EWM T4.07 Operating Instructions Manual
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EWM T4.07 Operating Instructions Manual

EWM T4.07 Operating Instructions Manual

Tetrix dc smart 2.0 (tetrix 230)
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Operating instructions
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T4.07 - Tetrix DC Smart 2.0 (Tetrix 230)
EN
099-00T407-EW501
Observe additional system documents!
14.07.2020

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Summary of Contents for EWM T4.07

  • Page 1 Operating instructions Control T4.07 - Tetrix DC Smart 2.0 (Tetrix 230) 099-00T407-EW501 Observe additional system documents! 14.07.2020...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.

  • Page 3: Table Of Contents

    Contents Notes on using these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................5 Notes on using these operating instructions .................. 5 Explanation of icons ........................5 Part of the complete documentation ....................6 3 Intended use ............................7 Use and operation solely with the following machines ..............
  • Page 4 Contents Notes on using these operating instructions Voltage reducing device ....................... 37 Machine configuration menu ......................38 5.6.1 Selecting, changing and saving parameters..............38 6 Rectifying faults ............................ 41 Error messages (power source) ....................41 Dynamic power adjustment ......................42 Resetting welding parameters to the factory settings ..............

  • Page 5: For Your Safety

    For your safety Notes on using these operating instructions For your safety Notes on using these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •...

  • Page 6: Part Of The Complete Documentation

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

  • Page 7: Intended Use

    • Do not improperly modify or convert the equipment! Use and operation solely with the following machines • Tetrix 230 Smart 2.0 (T4.07) Documents which also apply • Operating instructions for the connected welding machines • Documents of the optional expansions...

  • Page 8: Machine Control - Operating Elements

    Machine control – Operating elements Overview of control sections Machine control – Operating elements Overview of control sections For description purposes, the machine control has been divided into two sections (A, B) to ensure maximum clarity. The setting ranges for the parameter values are summarised in the parameter overview section >...

  • Page 9: Control Section A

    Machine control – Operating elements Overview of control sections 4.1.1 Control section A Figure 4-2 Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values > see 4.2 chapter Gas test push-button > see 5.1.1 chapter Operating mode >...
  • Page 10 Machine control – Operating elements Overview of control sections Item Symbol Description Voltage reduction device (VRD) signal light > see 5.5 chapter Signal light Status display Hold After each completed welding task, the last values used in the welding process for the welding current and welding voltage are shown on the displays, and the signal light will be on Excess temperature signal light...

  • Page 11: Control Section B

    Machine control – Operating elements Overview of control sections 4.1.2 Control section B Figure 4-3 Item Symbol Description Parameter selection push-button, left The welding sequence parameters are selected one after another in an anti-clockwise direction. For control systems without this button settings are done exclusively via the control button.

  • Page 12: Machine Display

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

  • Page 13: Setting Advanced Welding Parameters (Expert Menu)

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

  • Page 14: Functional Characteristics

    Functional characteristics TIG welding Functional characteristics TIG welding 5.1.1 Gas test – setting the shielding gas volume • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. • Set the relevant gas quantity for the application on the pressure regulator.

  • Page 15: Welding Task Selection

    Functional characteristics TIG welding 5.1.2 Welding task selection The setting of the tungsten electrode diameter has a direct influence on the machine functionality, TIG ig- nition behaviour and minimum current limits. The ignition energy is controlled by the set electrode diame- ter.

  • Page 16: Arc Ignition

    Functional characteristics TIG welding 5.1.3 Arc ignition To change the ignition type, use parameter to switch between HF start ( ) and lift arc ( ) in the Expert menu > see 5.1.8 chapter. 5.1.3.1 HF ignition Figure 5-2 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 17: Operating Modes (Functional Sequences)

    Functional characteristics TIG welding 5.1.4 Operating modes (functional sequences) 5.1.4.1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 Current Time Gas pre-flow Ignition current Up-slope time Spot time Main current (minimum to maximum current) Secondary current AMP% Pulse current Down-slope time...

  • Page 18: Non-Latched Mode

    Functional characteristics TIG welding 5.1.4.2 Non-latched mode Selection Figure 5-4 Sequence Figure 5-5 1st cycle: • Press torch trigger 1 and hold down. • Gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece. The arc ignites. •...

  • Page 19: Latched Mode

    Functional characteristics TIG welding 5.1.4.3 Latched mode Selection Figure 5-6 Sequence Figure 5-7 099-00T407-EW501 14.07.2020...

  • Page 20: Spotarc

    Functional characteristics TIG welding cycle • Press torch trigger 1; gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece. The arc ignites. • Welding current flows and immediately assumes the set ignition current (search arc at minimum setting).
  • Page 21 Functional characteristics TIG welding Figure 5-9 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.1.3 chapter. Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. •...

  • Page 22: Spotmatic

    Functional characteristics TIG welding 5.1.4.5 spotmatic In contrast to the spotArc operating mode, the arc is not ignited by pressing the torch trigger as is usual, but by briefly touching the tungsten electrode against the workpiece. The torch trigger is used for welding process activation.

  • Page 23: Average Value Pulse Welding

    Functional characteristics TIG welding As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.1.3 chapter. Selecting the process activation type for the welding process > see 5.6 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) only.
  • Page 24 Functional characteristics TIG welding Pulse current Figure 5-14 Pulse balance Figure 5-15 Pulse frequency Figure 5-16 099-00T407-EW501 14.07.2020...

  • Page 25: Pulsed Welding In The Upslope And Downslope Phases

    5.1.5 TIG activArc welding The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power sup- plied is kept virtually constant in the event of changes in the distance between the welding torch and the weld pool, e.g. during manual welding. Voltage losses as a result of a shortening of the distance between the torch and molten pool are compensated by a current rise (ampere per volt - A/V), and vice versa.

