EWM Tetrix 180 Comfort 5P TG Operating Instructions Manual Download Page 7

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Safety instructions

Explanation of icons

099-000097-EW501

14.03.2012

2.2

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

Summary of Contents for Tetrix 180 Comfort 5P TG

Page 1: ...Welding machine GB Tetrix 180 Comfort 5P TG Tetrix 180 Comfort 8P TG 099 000097 EW501 14 03 2012 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warr...

Page 2: ...ther form of liability regardless of type shall be accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whethe...

Page 3: ...view 17 4 3 Machine control Operating elements 18 4 3 1 Function sequence 20 5 Design and function 22 5 1 General 22 5 2 Workpiece lead general 22 5 3 Transport and installation 23 5 3 1 Adjusting the...

Page 4: ...52 5 8 2 Select welding task 53 5 8 3 Arcforce 53 5 8 4 Antistick 53 5 8 5 Hotstart current and Hotstart time 54 5 9 Remote control 55 5 9 1 Manual remote control RT1 19POL 55 5 9 2 RTG1 19POL manual...

Page 5: ...ion 68 6 3 Maintenance work 69 6 4 Disposing of equipment 69 6 4 1 Manufacturer s declaration to the end user 69 6 5 Meeting the requirements of RoHS 69 7 Rectifying faults 70 7 1 Checklist for rectif...

Page 6: ...l in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading...

Page 7: ...scription Press Do not press Turn Switch l 0 Switch off machine l 0 Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display example wait 4s press Inter...

Page 8: ...s and burns on contact Even low voltages can cause you to get a shock and lead to accidents Do not touch any live parts in or on the machine Connection cables and leads must be free of faults Switchin...

Page 9: ...ith flammable material Connect welding leads correctly Risk of accidents if these safety instructions are not observed Non observance of these safety instructions is potentially fatal Carefully read t...

Page 10: ...suspend all conductive power source components like casing transport vehicle and crane frames so they are insulated Do not place any other electronic devices such as drillers or angle grinders etc on...

Page 11: ...he user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the user must consider the following...

Page 12: ...ble for transport by hand only The machine may not be lifted by crane or suspended CAUTION Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself duri...

Page 13: ...s of dust acid corrosive gases or substances may damage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambient...

Page 14: ...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 This helps prevents th...

Page 15: ...ted conversion work not specifically authorised by the manufacturer The original copy of the declaration of conformity is enclosed with the unit 3 2 3 Welding in environments with increased electrical...

Page 16: ...lding current Connection for workpiece lead 4 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 Control lead...

Page 17: ...switch machine on off 2 HF HF Ignition type changeover switch HF Liftarc contact ignition HF HF ignition 3 COM PC interface serial D Sub connection socket 9 pole 4 G connecting nipple Shielding gas co...

Page 18: ...concepts Figure 4 3 Item Symbol Description 0 1 S Error status indicators Collective interference signal light Water deficiency signal light welding torch cooling Excess temperature signal light S saf...

Page 19: ...time setting range 0 01 sec to 20 0 sec Non latched Latched 6 TIG pulses key button TIG automated pulses frequency and balance TIG pulses with times lights up in green Fast TIG DC pulses with frequenc...

Page 20: ...current MMA I min to I max 1 A increments 5 sec Pulse time slope time from AMP to AMP Spot time Pulse time setting range 0 01 s to 20 0 s 0 01 s increments 0 5 s 0 1 s increments 0 5 s Die Pulszeit g...

Page 21: ...s 11 Balance TIG DC pulses 15 kHz Setting range 1 to 99 1 increments 12 Frequency TIG DC pulses 15 kHz Setting range 50 Hz to 15 kHz 13 activArc TIG welding process Switch activArc on or off Correct t...

Page 22: ...carried out alternately using different methods and if a welding torch and an electrode holder remain connected to the machine the open circuit welding voltage is applied simultaneously on all cables...

Page 23: ...le 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 Safe operation of the machine must be guaranteed at all ti...

Page 24: ...g the generator always ensure it is earthed as stated in the operating instructions The resulting network has to be suitable for operating devices according to protection class 1 5 5 1 Mains configura...

Page 25: ...eter torch control lead 12 pole Control lead for TIG up down torch with display option 6 Workpiece 7 Connection socket for welding current Workpiece lead connection Insert the welding current plug on...

Page 26: ...lace shielding gas cylinders in the holders provided for them and secure with fixing devices Avoid heating the shielding gas cylinder CAUTION Faults in the shielding gas supply An unhindered shielding...

