Page 1 Operating instructions Welding machines and accessories Tetrix 351 AC/DC AW FW Tetrix 451 AC/DC AW FW Tetrix 551 AC/DC AW FW 099-000115-EW501 Observe additional system documents! 20.11.2017...
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 ............................7 Notes on the use of these operating instructions ................7 Explanation of icons ........................8 Part of the complete documentation ....................9 Safety instructions ..........................
Page 4 Contents Notes on the use of these operating instructions 5.5.2 Select wire speed operating mode (KORREKTUR / MANUELL) ......... 45 5.5.3 Setting the welding current and wire speed ..............45 5.5.4 Operating modes (functional sequences) ..............46 5.5.4.1 Explanation of symbols ................. 46 5.5.4.2 Non-latched mode ..................
Page 5 Contents Notes on the use of these operating instructions 5.10.1 Explanation of symbols....................83 5.10.2 Creating a new JOB in the memory or copying a JOB ..........84 5.10.3 Loading an existing JOB from the free memory ............85 5.10.4 Resetting an existing JOB to the factory setting (Reset JOB)........
Page 6 10 Appendix A ............................125 10.1 JOB-List............................125 11 Appendix B ............................129 11.1 Parameter overview – setting ranges ..................129 11.1.1 TIG welding ......................... 129 11.1.2 MMA welding ......................129 12 Appendix C ............................130 12.1 Overview of EWM branches....................... 130 099-000115-EW501 20.11.2017...
Page 7: 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 8: 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 9: 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 10 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 11 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 12 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 13: 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 14: 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 15: Machine Description - Quick Overview
Machine description – quick overview Tetrix 351 AC/DC AW Machine description – quick overview Tetrix 351 AC/DC AW 4.1.1 Front view Figure 4-1 Item Symbol Description Lifting lug Main switch, machine on/off Machine control > see 4.3 chapter Carrying handle 099-000115-EW501 20.11.2017...
Page 16 Machine description – quick overview Tetrix 351 AC/DC AW Item Symbol Description 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 Wheels, guide castors Coolant tank Coolant tank cap Connection socket, welding torch control cable >...
Page 17: Rear View
Machine description – quick overview Tetrix 351 AC/DC AW 4.1.2 Rear view Figure 4-2 Item Symbol Description Intermediate hose package strain relief Securing elements for shielding gas cylinder (strap/chain) Mains connection cable > see 5.3.2.3 chapter G¼” connecting nipple Shielding gas connection on the pressure regulator. Connector plug (TIG hot wire) Welding current, minus potential Connection socket for “+”...
Page 18 Machine description – quick overview Tetrix 351 AC/DC AW Item Symbol Description Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply hotWire Control lead connection, hot wire power source 4-pole connection to the hot wire power source Connection socket (28-pole) Control lead Key button, automatic cutout...
Page 19: Tetrix 451, 551 Ac/Dc Aw
Machine description – quick overview Tetrix 451, 551 AC/DC AW Tetrix 451, 551 AC/DC AW 4.2.1 Front view Figure 4-3 Item Symbol Description Lifting lug Main switch, machine on/off Machine control > see 4.3 chapter Carrying handle 099-000115-EW501 20.11.2017...
Page 20 Machine description – quick overview Tetrix 451, 551 AC/DC AW Item Symbol Description 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 Wheels, guide castors Coolant tank Coolant tank cap Connection socket, welding torch control cable >...
Page 21: Rear View
Machine description – quick overview Tetrix 451, 551 AC/DC AW 4.2.2 Rear view Figure 4-4 Item Symbol Description Intermediate hose package strain relief Securing elements for shielding gas cylinder (strap/chain) Mains connection cable > see 5.3.2.3 chapter G¼” connecting nipple Shielding gas connection on the pressure regulator.
Page 22 Machine description – quick overview Machine control – Operating elements Item Symbol Description Connection socket (TIG) Welding current, minus potential Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply hotWire Control lead connection, hot wire power source 4-pole connection to the hot wire power source Connection socket (28-pole) Control lead...
Page 23: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-5 Item Symbol Description Polarity changeover (TIG manual) button Select material type (TIG Synergic) key button DC welding with positive polarity on the Chrome/nickel alloys / iron / electrode holder in relation to the steel alloys workpiece (pole reversing switch, MMA...
