Related Manuals for EWM T4.02
Summary of Contents for EWM T4.02
- Page 1 Operating instructions Control T4.02 - Tetrix AC/DC Comfort 2.0 (Tetrix 230) 099-00T402-EW501 Observe additional system documents! 02.07.2020...
- 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.
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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 5.1.10.7 Potentiometer torch (8-pole) ................. 38 5.1.10.8 Configuring the TIG potentiometer torch connection ........39 5.1.10.9 RETOX TIG torch (12-pole)................39 5.1.11 Expert menu (TIG) ......................40 MMA welding ..........................41 5.2.1 Welding task selection ....................41 5.2.2 Hotstart .........................
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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 AC/DC Comfort 2.0 (T4.02) 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 three sections (A, B, C) to ensure maximum clarity. The setting range 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: Control Section B
Machine control – Operating elements Overview of control sections Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values > see 4.2 chapter TIG ignition type signal light Signal light on: Lift arc ignition active/HF start off. You can switch the ignition type in the Expert menu (TIG) >... -
Page 11: Control Section C
Machine control – Operating elements Overview of control sections Item Symbol Description Balance signal light AC balance (JOBs 1–7), pulse balance Electrode diameter signal light Ignition optimisation (TIG)/tungsten balling basic setting (JOB 1-100) Gas post-flow time End current signal light AMP% Down-slope time signal light... -
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): Parameter Before welding During welding After welding (nominal values) (actual values) (hold values) Welding current Parameter times Parameter currents... -
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: Recurring Welding Tasks (Job 1-7)
Functional characteristics TIG welding 5.1.2.1 Recurring welding tasks (JOB 1–7) The user has 7 more memory locations at their disposal to save recurring or different welding tasks on a permanent basis. To do so, simply select the required memory location (JOB 1–7) and the welding task is set as described previously. -
Page 17: Tungsten Balling Function
Functional characteristics TIG welding 5.1.3.2 Tungsten balling function The tungsten balling function provides optimum tungsten balling, ensuring that the best ignition and welding results are achieved during AC welding. Optimum tungsten balling requires a sharpened electrode (about 15–25°) and the set electrode diameter on the machine control. -
Page 18: Alternating Current Waveforms
Functional characteristics TIG welding 5.1.3.3 Alternating current waveforms Selection EXIT Figure 5-5 Display Setting/selection Alternating current waveforms ------ Rectangular - Highest energy input (ex works) ------ Trapezoidal - An all-rounder, suitable for most applications ------ Sine - Low noise level 5.1.3.4 Automatic AC frequency Selecting the function AC frequency automatic is only possible in the JOB area 1-100. - Page 19 Functional characteristics TIG welding Selection < Figure 5-7 099-00T402-EW501 02.07.2020...
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Page 20: Arc Ignition
Functional characteristics TIG welding 5.1.4 Arc ignition To change the ignition type, use parameter to switch between HF start ( ) and lift arc ( ) in the Expert menu > see 5.1.11 chapter. 5.1.4.1 HF ignition Figure 5-8 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 21: Operating Modes (Functional Sequences)
Functional characteristics TIG welding 5.1.5 Operating modes (functional sequences) 5.1.5.1 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 time Pulse pause time... -
Page 22: Non-Latched Mode
Functional characteristics TIG welding 5.1.5.2 Non-latched mode Selection Figure 5-10 Sequence Figure 5-11 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 23: Latched Mode
Functional characteristics TIG welding 5.1.5.3 Latched mode Selection Figure 5-12 Sequence Figure 5-13 099-00T402-EW501 02.07.2020... -
Page 24: 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 25 Functional characteristics TIG welding Figure 5-15 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.1.4 chapter. Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. •...
