Table of Contents
Related Manuals for EWM Tetrix 451 AC/DC Smart 2.0 FW
Summary of Contents for EWM Tetrix 451 AC/DC Smart 2.0 FW
- Page 1 Operating instructions Power source Tetrix 451 AC/DC Smart 2.0 FW Tetrix 551 AC/DC Smart 2.0 FW Tetrix 451 AC/DC Comfort 2.0 FW Tetrix 551 AC/DC Comfort 2.0 FW 099-000251-EW501 Observe additional system documents! 27.10.2017...
- Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment.
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Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 Part of the complete documentation ....................7 Safety instructions .......................... - Page 4 Simultaneous welding on both sides, synchronisation types ............43 9.5.1 Synchronisation via cable (frequency 50Hz to 200Hz) ..........43 9.5.2 Synchronisation via mains voltage (50Hz / 60Hz) ............43 Computer communication ......................43 10 Appendix A ............................44 10.1 Overview of EWM branches......................44 099-000251-EW501 27.10.2017...
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Page 5: For Your Safety
For your safety Notes on the use of these operating instructions For your safety Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. •... -
Page 6: Explanation Of Icons
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release/tap/tip user must observe. Switch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Numerical value – adjustable Correct Menu entry Signal light lights up in green... -
Page 7: Part Of The Complete Documentation
For your safety Part of the complete documentation Part of the complete documentation These operating instructions are part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system. - Page 8 For your safety Safety instructions WARNING Risk of injury from electrical voltage! Voltages can cause potentially fatal electric shocks and burns on contact. Even low voltages can cause a shock and lead to accidents. • Never touch live components such as welding current sockets or stick, tungsten or wire electrodes! •...
- Page 9 For your safety Safety instructions WARNING Fire hazard! Due to the high temperatures, sparks, glowing parts and hot slag that occur during welding, there is a risk of flames. • Be watchful of potential sources of fire in the working area! •...
- Page 10 For your safety Safety instructions CAUTION Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •...
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Page 11: Transport And Installation
For your safety Transport and installation Transport and installation WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! • Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air! •... -
Page 12: Intended Use
3.2.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.2.2 Declaration of Conformity The labelled machine complies with the following EC directives in terms of its design and construction: •... -
Page 13: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-000251-EW501 27.10.2017... - Page 14 Machine description – quick overview Front view Item Symbol Description Lifting lug Main switch, machine on/off Machine control, see the relevant control operating instructions Carrying handle Automatic cut-out of coolant pump key button press to reset a triggered fuse Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply...
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Page 15: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 099-000251-EW501 27.10.2017... - Page 16 Machine description – quick overview Rear view Item Symbol Description Connection socket, 7-pole (digital) To connect digital accessories Retrofitting option > see 9 chapter PC interface, serial (D-Sub connection socket, 9-pole) Automation interface 19-pin (analogue) Option for retrofitting > see 5.5 chapter Securing elements for shielding gas cylinder (strap/chain) Mains connection cable >...
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Page 17: Design And Function
Design and function Transport and installation Design and function WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •... -
Page 18: Ambient Conditions
Design and function Transport and installation 5.1.2 Ambient conditions T he machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 19: Welding Torch Cooling System
Design and function Transport and installation 5.1.5 Welding torch cooling system Insufficient frost protection in the welding torch coolant! Depending on the ambient conditions, different liquids are used for cooling the welding torch > see 5.1.5.1 chapter. Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components. -
Page 20: Adding Coolant
Design and function Transport and installation 5.1.5.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. Figure 5-1 Item Symbol Description Coolant tank cap Coolant filter sieve Coolant tank "Min" mark Minimum coolant level • Unscrew and remove the coolant tank sealing cover. -
Page 21: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.6 Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc (flickering). Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel. -
Page 22: Stray Welding Currents
Design and function Transport and installation 5.1.6.1 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. •... -
Page 23: Mains Configuration
Design and function Transport and installation 5.1.7.1 Mains configuration The machine may be connected to: • a three-phase system with four conductors and an earthed neutral conductor • a three-phase system with three conductors of which any one can be earthed, e.g. -
Page 24: Tig Welding
Design and function TIG welding TIG welding 5.2.1 Welding torch and workpiece line connection Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. - Page 25 Design and function TIG welding Item Symbol Description Welding torch Welding torch hose package Connection socket, welding torch control cable > see 5.2.1.1 chapter G¼” connecting nipple, “-” welding current Shielding gas connection (with yellow insulating cap) for TIG welding torch Connection socket, “-”...
