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Summary of Contents for EWM Tetrix 230 Smart 5P TM
- Page 1 Operating instructions Welding machine Tetrix 230 Smart 5P TM Tetrix 230 Smart 8P TM 099-000156-EW501 22.08.2014 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
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Page 2: General Instructions
+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. No other form of liability, regardless of type, shall be accepted. -
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 5.8.7.4 Spotmatic ...................... 39 5.8.8 Pulses, function sequences ..................41 5.8.8.1 Automated pulses ..................41 5.8.9 TIG activArc welding ..................... 41 5.8.10 Welding torch (operating variants) ................42 5.8.10.1 Tap torch trigger (tapping function) ............... 42 5.8.11 Torch mode and up/down speed setting ..............
- Page 5 Contents Notes on the use of these operating instructions Welding torch cooling system ...................... 71 General accessories ........................71 10 Appendix A ............................72 10.1 Overview of EWM branches ......................72 099-000156-EW501 22.08.2014...
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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 (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu) EXIT 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 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 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.
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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
3.1.1.1 activArc 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
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 Item Symbol Description Carrying handle Machine control See Machine control – operating elements chapter Connection socket, 5-pole/8-pole (depending on variant) 5-pole: Control cable TIG standard torch 8-pole: Control cable TIG up/down or potentiometer torch Connection socket, "+"... -
Page 17: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description 4-pole connection socket Cooling unit voltage supply Ignition type changeover switch Liftarc (contact ignition) HF ignition Main switch, machine on/off Cooling air outlet Machine feet Mains connection cable G¼”... -
Page 18: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 Item Symbol Description Error/status indicators Collective interference signal light (see Rectifying faults chapter) Water deficiency signal light (welding torch cooling) Excess temperature signal light Display, 3-digit Welding process button MMA welding... - Page 19 Machine description – quick overview Machine control – Operating elements 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 dial Setting currents, times and parameters.
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Page 20: 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 21: Workpiece Lead, General
Design and function Workpiece lead, general Workpiece lead, general CAUTION Risk of burns due to incorrect connection of the workpiece lead! Paint, rust and dirt on the connection restrict the power flow and may lead to stray welding currents. Stray welding currents may cause fires and injuries! •... -
Page 22: Adjusting The Length Of The Carrying Strap
Design and function Machine cooling 5.3.1 Adjusting the length of the carrying strap NOTE To demonstrate adjustment, lengthening the strap is shown in the figure. To shorten, the strap's loops must be inched in the opposite direction. Figure 5-1 Machine cooling To obtain an optimal duty cycle from the power components, the following precautions should be observed: •... -
Page 23: 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 NOTE 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 24 Design and function Notes on the installation of welding current leads NOTE Use an individual welding lead to the workpiece for each welding machine! Figure 5-3 NOTE 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.
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Page 25: 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 26: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system 5.7.1 Cooling module connection NOTE Please note the relevant documentation of the accessory components. Figure 5-6 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: Tig Welding
Design and function TIG welding TIG welding 5.8.1 Welding torch and workpiece line connection NOTE Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-7 Item Symbol Description Welding torch Welding torch hose package Connection socket, "-"... -
Page 28: Torch Connection Options And Pin Assignments
Design and function TIG welding 5.8.1.1 Torch connection options and pin assignments Figure 5-8 5.8.2 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. •... -
Page 29: Connecting The Shielding Gas Supply
Design and function TIG welding 5.8.2.1 Connecting the shielding gas supply • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. Figure 5-9 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve •... -
Page 30: Setting The Shielding Gas Quantity
Design and function TIG welding 5.8.2.2 Setting the shielding gas quantity CAUTION Electric shocks! When setting the shielding gas quantity, high voltage ignition pulses or open circuit voltage are applied at the welding torch; these can lead to electric shocks and burning on contact. -
Page 31: Select Welding Task
Design and function TIG welding 5.8.3 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: Symbol Description Welding process button MMA welding... -
Page 32: Arc Ignition
Design and function TIG welding 5.8.5 Arc ignition 5.8.5.1 HF ignition Figure 5-11 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 33: Function Sequences/Operating Modes
Design and function TIG welding 5.8.6 Function sequences/operating modes The parameters for the function sequence are set using the “Select welding parameters” button and the “Welding parameter setting” rotary dial. Figure 5-13 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. -
Page 34: Tig Runtime Parameters
Design and function TIG welding 5.8.7 TIG runtime parameters ENTER EXIT Figure 5-14 Display Setting/selection Main current I1 (AMP) Main current setting Secondary current (AMP%) Setting range in percent: 1% to 100% (depending on main current). Setting range, absolute: Imin to Imax. Downslope time 0.00 s to 20.0 s (0.1 s increments). -
Page 35: Non-Latched Mode
Design and function TIG welding 5.8.7.1 Non-latched mode Figure 5-15 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 36: Latched Mode
Design and function TIG welding 5.8.7.2 Latched mode Figure 5-16 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 37: Spotarc
Design and function TIG welding 5.8.7.3 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 38 Design and function TIG welding Figure 5-17 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however (see chapter "Arc ignition"). Sequence: • Press and hold torch trigger 1. • The gas pre-flow time elapses. •...
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Page 39: Spotmatic
Design and function TIG welding 5.8.7.4 Spotmatic NOTE This function must be enabled before use, see "Advanced settings" 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. The torch trigger is used for process activation. - Page 40 Design and function TIG welding Figure 5-18 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however (see chapter "Arc ignition"). Select the process activation type (see chapter "Advanced settings"). Up- and down-slope times possible for long setting range of the spot time (0.01 s - 20.0 s) only. ...
