EWM Tetrix 300 Operating Instructions Manual
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EWM Tetrix 300 Operating Instructions Manual

Ac/dc synergic tm
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Operating instructions
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099-000121-EW501
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www.ewm-group.com
Welding machine
Tetrix 300 AC/DC Synergic TM
29.06.2015
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Summary of Contents for EWM Tetrix 300

  • Page 1 Operating instructions Welding machine Tetrix 300 AC/DC Synergic TM 099-000121-EW501 29.06.2015 Register now and benefit! Jetzt Registrieren und Profitieren! www.ewm-group.com...
  • 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 Safety instructions ..........................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 General ............................8 Transport and installation ......................12 2.4.1 Ambient conditions .......................
  • Page 4 Contents Notes on the use of these operating instructions 5.9.8.3 Automatic cut-out ..................41 5.9.9 Optimising the ignition characteristics for pure tungsten electrodes ......42 5.9.10 Optimal and fast spherical cup formation ..............42 5.9.11 Function sequences/operating modes ................43 5.9.11.1 Explanation of symbols .................
  • Page 5 7.6.1 Interface for automated welding ................. 100 Vent coolant circuit ........................101 8 Technical data ............................ 102 Tetrix 300 AC/DC Synergic ......................102 9 Accessories ............................103 Welding torch cooling system ....................103 Transport vehicle ........................103 Remote controls and accessories ....................103 Options ............................

  • Page 6: 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 7: Explanation Of Icons

    Safety instructions Explanation of icons Explanation of icons Symbol Description Special technical points which users must observe. Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER ENTER (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu)

  • Page 8: General

    Safety instructions General General DANGER 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 9 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 10 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
  • Page 11 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes - See 8 Technical data chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.

  • 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: Ambient Conditions

    Safety instructions Transport and installation 2.4.1 Ambient conditions CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work.

  • Page 14: Intended Use

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

  • Page 15: Documents Which Also Apply

    3.4.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.4.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •...

  • Page 16: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-000121-EW501 29.06.2015...
  • Page 17 Machine description – quick overview Front view Item Symbol Description Carrying handle Machine control- See 4.3 Machine control – Operating elements chapter Connection socket, 19-pole Remote control connection Cooling air inlet Connection socket, welding current “-” (with DC- polarity) connection for Electrode holder Connection socket, welding current “+”...

  • Page 18: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-000121-EW501 29.06.2015...
  • Page 19 Machine description – quick overview Rear view Item Symbol Description 19-pole mechanised welding interface (analogue) - See 5.15.1 TIG interface for mechanised welding chapter Connection socket, 7-pole Connection for peripheral devices with digital interface G¼” connecting nipple Shielding gas connection on the pressure regulator. Main switch, machine on/off Mains connection cable - See 5.6 Mains connection chapter...

  • Page 20: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 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 21 Machine description – quick overview Machine control – Operating elements Item Symbol Description Tungsten electrode diameter / Ignition optimisation / Spherical cap formation button  1.0mm,  1.6mm,  2.0mm,  2.4mm,  3.2mm,  4.0mm or greater Best ignition and stabilisation of the arc (DC, AC) and optimum spherical cup formation in the tungsten electrode according to the electrode diameter being used.

  • Page 22: Function Sequence

    Machine description – quick overview Machine control – Operating elements Item Symbol Description Status displays 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 Direct current welding Alternating current welding simultaneously: Alternating current welding, AC special...
  • Page 23 Machine description – quick overview Machine control – Operating elements Item Symbol Description AMP% Secondary current (TIG) / pulse pause current Setting range 1 % to 100 % (1 % increments). Percentage of the main current. Pulse break time/slope time from AMP to AMP% •...

  • Page 24: Design And Function

    Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •...

  • Page 25: Transport And Installation

    Design and function Transport and installation Transport and installation WARNING Risk of accident due to improper transport of machines that may not be lifted! Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only! •...

  • Page 26: Welding Torch Cooling System

    Design and function Welding torch cooling system Welding torch cooling system Please note the relevant documentation of the accessory components. Figure 5-1 Item Symbol Description 4-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead Cooling module Control and supply lead to the welding machine The cooling module and welding machine are connected using two leads.

  • Page 27: Mains Connection

    Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations! •...

  • Page 28: Notes On The Installation Of Welding Current Leads

    Design and function Notes on the installation of welding current leads 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 29 Design and function Notes on the installation of welding current leads Use an individual welding lead to the workpiece for each welding machine! Figure 5-4 Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders.

