EWM T 4.01 Operating Instructions Manual Download Page 1

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Operating instructions

Control

T4.01 - Tetrix DC Comfort 2.0

T4.09 - Tetrix DC Comfort 2.0

T4.12 - Tetrix DC Comfort 2.0

099-00T401-EW501 Observe additional system documents!

01.02.2022

Summary of Contents for T 4.01

Page 1: ...Operating instructions EN Control T4 01 Tetrix DC Comfort 2 0 T4 09 Tetrix DC Comfort 2 0 T4 12 Tetrix DC Comfort 2 0 099 00T401 EW501 Observe additional system documents 01 02 2022...

Page 2: ...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 This exclusion of liability shall be deemed ac...

Page 3: ...TIG welding 20 5 1 1 Setting the shielding gas volume gas test rinse hose package 20 5 1 1 1 Automatic gas post flow 20 5 1 2 Welding task selection 21 5 1 2 1 Recurring welding tasks JOB 1 100 22 5...

Page 4: ...by means of the JOB list 53 5 3 3 Select wire speed operating mode KORREKTUR MANUELL 54 5 3 4 Setting the welding current and wire speed 54 5 3 5 Operating modes functional sequences 55 5 3 5 1 Explan...

Page 5: ...s and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning sym bol The hazard is also highlighted using a symbol in the page margin CAUTION Working or ope...

Page 6: ...tch off machine Release Switch on machine Press and hold Switch Incorrect Invalid Turn Correct Valid Numerical value adjustable Input Signal light lights up in green Navigation Signal light flashes gr...

Page 7: ...cal specialist may interconnect the sources as per standard IEC 60974 9 2010 Installa tion and use and German Accident Prevention Regulation BVG D1 formerly VBG 15 or country specific regulations Befo...

Page 8: ...temperatures of 100 C or higher and arcing and work on live components Hearing protection against harming noise Explosion risk Apparently harmless substances in closed containers may generate excessi...

Page 9: ...s specified in the standard The user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the use...

Page 10: ...placement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the ma chine is switched off Requirements for connection to the public...

Page 11: ...on or connection points can heat up significantly during operation water cooled version When opening the coolant circuit escaping coolant may cause scalding Open the coolant circuit only when the powe...

Page 12: ...correctly No liability is accepted for any damages arising from improper usage The equipment must only be used in line with its designated purpose and by trained or expert personnel Do not improperly...

Page 13: ...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 exampl...

Page 14: ...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 paramet...

Page 15: ...tivate 4 Pulsing push button see 5 1 7 chapter Automated pulsing frequency and balance Signal light turns green Thermal pulsed TIG welding MMA pulse welding Signal light turns red Metallurgical pulsed...

Page 16: ...light see 5 6 chapter 13 Hold Signal light Status display After each completed welding task the last values used in the welding process for the welding current and welding voltage are shown on the dis...

Page 17: ...Signal light activArc see 5 1 5 chapter 7 Signal light two colour Green Pulse frequency MMA Red Pulse frequency TIG average value pulsing 8 Parameter selection push button left The welding sequence pa...

Page 18: ...that if no pulse variant was selected for example no pulse parameters will be available to set in the function sequence 4 2 1 Setting the welding current absolute percentage The welding current can be...

Page 19: ...settings Factory setting example value 20 Parameter is set to optimum value Decrease the parameter value To return to the factory settings 4 3 4 Setting advanced welding parameters Expert menu The Exp...

Page 20: ...just the shielding gas quantity to suit the welding task Setting instructions Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11 5 l min MIG brazing Wire diameter x 11 5...

Page 21: ...can also be set to meet individual requirements e g for thin panels a smaller diameter is recommended to reduce the ignition energy The electrode diameter setting determines the minimum current limit...

Page 22: ...individually for latched and non latched operation Selection Figure 5 2 When one or more of the recurring welding tasks has been selected the JOB signal light comes on 5 1 3 Arc ignition To change the...

Page 23: ...ing on the operat ing mode set to the ignition or main current set c Lift off the torch and swivel to the normal position Ending the welding process Release the torch trigger or press and release depe...

Page 24: ...n current minimum to maximum current AMP Secondary current Pulse time Pulse pause time Pulse current Latched operating mode Slope time from main current AMP to secondary current AMP TIG thermal pulsin...

