EWM Tetrix 200 MV Comfort puls 5P TG Operating Instructions Manual Download Page 72

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Rectifying faults

Checklist for rectifying faults

099-000229-EW501

14.04.2015

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 lens for aluminium applications and high-alloy steels



Unsuitable or worn welding torch equipment



Check size of gas nozzle and replace if necessary



Condensation (hydrogen) in the gas tube





Purge hose package with gas or replace

Summary of Contents for Tetrix 200 MV Comfort puls 5P TG

Page 1: ...ng instructions Welding machine Tetrix 200 MV Comfort puls 5P TG 099 000229 EW501 14 04 2015 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm gro...

Page 2: ...accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or not these instructions or the conditions and m...

Page 3: ...ting elements 18 4 3 1 Function sequence 20 5 Design and function 22 5 1 General 22 5 2 Workpiece lead general 23 5 3 Machine cooling 23 5 4 Transport and installation 24 5 4 1 Installation 24 5 4 1 1...

Page 4: ...anual remote control RT1 19POL 60 5 9 2 RTG1 19POL manual remote control 60 5 9 3 Manual remote control RTP1 19POL 60 5 9 4 Manual remote control RTP2 19POL 60 5 9 5 RTP3 spotArc 19POL manual remote c...

Page 5: ...W501 14 04 2015 5 8 Technical data 77 8 1 Tetrix 200 Comfort MV 77 9 Accessories 78 9 1 Remote controls and accessories 78 9 2 Options 78 9 3 Transport systems 78 9 4 General accessories 79 9 5 Comput...

Page 6: ...e hazard is also highlighted using a symbol in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information i...

Page 7: ...rve Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exi...

Page 8: ...hocks 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 Swit...

Page 9: ...accidents if these safety instructions are not observed Non observance of these safety instructions is potentially fatal Carefully read the safety information in this manual Observe the accident preve...

Page 10: ...currents Stray welding currents can destroy protective earth conductors damage equipment and electronic devices and cause overheating of components leading to fire Make sure all welding leads are sec...

Page 11: ...ard 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 user must consider the foll...

Page 12: ...itable 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 d...

Page 13: ...ties 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 ambie...

Page 14: ...arly useful in tacking and in spot welding 3 1 1 2 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...

Page 15: ...is enclosed with the unit 3 2 3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be used in environments with an increased elect...

Page 16: ...l See 4 3 Machine control Operating elements chapter 2 Connection socket 5 pole 5 pole Control cable TIG standard torch 3 Connection socket welding current Connection for workpiece lead 4 Cooling air...

Page 17: ...connection 3 Mains connection cable See 5 6 Mains connection chapter 4 Cooling air inlet 5 G connecting nipple Shielding gas connection on the pressure regulator 6 PC interface serial D Sub connectio...

Page 18: ...ter deficiency signal light welding torch cooling Excess temperature signal light safety sign signal light 2 Welding data display 3 digit Displays the welding parameters and the corresponding values 3...

Page 19: ...Symbol Description 0 6 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 7 Weldin...

Page 20: ...Main 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 Pulsze...

Page 21: ...crements 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 Co...

Page 22: ...he welding current connection If the welding current connections are not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by...

Page 23: ...es and injuries Clean the connections Fix the workpiece lead securely Do not use structural parts of the workpiece as a return lead for the welding current Take care to ensure faultless power connecti...

Page 24: ...may not be lifted by crane or suspended 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 operato...

Page 25: ...power sources without HF igniter MIG MAG for as long and as close as possible in parallel Lay the workpiece lead and hose package of power sources with HF igniter TIG for as long as possible in parall...

Page 26: ...501 14 04 2015 Use an individual welding lead to the workpiece for each welding machine Figure 5 3 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Alw...

Page 27: ...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 6 1 Mains configura...

Page 28: ...pole Control cable TIG standard torch 6 Workpiece 7 Connection socket for welding current Workpiece lead connection Insert the welding current plug on the welding torch into the welding current connec...

Page 29: ...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 gas supply from the shieldin...