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Page 26: Spotmatic
Functional characteristics TIG welding 5.1.5.5 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 27: Tig Activarc Welding
5.1.6 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 28: Pulse Welding
Functional characteristics TIG welding 5.1.8 Pulse welding The following pulse types can be selected: • Automated pulsing (TIG DC) • Thermal pulsing (TIG AC or TIG DC) • Metallurgical pulsing (TIG DC) • Average value pulses • AC special (TIG AC) 5.1.8.1 Automated pulses The automated pulsing pulse variant is only activated for DC welding in combination with the spotArc ope-... -
Page 29: Pulsed Welding In The Upslope And Downslope Phases
Functional characteristics TIG welding Pulse time setting EXIT Figure 5-22 Pulse pause setting EXIT Figure 5-23 5.1.8.3 Pulsed welding in the upslope and downslope phases The pulse function can also be deactivated if necessary during the up-slope and down-slope phases (parameter ) >... -
Page 30: Average Value Pulse Welding
Functional characteristics TIG welding 5.1.9 Average value pulse welding A special feature with average value pulses is that the power source will always maintain the preset average value. This makes this method especially suitable for welding according to welding procedure specifications. - Page 31 Functional characteristics TIG welding Selection Figure 5-27 Balance setting EXIT Figure 5-28 Frequency setting EXIT Figure 5-29 099-00T402-EW501 02.07.2020...
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Page 32: Ac Special
Functional characteristics TIG welding 5.1.9.2 AC special Is e.g. used to join metal sheets of different thickness. Figure 5-30 Figure 5-31 099-00T402-EW501 02.07.2020... -
Page 33: Welding Torch (Operating Variants)
Functional characteristics TIG welding 5.1.10 Welding torch (operating variants) Different torch versions can be used with this machine. Functions on the operating elements, such as torch triggers (BRT), rockers or potentiometers, can be modified individually via torch modes. Explanation of symbols for operating elements: Symbol Description Press torch trigger... -
Page 34: Standard Tig Torch (5-Pole)
Functional characteristics TIG welding 5.1.10.5 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 35 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)
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Page 36: Tig Up/Down Torch (8-Pole)
Functional characteristics TIG welding 5.1.10.6 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 37 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)
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Page 38: Potentiometer Torch (8-Pole)
Functional characteristics TIG welding 5.1.10.7 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch > see 5.1.10.8 chapter. Potentiometer torch with one torch trigger Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 Operating ele- Functions Mode... -
Page 39: 5.1.10.8 Configuring The Tig Potentiometer Torch Connection
Functional characteristics TIG welding 5.1.10.8 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 40: Expert Menu (Tig)
Functional characteristics TIG welding Functions Mode Operating ele- ments Welding current on/off TT 1 Secondary current TT 2 Secondary current (tapping function) TT 1 (tapping) (ex works) Increase welding current (up function) TT 3 Reduce welding current (down function) TT 4 Welding current on/off TT 1 Secondary current... -
Page 41: Mma Welding
Functional characteristics MMA welding Display Setting/selection Ignition type (TIG) ------- HF start active (ex works) ------- Lift arc ignition active 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 >... -
Page 42: Hotstart Current
Functional characteristics MMA welding 5.2.2.1 Hotstart current EXIT Figure 5-36 5.2.2.2 Hotstart time EXIT Figure 5-37 5.2.3 Antistick The Antistick feature prevents the electrode from annealing. Should the electrode stick, the machine automatically switches to the minimum current within approx. one second. This prevents the electrode from annealing. -
Page 43: Welding Current Polarity Reversal (Polarity Reversal)
Functional characteristics MMA welding 5.2.4 Welding current polarity reversal (polarity reversal) This function can be used to reverse the welding current polarity electronically. For example, when welding with different electrode types for which different polarities are stipulated by the manufacturer, the welding current polarity can be switched easily on the control. Figure 5-39 Not available for machines with voltage reduction device (VRD). -
Page 44: Average Value Pulse Welding
Functional characteristics Power-saving mode (Standby) 5.2.5 Average value pulse welding With average value pulsing, two currents are periodically toggled. The user can adjust the welding current (average current value AMP), pulse current Ipuls (parameter ), balance and frequency to the welding task. -
Page 45: Access Control
Functional characteristics Access control Access control The machine control can be locked to secure it against unauthorised or unintentional adjustment. The ac- cess block has the following effect: • The parameters and their settings in the machine configuration menu, Expert menu and operation se- quence can only be viewed but not changed. -
Page 46: 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 5-42 099-00T402-EW501 02.07.2020... - Page 47 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 5.1.10.2 chapter Up/down speed > see 5.1.10.3 chapter Increase value > rapid current change Decrease value > slow current change Current jump >...
- Page 48 Functional characteristics Machine configuration menu Display Setting/selection Error Error message after entering an incorrect machine code 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...
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Page 49: 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 50: 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 51: 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 52: 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 53: 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" 099-00T402-EW501 02.07.2020...
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