  • Page 26: Tig Antistick

    Functional characteristics TIG welding 5.1.6 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. In addition, wear at the tungsten electrode is reduced. After triggering the function the machine immediately switches to the gas post-flow process phase. The welder starts the new process again at the first cycle.

  • Page 27: Standard Tig Torch (5-Pole)

    Functional characteristics TIG welding 5.1.7.5 Standard TIG torch (5-pole) Standard torch with one torch trigger Operating ele- Figure Explanation of symbols ments BRT1 = torch trigger 1 (welding current on/off; secondary cur- rent via tapping function) Functions Mode Operating ele- ments Welding current on/off (ex works)
  • Page 28 Functional characteristics TIG welding Standard torch with one rocker (rocker, two torch triggers) Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Operating ele- Functions Mode ments Welding current on/off Secondary current (ex works) Secondary current (tapping function)

  • Page 29: Tig Up/Down Torch (8-Pole)

    Functional characteristics TIG welding 5.1.7.6 TIG up/down torch (8-pole) Up/down torch with one torch trigger Operating ele- Figure Explanation of symbols ments BRT 1 = torch trigger 1 Operating ele- Functions Mode ments Welding current on/off Secondary current (tapping function) )/(latched operating mode) (ex works) Increase welding current (up function...
  • Page 30 Functional characteristics TIG welding Up/down torch with two torch triggers Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 (left) BRT 2 = torch trigger 2 (right) Functions Mode Operating ele- ments Welding current on/off Secondary current Secondary current (tapping function) )/(latched operating mode) (ex works)

  • Page 31: Potentiometer Torch (8-Pole)

    Functional characteristics TIG welding 5.1.7.7 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch > see 5.1.7.8 chapter. Potentiometer torch with one torch trigger Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 Operating ele- Functions Mode...

  • Page 32: Configuring The Tig Potentiometer Torch Connection

    Functional characteristics TIG welding 5.1.7.8 Configuring the TIG potentiometer torch connection DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed.

  • Page 33: Expert Menu (Tig)

    Functional characteristics TIG welding 5.1.8 Expert menu (TIG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa- rameters shown may be limited, e.g. if a function is deactivated. ENTER EXIT Figure 5-20 Display Setting/selection Expert menu Ignition type (TIG)

  • Page 34: Mma Welding

    Functional characteristics MMA welding MMA welding 5.2.1 Welding task selection It is only possible to change the basic parameters when no welding current is flowing and any possible access control is disabled > see 5.4 chapter. The following welding task selection is an example of use. In general, the selection process always has the same sequence.

  • Page 35: Average Value Pulse Welding

    Functional characteristics MMA welding 5.2.4 Average value pulse welding Average value pulse welding means that two currents are switched periodically, a current average value (AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the rameter as a percentage of the current average value (AMP).

  • Page 36: Expert Menu (Mma)

    Functional characteristics MMA welding Pulse balance Figure 5-27 Pulse frequency Figure 5-28 5.2.5 Expert menu (MMA) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa- rameters shown may be limited, e.g. if a function is deactivated. The setting ranges for the parameter values are summarised in the Parameter overview sec- tion >...

  • Page 37: Power-Saving Mode (Standby)

    Functional characteristics Power-saving mode (Standby) Display Setting/selection Hotstart current Hotstart time Power-saving mode (Standby) You can activate the power-saving mode by either pressing the push-button > see 4 chapter for a pro- longed time or by setting a parameter in the machine configuration menu (time-controlled power-saving mode ) >...

  • Page 38: Machine Configuration Menu

    Functional characteristics Machine configuration menu Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.6.1 Selecting, changing and saving parameters ENTER EXIT NAVIGATION Figure 5-30 099-00T407-EW501 14.07.2020...
  • Page 39 Functional characteristics Machine configuration menu Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (ex works 1) > see 5.1.7.2 chapter Up/down speed > see 5.1.7.3 chapter Increase value > rapid current change Decrease value > slow current change Current jump >...
  • Page 40 Functional characteristics Machine configuration menu Display Setting/selection Access control – access code Setting: 000 to 999 (000 ex works) Machine code Querying the three-digit machine code (000 to 999), user input Error Error message after entering an incorrect machine code New machine code •...

  • Page 41: Rectifying Faults

    Rectifying faults Error messages (power source) Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dea- ler.

  • Page 42: Dynamic Power Adjustment

    Rectifying faults Dynamic power adjustment Dynamic power adjustment This requires use of the appropriate mains fuse. Observe mains fuse specification! This function enables aligning the machine to the mains connection fusing to avoid continuous tripping of the mains fuse. The maximum power input of the machine is limited by an exemplary value for the exis- ting mains fuse (several levels available).

  • Page 43: Appendix

    Appendix Parameter overview – setting ranges Appendix Parameter overview – setting ranges 7.1.1 TIG welding Name Display Setting range Main current AMP, depending on power source Gas pre-flow time Ignition current, percentage of AMP Ignition current, absolute, depending on power source Start time 0,01 0,01...

  • Page 44: Mma Welding

    Appendix Parameter overview – setting ranges Name Display Setting range Amplitude balance [1], [2], [3] Dynamic power adjustment Machines with control Comfort 2.0. Machines for AC welding (AC). Machine series Tetrix 300. Machine series Tetrix 230. 7.1.2 MMA welding Name Display Setting range Main current AMP, depending on power source...

  • Page 45: Searching For A Dealer

    Appendix Searching for a dealer Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-00T407-EW501 14.07.2020...

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