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EWM HIGHTEC WELDING TETRIX 301 COMFORT activArc Operating Instructions Manual

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Operating instructions
Welding machines for TIG and MMA welding
TETRIX 301, 351, 421, 521 COMFORT activArc
N. B. These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machines may only be operated by personnel who are familiar with the appropriate safety
regulations.
The machines bear the conformity mark and thus comply with the
•
EC Low Voltage Directive (2006/95/ EG)
•
EC EMC Directive (2004/108/ EG)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.
The content of the operating instructions does not constitute grounds for any claims on the part
©
of the buyer.
The copyright to these operating instructions remains with the manufacturer.
Reprinting, including extracts, only with written approval.
© 2009
Subject to alteration.
Dr. Günter-Henle-Straße 8 • D-56271 Mündersbach
Fon +49 2680 181-0 • Fax +49 2680 181-244
Item No.: 099-000089-EWM01
HIGHTEC WELDING GmbH
www.ewm.de
•
info@ewm.de
Revised: 14.09.2009
EWM

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Summary of Contents for EWM HIGHTEC WELDING TETRIX 301 COMFORT activArc

  • Page 1 HIGHTEC WELDING GmbH Dr. Günter-Henle-Straße 8 • D-56271 Mündersbach Fon +49 2680 181-0 • Fax +49 2680 181-244 www.ewm.de • info@ewm.de Operating instructions Welding machines for TIG and MMA welding TETRIX 301, 351, 421, 521 COMFORT activArc N. B. These operating instructions must be read before commissioning. Failure to do so may be dangerous.
  • Page 2 Thank you for the trust that you have placed in us. We look forward to a long-term and, above all, successful partnership with you. Yours faithfully EWM HIGHTEC WELDING GmbH Bernd Szczesny Executive management...
  • Page 3 Machine and Company Data Please enter the EWM machine data and your company’s data in the appropriate fields. EWM HIGHTEC WELDING GMBH D-56271 MÜNDERSBACH TYP: SNR: ART: PROJ: GEPRÜFT/CONTROL: Name of Customer / company Name of Customer / company Adress...

  • Page 4: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................4 2 Safety instructions ..........................7 Notes on the use of these operating instructions................7 General............................9 Transport and installation......................12 2.3.1 Lifting by crane ......................13 Ambient conditions........................14 2.4.1 In operation........................14 2.4.2 Transport and storage ....................14 3 Technical data............................15 TETRIX 301-521 ..........................15...
  • Page 5 Contents Notes on the use of these operating instructions 5.3.2 Hotstart ......................... 46 5.3.2.1 Hotstart current ..................... 46 5.3.2.2 Hotstart time....................47 5.3.3 Arcforce ........................47 5.3.4 Antistick ........................47 Key switch............................ 47 Remote control..........................48 5.5.1 Manual remote control RT 1..................48 5.5.2 Manual remote control RTP 1 ..................48 5.5.3...
  • Page 6 Contents Notes on the use of these operating instructions 7.3.7 Measurement of protective conductor resistance............75 7.3.8 Functional test of the welding machine ................75 7.3.9 Documentation of the test.....................75 Repair Work ..........................76 Disposing of equipment........................77 7.5.1 Manufacturer's declaration to the end user ..............77 Meeting the requirements of RoHS....................77 8 Warranty ..............................78 General Validity..........................78...

  • Page 7: Safety Instructions

    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. •...
  • Page 8 Safety instructions Notes on the use of these operating instructions Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet points, e.g.: • Insert the welding current lead socket into the relevant socket and lock. Symbol Description Press Do not press...

  • Page 9: General

    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! •...
  • Page 10 Safety instructions General WARNING Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
  • Page 11 Safety instructions General CAUTION Obligations of the operator! In the European Economic Area (EEA), the relevant national version of the basic guidelines must be followed and observed! • National version of the basic guidelines (89/391/EEC) as well as the relevant individual guidelines.

  • Page 12: Transport And Installation

    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! •...

  • Page 13: Lifting By Crane

    Safety instructions Transport and installation 2.3.1 Lifting by crane DANGER Risk of injury during lifting by crane! When lifting the equipment by crane, serious injuries can be inflicted by falling equipment or add-on units. • Transport on all lifting lugs at the same time (see Fig.

  • Page 14: Ambient Conditions

    Safety instructions Ambient conditions Ambient conditions CAUTION Equipment damage due to dirt accumulation! Unusually high quantities of dust, acid, corrosive gases or substances may damage the equipment. • Avoid high volumes of smoke, vapour, oil vapour and grinding dust! • Avoid ambient air containing salt (sea air)! Non-permissible ambient conditions! Insufficient ventilation results in a reduction in performance and equipment damage.