Page 27: ...mbol Description 0 1 Pressure regulator 2 Shielding gas cylinder 3 Output side of the pressure regulator 4 Cylinder valve Tighten the pressure regulator screw connection on the gas bottle valve to be...

Page 28: ...is can introduce air to the weld pool and may cause pores to form Adjust the shielding gas quantity to suit the welding task 5 6 3 3 Gas test Operating element Action Result x x Press the Select weldi...

Page 29: ...epeatedly makes all the required welding settings and re adjusts them for each individual welding task Operating element Action Result Select and display welding process TIG welding Select and display...

Page 30: ...standard operation JOB 0 A JOB can only be switched if no welding current is flowing The up slope and down slope times can be set separately for non latched and latched 5 7 3 Welding data display The...

Page 31: ...tungsten electrode tip onto the workpiece and press the torch trigger liftarc current flowing regardless of the main current set b Incline the torch over the torch gas nozzle to produce a gap of appro...

Page 32: ...r Setting flows times and parameters 5 7 6 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 I Current t Time Gas pre flows Istart Ignition current tUp Up slope tim...

Page 33: ...n current phase the welding current drops at the slope time set tS1 to the secondary current AMP After torch trigger 2 is released the welding current rises at the slope time set tS2 back to the main...

Page 34: ...Setting slope times for secondary current AMP or pulse edges Step 3 Press torch trigger 1 The main current drops with the set down slope time to the end crater current Iend minimum current Step 4 Rele...

Page 35: ...TIG spotArc Operating element Action Result Signal light comes on The spot time can be set for approx 4 sec using the Welding parameter setting rotary dial Spot time setting range 0 01 sec to 20 0 sec...

Page 36: ...start HF is switched off The welding current increases in the adjusted up slope time to the main current AMP NOTE The process ends when the set spotArc time elapses or if the torch trigger is released...

Page 37: ...chapter entitled Arc ignition The torch trigger must first be pressed once to activate the function The spotArc signal light starts to flash rapidly The user must now start the welding process within...

Page 38: ...the main current AMP NOTE Pressing torch trigger 1 starts the slope tS1 from main current AMP to secondary current AMP Releasing the torch trigger starts the slope tS2 from the secondary current AMP b...

Page 39: ...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 th...

Page 40: ...h 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 Figure 5 17 Operating element Action Result Display Select TIG p...

Page 41: ...18 Operating element Action Result Select kHz pulses Press TIG pulses key button until signal light comes on in red Select balance Setting range 1 to 99 1 increments Select frequency Setting range 50...

Page 42: ...ful in tacking and in spot welding TIG activArc combined with pulse variant TIG automated pulses or kHz pulses metallurgic pulses improves the positive properties of the process further depending on t...

Page 43: ...ing elements such as torch triggers TT rockers or potentiometers can be modified individually via torch modes Explanation of symbols for operating elements Symbol Description BRT 1 Press torch trigger...

Page 44: ...s in the individual modes can be found in the tables for the corresponding torch types The welding process can of course be switched on and off in all modes using torch trigger 1 TT 1 0 1 0 1 Figure 5...

Page 45: ...ating elements Welding current On Off BRT 1 Secondary current Latched mode 1 factory set BRT 1 Standard torch with two torch triggers Diagram Operating elements Explanation of symbols BRT1 torch trigg...

Page 46: ...2 torch trigger 2 Functions mode Operating elements Welding current On Off BRT 1 Secondary current BRT 2 Secondary current tapping mode Latched mode 1 factory set BRT 1 Welding current On Off BRT 1 B...

Page 47: ...Latched mode BRT 1 Increase welding current infinite adjustment up function Up Reduce welding current infinite adjustment down function 1 factory set Down Welding current on off BRT 1 Secondary curren...

Page 48: ...1 Increase welding current infinite adjustment up function Up Reduce welding current infinite adjustment down function 1 factory set Down Welding current on off BRT 1 Secondary current BRT 2 Secondary...

Page 49: ...gger 1 Functions Mode Operating elements Welding current On Off BRT 1 Secondary current tapping mode BRT 1 Increase welding current infinite adjustment Reduce welding current infinite adjustment 3 Pot...

Page 50: ...and 3 are not used with this type of torch or respectively are not appropriate Welding current on off TT 1 Secondary current TT 2 Secondary current tapping function TT 1 tapping Raise welding current...

Page 51: ...e first increment Figure 5 20 l 0 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 sett...

