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........................
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Contents Notes on the use of these operating instructions 5.7.6 Function sequences/operating modes................32 5.7.6.1 Explanation of symbols .................32 5.7.6.2 Tap torch trigger (tapping function) ...............32 5.7.6.3 Non-latched mode ..................33 5.7.6.4 Latched mode....................34 5.7.6.5 SpotArc......................35 5.7.6.6 Spotmatic ......................37 5.7.6.7 Non-latched operation, version C..............38 5.7.7 Pulses, function sequences ..................39 5.7.7.1...
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Tetrix 180 Comfort ........................75 9 Accessories ............................76 Remote controls and accessories....................76 Options............................76 Transportsysteme ........................76 General accessories ........................76 Computer communication......................76 10 Appendix A ............................77 10.1 Overview of EWM branches ......................77 099-000097-EW501 14.03.2012...
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. •...
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...
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. •...
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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! •...
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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! •...
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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.
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! •...
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.
3.1.2 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.
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: •...
Machine description Front view Machine description Front view Figure 4-1 Item Symbol Description Carrying strap Machine control See Machine control – operating elements chapter Connection socket, “+” welding current Connection for workpiece lead Connection socket, 5-pole/8-pole/12-pole 5-pole: Standard TIG torch control lead 8-pole: TIG Up/Down or potentiometer torch control lead 12-pole:...
Machine description Machine control – Operating elements Machine control – Operating elements NOTE Machine control provides the user with up to 8 welding tasks (JOBs). JOB 0 represents manual operating mode. This is where you can change/optimise all parameters directly in machine control (see chapter "Operating concepts"). Figure 4-3 Item Symbol Description...
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Machine description Machine control – Operating elements Item Symbol Description Operating mode button spotArc (spot time setting range 0.01 sec. to 20.0 sec.) Non-latched Latched TIG pulses key button TIG automated pulses (frequency and balance) TIG pulses with times, lights up in green / Fast TIG DC pulses with frequency and balance, lights up in red Welding parameter setting rotary transducer Setting flows, times and parameters.
Machine description Machine control – Operating elements 4.3.1 Function sequence Figure 4-4 Item Symbol Description Gas pre-flow time (TIG) absolute setting range 0.0 sec to 20.0 sec (0.1s increments). AMP% Ignition current (TIG) Hotstart current (MMA) Percentage of the main current. Percentage of the main current.
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Machine description Machine control – Operating elements Item Symbol Description Gas post-flow time (TIG) Setting ranges: 0.00 sec to 40.0 sec (0.1 sec increments). Balance TIG DC pulses (15 kHz) Setting range: 1% to +99% (1% increments). Frequency TIG DC pulses (15 kHz) Setting range: 50 Hz to 15 kHz activArc TIG welding process •...
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! •...
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! •...
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 (any phase sequence for three-phase machines)!
Design and function TIG welding TIG welding 5.6.1 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 Welding torch Welding torch hose package Connection socket, "-"...
Design and function TIG welding 5.6.2 Torch connection options and pin assignments Figure 5-4 5.6.3 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. •...
Design and function TIG welding 5.6.3.1 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 5-5 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve •...
Design and function TIG welding 5.6.3.2 Setting the shielding gas quantity NOTE Rule of thumb for the gas flow rate: Diameter of gas nozzle in mm corresponds to gas flow in l/min. Example: 7mm gas nozzle corresponds to 7l/min gas flow. Incorrect shielding gas setting! If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to form.
Design and function Select welding task Select welding task NOTE Machine control provides the user with up to 8 welding tasks (JOBs). JOB 0 represents manual operating mode. This is where you can change/optimise all parameters directly in machine control (see chapter "Operating concepts"). 5.7.1 Manual, standard operation (JOB 0) "Manual, standard operation (JOB 0)"...
Design and function Select welding task 5.7.2 Save welding tasks (JOBs) You can select, change and save the required welding parameters for recurring welding tasks (JOBs) in up to 7 JOBs (JOB 1 to JOB 7). 5.7.2.1 Displaying and changing the JOB number Operating Action Result...
Design and function Select welding task 5.7.4 Arc ignition 5.7.4.1 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.
Design and function Select welding task 5.7.6 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 5-9 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.
Design and function Select welding task 5.7.6.3 Non-latched mode Figure 5-10 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. •...
Design and function Select welding task 5.7.6.4 Latched mode AMP% start Down Figure 5-11 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. •...
Design and function Select welding task 5.7.6.5 SpotArc The TIG SpotArc function is activated with the pulse variant automated frequencies by default, because this combination produces the most effective results. The user can of course combine the function with other pulse variants depending on the selected welding process. Pulse time (t1) and pulse break time (t2) can be set independently, but the spot time (tP) should be much greater than the pulse time in order to achieve an appropriate result.