  • Page 15: Technical Data

    Technical data TETRIX 301-521 Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! TETRIX 301-521 TETRIX Setting ranges Welding current 5 A to 300 A 5 A to 350 A 5 A to 420 A 5 A to 520 A Welding voltage (TIG) 10.2 to 22.0 V...

  • Page 16: Machine Description

    Machine description TETRIX 301-521 Machine description 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). TETRIX 301-521 4.1.1 Front view Figure 4-1 Item No.: 099-000089-EWM01...
  • Page 17 Machine description TETRIX 301-521 Item Symbol Description Lifting lug Main switch, machine on/off Machine control See Machine control – operating elements chapter Carrying handle Connection socket, 8-pole / 12-pole 8-pole: TIG Up/Down or potentiometer torch control lead 12-pole: Control lead for TIG up/down torch with LED display (option) Key switch for protection against unauthorised use Position “1”...

  • Page 18: Rear View

    Machine description TETRIX 301-521 4.1.2 Rear view Figure 4-2 Item No.: 099-000089-EWM01...
  • Page 19 Machine description TETRIX 301-521 Item Symbol Description 7-pole connection socket (digital) Wire feed unit connection 7-pole connection socket (digital) For connecting digital accessory components (documentation interface, robot interface digital or remote control, etc.). PC interface, serial (D-SUB connection socket, 9-pole) Automation interface, 19-pole (analogue) (see Function Specification chapter) analog...

  • Page 20: Machine Control - Operating Elements

    Machine description Machine control – Operating elements Machine control – Operating elements NOTE Machine control provides the user with up to 8 welding tasks (JOBs). JOB 0 represents manual operating mode. This is where you can change/optimise all parameters directly in machine control (see chapter "Operating concepts"). COMFORT T 3.24 Puls...
  • Page 21 Machine description Machine control – Operating elements Item Symbol Description Welding parameter setting rotary dial Setting all parameters such as ignition, welding, end current, gas pre-flow and gas post-flow times, pulse edges, etc. Three-figure LED display Welding parameter display (see also chap. “Welding data display”). Error/status indicators Collective interference signal light (see Operating problems chapter) Water deficiency signal light (welding torch cooling)

  • Page 22: Function Sequence

    Machine description Machine control – Operating elements 4.2.1.1 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. Gas pre-flow time (TIG), absolute setting range 0.0 sec to 20.0 sec (0.1s increments). Ignition current (TIG) Hotstart current (MMA) AMP%...
  • Page 23 Machine description Machine control – Operating elements Item Symbol Description Secondary current (TIG) / pulse pause current AMP% Setting range 1 % to 100 % (1 % increments). Percentage of the main current. Down-slope time (TIG) 0.00 sec to 20.0 sec (0.1 sec increments). The down-slope time can be set separately for non-latched and latched.

  • Page 24: Functional Characteristics

    Functional characteristics Operating concepts Functional characteristics NOTE Machine control provides the user with up to 8 welding tasks (JOBs). JOB 0 represents manual operating mode. This is where you can change/optimise all parameters directly in machine control (see chapter "Operating concepts"). Operating concepts The welding task (JOB) can be selected in two ways: •...

  • Page 25: Save Welding Tasks (Jobs)

    Functional characteristics Operating concepts 5.1.2 Save welding tasks (JOBs) You can select, change and save the required welding parameters for recurring welding tasks (JOBs) in up to 7 JOBs (JOB 1 to JOB 7). 5.1.2.1 Displaying and changing the JOB number Operating Action Result...

  • Page 26: Tig Welding

    Functional characteristics TIG welding TIG welding 5.2.1 Arc ignition 5.2.1.1 HF ignition Figure 5-1 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 27: Function Sequences/Operating Modes

    Functional characteristics TIG welding 5.2.3 Function sequences/operating modes The "Select welding parameter" button and the "Welding parameter setting" rotary transducer can be used to control all the parameters for the TIG process: Figure 5-3 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.

  • Page 28: Non-Latched Mode

    Functional characteristics TIG welding 5.2.3.2 Non-latched mode Figure 5-4 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 •...

  • Page 29: Latched Mode

    Functional characteristics TIG welding 5.2.3.3 Latched mode AMP% start Down Figure 5-5 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).