Page 24 Machine description – quick overview Machine control – Operating elements Item Symbol Description Select seam type button ------- Fillet weld ------- Butt joint ------ Fillet weld - lap joint -------- Vertical-down Operating mode / Power-saving mode button -- spotArc / spotmatic (spot time setting range) --------- Non-latched ------ Latched Press for 3 s to put machine into power-saving mode.
Page 25: Function Sequence
Machine description – quick overview Machine control – Operating elements 4.3.1 Function sequence Figure 4-6 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. Gas pre-flow time signal light AMP% Signal light...
Page 26 Machine description – quick overview Machine control – Operating elements Item Symbol Description Welding current polarity, MMA AC/DC > see 5.9 chapter Signal light activArc > see 5.7.13 chapter 099-000115-EW501 20.11.2017...
Page 27: 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 28: 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 29: 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 30: 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 31: 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 32: 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 33: Mains Configuration
Design and function Transport and installation 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 34: Tig Cold Wire Welding
Design and function TIG cold wire welding TIG cold wire welding 5.2.1 Connection plan Tetrix drive 4L TIG 450 WD CW RT AW 1 hotwire Tetrix AW Figure 5-7 099-000115-EW501 20.11.2017...
Page 35: Legend
Design and function TIG cold wire welding 5.2.1.1 Legend Shielding gas Welding current(minus potential) Coolant input (marked in colour) Coolant output (marked in colour) Control lead (28-pole) Hose package (TP = tube package) Welding current (minus potential, TIG hot wire) Welding current (plus potential, workpiece) Control lead, hot wire (signal input, 4-pole) hotwire...
Page 36: Installation
Design and function TIG cold wire welding 5.2.2 Installation 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 37 Design and function TIG hot wire welding • Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right. • Push the cable plug for the welding current (TIG) onto the connection socket (TIG) and lock by turning to the right.
Page 38: Tig Hot Wire Welding
Design and function TIG hot wire welding TIG hot wire welding 5.3.1 Connection plan Tetrix drive 4L TIG 450W HW 12POL hotwire Tetrix Hotwire RT AW 1 hotwire Tetrix AW Figure 5-9 099-000115-EW501 20.11.2017...
Page 39: Legend
Design and function TIG hot wire welding 5.3.1.1 Legend Shielding gas Welding current(minus potential) Coolant input (marked in colour) Coolant output (marked in colour) Control lead (28-pole) Hose package (TP = tube package) Welding current (minus potential, TIG hot wire) Welding current (plus potential, workpiece) Control lead, hot wire (signal input, 4-pole) hotwire...
Page 40: Installation
Design and function TIG hot wire welding 5.3.2 Installation 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 41: Power Source For Hot Wire Welding
Design and function TIG hot wire welding 5.3.2.2 Power source for hot wire welding CAUTION Hazards due to improper mounting! In this system, the hot wire power source is positioned on the carrier platform of the mobile power source (filler wire). •...
Page 42: Mains Connection
Design and function TIG hot wire welding 5.3.2.3 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • For hot wire welding, this machine may only be connected to the primary power source (Tetrix series) via the connection intended for this power source.
Page 43: Intermediate Hose Package Connection
Design and function TIG hot wire welding 5.3.2.4 Intermediate hose package connection Figure 5-13 Item Symbol Description Wire feed unit Intermediate hose package Intermediate hose package strain relief Connection socket (28-pole) Control lead Connecting thread (G¼") Shielding gas Connector plug (TIG) Welding current, minus potential Quick connect coupling (red) coolant return...
Page 44: Welding Data Display
Design and function Welding data display • Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right. • Push the cable plug for the welding current (TIG) onto the connection socket (TIG) and lock by turning to the right.
Page 45: Configuring The Welding Machine For Mechanical Arc Fusion Welding
Design and function Configuring the welding machine for mechanical arc fusion welding Configuring the welding machine for mechanical arc fusion welding Before the welding machine is commissioned it has to be configured for mechanical arc fusion welding (cold or hot wire welding). The following basic settings are made in the Expert menu >...