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Page 26: Connection Assignment, Welding Torch Control Cable
Design and function TIG welding 5.2.1.1 Connection assignment, welding torch control cable TIG welding machines are equipped ex works with a dedicated connection socket for the welding torch control cable (5- or 8-pole). As mobile machines offer more free space, they may even feature two control cable connection sockets. -
Page 27: Connecting The Shielding Gas Supply
Design and function MMA welding 5.2.2.1 Connecting the shielding gas supply Figure 5-9 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve • Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out any dirt. - Page 28 Design and function Remote control Figure 5-10 Item Symbol Description Workpiece Connection socket, “+” welding current Connection for workpiece lead Electrode holder Connection socket, “-” welding current Electrode holder connection G¼" connecting nipple Shielding gas connection (with yellow insulating cap) for TIG welding torch Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.
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Page 29: Remote Control
Design and function Remote control Remote control The remote controls are operated on the 19-pole remote control connection socket (analogue). 5.4.1 RT1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. 5.4.2 RTG1 19POL Functions... -
Page 30: Rt Ac 1 19Pol
Design and function Interfaces for automation ActivArc welding is not possible in combination with the foot-operated remote control. Figure 5-11 Symbol Meaning Actuate foot-operated remote control (start welding process) Operate foot-operated remote control (set welding current according to application) Release foot-operated remote control (end welding process) Ramp function parameters (RTF) on -------- Welding current rises to the specified main current level in a ramp function off -------- Welding current immediately jumps to the specified main current level... -
Page 31: Interfaces For Automation
Design and function Interfaces for automation Interfaces for automation WARNING 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 32: Automation Interface
Design and function Interfaces for automation 5.5.1 Automation interface WARNING No function of the external interrupt equipment (emergency stop switch)! If the emergency stop circuit has been set up using an external interrupt equipment connected to the interface for automated welding, the machine must be configured for this setup. -
Page 33: Remote Control Connection Socket, 19-Pole
Design and function Interfaces for automation 5.5.2 Remote control connection socket, 19-pole Figure 5-12 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 34: Pc Interface
Design and function PC interface PC interface PC 300 welding parameter software Set all welding parameters on the PC and simply transfer to one or more welding machines (accessory, set consisting of software, interface, connection leads) • Manage up to 510 JOBs •... -
Page 35: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed. -
Page 36: Maintenance Work, Intervals
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-000251-EW501 27.10.2017... -
Page 37: Disposing Of Equipment
• Information about returning used equipment or about collections can be obtained from the respective municipal administration office. • In addition to this, returns are also possible throughout Europe via EWM sales partners. 099-000251-EW501 27.10.2017... -
Page 38: 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 39: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Unstable arc Material inclusions in the tungsten electrode due to contact with filler material or workpiece Regrind or replace the tungsten electrode Incompatible parameter settings Check settings and correct if necessary Pore formation ... -
Page 40: Technical Data
Technical data Tetrix 451 AC/DC Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 451 AC/DC Welding current 5 A–450 A Welding voltage 10.2 V–28.0 V 20.2 V–38.0 V Duty cycle at 40 °C 450 A (80% DC) 420 A (100% DC) 10 min. -
Page 41: Tetrix 551 Ac/Dc
Technical data Tetrix 551 AC/DC Tetrix 551 AC/DC Welding current 5 A–550 A Welding voltage 10.2 V–32.0 V 20.2 V–42.0 V Duty cycle at 40 °C 550 A (60% DC) 420 A (100% DC) 10 min. (60% DC ≙ 6 min. welding, 4 min. pause) Load cycle Open circuit voltage 79 V... -
Page 42: Accessories
Accessories Remote controls and accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Remote controls and accessories Type Designation Item no. RTF1 19POL 5 M Foot-operated remote control current with 094-006680-00000 connection cable RT1 19POL... -
Page 43: General Accessories
Accessories General accessories General accessories Type Designation Item no. DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 GH 2X1/4'' 2M Gas hose 094-000010-00001 32A 5POLE/CEE Machine plug 094-000207-00000 ADAP 8-5 POL 8 to 5-pole adapter 092-000940-00000 Simultaneous welding on both sides, synchronisation types 9.5.1 Synchronisation via cable (frequency 50Hz to 200Hz) For simultaneous, two-sided welding according to the master/slave principle, both welding... -
Page 44: Overview Of Ewm Branches
Appendix A Overview of EWM branches Appendix A 10.1 Overview of EWM branches 099-000251-EW501 27.10.2017...
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