  • Page 30: Spotarc

    Functional characteristics TIG welding 5.2.3.4 SpotArc The TIG SpotArc function is activated with the pulse variant automated frequencies by default, because this combination produces the most effective results. The user can of course combine the function with other pulse variants depending on the selected welding process. Pulse time (t1) and pulse break time (t2) can be set independently, but the spot time (tP) should be much greater than the pulse time in order to achieve an appropriate result.
  • Page 31 Functional characteristics TIG welding Figure 5-6 Sequence: • 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 •...

  • Page 32: Non-Latched Operation, Version C

    Functional characteristics TIG welding 5.2.3.5 Non-latched operation, version C Figure 5-7 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).

  • Page 33: Pulses, Function Sequences

    Functional characteristics TIG welding 5.2.4 Pulses, function sequences NOTE The function sequences in pulses basically behave in the same way as in standard welding, but during the main current phase there is a continual switching back and forth between the pulse and pause currents at the relevant times. 5.2.4.1 Non-latched mode Figure 5-8...

  • Page 34: Pulse Variants

    Functional characteristics TIG welding 5.2.5 Pulse variants 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). 5.2.5.1 Pulses (thermal pulses) With thermal pulses, the pulse and pause times (frequency up to 200 Hz) and the pulse edges (ts1 and ts2) are entered in seconds on the control.

  • Page 35: Khz Pulses (Metallurgic Pulses)

    Functional characteristics TIG welding 5.2.5.2 KHz pulses (metallurgic pulses) The kHz pulses (metallurgic pulses) use the plasma pressure produced at high currents (arc pressure) which is used to achieve a constricted arc with concentrated heat feeding. The frequency can be infinitely adjusted from 50 Hz to 15 kHz and the pulse balance from 1-99 %.

  • Page 36: Tig Activarc Welding

    Functional characteristics TIG welding 5.2.6 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.

  • Page 37: Welding Torch (Operating Variants)

    Functional characteristics TIG welding 5.2.8 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...

  • Page 38: Torch Mode And Up/Down Speed Setting

    Functional characteristics TIG welding 5.2.9 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.

  • Page 39: Standard Tig Torch (5-Pole)

    Functional characteristics TIG welding 5.2.9.1 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 BRT 1 Welding current On/Off (factory-set) BRT 1...
  • Page 40 Functional characteristics 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 BRT 1 Welding current On/Off Secondary current BRT 2 (factory-set)

  • Page 41: Tig Up/Down Torch (8-Pole)

    Functional characteristics TIG welding 5.2.9.2 TIG up/down torch (8-pole) Up/down torch with one torch trigger Diagram Operating Explanation of symbols elements TT 1 = torch trigger 1 Functions Mode Operating elements BRT 1 Welding current on/off BRT 1 Secondary current (tapping mode) / (Latched mode) (factory- set) Increase welding current, infinite adjustment (up function)
  • Page 42 Functional characteristics TIG welding Up/down torch with two torch triggers Diagram Operating Explanation of symbols elements TT 1 = torch trigger 1 (left) TT 2 = torch trigger 2 (right) Functions Mode Operating elements BRT 1 Welding current on/off BRT 2 Secondary current BRT 1 (factory-...

  • Page 43: Potentiometer Torch (8-Pole)

    Functional characteristics TIG welding 5.2.9.3 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 Mode...

  • Page 44: Retox Tig Torch (12-Pole)

    Functional characteristics TIG welding 5.2.9.4 RETOX TIG torch (12-pole) NOTE 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 BRT 1 BRT 3...

  • Page 45: 5.2.10 Setting The First Increment

    Functional characteristics TIG welding 5.2.10 Setting the first increment Figure 5-13 Figure 5-14 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! Item No.: 099-000089-EWM01...

  • Page 46: Mma Welding

    Functional characteristics MMA welding MMA welding 5.3.1 Selection and adjustment Operating Action Result Displays element Select MMA welding process Display shows the last current value signal light lights up in green used for welding. Set welding current Welding current is displayed.

  • Page 47: Hotstart Time

    Functional characteristics Key switch 5.3.2.2 Hotstart time Operating Action Result Displays element Select hotstart time welding parameter Press until hotstart time light comes on Set hotstart time 5.3.3 Arcforce Shortly before the electrode threatens to stick, the arcforcing device sets an increased current designed to prevent the electrode sticking.