Page 25: ...welding cur rent decreases to the secondary current AMP in the set slope time If torch trigger 2 is released the welding current increases again to the main current AMP in the set slope time The param...

Page 26: ...Functional characteristics TIG welding 26 099 00T401 EW501 01 02 2022 5 1 4 3 Latched mode Selection Figure 5 7 Sequence Figure 5 8...

Page 27: ...third cycle will be omitted 4th cycle Release torch trigger 1 arc is extinguished Set gas post flow time runs When the foot operated remote control is connected the machine switches automatically to n...

Page 28: ...jump from the electrode to the workpiece The arc ignites The welding current flows and immediately assumes the value of the start current HF switches off The welding current ramps up to the main curr...

Page 29: ...torch trigger Process activation is automatically terminated after 30 s of inactivity Permanent process activation The welding process is activated by pressing the torch trigger once The following ar...

Page 30: ...ess and release the torch trigger tap to reactivate the welding process only for separate process activation Touching the welding torch with the tungsten electrode tip against the workpiece again will...

Page 31: ...vents the tungsten electrode sticking in the molten pool and the tungsten inclusions are reduced Selection 4s Figure 5 14 Setting Parameter setting The activArc parameter control can be adjusted speci...

Page 32: ...the weld pool that have a positive effect on the gap bridging The required pulse parameters are automatically defined by the machine control If required the function can be disabled by pressing the pu...

Page 33: ...se setting 4s Figure 5 19 Pulse edge setting The and pulse edges can be set in the Expert menu TIG see 5 1 11 chapter 5 1 7 3 Pulsed welding in the upslope and downslope phases The pulse function can...

Page 34: ...the plasma force arc force occurring at high currents which al lows you to achieve a constricted arc with concentrated heat input Unlike thermal pulsing no times are set a frequency and the balance ar...

Page 35: ...ctivated the red signal lights for the main current AMP and secondary current AMP light up at the same time Average value pulse welding means that the system switches between two currents periodically...

Page 36: ...he secondary current The functionality of the individual modes can be found in the corresponding torch type tables The torch modes are set using the torch configuration parameters in the machine confi...

Page 37: ...ts Welding current on off 1 ex works Secondary current latched operation Standard torch with two torch triggers Figure Operating ele ments Explanation of symbols BRT1 torch trigger 1 BRT2 torch trigge...

Page 38: ...rch trigger 2 Functions Mode Operating ele ments Welding current on off 1 ex works Secondary current Secondary current tapping function 1 latched operating mode Welding current on off 2 Secondary curr...

Page 39: ...perating ele ments Welding current on off 1 ex works Secondary current tapping function 1 latched operating mode Increase welding current up function2 Decrease welding current down function2 Welding c...

Page 40: ...condary current Secondary current tapping function 1 latched operating mode Increase welding current up function2 Decrease welding current down function2 Modes 2 and 3 are not used with this type of t...

Page 41: ...bols BRT 1 torch trigger 1 Functions Mode Operating ele ments Welding current on off 3 Secondary current tapping function1 Increase welding current Decrease welding current Potentiometer torch with tw...

Page 42: ...be repaired or modified by specialist skilled persons The warranty becomes null and void in the event of unauthorised interference Appoint only skilled persons for repair work trained service personn...

Page 43: ...g Increase JOB number BRT 3 Decrease JOB number BRT 4 Gas test BRT 2 3 s Welding current on off 6 BRT 1 Secondary current BRT 2 Secondary current tapping function BRT 1 tapping Increase welding curren...

Page 44: ...The user sets the main current at the welding machine to 200 A The user presses the remote control pe dal very quickly down by approx 50 of the pedal travel RTF start ramp switched on The welding curr...

Page 45: ...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 th...

Page 46: ...ored that don t require regular setting The number of pa rameters shown may be limited e g if a function is deactivated Figure 5 30 Display Setting selection Expert menu Start time duration of start c...

Page 47: ...can be disabled during pulse pauses not the case for automated pul sing or kHz pulsing Function disabled Function enabled ex works Filler wire diameter manual setting Setting the wire diameter betwee...

Page 48: ...rch or the intermediate hose package AW has been chan ged The resistance value of the cables can be set directly or can be aligned by the power source In the delivery state the cable resistance is set...

