EWM Tetrix 230 AC/DC Comfort 8P TM Operating Instructions Manual Download Page 3

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Contents

Notes on the use of these operating instructions

099-000159-EW501

16.08.2016

1 Contents

Contents .................................................................................................................................................. 3

Safety instructions ................................................................................................................................. 6

2.1

Notes on the use of these operating instructions .......................................................................... 6

2.1.1

Explanation of icons ....................................................................................................... 7

2.2

General .......................................................................................................................................... 8

2.3

Transport and installation ............................................................................................................ 12

Intended use ......................................................................................................................................... 13

3.1

Documents which also apply ....................................................................................................... 13

3.1.1

Warranty ....................................................................................................................... 13

3.1.2

Declaration of Conformity ............................................................................................. 13

3.1.3

Welding in environments with increased electrical hazards ......................................... 13

3.1.4

Service documents (spare parts and circuit diagrams) ................................................ 13

3.1.5

Calibration/Validation ................................................................................................... 13

Machine description – quick overview .............................................................................................. 14

4.1

Front view .................................................................................................................................... 14

4.2

Rear view ..................................................................................................................................... 15

4.3

Machine control – Operating elements ........................................................................................ 16

4.3.1

Function sequence ....................................................................................................... 18

Design and function ............................................................................................................................. 19

5.1

General ........................................................................................................................................ 19

5.2

Transport and installation ............................................................................................................ 20

5.2.1

Ambient conditions ....................................................................................................... 20

5.2.1.1

In operation ................................................................................................... 20

5.2.1.2

Transport and storage ................................................................................... 20

5.2.2

Adjusting the length of the carrying strap ..................................................................... 21

5.3

Machine cooling ........................................................................................................................... 21

5.4

Workpiece lead, general .............................................................................................................. 21

5.5

Notes on the installation of welding current leads ....................................................................... 22

5.6

Mains connection ......................................................................................................................... 24

5.6.1

Mains configuration ...................................................................................................... 24

5.7

Welding torch cooling system ...................................................................................................... 25

5.7.1

Welding torch cooling unit connection .......................................................................... 25

5.8

Welding data display .................................................................................................................... 25

5.9

TIG welding .................................................................................................................................. 26

5.9.1

Welding torch and workpiece line connection .............................................................. 26

5.9.1.1

Torch connection options and pin assignments ............................................ 27

5.10

Shielding gas supply (shielding gas cylinder for welding machine) ............................................. 27

5.10.1

Connecting the shielding gas supply ............................................................................ 28

5.10.2

Gas test – setting the shielding gas volume ................................................................. 29

5.10.3

Welding task selection .................................................................................................. 30

5.10.3.1

Recurring welding tasks (JOB 1–7) .............................................................. 31

5.10.3.2

Welding parameter setting ............................................................................ 31

5.10.4

Optimising the ignition characteristics for pure tungsten electrodes ............................ 32

5.10.4.1

Manual, standard operation (JOB 0) ............................................................. 32

5.10.4.2

JOB operation (JOB 1 to 7) ........................................................................... 32

5.10.5

Optimal and fast spherical cup formation ..................................................................... 33

5.10.6

Automatic AC frequency ............................................................................................... 34

5.10.6.1

Manual, standard operation (JOB 0) ............................................................. 34

5.10.6.2

JOB operation (JOB 1 to 7) ........................................................................... 35

5.10.7

Arc ignition .................................................................................................................... 36

5.10.7.1

HF ignition ..................................................................................................... 36

5.10.7.2

Liftarc ............................................................................................................ 36

5.10.7.3

Automatic cut-out .......................................................................................... 36

5.10.8

Function sequences/operating modes ......................................................................... 37

5.10.8.1

Explanation of symbols ................................................................................. 37

5.10.8.2

Non-latched mode ......................................................................................... 38

Summary of Contents for Tetrix 230 AC/DC Comfort 8P TM

Page 1: ... EN Welding machine Tetrix 230 AC DC Comfort 5P TM Tetrix 230 AC DC Comfort 8P TM 099 000159 EW501 16 08 2016 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group com ...

Page 2: ...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 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 methods are...

Page 3: ... the installation of welding current leads 22 5 6 Mains connection 24 5 6 1 Mains configuration 24 5 7 Welding torch cooling system 25 5 7 1 Welding torch cooling unit connection 25 5 8 Welding data display 25 5 9 TIG welding 26 5 9 1 Welding torch and workpiece line connection 26 5 9 1 1 Torch connection options and pin assignments 27 5 10 Shielding gas supply shielding gas cylinder for welding m...