  • Page 48: Remote Control

    Functional characteristics Remote control Remote control NOTE The remote control is operated on the 19-pole remote control connection socket. • If required, extension cables are available in different lengths (see chapter Accessories). • Plug the remote control unit into the remote control connection socket on the welding machine or wire feed unit and lock it only when the machine is switched off.

  • Page 49: Foot-Operated Remote Control Rtf 1

    Functional characteristics Remote control 5.5.5 Foot-operated remote control RTF 1 Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. • Start/stop welding operation ActivArc welding is not possible in combination with the RTF 1 foot-operated remote control. FFr >...

  • Page 50: Interfaces For Automation

    Functional characteristics Interfaces for automation Interfaces for automation CAUTION Damage to the machine due to improper connection! Unsuitable control leads or incorrect connection of input and output signals can cause damage to the machine. • Only use shielded control leads! •...

  • Page 51: Remote Control Connection Socket, 19-Pole

    Functional characteristics Interfaces for automation 5.6.2 Remote control connection socket, 19-pole I>0 0-10V 10-100K 10-100K 0-10V +15V (max. 75mA) -15V (max. 25mA) START / STOP AMP / AMP% (PULS) (1V=100A) SOLL Figure 5-16 Pos. Signal shape Designation Output Connection for cable screen (PE) Output Current flows signal I>0, galvanically isolated (max.

  • Page 52: Advanced Settings

    Functional characteristics Advanced settings Advanced settings 5.7.1 Setting slope times for secondary current AMP% or pulse edges Figure 5-17 Figure 5-18 Display Setting/selection Expert menu Slope time tS1 (main current to secondary current) Setting: 0.00 s to 20.0 s (factory setting 0.01 s) Slope time tS2 (secondary current to main current) Setting: 0.00 s to 20.0 s (factory setting 0.01 s) Item No.: 099-000089-EWM01...

  • Page 53: Tig Non-Latched Operating Mode, C Version

    Functional characteristics Advanced settings 5.7.2 TIG non-latched operating mode, C version Figure 5-19 Display Setting/selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display Non-latched operation (C version) • on = on • off = off (factory setting) Item No.: 099-000089-EWM01...

  • Page 54: Configuring The Tig Potentiometer Torch Connection

    Functional characteristics Advanced settings 5.7.3 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 two minutes after the mains plug is removed.

  • Page 55: Welding Current Display (Ignition, Secondary, End And Hotstart Currents)

    Functional characteristics Advanced settings 5.7.4 Welding current display (ignition, secondary, end and hotstart currents) The welding currents for secondary current, ignition current and end current (expert menu) can be displayed as percentages (factory setting) or absolute values on the machine display. Figure 5-21 Display Setting/selection...

  • Page 56: Ramp Function Foot-Operated Remote Control Rtf 1

    Functional characteristics Advanced settings 5.7.5 Ramp function foot-operated remote control RTF 1 Figure 5-22 Display Setting/selection Exit the menu Exit Machine configuration 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 Switch off...

  • Page 57: Menus And Sub-Menus On The Machine Control

    Functional characteristics Menus and sub-menus on the machine control Menus and sub-menus on the machine control 5.8.1 Direct menus (direct access to parameters) Functions, parameters and their values can be accessed directly, e.g. can be selected by pressing a button once. 5.8.2 Expert menu (TIG) The expert menu includes functions and parameters which are either not set on the machine control, or...

  • Page 58: Machine Configuration Menu

    Functional characteristics Menus and sub-menus on the machine control 5.8.3 Machine configuration menu Figure 5-24 NOTE ENTER (enter the menu) • Switch off machine at the main switch • Press and hold the "welding parameters" button and switch the machine on again at the same time.
  • Page 59 Functional characteristics Menus and sub-menus on the machine control Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode • Modes 1-6: with tapping function (factory setting 1) • Modes 11-16: without tapping function Setting the first increment Setting: 1 to 20 (factory setting 1) Up-/Down speed (not available in modes 4 and 14) Increase value...
  • Page 60 Functional characteristics Menus and sub-menus on the machine control Display Setting/selection Error output to mechanised welding interface, contact SYN_A • on = function on • off = function off (factory setting) Software version query (example) System bus ID 02c0= Version number System bus ID and version number are separated by a dot.

  • Page 61: Commissioning

    Commissioning General Commissioning General DANGER 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! •...

  • Page 62: Area Of Application - Proper Usage

    Commissioning Area of application – proper usage Area of application – proper usage WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! •...

  • Page 63: Mains Connection

    Commissioning 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 (any phase sequence for three-phase machines)! •...

