EWM Tetrix 300 Classic cel TM Operating Instructions Manual
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EWM Tetrix 300 Classic cel TM Operating Instructions Manual

EWM Tetrix 300 Classic cel TM Operating Instructions Manual

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099-000171-EW501
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Welding machine
Tetrix 300 Classic cel TM
03.05.2012
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  • Page 1 Operating instructions Welding machine Tetrix 300 Classic cel TM 099-000171-EW501 03.05.2012 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
  • Page 2 © EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer.

  • 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 Ambient conditions........................13 2.5.1 In operation........................
  • Page 4 Contents Notes on the use of these operating instructions 5.7.10 Welding torch (operating variants)................40 5.7.10.1 Tap torch trigger (tapping function) ...............40 5.7.11 Torch mode and up/down speed setting ..............41 5.7.11.1 Standard TIG torch (5-pole) ................42 5.7.11.2 TIG up/down torch (8-pole) ................44 5.7.11.3 Potentiometer torch (8-pole) .................46 5.7.12 Setting the first increment .....................47...
  • Page 5 9 Accessories ............................74 General accessories ........................74 Welding torch cooling system ...................... 74 Remote controls and accessories....................74 Options............................74 Transportsysteme ........................74 Computer communication......................74 10 Appendix A ............................75 10.1 Overview of EWM branches ......................75 099-000171-EW501 03.05.2012...

  • 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 Press Do not press Turn Switch Switch off machine Switch on machine ENTER (enter the menu) NAVIGATION (Navigating in the menu) EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use...

  • 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 Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...
  • 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 technical data): 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 Ambient conditions 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

    Intended use Applications Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with proper usage and by trained or expert staff! •...

  • Page 15: Documents Which Also Apply

    Intended use Documents which also apply Documents which also apply 3.2.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.2.2 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 4-1 099-000171-EW501 03.05.2012...
  • Page 17 Machine description – quick overview Front view Item Symbol Description Carrying handle Machine control See 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 4-2 099-000171-EW501 03.05.2012...
  • Page 19 Machine description – quick overview Rear view Item Symbol Description Ignition type changeover switch = HF ignition = Liftarc (contact ignition) PC interface, serial (D-Sub connection socket, 9-pole) G¼” connecting nipple Shielding gas connection on the pressure regulator. Cooling air outlet Mains connection cable 4-pole connection socket Cooling unit voltage supply...

  • Page 20: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 Item Symbol Description Electrode characteristics key button (MMA welding) To achieve optimum welding properties for the electrode you need to select the electrode type used at the welding machine control. Rutil rutile Rutilbas rutile-basic...
  • Page 21 Machine description – quick overview Machine control – Operating elements Item Symbol Description Error/status indicators Collective interference signal light Water deficiency signal light (welding torch cooling) Excess temperature signal light safety sign signal light Three-figure LED display Welding parameter display (see also chap. “Welding data display”). 099-000171-EW501 03.05.2012...

  • Page 22: Function Sequence

    Machine description – quick overview Machine control – Operating elements 4.3.1 Function sequence Figure 4-4 Item Symbol Description Gas and current parameters button Gas pre-flow time / gas test / gas rinsing (TIG) Gas pre-flows: Setting range 0.0 sec to 20.0 sec (0.1s increments). Gas test: Shielding gas flows up to 20 sec.
  • Page 23 Machine description – quick overview Machine control – Operating elements Item Symbol Description Signal light for secondary current downslope time (tS1)/pulse time (t1) • Downslope time (tS1): Period from main current AMP to secondary current AMP%. • Pulse time (t1): Main current phase (AMP) during pulses. See chapter "Advanced settings".

  • 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: Cooling Module Connection

    Design and function Cooling module connection Cooling module connection NOTE Observe the fitting and connection instructions given in the relevant operating instructions for the cooling unit. Figure 5-1 Item Symbol Description 8-pole connection socket Cooling unit control lead 4-pole connection socket Cooling unit voltage supply Cooling module Control and supply lead to the welding machine...

  • 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: Tig Welding

    Design and function TIG welding TIG welding 5.7.1 Welding torch and workpiece line connection NOTE Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-3 Item Symbol Description Workpiece Connection socket for "+" welding current Workpiece lead connection Welding torch Welding torch hose package...

  • Page 29: 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). NOTE Please note the relevant documentation of the accessory components.

  • Page 30: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function TIG welding 5.7.3 Shielding gas supply (shielding gas cylinder for welding machine) 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 31: Gas Test

    Design and function TIG welding Figure 5-6 Item Symbol Description Connecting nipple G¼, shielding gas connection • Connect crown nut of the shielding gas line to the G¼“ connecting nipple. 5.7.3.2 Gas test NOTE Rule of thumb for the gas flow rate: Diameter of gas nozzle in mm corresponds to gas flow in l/min.