  • Page 30: Welding Data Display

    Design and function Welding data display Welding data display The following welding parameters can be displayed before (nominal values), during (actual values) or after welding (hold values): left-hand display Parameter Before welding During welding After welding (nominal values) (actual values) (hold values) ...

  • Page 31: Welding Current Display (Ignition, Secondary, End And Hotstart Currents)

    Design and function Welding data display 5.8.2 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. ENTER EXIT NAVIGATION...

  • Page 32: Tig Welding

    Design and function TIG welding TIG welding 5.9.1 Welding torch and workpiece line connection Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-7 Item Symbol Description Workpiece Connection socket for "+" welding current Workpiece lead connection Welding torch Welding torch hose package...

  • Page 33: Torch Connection Options And Pin Assignments

    Design and function TIG welding If fitted: • Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings: Return line red to quick connect coupling, red (coolant return) and supply line blue to quick connect coupling, blue (coolant supply). Please note the relevant documentation of the accessory components.
  • Page 34 Design and function TIG welding Figure 5-9 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve • Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight. • Screw gas hose connection crown nut onto the output side of the pressure regulator. 099-000121-EW501 29.06.2015...

  • Page 35: Setting The Shielding Gas Quantity

    Design and function TIG welding 5.9.2.2 Setting the shielding gas quantity Rule of thumb for the gas flow rate: Diameter of gas nozzle in mm corresponds to gas flow in l/min. Example: 7mm gas nozzle corresponds to 7l/min gas flow. Incorrect shielding gas setting! •...
  • Page 36 Design and function TIG welding Figure 5-10 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), • Material type (B) and •...

  • Page 37: Synergic Parameter Setting In The Functional Sequence

    Design and function TIG welding 5.9.3 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 Function sequence chapter with the exception of the gas pre-flow time.

  • Page 38: Set The Operating Principle (Conventional/Synergic)

    Design and function TIG welding 5.9.4.1 Set the operating principle (conventional/synergic) ENTER EXIT NAVIGATION Figure 5-13 Display Setting/selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display Operating principle • on = synergic parameter setting (factory setting) •...

  • Page 39: Select Welding Task

    Design and function TIG welding 5.9.5 Select welding task The welding task is selected using the buttons on the machine control on the welding machine. Signal lights (LED) display the welding parameter selection. It is only possible to change the basic welding parameters if: No welding current is flowing and The key switch (option) is set to position “1”.
  • Page 40 Design and function TIG welding • Keep the "welding parameters" button pressed for 4 s. NAVIGATION (Navigating in the menu) • Parameters are selected by pressing the "welding parameters" button. • Set or change the parameters by turning the "welding parameter setting" rotary dial. EXIT (leave the menu) •...

  • Page 41: Arc Ignition

    Design and function TIG welding 5.9.8 Arc ignition 5.9.8.1 HF ignition Figure 5-15 The arc is started without contact from high-voltage ignition pulses. a) Position the welding torch in welding position over the workpiece (distance between the electrode tip and workpiece should be approx. 2-3mm). b) Press the torch trigger (high voltage ignition pulses ignite the arc).

  • Page 42: Optimising The Ignition Characteristics For Pure Tungsten Electrodes

    Design and function TIG welding 5.9.9 Optimising the ignition characteristics for pure tungsten electrodes This parameter can be used to improve the ignition characteristics of “pure tungsten electrodes”, for example. The parameter is a %-value (factory-set to 20) and is changed across all JOBs. Control element Action Result...

  • Page 43: Function Sequences/Operating Modes

    Design and function TIG welding 5.9.11 Function sequences/operating modes Figure 5-17 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. Welding parameter setting rotary transducer Setting of all parameters such as welding current, sheet metal thickness, gas pre-flow time, etc.

  • Page 44: Non-Latched Mode

    Design and function TIG welding 5.9.11.2 Non-latched mode Figure 5-18 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 45: Latched Mode

    Design and function TIG welding 5.9.11.3 Latched mode Figure 5-19 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 46: Spotarc

    Design and function TIG welding 5.9.11.4 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 47 Design and function TIG welding Figure 5-20 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however- See 5.9.8 Arc ignition chapter. Sequence: • Press and hold torch trigger 1. • The gas pre-flow time elapses.