  • Page 64: Welding Torch Cooling System

    Commissioning Welding torch cooling system Welding torch cooling system 6.7.1 General 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). •...

  • Page 65: Adding Coolant

    Commissioning Welding torch cooling system 6.7.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. NOTE After the initial filling, wait for at least one minute when the machine is switched on so that the tube package is filled with coolant completely and without bubbles. With frequent changes of torch and during the initial filling process, the cooling unit tank should be topped up as necessary.

  • Page 66: Tig Welding

    Commissioning TIG welding TIG welding 6.8.1 Welding torch connection The TIG welding torch is to be equipped to suit the relevant welding task! • Fit suitable tungsten electrodes and • an appropriate shielding gas nozzle. • Observe the operating instructions for the TIG welding torch! Figure 6-3 Item Symbol Description...

  • Page 67: Connection For Workpiece Lead

    Commissioning TIG welding • Insert the welding current plug on the welding torch into the welding current connection socket and lock by turning to the right. • Screw welding torch shielding gas connection tightly onto the G¼" connection nipple, welding current “-”.

  • Page 68: Connecting The Shielding Gas Supply

    Commissioning TIG welding 6.8.4.1 Connecting the shielding gas supply Figure 6-5 Item Symbol Description Pressure reducer Shielding gas cylinder Output side of the pressure reducer Cylinder valve • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. NOTE Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to expel any dirt.

  • Page 69: Setting The Shielding Gas Quantity

    Commissioning MMA welding 6.8.4.2 Setting the shielding gas quantity CAUTION Electric shocks! When setting the shielding gas quantity, high voltage ignition pulses or open circuit voltage are applied at the welding torch; these can lead to electric shocks and burning on contact.

  • Page 70: Connecting The Electrode Holder And Workpiece Lead

    Commissioning MMA welding 6.9.1 Connecting the electrode holder and workpiece lead Figure 6-6 Item Symbol Description G¼” connecting nipple, “-” welding current Shielding gas connection (with yellow insulating cap) for TIG welding torch Connection socket, “-” welding current Electrode holder connection Connection socket, “+”...

  • Page 71: Pc Interface

    Commissioning PC interface 6.10 PC interface 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. •...

  • Page 72: Maintenance And Testing

    Maintenance and testing General Maintenance and testing NOTE The maintenance, cleaning and testing work described below must be conducted correctly and on an annual basis in order qualify for claims under the EWM warranty. General When used in the specified environmental conditions and under normal operating conditions, this machine is largely maintenance-free and requires a minimum of care.

  • Page 73: Test

    Maintenance and testing Test Test NOTE Additional machines and add-on parts (e.g. cooling units, wire feed devices, welding torches,...) should be tested together with the welding power source. Some points, such as: insulation and protective conductor resistance, can be tested directly at the same time and it can be ensured that the total leakage current from the welding power source, additional machines and add-on parts does not exceed the limits.

  • Page 74: Scope Of The Test

    Maintenance and testing Test 7.3.2 Scope of the test a) Visual inspection b) Electrical test: measurement of • open circuit voltage • insulation resistance, or alternatively • leakage currents • protective conductor resistance c) Functional test d) Documentation 7.3.3 Visual inspection The key areas in the test are: 1.

  • Page 75: Measuring The Leakage Current (Protective Conductor And Contact Current)

    Maintenance and testing Test 7.3.6 Measuring the leakage current (protective conductor and contact current) Note: Even if the leakage current measurement according to the standard is only an alternative to the insulation resistance measurement, EWM recommends always performing both measurements, especially following repair work.

  • Page 76: Repair Work

    Maintenance and testing Repair Work Repair Work Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine. Return deliveries of defective equipment subject to warranty may only be made through your dealer.

  • Page 77: Disposing Of Equipment

    In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM HIGHTEC Welding GmbH 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).

  • Page 78: Warranty

    Warranty General Validity Warranty General Validity 3-year warranty on all new EWM machines*: • Power sources • Wire feeds • Cooling units • Trolleys * If these are operated with genuine EWM accessories (such as intermediate tube package, remote control, remote control extension cable, coolant, etc.). 1-year warranty on: •...

  • Page 79: Warranty Declaration

    Warranty Warranty Declaration Warranty Declaration Your 3-year warranty Regardless of statutory warranty rights and based on our General Terms and Conditions, EWM HIGHTEC WELDING GmbH provides a 3-year warranty for its welding products starting on the date of purchase. Different warranty periods apply to accessories and spare parts; please see the “General Validity”...

