EWM Tetrix DC Smart 2.0 T4.05 Operating Instructions Manual
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EWM Tetrix DC Smart 2.0 T4.05 Operating Instructions Manual

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Operating instructions
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T4.05 - Tetrix DC Smart 2.0
EN
T4.11 - Tetrix DC Smart 2.0
T4.13 - Tetrix DC Smart 2.0
099-00T405-EW501
Observe additional system documents!
14.02.2022

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Summary of Contents for EWM Tetrix DC Smart 2.0 T4.05

  • Page 1 Operating instructions Control T4.05 - Tetrix DC Smart 2.0 T4.11 - Tetrix DC Smart 2.0 T4.13 - Tetrix DC Smart 2.0 099-00T405-EW501 Observe additional system documents! 14.02.2022...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.

  • Page 3: Table Of Contents

    Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................6 Notes on using these operating instructions ................6 Explanation of icons ....................... 7 Safety instructions ........................8 Transport and installation ....................11 3 Intended use ..........................
  • Page 4 Contents Notes on using these operating instructions MMA welding ........................44 5.2.1 Welding task selection ..................44 5.2.2 Hotstart ......................... 45 5.2.3 Arcforce ......................... 45 5.2.4 Antistick ......................... 45 5.2.5 Average value pulse welding ................46 5.2.6 Expert menu (MMA) ....................47 Power-saving mode (Standby) .....................
  • Page 5 Contents Notes on using these operating instructions 099-00T405-EW501 14.02.2022...

  • Page 6: 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 7: Explanation Of Icons

    For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the u- Activate and release / Tap / Tip ser must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Correct / Valid...

  • Page 8: Safety Instructions

    For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
  • Page 9 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
  • Page 10 For your safety Safety instructions CAUTION 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 11: Transport And Installation

    For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.
  • Page 12 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.

  • Page 13: Intended Use

    Intended use Use and operation solely with the following machines Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and stand- ards applicable for use in industry and trade. It may only be used for the welding proce- dures indicated at the rating plate.

  • Page 14: Part Of The Complete Documentation

    Intended use Documents which also apply 3.3.1 Part of the complete documentation This document is 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 15: Machine Control - Operating Elements

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

  • Page 16: 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 Push-button gas test / rinse hose package > see 5.1.1 chapter Operating mode >...

  • Page 17: Control Section B

    Machine control – Operating elements Overview of control sections Item Symbol Description Voltage reduction device (VRD) signal light > see 5.5 chapter Signal light Status display Hold After each completed welding task, the last values used in the welding process for the welding current and welding voltage are shown on the displays, and the signal light will be on Excess temperature signal light...

  • Page 18: Machine Display

    Machine control – Operating elements Machine display Item Symbol Description Signal light, two colour AMP% Red: Secondary or pulse pause current (% of AMP) Green: Pulse pause time /slope time (Expert menu) Signal light, two colour Red: Main or pulse current Green: Pulse time /slope time (AMP to AMP%, Expert menu)

  • Page 19: Welding Parameter Setting In The Operation Sequence

    Machine control – Operating elements Operating the machine control 4.3.3 Welding parameter setting in the operation sequence Set a welding parameter in the functional sequence by clicking (select) and turning the click wheel (navi- gate to the desired parameter). Press again to apply the selected parameter as the setting (corresponding parameter value and signal light flash).

  • Page 20: Functional Characteristics

    Functional characteristics TIG welding Functional characteristics TIG welding 5.1.1 Setting the shielding gas volume (gas test)/rinse hose package • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. •...

  • Page 21: 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 ignition behaviour and minimum current limits. The ignition energy is controlled by the set electrode dia- meter.

  • Page 22: Hf Ignition

    Functional characteristics TIG welding 5.1.3.1 HF ignition Figure 5-2 The arc is started without contact using high-voltage ignition pulses: a) Position the welding torch in the welding position above the workpiece (distance between the electrode tip and the workpiece approx. 2-3 mm). b) Press the torch trigger (high-voltage ignition pulses start the arc).