Page 46: Operating Modes (Functional Sequences)
Design and function Configuring the welding machine for mechanical arc fusion welding 5.5.4 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 47: Non-Latched Mode
Design and function Configuring the welding machine for mechanical arc fusion welding 5.5.4.2 Non-latched mode Figure 5-15 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 48: 3-Cycle Operation
Design and function Configuring the welding machine for mechanical arc fusion welding 5.5.4.3 3-cycle operation Figure 5-16 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 current, until the welding process ends.
Page 49: Tig Welding
Design and function TIG welding TIG welding 5.6.1 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 50: 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 51: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function TIG welding 5.6.2 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 52: Tig Synergic Operating Principle
Design and function TIG Synergic operating principle TIG Synergic operating principle Figure 5-21 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 53: Synergic Parameter Setting In The Functional Sequence
Design and function TIG Synergic operating principle 5.7.1 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 54: Welding Task Selection
Design and function TIG Synergic operating principle 5.7.3 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 5-24 5.7.4...
Page 55: Gas Test
Design and function TIG Synergic operating principle 5.7.4.1 Gas test EXIT Figure 5-25 • Set the required shielding gas quantity at the pressure regulator. “Purge hose package” function 5.7.4.2 EXIT Figure 5-26 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! 099-000115-EW501 20.11.2017...
Page 56: Optimising The Ignition Characteristics For Pure Tungsten Electrodes
Design and function TIG Synergic operating principle 5.7.5 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 57: Ac Balance (Optimise Cleaning Effect And Penetration Characteristics)
Design and function TIG Synergic operating principle 5.7.7 AC balance (optimise cleaning effect and penetration characteristics) To weld aluminium and aluminium alloys, AC welding is used in combination with a continuous change in polarity of the tungsten electrode. The process encompasses two phases (half-waves): a positive and a negative one.
Page 58: Arc Ignition
Design and function TIG Synergic operating principle 5.7.9 Arc ignition 5.7.9.1 HF ignition Figure 5-31 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 59: Operating Modes (Functional Sequences)
Design and function TIG Synergic operating principle 5.7.10 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 60: Latched Mode
Design and function TIG Synergic operating principle Sequence Figure 5-34 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 61 Design and function TIG Synergic operating principle Sequence Figure 5-36 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 62: Spotarc
Design and function TIG Synergic operating principle 5.7.10.4 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 63: Spotmatic
Design and function TIG Synergic operating principle Figure 5-38 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 5.7.9.2 chapter. Sequence: • Press and hold torch trigger 1. •...
Page 64 Design and function TIG Synergic operating principle Figure 5-39 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 5.7.9.2 chapter. Selecting the process activation type for the welding process > see 5.17 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) only.
Page 65: Non-Latched Operation, Version C
Design and function TIG Synergic operating principle 5.7.10.6 Non-latched operation, version C Figure 5-40 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. •...
Page 66: Alternating Current Waveforms
Design and function TIG Synergic operating principle 5.7.10.7 Alternating current waveforms Figure 5-41 Waveform Description, areas of application Name Symbol Square Maximum energy input and safe welding (aluminium/magnesium alloys) Trapezoidal An all-rounder, suitable for most applications (aluminium/silicum alloys) Sine Low noise level (aluminium 99%) 099-000115-EW501 20.11.2017...
Page 67: Pulse Welding
Design and function TIG Synergic operating principle 5.7.11 Pulse welding The following pulse types can be selected: • Automated pulsing (TIG DC) • Thermal pulsing (TIG AC or TIG DC) • Metallurgical pulsing (TIG DC) • AC special (TIG AC) 5.7.11.1 Automated pulses The automated pulses are used with tacking and spot welding of workpieces in particular.
Page 68 Design and function TIG Synergic operating principle The pulse function can also be deactivated if necessary during the up-slope and down-slope phases (parameter ) > see 5.17 chapter. Figure 5-44 Selection Figure 5-45 099-000115-EW501 20.11.2017...
Page 69: Metallurgical Pulsing (Khz Pulsing)
Design and function TIG Synergic operating principle Pulse time setting Figure 5-46 Pulse pause setting Figure 5-47 Pulse edge setting pulse edges can be set in the Expert menu (TIG) > see 5.7.15 chapter. 5.7.11.3 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 70 Design and function TIG Synergic operating principle Selection Figure 5-49 Balance setting EXIT Figure 5-50 Frequency setting EXIT Figure 5-51 099-000115-EW501 20.11.2017...