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Page 41: Pulses, Function Sequences
5.8.9 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 42: Welding Torch (Operating Variants)
Design and function TIG welding 5.8.10 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 43: Torch Mode And Up/Down Speed Setting
Design and function TIG welding 5.8.11 Torch mode and up/down speed setting The user has the modes 1 to 4 and modes 11 to 14 available. Modes 11 to 14 include the same function options as 1 to 4, 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 44: Standard Tig Torch (5-Pole)
Design and function TIG welding 5.8.11.1 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 Welding current On/Off (factory-set) Secondary current (Latched mode) Standard torch with two torch triggers:... - Page 45 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)
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Page 46: Tig Up/Down Torch (8-Pole)
Design and function TIG welding 5.8.11.2 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 Welding current on/off Secondary current (tapping mode) / (Latched mode) (factory- set) Increase welding current, infinite adjustment (up function) - Page 47 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)
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Page 48: Potentiometer Torch (8-Pole)
Design and function TIG welding 5.8.11.3 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 49: Configuring The Tig Potentiometer Torch Connection
Design and function TIG welding 5.8.11.4 Configuring the TIG potentiometer torch connection 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 50: 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 51: Select Welding Task
Design and function MMA welding 5.9.2 Select welding task Operating Action Result element Select MMA welding process signal light lights up in green Set welding current 5.9.3 Hotstart current and Hotstart time The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) =... -
Page 52: Remote Control
Design and function Remote control 5.10 Remote control NOTE Insert the remote control control cable into the 19-pole connection socket for remote control connection and lock. 5.10.1 Manual remote control RT1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. -
Page 53: Foot-Operated Remote Control Rtf1 19Pol 5 M / Rtf2 19Pol 5 M
Design and function Remote control 5.10.6 Foot-operated remote control RTF1 19POL 5 M / RTF2 19POL 5 M Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. • Start/stop welding operation (TIG) ActivArc welding is not possible in combination with the foot-operated remote control. -
Page 54: Interfaces For Automation
Design and function Interfaces for automation 5.11 Interfaces for automation 5.11.1 Remote control connection socket, 19-pole 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. •... -
Page 55: Machine Configuration Menu
Design and function Machine configuration menu 5.12 Machine configuration menu The machine menu includes basic functions such as torch modes, display settings and the service menu. 5.12.1 Selecting, changing and saving parameters NOTE ENTER (enter the menu) • Switch off machine at the main switch •... -
Page 56: Testing The Machine Fan
Design and function Machine configuration menu 5.12.3 Testing the machine fan The machine fan can be switched on at the machine controls so that you can check that it is working correctly. ENTER NAVIGATION EXIT Figure 5-28 Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access Service menu Service settings... -
Page 57: Limiting The Mains Current (10A)
Design and function Machine configuration menu 5.12.4 Limiting the mains current (10A) If the plug socket has a 10A mains fuse in order to comply with national regulations, it may be necessary to reduce the mains current of the welding machine to 10A in order to avoid triggering the fuse. This restricts the welding machine's power input. -
Page 58: Protecting Welding Parameters From Unauthorised Access
Design and function Machine configuration menu 5.12.5 Protecting welding parameters from unauthorised access To protect against unauthorised or unintentional changes to the welding parameters, you can lock the machine controls with a software key (3-digit machine code). If the access lock is active, only the following parameters can be changed: •... -
Page 59: Changing The Three-Digit Machine Code
Design and function Machine configuration menu 5.12.5.1 Changing the three-digit machine code In this menu you can change the 3-digit machine code. After entering and confirming the old code, you can enter a new code. The correct machine code is necessary for activating and deactivating the access lock! ENTER NAVIGATION EXIT... -
Page 60: Setting The Welding Current (Absolute/Percentage)
Design and function Machine configuration menu 5.12.6 Setting the welding current (absolute/percentage) The welding currents for start current, secondary current, end current and hotstart current can be set as percentages (factory setting) or absolute values. If absolute current display is set, the "AMP" signal light for the main current is lit in addition to the respective "AMP%"... -
Page 61: Spotarc / Spotmatic Configuration
Design and function Machine configuration menu 5.12.7 spotarc / Spotmatic configuration ENTER EXIT Figure 5-33 Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access Settings Settings for machine functions and parameter displays Spotmatic Function switched off Spotmatic Function switched on Exit the menu Exit Setting spot time... -
Page 62: 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 63: 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 2002/95/EC). -
Page 64: 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 65 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 ...
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Page 66: 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 67: 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. RESET Aut om at ic Puls Figure 7-1 Display Setting/selection Input confirmation User entries are applied, release button(s). -
Page 68: 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! ENTER NAVIGATION EXIT Figure 7-2 Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access Service menu Service settings Exit the menu... -
Page 69: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit NOTE 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 7-3 099-000156-EW501 22.08.2014... -
Page 70: Technical Data
Technical data Tetrix 230 Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 230 Setting range Welding current 3 A-230 A 5 A-180 A Welding voltage 10.1 V-19.2 V 20.2-27.2 V Duty cycle (DC) at 25 °C 45% DC 230 A 180 A... -
Page 71: Accessories
Accessories Remote controls and accessories Accessories NOTE 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. RT1 19POL Remote control current 090-008097-00000 RTG1 19POL Remote control, current 090-008106-00000 RTP1 19POL... - Page 72 Appendix A Overview of EWM branches Appendix A 10.1 Overview of EWM branches 099-000156-EW501 22.08.2014...
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