  • Page 48: Spotmatic

    Design and function TIG welding 5.9.11.5 Spotmatic This function must be enabled before use- See 5.18 Machine configuration menu chapter. In contrast to the spotarc operating mode, the arc ignites not by pressing the torch trigger as is usual, but by shortly touching the tungsten electrode against the workpiece.

  • Page 49: Non-Latched Operation, Version C

    Design and function TIG welding 5.9.11.6 Non-latched operation, version C Figure 5-22 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 50: Pulses, Function Sequences

    Design and function TIG welding 5.9.12 Pulses, function sequences 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.

  • Page 51: Pulse Variants

    Design and function TIG welding 5.9.13 Pulse variants 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). 5.9.13.1 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 52: Khz Pulses (Metallurgic Pulses)

    Design and function TIG welding 5.9.13.2 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 53: Ac Pulses

    Design and function TIG welding 5.9.13.4 AC pulses (AC pulse, max. 50Hz) Setting: = pulse current AMP% = pulse pause current / basic current tpuls = pulse time tpause = pulse pause time Figure 5-27 5.9.13.5 AC special Application: e.g. for welding thick metal sheets onto thin metal sheets. Operating Action Result...

  • Page 54: Tig Activarc Welding

    TIG welding 5.9.14 TIG activArc welding The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power supplied is kept virtually constant in the event of changes in the distance between the welding torch and the weld pool, e.g. during manual welding. Voltage losses as a result of a shortening of the distance between the torch and molten pool are compensated by a current rise (ampere per volt - A/V), and vice versa.

  • Page 55: Welding Torch (Operating Variants)

    Design and function TIG welding 5.9.16 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 56: Torch Mode And Up/Down Speed Setting

    Design and function TIG welding 5.9.17 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 57: Standard Tig Torch (5-Pole)

    Design and function TIG welding 5.9.17.1 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 Welding current On/Off (factory-set) Secondary current (Latched mode) Standard torch with two torch triggers:...
  • Page 58 Design and function TIG welding Standard torch with one rocker (MG rocker, two torch triggers) Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Functions mode Operating elements Welding current On/Off Secondary current (factory-set) Secondary current (tapping mode) / (latched mode)

  • Page 59: Tig Up/Down Torch (8-Pole)

    Design and function TIG welding 5.9.17.2 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 Welding current on/off Secondary current (tapping mode) / (latched mode) (factory- set) Increase welding current, infinite adjustment (up function)
  • Page 60 Design and function 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 Welding current on/off Secondary current Secondary current (tapping mode) / (latched mode) (factory- set)

  • Page 61: Potentiometer Torch (8-Pole)

    Design and function TIG welding 5.9.17.3 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch- See 5.9.17.4 Configuring the TIG potentiometer torch connection chapter. Potentiometer torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions...

  • Page 62: Configuring The Tig Potentiometer Torch Connection

    Design and function TIG welding 5.9.17.4 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 63: Retox Tig Torch (12-Pole)

    Design and function TIG welding 5.9.17.5 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 64: Specifying Max. No. Of Accessible Jobs

    Design and function TIG welding 5.9.17.6 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 65: Setting The First Increment

    Design and function TIG welding 5.9.17.7 Setting the first increment Figure 5-34 ENTER EXIT NAVIGATION Figure 5-35 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) This function is only available when using up/down torches in modes 4 and 14! 099-000121-EW501 29.06.2015...

  • Page 66: Mma Welding

    Design and function MMA welding 5.10 MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •...

  • Page 67: Welding Current Polarity Reversal (Polarity Reversal)

    Design and function MMA welding element MMA welding process selection. Signal light lights up in green. Set welding current. If necessary, the pulse function can be enabled as well. Signal light lights up in green- See 5.10.9 MMA pulse welding in the vertical up position (PF) chapter.

  • Page 68: Frequency And Balance Setting

    Design and function MMA welding 5.10.5 Frequency and balance setting Operating Action Result Displays element Switch on welding current polarity "AC" - See 5.10.3 Welding current polarity reversal (polarity reversal) chapter Select the welding parameter alternating current frequency. Press until signal light comes on.

  • Page 69: Hotstart Time

    Design and function MMA welding 5.10.6.2 Hotstart time Control element Action Result Displays Select hotstart time welding parameter: Press until the hotstart time signal light sec comes Set hotstart time. 5.10.7 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current.