  • Page 80: Operating Problems, Causes And Remedies

    Operating problems, causes and remedies Error messages (power source) Operating problems, causes and remedies All machines are subject to rigorous production checks and final checks. If despite this, anything fails to work at any time, please check the machine using the following chart. If none of the fault rectification procedures described leads to the correct functioning of the machine, please inform your authorised dealer.

  • Page 81: Resetting Welding Parameters To The Factory Settings

    Operating problems, causes and remedies 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. Figure 9-1 Display Setting/selection Exit the menu Exit Service menu Modifications to the service menu may only be carried out by authorised maintenance...

  • Page 82: Display Machine Control Software Version

    Operating problems, causes and remedies 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! Figure 9-2 Display Setting/selection Exit the menu Exit Service menu Modifications to the service menu may only be carried out by authorised maintenance staff! Software version query (example)

  • Page 83: General Operating Problems

    Operating problems, causes and remedies General operating problems General operating problems Problem Possible cause > remedy Machine control without displaying the signal • Phase failure > check mains connection (fuses) lights after switching on no welding performance • Phase failure > check mains connection (fuses) various parameters cannot be set •...

  • Page 84: Accessories, Options

    Accessories, options Welding torch, electrode holder and workpiece lead Accessories, options 10.1 Welding torch, electrode holder and workpiece lead 10.1.1 TETRIX 301 Type Designation Item no. TIG 260 WD 4M 5P 2T TIG welding torch, 4m, water-cooled, double 094-010990-00600 pressure TIG 260 WD 4M 8P 2T UD TIG welding torch, 4m, water-cooled, double 094-010989-00000...

  • Page 85: Options

    Accessories, options Options 10.3 Options Type Designation Item no. ON 7POL Optional 7-pole retrofit connection socket 092-001826-00000 Accessory components and digital interfaces ON 19POL 500 Optional 19-pole retrofit connection socket 092-001951-00000 Accessory components and analogue A interface ON 12POL RETOX TIG Optional 12-pole retrofit connection socket 092-001807-00000 ON FILTER T/P...

  • Page 86: Circuit Diagrams

    Circuit diagrams TETRIX 301 COMFORT Circuit diagrams NOTE Original format circuit diagrams are located inside the machine. 11.1 TETRIX 301 COMFORT Figure 11-1 Item No.: 099-000089-EWM01...
  • Page 87 Circuit diagrams TETRIX 301 COMFORT Figure 11-2 Item No.: 099-000089-EWM01...
  • Page 88 Circuit diagrams TETRIX 301 COMFORT Figure 11-3 Item No.: 099-000089-EWM01...

  • Page 89: Tetrix 351 Comfort

    Circuit diagrams TETRIX 351 COMFORT 11.2 TETRIX 351 COMFORT Figure 11-4 Item No.: 099-000089-EWM01...
  • Page 90 Circuit diagrams TETRIX 351 COMFORT Figure 11-5 Item No.: 099-000089-EWM01...
  • Page 91 Circuit diagrams TETRIX 351 COMFORT Figure 11-6 Item No.: 099-000089-EWM01...

  • Page 92: Tetrix 421 Comfort

    Circuit diagrams TETRIX 421 COMFORT 11.3 TETRIX 421 COMFORT Figure 11-7 Item No.: 099-000089-EWM01...
  • Page 93 Circuit diagrams TETRIX 421 COMFORT Figure 11-8 Item No.: 099-000089-EWM01...
  • Page 94 Circuit diagrams TETRIX 421 COMFORT Figure 11-9 Item No.: 099-000089-EWM01...

  • Page 95: Tetrix 521 Comfort

    Circuit diagrams TETRIX 521 COMFORT 11.4 TETRIX 521 COMFORT Figure 11-10 Item No.: 099-000089-EWM01...
  • Page 96 Circuit diagrams TETRIX 521 COMFORT Figure 11-11 Item No.: 099-000089-EWM01...
  • Page 97 Circuit diagrams TETRIX 521 COMFORT Figure 11-12 Item No.: 099-000089-EWM01...

  • Page 98: Declaration Of Conformity

    Declaration of Conformity EG - Konformitätserklärung EC – Declaration of Conformity Déclaration de Conformité CE Name des Herstellers: EWM HIGHTEC WELDING GmbH Name of manufacturer: (nachfolgend EWM genannt) Nom du fabricant: (In the following called EWM) (nommé par la suite EWM) Anschrift des Herstellers: Dr.- Günter - Henle - Straße 8...

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