  • Page 23: Operating Modes (Functional Sequences)

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

  • Page 24: Non-Latched Mode

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

  • Page 25: Latched Mode

    Functional characteristics TIG welding 5.1.4.3 Latched mode Selection Figure 5-6 Sequence Figure 5-7 099-00T405-EW501 14.02.2022...

  • Page 26: Spotarc

    Functional characteristics TIG welding 1st cycle • Press torch trigger 1 , the gas pre-flow time elapses. • HF start pulses jump from the electrode to the workpiece. The arc ignites. • Welding current flows and immediately assumes the set start current (search arc at minimum set- ting).
  • Page 27 Functional characteristics TIG welding Figure 5-9 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.1.3 chapter. Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. •...

  • Page 28: Spotmatic

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

  • Page 29: Non-Latched Operation, Version C

    Functional characteristics TIG welding As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.1.3 chapter. Selecting the process activation type for the welding process > see 5.6 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) only.

  • Page 30: Average Value Pulse Welding

    Functional characteristics TIG welding 5.1.5 Average value pulse welding Once the pulse function is activated, the red signal lights for the main current AMP and secondary current AMP% light up at the same time. Average value pulsing means that the system switches between two currents periodically, an average current value (AMP), a pulse current (Ipuls), a balance ( ) and a fre- quency (...

  • Page 31: Pulsed Welding In The Upslope And Downslope Phases

    Functional characteristics TIG welding Pulse balance Figure 5-16 Pulse frequency Figure 5-17 5.1.5.1 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 ) > see 5.6 chapter. Figure 5-18 5.1.5.2 Automated pulses...

  • Page 32: 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 33: Torch Mode Setting

    Functional characteristics TIG welding 5.1.8.2 Torch mode setting Modes 1 to 6 and 11 to 16 are available to the user. Modes 11 to 16 feature the same functionality as 1 to 6, but without the tapping function > see 5.1.8.1 chapter for the secondary current. The functionality of the individual modes can be found in the corresponding torch type tables.

  • Page 34: Standard Tig Torch (5-Pole)

    Functional characteristics TIG welding 5.1.8.5 Standard TIG torch (5-pole) Standard torch with one torch trigger Figure Operating ele- 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 Functions Mode Operating ele- ments Welding current on/off Secondary current (ex works) Secondary current (tapping function)

  • Page 36: Tig Up/Down Torch (8-Pole)

    Functional characteristics TIG welding 5.1.8.6 TIG up/down torch (8-pole) Up/down torch with one torch trigger Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 Functions Mode Operating ele- 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)

  • Page 38: Potentiometer Torch (8-Pole)

    Functional characteristics TIG welding 5.1.8.7 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch > see 5.1.8.8 chapter. Potentiometer torch with one torch trigger Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 Functions Mode Operating ele-...

  • Page 39: Configuring The Tig Potentiometer Torch Connection

    Functional characteristics TIG welding 5.1.8.8 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: Rtf 1 Foot-Operated Remote Control

    Functional characteristics TIG welding 5.1.9 RTF 1 foot-operated remote control 5.1.9.1 RTF start ramp The RTF start ramp function prevents the energy input at the start of welding from being too high and too fast should the user press the remote control pedal too fast and too strongly. Example: The user sets the main current at the welding machine to 200 A.

  • Page 41: Rtf Response

    Functional characteristics TIG welding 5.1.9.2 RTF response This function controls the current response during the main current phase. The user can choose between linear and logarithmic response. The logarithmic setting is especially suited for welding with low currents, e.g. for thin panels, as the logarithmic response enables a better control of the welding current. In the machine configuration menu, the RTF response function can be toggled between linear response...

  • Page 42: Expert Menu (Tig)

    Functional characteristics TIG welding 5.1.10 Expert menu (TIG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa- rameters shown may be limited, e.g. if a function is deactivated. ENTER EXIT Figure 5-23 Display Setting/selection Expert menu Gas pre-flow time...

