torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions...
Design and function TIG welding 5.8.7.6 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.
Design and function TIG welding 5.8.7.7 Setting the first increment Figure 5-23 ENTER EXIT NAVIGATION Figure 5-24 Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Setting the first increment Setting: 1 to 20 (factory setting 1) NOTE This function is only available when using up/down torches in modes 4 and 14! 099-000128-EW501...
Design and function MMA welding MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •...
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Design and function MMA welding Item Symbol Description Electrode holder Connection socket, “-” welding current Electrode holder connection Workpiece Connection socket, “+” welding current Connection for workpiece lead • Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right.
Design and function MMA welding 5.9.2 Select welding task Operating Action Result element Select MMA welding process signal light lights up in green Set welding current 5.9.2.1 Hotstart current and Hotstart time The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) =...
Design and function MMA welding 5.9.2.2 Arcforce Shortly before the electrode threatens to stick, the arcforcing device sets an increased current designed to prevent the electrode sticking. Operating Action Result Displays element Select arcforcing welding parameter signal light lights up in red Set arcforcing = low current increase >...
Design and function Remote control 5.10 Remote control NOTE Insert the remote control control cable into the 19-pole connection socket for remote control connection and lock. 5.10.1 Manual remote control RT1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine.
Design and function Remote control 5.10.6 Foot-operated remote control RTF1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. • Start/stop welding operation (TIG) ActivArc welding is not possible in combination with the foot-operated remote control. Figure 5-28 Symbol Meaning...
Design and function Interfaces for automation 5.10.6.1 Ramp function foot-operated remote control RTF 1 ENTER EXIT NAVIGATION Figure 5-29 Display Setting/selection Exit the menu Exit Machine configuration (part two) Settings for machine functions and parameter display Ramp function Remote control RTF 1 The ramp function can be switched on and off Switch on Switching on machine function...
Design and function Interfaces for automation 5.11.1 Remote control connection socket, 19-pole Figure 5-30 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 =...
Design and function Interfaces for automation 5.11.2 TIG interface for mechanised welding NOTE These accessory components can be retrofitted as an option, see Accessories chapter. Signal Designation Diagram shape Output Connection for cable screen Output REGaus For servicing purposes only Input SYN_E Synchronisation for master/slave operation...
Design and function PC Interfaces 5.12 PC Interfaces CAUTION Equipment damage or faults may occur if the PC is connected incorrectly! Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission. The PC may be destroyed due to high frequency ignition pulses. •...
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Design and function Machine configuration menu EXIT ENTER NAVIGATION Figure 5-31 099-000128-EW501 16.07.2014...
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Design and function Machine configuration menu Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (factory setting 1) Up-/Down speed Increase value = rapid current change (factory setting 10) Reduce value = slow current change Setting the first increment Setting: 1 to 20 (factory setting 1) Machine configuration...
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Design and function Machine configuration menu Display Setting/selection activArc voltage measuring • on = function on (factory setting) • off = function off Error output to automated welding interface, contact SYN_A AC synchronisation or hot wire (factory setting) Error signal, negative logic Error signal, positive logic AVC (Arc voltage control) connection Automation menu...
Maintenance, care and disposal General Maintenance, care and disposal DANGER Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. •...
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).
Maintenance, care and disposal Checklist for 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.
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Maintenance, care and disposal Checklist for rectifying faults No arc ignition Incorrect ignition type setting. Set ignition type changeover switch to the HF ignition setting. Bad arc ignition Material inclusions in the tungsten electrode due to contact with filler material or workpiece ...
Maintenance, care and disposal Error messages (power source) Error messages (power source) NOTE A welding machine error is indicated by the collective fault signal lamp (A1) lighting up and an error code (see table) being displayed in the machine control display. In the event of a machine error, the power unit shuts down.
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Maintenance, care and disposal Error messages (power source) Error message Possible cause Remedy Err 20 Coolant Check coolant level and refill if necessary • The flow quantity of the torch coolant Check coolant level in the reverse cooler • has fallen below the permissible Check coolant lines for leaks and kinks minimum ->...
Maintenance, care and disposal Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings. ENTER EXIT NAVIGATION Figure 6-1 Display Setting/selection Exit the menu Exit Service menu...
Maintenance, care and disposal Display machine control software version Display machine control software version NOTE The query of the software versions only serves to inform the authorised service staff! ENTER EXIT NAVIGATION Figure 6-2 Display Setting/selection Exit the menu Exit Service menu Modifications to the service menu may only be carried out by authorised maintenance staff!
Maintenance, care and disposal Vent coolant circuit 6.10 Vent coolant circuit NOTE 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 6-3 099-000128-EW501 16.07.2014...
Technical data Tetrix 351 FW Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 351 FW Welding current 5 A to 350 A Welding voltage 10.2 V to 24.0 V 20.2 V to 34.0 V Duty cycle at 40 °C 100% DC 350 A...
Technical data Tetrix 401 FW Tetrix 401 FW Welding current 5 A to 400 A Welding voltage 10.2 V to 26.0 V 20.2 V to 36.0 V Duty cycle at 40 °C 100% DC 400 A Load alternation 10 min. (60% DC 6 min.
Technical data Tetrix 451 FW Tetrix 451 FW Welding current 5 A to 450 A Welding voltage 10.2 V to 28.0 V 20.2 V to 38.0 V Duty cycle at 40 °C 80% DC 450 A 100% DC 420 A ...
Technical data Tetrix 551 FW Tetrix 551 FW Welding current 5 A to 550 A Welding voltage 10.2 V to 32.0 V 20.2 V to 42.0 V Duty cycle at 40 °C 60% DC 550 A 100% DC 420 A ...
Accessories Remote controls and accessories Accessories NOTE 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 19POLE 5M Foot-operated remote control current with 094-006680-00000 connection cable RTF2 19POL 5 m...
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