Page 52: ...nipple protects against electrical voltage and dirt 5 8 1 Connecting the electrode holder and workpiece lead NOTE Polarity depends on the instructions from the electrode manufacturer given on the ele...

Page 53: ...Operating element Action Result Displays 1 x Select arcforcing welding parameter The signal light lights up in red Set arcforcing 40 low current increase soft arc 0 default setting 40 high current in...

Page 54: ...ion of the stick electrodes using an increased ignition current a Hotstart time b Hotstart current I Welding current t Time Figure 5 24 Operating element Action Result Display Select expert menu 4 sec...

Page 55: ...pending on the preselected main current on the welding machine Pulse spot normal Pulse spot and break times are infinitely adjustable 5 9 4 Manual remote control RTP2 19POL RTP2 Functions TIG MMA Infi...

Page 56: ...ol I start I FFr on FFr off end I t Figure 5 25 Symbol Meaning Actuate foot operated remote control start welding process Operate foot operated remote control set welding current according to applicat...

Page 57: ...10V 0V 15V max 75mA 15V max 25mA START STOP AMP AMP PULS 10 100K A B C N P R S T U V D E F G H J K L M Figure 5 26 Pos Pin Signal shape Designation 1 A Output Connection for cable screen PE 2 B L Outp...

Page 58: ...erating elements functions cannot be changed Welding process button Welding current polarity button Parameter values in the function sequence can be displayed but not changed 5 12 PC interface CAUTION...

Page 59: ...lope 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 sett...

Page 60: ...14 03 2012 5 13 2 TIG non latched operating mode C version l 0 Figure 5 29 Display Setting selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display Non...

Page 61: ...the accident prevention regulations in your country Inform persons in the working area that they must observe the regulations CAUTION Test Before re commissioning it is essential that an inspection a...

Page 62: ...xpert menu can be displayed as percentages factory setting or absolute values on the machine display l 0 Figure 5 31 Display Setting selection Exit the menu Exit Machine configuration Settings for mac...

Page 63: ...control RTF 1 l 0 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 functi...

Page 64: ...tting 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 f...

Page 65: ...parameters button and switch the machine on again at the same time NAVIGATION navigating in the menu Parameters are selected by pressing the welding parameters button Set or change the parameters by...

Page 66: ...display switching MMA on actual value display off setpoint value display factory setting spotMatic Variation of operation mode spotArc ignition with workpiece contact on on off off factory setting Ram...

Page 67: ...the service menu may only be carried out by authorised maintenance staff Reset reset to factory settings off aus factory setting CFG Reset the values in the machine configuration menu CPL Complete res...

Page 68: ...ion 6 2 1 2 Functional test Welding current cables check that they are fitted correctly and secured Gas cylinder securing elements Operating message safety and adjustment devices Functional test 6 2 2...

Page 69: ...pean provisions guideline 2002 96 EG of the European Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must...

Page 70: ...erformance Phase failure check mains connection fuses a Various parameters cannot be set Entry level is blocked disable access lock see chapter entitled Lock welding parameters against unauthorised ac...

Page 71: ...ings and correct if necessary Pore formation a Inadequate or missing gas shielding Check shielding gas setting and replace shielding gas cylinder if necessary Shield welding site with protective scree...

Page 72: ...ion menu off status Connect wire feed unit Temperature error Allow machine to cool down Err 4 Error in emergency stop circuit interface for mechanised welding Check the external shut down equipment Ch...

Page 73: ...Service menu Modifications to the service menu may only be carried out by authorised maintenance staff Reset reset to factory settings off aus factory setting CFG Reset the values in the machine confi...

Page 74: ...software versions only serves to inform the authorised service staff l 0 Figure 7 2 Display Setting selection Exit the menu Exit Service menu Modifications to the service menu may only be carried out...

Page 75: ...cle at 40 C 35 DC 180 A 150 A 60 DC 150 A 120 A 100 DC 120 A 100 A Load alternation 10 min 60 DC 6 min welding 4 min pause Open circuit voltage 90 V Mains voltage tolerances 1 x 230 V 40 to 15 Frequen...

Page 76: ...etox TIG 180 270 Optional retrofit 12 pole torch connection socket for TETRIX 180 from serial no 196718 onwards 092 002466 00000 ON 8pol 02 Tetrix 180 Optional retrofit 8 pole torch connection socket...

Page 77: ...Appendix A Overview of EWM branches 099 000097 EW501 14 03 2012 77 10 Appendix A 10 1 Overview of EWM branches...

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