Page 71: Ac Special
Design and function TIG Synergic operating principle 5.7.11.4 AC special Is e.g. used to join metal sheets of different thickness. Figure 5-52 Selection Figure 5-53 pulse edges can be set in the Expert menu (TIG) > see 5.7.15 chapter. 5.7.12 TIG antistick The function prevents uncontrolled re-ignition following the sticking of the tungsten electrode in the weld pool by switching off the welding current.
Page 72: Activarc
TIG Synergic operating principle 5.7.13 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.
Page 73: Synchronisation Via Cable (Frequency 50Hz To 200Hz)
Design and function TIG Synergic operating principle 5.7.14.2 Synchronisation via cable (frequency 50Hz to 200Hz) This application describes synchronisation (master/slave operation) with two machines in the Tetrix series. The following components are required: • The synchronisation interface SYNINT X10 • Control lead (connecting cable) of the relevant length •...
Page 74: Expert Menu (Tig)
Design and function TIG Synergic operating principle 5.7.15 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 5-57 Display Setting/selection Expert menu...
Page 75: 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 76 Design and function MMA welding Figure 5-58 Item Symbol Description Electrode holder Connection socket, “-” welding current Electrode holder connection Workpiece Connection socket, “+” welding current Connection for workpiece lead 099-000115-EW501 20.11.2017...
Page 77: Welding Task Selection
Design and function Welding current polarity reversal (polarity reversal) Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging. • Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right.
Page 78: Frequency And Balance Setting
Design and function Welding current polarity reversal (polarity reversal) 5.9.2 Frequency and balance setting Balance setting Figure 5-61 Frequency setting Figure 5-62 5.9.3 Hotstart The hot start function improves the arc striking. After striking the stick electrode, the arc ignites at the increased hot start current and decreases to the set main current once the hot start time has elapsed.
Page 79: Hotstart Current
Design and function Welding current polarity reversal (polarity reversal) 5.9.3.1 Hotstart current EXIT Figure 5-64 5.9.3.2 Hotstart time EXIT Figure 5-65 099-000115-EW501 20.11.2017...
Page 80: Arcforce
Design and function Welding current polarity reversal (polarity reversal) 5.9.4 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 81: Average Value Pulsing In The Vertical-Up Position (Pf)
Design and function Welding current polarity reversal (polarity reversal) 5.9.6 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 82 Design and function Organising welding tasks (Mode "JOB Manager") Pulse pause current setting Figure 5-71 Balance setting Figure 5-72 Frequency setting Figure 5-73 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 83: Organising Welding Tasks (Mode "Job Manager")
Design and function Organising welding tasks (Mode "JOB Manager") 5.10 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 84: Creating A New Job In The Memory Or Copying A Job
Design and function Organising welding tasks (Mode "JOB Manager") 5.10.2 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 85: Loading An Existing Job From The Free Memory
Design and function Organising welding tasks (Mode "JOB Manager") 5.10.3 Loading an existing JOB from the free memory EXIT Figure 5-75 5.10.4 Resetting an existing JOB to the factory setting (Reset JOB) Figure 5-76 099-000115-EW501 20.11.2017...
Page 86: Resetting Jobs 1-128 To The Factory Setting (Reset All Jobs)
Design and function Organising welding tasks (Mode "JOB Manager") 5.10.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs) Figure 5-77 5.10.6 Exit JOB Manager without changes EXIT Figure 5-78 099-000115-EW501 20.11.2017...
Page 87: Welding Programs
Design and function Welding programs 5.11 Welding programs Changes made to the other welding parameters during the course of the program have the equivalent effect on all programs. The change to the welding parameters is saved immediately in the JOB. The welding machine has 16 programs, which you can change during welding.
Page 88: Example "Program With Synergetic Setting
Design and function Remote control (only applies to the welding torch). According to the factory setting, all 16 programs can be called up. If necessary these can be limited to a specific number. To limit the number of programs, the welding current needs to be set to 0A for the next, unused program.
Page 89: Rtg1 19Pol
Design and function Remote control 5.12.2 RTG1 19POL Functions • Infinite setting of the welding current (0% to 100%) depending on the main current preselected at the welding machine 5.12.3 RTP1 19POL Functions • TIG/MMA • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine.