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Design and function Select welding task Sequence: • 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 •...
Design and function Select welding task 5.7.6.6 Spotmatic The arc is ignited fully automatically without actuating the torch trigger by simply touching the tip of the electrode with the workpiece. Hundreds of reproducible tacks can be made without tungsten inclusions. NOTE Selection and adjustment are made in the same way as with spotArc operating mode (see chapter TIG spotArc).
Design and function Select welding task 5.7.6.7 Non-latched operation, version C Figure 5-14 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).
Design and function Select welding task 5.7.7 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").
Design and function Select welding task 5.7.8 Pulse variants NOTE The machines have an integrated pulse device. With pulses, the machine switches back and forth between the pulse current (main current) and pause current (secondary current). Pulses (thermal pulses) With thermal pulses, the pulse and pause times (frequency up to 200 Hz) and the pulse edges (ts1 and ts2) are entered in seconds on the control.
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Design and function Select welding task KHz pulses (metallurgic pulses) The kHz pulses (metallurgic pulses) use the plasma pressure produced at high currents (arc pressure) which is used to achieve a constricted arc with concentrated heat feeding. The frequency can be infinitely adjusted from 50 Hz to 15 kHz and the pulse balance from 1-99 %.
5.7.9 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.
Design and function Select welding task 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...
Design and function Select welding task 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.
Design and function Select welding task 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)
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Design and function Select welding task 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...
Design and function Select welding task 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...
Design and function Select welding task 5.7.11.4 RETOX TIG torch (12-pole) NOTE For operation with this welding torch, the welding machine must be equipped with the retrofit option "ON 12POL RETOX TIG" (12-pole torch connection socket)! Diagram Operating elements Explanation of symbols TT= torch trigger BRT 1 BRT 3...
Design and function Select welding task 5.7.12 Setting the first increment Figure 5-20 Figure 5-21 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! 099-000097-EW501 14.03.2012...
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 •...
Design and function MMA welding 5.8.2 Select welding task Operating Action Result element Select MMA welding process signal light lights up in green Set welding current 5.8.3 Arcforce Shortly before the electrode threatens to stick, the arcforcing device sets an increased current designed to prevent the electrode sticking.
Design and function MMA welding 5.8.5 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 5-24 Operating Action Result Display...
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...
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) ActivArc welding is not possible in combination with the RTF 1 foot-operated remote control. FFr >...
Design and function Interfaces for automation 5.10 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! •...
Design and function Protecting welding parameters from unauthorised access 5.11 Protecting welding parameters from unauthorised access NOTE These accessory components can be retrofitted as an option, see Accessories chapter. To protect against unauthorised or unintentional adjustment of the welding parameters on the machine, the control input can be locked with the aid of a key switch.
Design and function Advanced settings 5.13 Advanced settings 5.13.1 Setting slope times for secondary current AMP% or pulse edges Figure 5-27 Figure 5-28 Display Setting/selection Expert menu 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) 099-000097-EW501...
Design and function Advanced settings 5.13.2 TIG non-latched operating mode, C version Figure 5-29 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) 099-000097-EW501 14.03.2012...
Design and function Advanced settings 5.13.3 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.
Design and function Advanced settings 5.13.4 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 5-31 Display Setting/selection...
Design and function Advanced settings 5.13.5 Ramp function foot-operated remote control RTF 1 Figure 5-32 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...
Design and function Menus and sub-menus on the machine control 5.14 Menus and sub-menus on the machine control 5.14.1 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.
Design and function Menus and sub-menus on the machine control 5.14.3 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.
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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...
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Design and function Menus and sub-menus on the machine control Display Setting/selection Orbital welding Correction value for orbital current Service menu Modifications to the service menu may only be carried out by authorised maintenance staff! Reset (reset to factory settings) •...
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! •...
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. •...
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.
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Rectifying faults Checklist for rectifying faults 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 Inadequate or missing gas shielding Check shielding gas setting and replace shielding gas cylinder if necessary Shield welding site with protective screens (draughts affect the welding result) Use gas diffuser for aluminium applications and high-alloy steels...
Rectifying faults Error messages (power source) Error messages (power source) 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.
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)
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...
Technical data Tetrix 180 Comfort Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Tetrix 180 Comfort Welding current setting range 5A-180 A 5A-150 A Welding voltage setting range 10.2 V-17.2 V 20.2 V-26.0 V Duty cycle at 25 °C 35% DC 180 A...
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. RTF1 19POLE 5M Foot-operated remote control current with 094-006680-00000 connection cable RT1 19POL...
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