Page 4: ...5 11 3 2 Hotstart time 61 5 11 4 Antistick 62 5 11 5 Pulse welding 62 5 12 Remote control 64 5 12 1 RT1 19POL 64 5 12 2 RTG1 19POL 64 5 12 3 RTP1 19POL 64 5 12 4 RTP 2 64 5 12 5 RTP3 spotArc 19POL 64 5 12 6 RTF1 19POL 64 5 13 Interfaces for automation 65 5 13 1 Remote control connection socket 19 pole 65 5 13 2 Power saving mode Standby 66 5 14 Access control 66 5 15 Machine configuration menu 66 ...

Page 5: ...AC DC 78 9 Accessories 79 9 1 Remote controls and accessories 79 9 2 Transport vehicle 79 9 3 Options 79 9 4 Welding torch cooling system 79 9 5 General accessories 79 10 Appendix A 80 10 1 Parameter overview setting information 80 10 1 1 TIG welding 80 10 1 2 MMA welding 81 11 Appendix B 82 11 1 Overview of EWM branches 82 ...

Page 6: ...y observed to prevent serious and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning symbol The 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 includes the CAUTION keyword in its heading with a general ...

Page 7: ...p l 0 Switch off machine Release do not activate l 0 Switch on machine Press and hold switch Wrong Turn Correct Numerical value adjustable Menu entry Signal light lights up in green Navigating the menu Signal light flashes green Exit menu Signal light lights up in red 4s Time representation e g wait 4 s activate Signal light flashes red Interruption in the menu display other setting options possib...

Page 8: ...ot workpieces and sparks results in burns Use welding shield or welding helmet with the appropriate safety level depending on the application Wear dry protective clothing e g welding shield gloves etc according to the relevant regulations in the country in question Protect persons not involved in the work against arc beams and the risk of glare using safety curtains Explosion risk Apparently harml...

Page 9: ...not couple welding machines with pole reversing switch PWS series or machines for AC welding as a minor error in operation can cause the welding voltages to be combined CAUTION 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...

Page 10: ... 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 user must consider the following see also EN 60974 10 Appendix A Mains control signal and telecommunication lines Radios and televisions Computers and other control systems Safety equipment The health of neighbouring pers...

Page 11: ...oy protective earth conductors damage equipment and electronic devices and cause overheating of components leading to fire Make sure all welding leads are securely connected and check regularly Always ensure a proper and secure electrical connection to the workpiece Set up attach or suspend all conductive power source components like casing transport vehicle and crane frames so they are insulated ...

Page 12: ...N Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to IEC 60974 1 Set up and transport the machine on level solid ground Secure add on parts using suitable equipment Risk of accidents due to supply lines During transport attached supply lines mains leads c...

Page 13: ...tage Directive LVD 2014 35 EC Electromagnetic Compatibility Directive EMC 2014 30 EC Restriction of Hazardous Substance RoHS 2011 65 EC In case of unauthorised changes improper repairs non compliance with specified deadlines for Arc Welding Equipment Inspection and Testing during Operation and or prohibited modifications which have not been explicitly authorised by EWM this declaration shall be vo...

Page 14: ...torch control lead 8 pole TIG Up Down or potentiometer torch control lead 12 pole Control lead for TIG up down torch with display 4 Connection socket welding current TIG Connection for workpiece lead MMA Electrode holder or workpiece lead connection 5 Cooling air inlet 6 Connection socket welding current TIG TIG welding torch connection MMA Electrode holder or workpiece lead connection 7 G connect...

Page 15: ...lead 2 Ignition type changeover switch see 5 10 7 chapter Liftarc contact ignition HF ignition 3 Main switch machine on off 4 Cooling air outlet 5 Machine feet 6 Mains connection cable see 5 6 chapter 7 G connecting nipple Shielding gas connection on the pressure regulator 8 4 pole connection socket Cooling unit voltage supply 9 Connection socket 19 pole Remote control connection HF HF HF HF ...

Page 16: ...iption 0 1 Error status indicators Collective interference signal light see 7 2 chapter Water deficiency signal light welding torch cooling Excess temperature signal light safety sign signal light 2 Functional sequence see 4 3 1 chapter 3 Welding parameter setting rotary dial Setting currents times and parameters 4 Alternating current frequency TIG AC rotary dial 5 Alternating current balance TIG ...