  • Page 32: Rinse Hose Package" Function

    Design and function TIG welding 5.7.3.3 “Rinse hose package” function Operating Action Result Displays element Select rinse hose package. Shielding gas flows continuously until the gas test button is 5 sec. pressed again. “AMP%” LED flashes. 5.7.3.4 Automatic gas post-flow When the automatic gas post-flow function is activated, the gas post-flow time is defined by the machine control depending on the application (4.0 s to 40.0 s).

  • Page 33: Select Welding Task

    Design and function TIG welding 5.7.4 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. Set the welding task in the following order: Item Symbol Description Welding process button...

  • Page 34: Arc Ignition

    Design and function TIG welding 5.7.6 Arc ignition 5.7.6.1 HF ignition Figure 5-7 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 35: Function Sequences/Operating Modes

    Design and function TIG welding 5.7.8 Function sequences/operating modes 5.7.8.1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 Current Time Gas pre-flows Ignition current start Up-slope time Spot time Main current (minimum to maximum current) AMP% Secondary current (0% to 100% of AMP) Pulse time...

  • Page 36: Non-Latched Mode

    Design and function TIG welding 5.7.8.2 Non-latched mode Figure 5-9 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 37: Latched Mode

    Design and function TIG welding 5.7.8.3 Latched mode AMP% start Down Figure 5-10 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 38: Non-Latched Operation, Version C

    Design and function TIG welding 5.7.8.4 Non-latched operation, version C Figure 5-11 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 39: Pulses, Function Sequences

    Design and function TIG welding 5.7.9 Pulses, function sequences NOTE The function sequences in pulses basically behave in the same way as in standard welding, but during the main current phase there is a continual switching back and forth between the pulse and pause currents at the relevant times. The pulse function can also be deactivated if necessary during the upslope and downslope phases (see chapter "Advanced settings").

  • Page 40: Welding Torch (Operating Variants)

    Design and function TIG welding 5.7.10 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 41: 5.7.11 Torch Mode And Up/Down Speed Setting

    Design and function TIG welding 5.7.11 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 42: Standard Tig Torch (5-Pole)

    Design and function TIG welding 5.7.11.1 Standard TIG torch (5-pole) Standard torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT1 = Torch trigger 1 (welding current on/off; secondary current via tapping function) Functions mode Operating elements BRT 1 Welding current On/Off (factory-set) BRT 1...
  • Page 43 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 BRT 1 Welding current On/Off Secondary current BRT 2 (factory-set)

  • Page 44: Tig Up/Down Torch (8-Pole)

    Design and function TIG welding 5.7.11.2 TIG up/down torch (8-pole) Up/down torch with one torch trigger Diagram Operating Explanation of symbols elements TT 1 = torch trigger 1 Functions Mode Operating elements BRT 1 Welding current on/off BRT 1 Secondary current (tapping mode) / (Latched mode) (factory- set) Increase welding current, infinite adjustment (up function)
  • Page 45 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 BRT 1 Welding current on/off BRT 2 Secondary current BRT 1...

  • Page 46: Potentiometer Torch (8-Pole)

    Design and function TIG welding 5.7.11.3 Potentiometer torch (8-pole) NOTE The welding machine needs to be configured for operation with a potentiometer torch (see chap. "Configuring TIG potentiometer torch") Potentiometer torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions...

  • Page 47: 5.7.12 Setting The First Increment

    Design and function TIG welding 5.7.12 Setting the first increment Figure 5-15 Figure 5-16 Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Setting the first increment Setting: 1 to 20 (factory setting 1) NOTE This function is only available when using up/down torches in modes 4 and 14! 099-000171-EW501 03.05.2012...

  • Page 48: Mma Welding

    Design and function MMA welding 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 49 Design and function MMA welding • Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right. • Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and lock by turning to the right.

  • Page 50: Select Welding Task

    Design and function MMA welding 5.8.2 Select welding task Operating Action Result element MMA welding process selection Signal light lights up in green. Electrode characteristics selection To achieve optimum welding properties for the electrode you need to select the electrode type used at the welding machine control. Rutil rutile Rutilbas rutile-basic...

  • Page 51: Hotstart Current And Hotstart Time

    Design and function MMA welding 5.8.4 Hotstart current and Hotstart time The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current Welding current Time Figure 5-18 Operating Action Result Displays...

  • Page 52: Remote Control

    Design and function Remote control Remote control NOTE The remote control is operated on the 19-pole remote control connection socket. 5.9.1 Manual remote control RT1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. 5.9.2 RTG1 19POL manual remote control Functions...

  • Page 53: Foot-Operated Remote Control Rtf1 19Pol

    Design and function Remote control 5.9.6 Foot-operated remote control RTF1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. • Start/stop welding operation (TIG) FFr > off FFr > on start Figure 5-20 Symbol...