Page 90: Rtf Start Ramp
Design and function Remote control 5.12.8.1 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 91: Rtf Response
Design and function Remote control 5.12.8.2 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 92: Up/Down Speed
Design and function Remote control 5.12.9.3 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 93 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 94 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 95: Tig Up/Down Torch (8-Pole)
Design and function Remote control 5.12.9.6 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 96 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 97: Potentiometer Torch (8-Pole)
Design and function Remote control 5.12.9.7 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch > see 5.12.9.8 chapter. Potentiometer torch with one torch trigger Figure Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions Mode Operating...
Page 98: Configuring The Tig Potentiometer Torch Connection
Design and function Remote control 5.12.9.8 Configuring the TIG potentiometer torch connection DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed.
Page 99: Retox Tig Torch (12-Pole)
Design and function Remote control 5.12.9.9 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 100: Specifying Max. No. Of Accessible Jobs
Design and function Interfaces for automation 5.12.9.10 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 101: Automation Interface
Design and function Interfaces for automation 5.13.1 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 102: Remote Control Connection Socket, 19-Pole
Design and function Interfaces for automation 5.13.2 Remote control connection socket, 19-pole Figure 5-86 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 103: Pc Interface
Design and function PC interface 5.14 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 104: Access Control
Design and function Access control 5.16 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 105: Machine Configuration Menu
Design and function Machine configuration menu 5.17 Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.17.1 Selecting, changing and saving parameters ENTER EXIT NAVIGATION Figure 5-88 Display Setting/selection Exit the menu Exit 099-000115-EW501 20.11.2017...
Page 106 Design and function Machine configuration menu Display Setting/selection Torch configuration menu Set welding torch functions Torch mode (ex works 1) > see 5.12.9.2 chapter Alternative welding start – tapping start Available from torch mode 11 (welding stop by tapping remains active). ------- Function enabled (ex works) ------- Function disabled Up/down speed >...
Page 107 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 108 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 109 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 110: Aligning The Cable Resistance
Design and function Aligning the cable resistance 5.18 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 111 Design and function Aligning the cable resistance 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 112: 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 113: 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! 099-000115-EW501 20.11.2017...
Page 114: 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. 099-000115-EW501 20.11.2017...
Page 115: 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 116: 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 117: 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 118: 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 119: 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 7-1 099-000115-EW501...
Page 120: Technical Data
Technical data Tetrix 351 AC/DC AW Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 351 AC/DC AW 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 (60% DC) 350 A (60% DC) 300 A (100% DC)
Page 121: Tetrix 451 Ac/Dc Aw
Technical data Tetrix 451 AC/DC AW Tetrix 451 AC/DC AW 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 122: Tetrix 551 Ac/Dc Aw
Technical data Tetrix 551 AC/DC AW Tetrix 551 AC/DC AW 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 123: 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 124: Tetrix 451, 551 Ac/Dc
Accessories General accessories 9.3.2 Tetrix 451, 551 AC/DC Type Designation Item no. ON Filter Tetrix XL Retrofit option, dirt filter for air inlet 092-004999-00000 ON Holder Gas Bottle <50L Optional retrofit holding plate for gas cylinder <50l 092-002345-00000 TETRIX XL General accessories Type Designation...
Page 125: Job-List
Appendix A JOB-List Appendix A 10.1 JOB-List Process Material Wire Seam position  Reserved   CrNi/ Fe/ St   CrNi/ Fe/ St   CrNi/ Fe/ St       CrNi/ Fe/ St   ...
Page 126 Appendix A JOB-List Process Material Wire Seam position    Cu/CuZn >3,2   Cu/CuZn   Cu/CuZn   Cu/CuZn     Cu/CuZn     Cu/CuZn   Cu/CuZn >3,2   Cu/CuZn  ...
Page 127 Appendix A JOB-List Process Material Wire Seam position    AlSi     AlSi     AlSi     AlSi >3,2   AlSi   AlSi   AlSi    ...
Page 128 Appendix A JOB-List Process Material Wire Seam position      Al99 >3,2   Al99   Al99   Al99     Al99     Al99     Al99 >3,2 TIG manual/TIG classic Classic electrode Reserved...
Page 129: 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 130: Overview Of Ewm Branches
Appendix C Overview of EWM branches Appendix C 12.1 Overview of EWM branches 099-000115-EW501 20.11.2017...

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