Page 30: ...ymbol 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 31: ...etting is too low or too high this can introduce air to the weld pool and may cause pores to form Adjust the shielding gas quantity to suit the welding task 5 7 2 3 Gas test Operating element Action R...

Page 32: ...o position 1 Manual standard operation JOB 0 is set by default on delivery and every time the machine control is reset This means that the welder repeatedly makes all the required welding settings and...

Page 33: ...g the JOB number Operating element Action Result n x Select JOB display Change the JOB number 1 x If the display switchover is pressed or if there is no keyboard input for 5 seconds the new JOB will b...

Page 34: ...ns that if for example you have not selected a pulse variant then you cannot set any pulse times in the function sequence 5 7 5 2 Welding current display ignition secondary end and hotstart currents T...

Page 35: ...ding parameters button Set or change the parameters by turning the welding parameter setting rotary dial EXIT leave the menu After 4 s the machine will return automatically to the ready to operate sta...

Page 36: ...ten 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 approx 2 3...

Page 37: ...and operating mode used 2 Welding parameter setting rotary dial Setting currents times and parameters 5 7 8 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 I Curr...

Page 38: ...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 c...

Page 39: ...s torch trigger 1 The main current drops with the set down slope time to the end crater current Iend minimum current Step 4 Release torch trigger 1 the arc extinguishes The set gas post flow time begi...

Page 40: ...preselected The user can change the interval in the Configuration menu See 5 12 Machine configuration menu chapter Selecting and setting TIG spotArc Operating element Action Result Signal light comes...

Page 41: ...e to the workpiece the arc ignites The welding current flows and immediately assumes the value set for the ignition current Istart HF is switched off The welding current increases in the adjusted up s...

Page 42: ...process activation The process can be activated separately for each spot or permanently See 5 12 Machine configuration menu chapter Separate process activation The welding process has to be reactivat...

Page 43: ...carefully against the workpiece Incline the torch over the torch gas nozzle until there is a gap of approx 2 3 mm between the electrode tip and the workpiece Shielding gas flows in the set gas pre fl...

Page 44: ...rent increases in the set up slope time to the main current AMP Pressing torch trigger 1 starts the slope tS1 from main current AMP to secondary current AMP Releasing the torch trigger starts the slop...

Page 45: ...9 EW501 14 04 2015 45 ENTER EXIT NAVIGATION l 0 Figure 5 20 Display Setting selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display Non latched operatio...

Page 46: ...g 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 dur...

Page 47: ...mal 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 23 Operating element Action Result Display Select TIG pulses...

Page 48: ...rating 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 Hz to...

Page 49: ...prevents the tungsten electrode sticking in the molten pool and the tungsten inclusions are reduced This is particularly useful in tacking and in spot welding Operating element Action Result Display n...

Page 50: ...ch 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 Tap torch trigger Ta...

Page 51: ...ndividual 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 ENTER EXIT NAVIGATION l 0...

Page 52: ...ion Functions mode Operating elements Welding current On Off 1 factory set Secondary current Latched mode Standard torch with two torch triggers Diagram Operating elements Explanation of symbols BRT1...

Page 53: ...f symbols BRT 1 torch trigger 1 BRT 2 torch trigger 2 Functions mode Operating elements Welding current On Off 1 factory set Secondary current Secondary current tapping mode latched mode Welding curre...

Page 54: ...rement Figure 5 27 ENTER EXIT NAVIGATION l 0 Figure 5 28 Display Setting selection Exit the menu Exit Torch configuration menu Set welding torch functions Setting the first increment Setting 1 to 20 f...

Page 55: ...ar appropriate safety gloves Use insulated tongs to remove spent stick electrodes or to move welded workpieces and Always put the electrode holder down on an insulated surface Shielding gas connection...

Page 56: ...g current Workpiece lead or electrode holder connection 3 Workpiece 4 Connection socket for welding current Electrode holder or workpiece lead connection 5 Connecting nipple G shielding gas connection...

Page 57: ...rease the current to impede sticking of the electrode Operating element Action Result Display 1 x Parameter selection Signal light lights up in red Set parameter 40 low increase of the current soft ar...