  • Page 54: Pc Interface

    Design and function PC interface 5.10 PC interface CAUTION Equipment damage or faults may occur if the PC is connected incorrectly! Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission. The PC may be destroyed due to high frequency ignition pulses. •...

  • Page 55: Interfaces For Automation

    Design and function Interfaces for automation 5.11 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 56: Advanced Settings

    Design and function Advanced settings 5.12 Advanced settings 5.12.1 Setting slope times for secondary current AMP% or pulse edges Figure 5-22 Figure 5-23 Display Setting/selection Slope time tS1 (main current to secondary current) Setting: 0.00 s to 20.0 s (factory setting 0.01 s) Slope time tS2 (secondary current to main current) Setting: 0.00 s to 20.0 s (factory setting 0.01 s) 099-000171-EW501...

  • Page 57: 5.12.2 Tig Non-Latched Operating Mode, C Version

    Design and function Advanced settings 5.12.2 TIG non-latched operating mode, C version Figure 5-24 Display Setting/selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display Non-latched operation (C version) • on = on • off = off (factory setting) 099-000171-EW501 03.05.2012...

  • Page 58: 5.12.3 Configuring The Tig Potentiometer Torch Connection

    Design and function Advanced settings 5.12.3 Configuring the TIG potentiometer torch connection DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed.

  • Page 59: Welding Current Display (Ignition, Secondary, End And Hotstart Currents)

    Design and function Advanced settings 5.12.4 Welding current display (ignition, secondary, end and hotstart currents) The welding currents for secondary current, ignition current and end current (expert menu) can be displayed as percentages (factory setting) or absolute values on the machine display. Figure 5-26 Display Setting/selection...

  • Page 60: Ramp Function Foot-Operated Remote Control Rtf 1

    Design and function Advanced settings 5.12.5 Ramp function foot-operated remote control RTF 1 Figure 5-27 Display Setting/selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display Ramp function Remote control RTF 1 The ramp function can be switched on and off Switch on Switching on machine function Switch off...

  • Page 61: Menus And Sub-Menus On The Machine Control

    Design and function Menus and sub-menus on the machine control 5.13 Menus and sub-menus on the machine control 5.13.1 Direct menus (direct access to parameters) Functions, parameters and their values can be accessed directly, e.g. can be selected by pressing a button once.

  • Page 62: 5.13.3 Machine Configuration Menu

    Design and function Menus and sub-menus on the machine control 5.13.3 Machine configuration menu NOTE ENTER (enter the menu) • Switch off machine at the main switch • Press and hold the "welding parameters" button and switch the machine on again at the same time.
  • Page 63 Design and function Menus and sub-menus on the machine control Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (factory setting 1) Setting the first increment Setting: 1 to 20 (factory setting 1) Up-/Down speed Increase value = rapid current change (factory setting 10) Reduce value...
  • Page 64 Design and function Menus and sub-menus on the machine control Display Setting/selection Automation menu Fast take-over of control voltage (automation) • on = function on • off = function off (factory setting) Orbital welding • off = off (ex works) •...

  • Page 65: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! •...

  • Page 66: Maintenance Work

    Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922. •...

  • Page 67: 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 68 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 Regrind or replace the tungsten electrode Bad current transfer on ignition Check the setting on the "Tungsten electrode diameter/Ignition optimisation"...

  • Page 69: Machine Faults (Error Messages)

    Rectifying faults Machine faults (error messages) Machine faults (error messages) NOTE 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 70: Resetting Welding Parameters To The Factory Settings

    Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings. Figure 7-1 Display Setting/selection Exit the menu Exit Service menu Modifications to the service menu may only be carried out by authorised maintenance staff! Reset (reset to factory settings)

  • Page 71: Display Machine Control Software Version

    Rectifying faults Display machine control software version Display machine control software version NOTE The query of the software versions only serves to inform the authorised service staff! Figure 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 72: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit NOTE Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. 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 7-3 099-000171-EW501...
  • Page 73 Technical data Tetrix 300 Classic Cel Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 300 Classic Cel Setting range for welding current 5 A to 300 A Setting range for welding voltage 10.2 V to 22.0 V 20.2 V to 32.0 V Duty cycle at 40 °C...
  • Page 74 Accessories General accessories Accessories NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. DM1 35L/MIN Manometer pressure regulator 094-000009-00000 DM AR D F1 Flowmeter pressure regulator 094-001980-00000 ADAP1 G1/4-G1/8 Threaded adapter, G1/4 to G1/8...
  • Page 75 Appendix A Overview of EWM branches Appendix A 10.1 Overview of EWM branches 099-000171-EW501 03.05.2012...

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