  • Page 70: Mma Pulse Welding In The Vertical Up Position (Pf)

    Design and function MMA welding 5.10.9 MMA pulse welding 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 71: 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 72: Selection And Adjustment

    Design and function Welding programs 5.11.1 Selection and adjustment Setting welding programs using the welding machine control Operating Action Result Display element Press button until signal light PROG comes on. Welding current (left) and program no. (right) Select or retrieve program no., e.g. no. 1 Set operating mode (can be specified separately for each No change program).

  • Page 73: Example "Program With Synergetic Setting

    Design and function Welding programs 5.11.3 Example "Program with synergetic setting" Figure 5-38 5.11.4 Example "Program with conventional setting" Figure 5-39 5.11.5 Accessories for switching over programs The user can change, retrieve and save programs using the following components. Programs Component Create and change Retrieve...

  • Page 74: Organising Welding Tasks (Mode "Job Manager")

    Design and function Organising welding tasks (Mode "JOB Manager") 5.12 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 75: Creating A New Job In The Memory Or Copying A Job

    Design and function Organising welding tasks (Mode "JOB Manager") 5.12.2 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 76: Loading An Existing Job From The Free Memory

    Design and function Organising welding tasks (Mode "JOB Manager") 5.12.3 Loading an existing JOB from the free memory Operating Action Result Display element Press until the “VOLT” Select JOB Manager mode signal light is on Select JOB Manager mode 2 sec. Select the required JOB number using the rotary transducer (e.g.

  • Page 77: Resetting Jobs 1-128 To The Factory Setting (Reset All Jobs)

    Design and function Organising welding tasks (Mode "JOB Manager") 5.12.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs) Operating Action Result Display element Press until the “VOLT” Select JOB Manager mode signal light is on Select JOB Manager mode 2 sec.

  • Page 78: Remote Control

    Design and function Remote control 5.13 Remote control The remote controls are operated on the 19-pole remote control connection socket (analogue). 5.13.1 Manual remote control RT1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine.

  • Page 79: Manual Remote Control Rt Pws 1 19Pol

    Design and function Remote control 5.13.7 Manual remote control RT PWS 1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current at the welding machine • Pole reversing switch, suitable for machines with PWS function 5.13.8 Foot-operated remote control RTF1 19POL 5 M / RTF2 19POL 5 M Functions •...

  • Page 80: Ramp Function Foot-Operated Remote Control Rtf 1 / Rtf 2

    Design and function Remote control 5.13.8.1 Ramp function foot-operated remote control RTF 1 / RTF 2 ENTER EXIT NAVIGATION Figure 5-41 Display Setting/selection Exit the menu Exit Machine configuration (part two) Settings for machine functions and parameter display Ramp function Remote control RTF 1 The ramp function can be switched on and off Switch on Switching on machine function...

  • Page 81: Simultaneous Welding On Both Sides, Synchronisation Types

    Design and function Simultaneous welding on both sides, synchronisation types 5.14 Simultaneous welding on both sides, synchronisation types This function is important, if two power sources are used to simultaneously weld on both sides, as is sometimes required for welding thick aluminium materials in the PF position. This ensures that, with alternating currents, the positive and negative pole phases are present on both power sources simultaneously, thus avoiding the arcs negatively influencing each other.

  • Page 82: Synchronisation Via Cable (Frequency 50Hz To 200Hz)

    Design and function Simultaneous welding on both sides, synchronisation types 5.14.2 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 •...

  • Page 83: Interfaces For Automation

    Design and function Interfaces for automation 5.15 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 84: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.15.2 Remote control connection socket, 19-pole Figure 5-42 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 85: Protecting Welding Parameters From Unauthorised Access

    Design and function Protecting welding parameters from unauthorised access 5.16 Protecting welding parameters from unauthorised access These accessory components can be retrofitted as an option - See 9 Accessories 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.
  • Page 86 Design and function Machine configuration menu ENTER EXIT NAVIGATION Figure 5-43 Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions 099-000121-EW501 29.06.2015...
  • Page 87 Design and function Machine configuration menu Display Setting/selection Torch mode (factory setting 1) Up-/Down speed Increase value = rapid current change (factory setting 10) Reduce value = slow current change Setting the first increment Setting: 1 to 20 (factory setting 1) Get JOB number Set maximum selectable jobs (setting: 1 to 128, factory setting 10).
  • Page 88 Design and function Machine configuration menu Display Setting/selection Ramp function Remote control RTF 1 The ramp function can be switched on and off Tungsten balling with RT AC remote control Function switched off (factory setting) Function switched on (in addition, the "AC Balance" rotary knob at the RT AC remote control has to be turned to the left stop) Tungsten balling (old variant) •...
  • Page 89 Design and function Machine configuration menu Display Setting/selection Error output to automated welding interface, contact SYN_A AC synchronisation or hot wire (factory setting) Error signal, negative logic Error signal, positive logic AVC (Arc voltage control) connection Gas monitoring Depending on where the gas sensor is situated, the use of a pilot static tube and the welding process monitoring phase.