Page 58: ...current Operating element Action Result Displays x x Select hotstart current welding parameter Press until hotstart current signal light AMP comes on Set hotstart current The factory setting is a val...

Page 59: ...dependent on the main current Signal light AMP on Setting range 1 to 200 increments of 1 142 ex works Pulse pause current selection percentage dependent on the main current Signal light AMP on Settin...

Page 60: ...epending 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 Functions TIG MMA Infinite...

Page 61: ...on TIG ActivArc welding is not possible in combination with the foot operated remote control Figure 5 32 Symbol Meaning Actuate foot operated remote control start welding process Operate foot operated...

Page 62: ...s chapter or by setting a parameter in the configuration menu time based power saving mode When power saving mode is activated both machine displays show the horizontal digit in the centre of the disp...

Page 63: ...cification for main current 0 10V 0V Imin 10V Imax 5 D Input Control value specification for secondary current 0 10V 0V Imin 10V Imax 6 J U Output Reference 0V 7 K Output Power supply 15V max 75mA 8 V...

Page 64: ...e relevant documentation of the accessory components 5 12 Machine configuration menu The machine menu includes basic functions such as torch modes display settings and the service menu 5 12 1 Selectin...

Page 65: ...Design and function Machine configuration menu 099 000229 EW501 14 04 2015 65 EXIT NAVIGATION ENTER l 0 Figure 5 35...

Page 66: ...play off setpoint value display factory setting Pulses in the upslope and downslope phases The function can be switched on or off TIG antistick on function active factory setting off function inactive...

Page 67: ...factory setting off function off Error output to automated welding interface contact SYN_A off AC synchronisation or hot wire factory setting FSn Error signal negative logic FSP Error signal positive...

Page 68: ...ion menu CPL Complete reset of all values and settings The reset is performed when leaving the menu EXIT Software version query example 07 System bus ID 0340 Version number System bus ID and version n...

Page 69: ...arts please quote the machine type serial number and item number of the machine as well as the type designation and item number of the spare part 6 1 General When used in the specified environmental c...

Page 70: ...an Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be collected separately The symbol depicting a was...

Page 71: ...s after switching on Phase failure check mains connection fuses No welding performance Phase failure check mains connection fuses Connection problems Make control lead connections and check that they...

Page 72: ...ettings 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 scre...

Page 73: ...ge Switch machine off and on again inform the service department if the error continues Err 10 PE error Err 11 FastStop position Edge Acknowledge error signal 0 to 1 via robot interface if available E...

Page 74: ...t error Err 23 HF choke excess temperature High frequency blocking inductor excess temperature The excess temperature of the high frequency blocking inductor has triggered Allow equipment to cool down...

Page 75: ...nu Exit 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 machi...

Page 76: ...ions only serves to inform the authorised service staff ENTER EXIT NAVIGATION l 0 Figure 7 2 Display Setting selection Exit the menu Exit Service menu Modifications to the service menu may only be car...

Page 77: ...A 50 DC 150 A 60 DC 150 A 100 DC 120 A 120 A Duty cycle at 40 C 25 DC 200 A 35 DC 150 A 110 A 150 A 60 DC 120 A 90 A 150 A 120 A 100 DC 100 A 80 A 120 A 100 A Load alternation 10 min 60 DC 6 min weld...

Page 78: ...3 spotArc 19POL spotArc remote control for spot welding pulses 090 008211 00000 RA5 19POL 5M Remote control e g connection cable 092 001470 00005 RA10 19POL 10M Remote control e g connection cable 092...

Page 79: ...00 GH 2X1 4 2M Gas hose 094 000010 00001 ADAP 8 5 POL 8 to 5 pole adapter 092 000940 00000 DM AR D F1 Flowmeter pressure regulator 094 001980 00000 ADAP CEE16 SCHUKO Earth contact coupling CEE16A plug...

Page 80: ...Appendix A Overview of EWM branches 80 099 000229 EW501 14 04 2015 10 Appendix A 10 1 Overview of EWM branches...

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