  • Page 43: 5.1.11 Aligning The Cable Resistance

    Functional characteristics TIG welding Display Setting/selection End current time (duration of end current) Parameter activArc > see 5.1.6 chapter Setting the intensity Ignition type (TIG) -------HF start active (ex works) -------Lift arc ignition active 5.1.11 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 chan- ged.

  • Page 44: Mma Welding

    Functional characteristics MMA welding 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Unfasten the tungsten electrode and extract. 2 Configuration • Activate the rotary knob while switching on the welding machine at the same time. •...

  • Page 45: Hotstart

    Functional characteristics MMA welding 5.2.2 Hotstart The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent metal at the beginning of the welding process. The ignition takes place here with increased current (hot start current) over a certain time (hot start time).

  • Page 46: Average Value Pulse Welding

    Functional characteristics MMA welding 5.2.5 Average value pulse welding Average value pulse welding means that two currents are switched periodically, a current average value (AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the para- meter as a percentage of the current average value (AMP).

  • Page 47: Expert Menu (Mma)

    Functional characteristics MMA welding Pulse balance Figure 5-32 Pulse frequency Figure 5-33 5.2.6 Expert menu (MMA) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa- rameters shown may be limited, e.g. if a function is deactivated. The setting ranges for the parameter values are summarised in the Parameter overview sec- tion >...

  • Page 48: Power-Saving Mode (Standby)

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

  • Page 49: 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 5-35 Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (ex works 1) >...
  • Page 50 Functional characteristics Machine configuration menu Display Setting/selection Alternative welding start – tapping start Available from torch mode 11 (welding stop by tapping remains active). ------- Function enabled (ex works) ------- Function disabled Up/down speed > see 5.1.8.3 chapter Increase value > rapid current change Decrease value >...
  • Page 51 Functional characteristics Machine configuration menu Display Setting/selection Process activation setting > see 5.1.4.5 chapter -------Separate process activation (ex works) -------Permanent process activation Torch cooling mode -------Automatic operation (ex works) -------Permanently enabled -------Permanently disabled Welding torch cooling, post-flow time Setting 1–60 min. (ex works 5 min.) Time-based power-saving mode >...
  • Page 52 Functional characteristics Machine configuration menu Display Setting/selection Minimum current limit (TIG) > see 5.1.2 chapter Depending on the set tungsten electrode diameter ------- Function disabled ------- Function enabled (ex works) Access control – access code Setting: 000 to 999 (000 ex works) Access control >...

  • Page 53: Rectifying Faults

    Rectifying faults Warnings 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 54: Error Messages

    Rectifying faults Error messages Error messages Depending on the options of the machine display, a fault is shown as follows: Display type - machine control Display Graphic display two 7-segment displays one 7-segment display The possible cause of the fault is signalled by a corresponding fault number (see table). In the case of an error, the power unit shuts down.

  • Page 55: Resetting Welding Parameters To The Factory Settings

    Rectifying faults Resetting welding parameters to the factory settings Error Possible cause Remedy Electronics error (I>0 error) Electronics error (Uact error) Switch the machine off and on. If the error persists, no- Electronics error (A/D channel error) tify Service. Electronics error (slope error) Electronics error (S sign) Electronics error (temperature error) Allow the machine to cool.

  • Page 56: 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 57: Disposing Of Equipment

    Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html.

  • Page 58: Appendix

    Appendix Parameter overview – setting ranges Appendix Parameter overview – setting ranges 8.1.1 TIG welding Name Display Setting range Main current AMP, depending on power source Gas pre-flow time Start current, percentage of AMP Start current, absolute, depending on power source Start time 0,01 0,01...

  • Page 59: 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. 8.1.2 MMA welding Name Display Setting range Main current AMP, depending on power source...

  • Page 60: 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" 099-00T405-EW501 14.02.2022...

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