Page 49: ...fly which is used to determine and display the cable resistance The value can be between 0 m and 60 m The new value is immediately saved without requiring further confirmation If no value is shown on...

Page 50: ...ufficient 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 A Hot...

Page 51: ...lting electrode types at low current strengths with a short arc in particular 4s Figure 5 36 5 2 4 Antistick The Antistick feature prevents the electrode from annealing Should the electrode stick desp...

Page 52: ...current e g 100 A Ipuls pulse current x AMP e g 140 x 100 A 140 A IPP pulse pause current 1 200 of AMP Tpuls duration of one pulse cycle 1 e g 1 100 Hz 10 ms Balance Selection Figure 5 39 With manual...

Page 53: ...t the welding current average value AMP is maintained at all times Figure 5 40 AMP Main current e g 100 A Ipuls Pulse current x AMP e g 140 x 100 A 140 A IPP Pulse pause current Tpuls Duration of one...

Page 54: ...and can be corrected as a percentage on the wire feed unit In the wire feed unit underneath the cap is a switch for selecting the operating mode 5 3 4 Setting the welding current and wire speed Opera...

Page 55: ...elding current on or off Torch trigger 1 BRT 1 switches the wire feed on or off The operator can choose between three operating modes see following function sequences Figure 5 42 5 3 5 1 Explanation o...

Page 56: ...he selected up slope time 1st cycle wire Press torch trigger 1 BRT 1 Wire electrode is advanced 2nd cycle wire Release BRT 1 Wire electrode advance stops 3rd cycle current Press BRT 2 The main current...

Page 57: ...tapping the BRT 1 By pressing and releasing tapping the BRT 1 again wire feeding will stop It is not necessary to keep the torch trigger pressed This is especially helpful with long welding seams 5 4...

Page 58: ...s block activation is indicated by the Access block active signal light see 4 chapter Disabling access block Enter the access code for the access block Select parameter and enter the previously select...

Page 59: ...u Basic machine settings are defined in the machine configuration menu 5 7 1 Selecting changing and saving parameters l 0 A A B A A A A A B B B B B B B B B B B B B B B B B B B B B B B B B B A B B B B...

Page 60: ...ion secondary end and hot start cur rent see 4 2 1 chapter Welding current setting absolute Welding current setting as a percentage of the main current ex works Non latched operation version C see 5 1...

Page 61: ...Welding current polarity switching 1 polarity switching at the RT PWS 1 19POL remote control ex works polarity switching at the welding machine control spotmatic operating mode see 5 1 4 5 chapter Ig...

Page 62: ...ic AVC Arc voltage control connection Gas monitoring Depending on where the gas sensor is situated the use of a pilot static tube and the welding process monitoring phase Function disabled ex works Mo...

Page 63: ...nual rC on off operating mode 3 Select machine function control with external control voltages signals with machine control Software version query System bus ID and version number are separated by a d...

Page 64: ...service personnel if required Warning code Possible cause Remedy 1 Machine excess temperature Allow the machine to cool down 2 Half wave failures Check process parameters 3 Welding torch cooling warn...

Page 65: ...up if necessary 8 Gas error Check the gas supply 9 Secondary overvoltage Switch the machine off and on If the error persists no tify Service 10 PE error 11 FastStop position Slope Acknowledge error si...

Page 66: ...lding process 49 Arc interruption Inform service 51 Error in the emergency stop circuit interface for automated welding Check the external shutdown devices Check jumper JP 1 on PCB T320 1 57 Auxiliary...

Page 67: ...es Observe the maintenance instructions In the event that the provisions of one of the below stated tests are not met the machine must not be operated again until it has been repaired and a new test h...

Page 68: ...tem separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private households can be disposed of free of...

Page 69: ...s 0 00 20 0 Down slope time 1 0 s 0 0 20 0 End current percentage of AMP 20 1 200 End current absolute depending on power source A End current time 0 01 s 0 01 20 0 Gas post flow time 8 s 0 0 40 0 Ele...

Page 70: ...current AMP depending on power source A Hot start current percentage of AMP 120 1 200 Hot start current percentage of AMP 1 150 1 150 Hot start current absolute depending on power source A Hot start...

Page 71: ...Appendix Searching for a dealer 099 00T401 EW501 01 02 2022 71 8 2 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide...

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