  • Page 90: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.18.2 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 91: Power-Saving Mode (Standby)

    Design and function Machine configuration menu 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 92: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal DANGER Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. •...

  • Page 93: Annual Test (Inspection And Testing During Operation)

    In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU).

  • Page 94: 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 95 Rectifying faults Checklist for rectifying faults No arc ignition  Incorrect ignition type setting.  Set ignition type changeover switch to the HF ignition setting. Bad arc ignition  Material inclusions in the tungsten electrode due to contact with filler material or workpiece ...

  • Page 96: Warnings (Power Source)

    Rectifying faults Warnings (power source) Warnings (power source) A warning is denoted by the letter A on the machine display, or Att in case of multiple machine displays. The possible cause of the warning is signalled by the respective error code (see table). The display of possible error numbers depends on the machine version (interfaces/functions).

  • Page 97: Error Messages (Power Source)

    Rectifying faults Error messages (power source) Error messages (power source) A welding machine error is indicated by the collective fault signal lamp (A1) lighting up and an error code (see table) being displayed in the machine control display. In the event of a machine error, the power unit shuts down.
  • Page 98 Rectifying faults Error messages (power source) Error message Possible cause Remedy Err 20 Coolant Check coolant level and refill if necessary • The flow quantity of the torch coolant Check coolant level in the reverse cooler • has fallen below the permissible Check coolant lines for leaks and kinks minimum ->...

  • Page 99: Resetting Welding Parameters To The Factory Settings

    Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. ENTER EXIT NAVIGATION Figure 7-1 Display Setting/selection Exit the menu Exit Service menu Modifications to the service menu may only be carried out by authorised maintenance...

  • Page 100: Display Machine Control Software Version

    Rectifying faults Display machine control software version Display machine control software version The query of the software versions only serves to inform the authorised service staff! ENTER EXIT NAVIGATION Figure 7-2 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) System bus ID...

  • Page 101: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit 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 7-3 099-000121-EW501 29.06.2015...

  • Page 102: Technical Data

    Technical data Tetrix 300 AC/DC Synergic Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 300 AC/DC Synergic Welding current setting range 5 A to 300 A (DC) 5 A to 270 A...

  • Page 103: Accessories

    Accessory components and digital interfaces ON 12pol Retox Tetrix Optional 12-pole retrofit connection socket 092-001807-00000 300/400/401/351/451/551 ON 19POL Tetrix 300/351 Optional 19-pole retrofit connection socket 092-001827-00000 Accessory components and analogue A interface ON Filter 300 Dirt filter for air inlet...

  • Page 104: General Accessories

    Accessories General accessories General accessories Type Designation Item no. DMDIN TN 200B AR/MIX 35L Manometer pressure regulator 094-000009-00000 DM AR D F1 Flowmeter pressure regulator 094-001980-00000 GH 2X1/4'' 2M Gas hose 094-000010-00001 5POLE/CEE/16A/M Machine plug 094-000712-00000 Simultaneous welding on both sides, synchronisation types 9.6.1 Synchronisation via cable (frequency 50Hz to 200Hz) For simultaneous, two-sided welding according to the master/slave principle, both welding...

  • Page 105: 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 106 Appendix A JOB-List Process Material Wire Seam position      Cu/CuZn   Cu/CuZn >3.2   Cu/CuZn   Cu/CuZn   Cu/CuZn     Cu/CuZn     Cu/CuZn   Cu/CuZn >3.2 ...
  • Page 107 Appendix A JOB-List Process Material Wire Seam position    AlSi   AlSi   AlSi     AlSi     AlSi     AlSi >3.2   AlSi   AlSi ...
  • Page 108 Appendix A JOB-List Process Material Wire Seam position    Al99     Al99     Al99     Al99 >3.2   Al99   Al99   Al99    ...

  • Page 109: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 11.1 Overview of EWM branches 099-000121-EW501 29.06.2015...

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