Page 17: ...Alternating current welding with sinusoidal current output wave form Low noise level 8 Pulsing push button TIG automated pulsing frequency and balance Signal light lights up in green Pulsing thermal pulsing MMA pulse welding Signal light lights up in red kHz pulsing metallurgical pulsing Special TIG AC 9 Operating mode Power saving mode button spotArc spotmatic spot time setting range Non latched ...

Page 18: ... 6 AMP Main current TIG pulse current I min to I max 1 A increments Main current MMA I min to I max 1 A increments 7 sec Pulse break time TIG pulses The pulse break time applies to the secondary current phase AMP TIG AC Special The pulse break time applies to the DC phase with AC special 8 AMP Secondary current pulse pause current 9 sec Down slope time signal light 10 AMP End crater current signal...

Page 19: ...rrent 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 Connection and welding leads e g electrode holder welding torch workpiece lead interfaces may only be connected when the machine is switched off ...

Page 20: ... automatically after the power source is switched on Protective dust caps protect the connection sockets and therefore the machine against dirt and damage The protective dust cap must be fitted if there is no accessory component being operated on that connection The cap must be replaced if faulty or if lost 5 2 1 Ambient conditions T he machine must not be operated in the open air and must only be...

Page 21: ...e cooling air inlet and outlet clear Observe the minimum distance of 0 5 m from obstacles 5 4 Workpiece lead general CAUTION Risk of burning due to incorrect welding current connection If the welding current plugs machine connections are not locked or if the workpiece connection is contaminated paint rust these connections and leads can heat up and cause burnings when touched Check welding current...

Page 22: ...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 parallel with a distance of 20 cm to avoid HF sparkover Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences Always keep leads as short as possible For optimum welding results max 30 m welding lead interm...

Page 23: ...nd cause overheating of components leading to fire Make sure all welding leads are securely connected and check regularly Always ensure a proper and secure electrical connection to the workpiece Set up attach or 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 grin...

Page 24: ... an electrician When operating 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 configuration The machine may only be connected to a one phase system with two conductors and an earthed neutral conductor Figure 5 6 Legend Item Designation Colour code L Outer co...

Page 25: ... welding machine The cooling module and welding machine are connected using two leads Insert the control lead plug on the welding machine Insert the power supply lead plug on the welding machine 5 8 Welding data display The following welding parameters can be displayed before nominal values during actual values or after welding hold values Parameter Nominal values Actual values Hold values Welding...

Page 26: ...socket for welding current Workpiece lead connection Insert the welding current plug on the welding torch into the welding current connection socket and lock by turning to the right Remove yellow protective cap on G connecting nipple Screw welding torch shielding gas connection tightly onto the G connection nipple Insert the welding torch control lead plug into the connection socket for the weldin...

Page 27: ... and secure with fastening elements chain belt Attach the fastening elements within the upper half of the shielding gas cylinder The fastening elements must tightly enclose the shielding gas cylinder An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results In addition a blocked shielding gas supply may result i...

Page 28: ... regulator 2 Shielding gas cylinder 3 Output side of the pressure regulator 4 Cylinder valve Before connecting the pressure regulator to the gas cylinder open the cylinder valve briefly to blow out any dirt Tighten the pressure regulator screw connection on the gas bottle valve to be gas tight Screw gas hose connection crown nut onto the output side of the pressure regulator Figure 5 11 Item Symbo...

Page 29: ...ep the welding torch electrically insulated from persons animals or equipment during the setting procedure Press the torch trigger and set the shielding gas quantity with the flow gauge of the pressure regulator 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 t...

Page 30: ...ten electrode diameter Obviously the value can also be adjusted to different needs The following welding task is an example of use mm inch Figure 5 12 Note the differences between JOB 0 and JOBs 1 to 7 The parameter values for AC frequency AC balance and Tungsten electrode diameter optimisation of ignition are set with the respective rotary dials in JOB 0 In JOBs 1 to 7 this setting takes place in...

Page 31: ...ode diameter are exceptions These settings are made in the operation sequence signal lights with same name Switching a JOB is only possible if no welding current flows Up slope and down slope times can be set individually for latched and non latched operation Selection Figure 5 13 When one or more of the recurring welding tasks JOB 1 7 has been selected the JOB signal light comes on 5 10 3 2 Weldi...

Page 32: ...ignition and stabilisation of the arc DC AC and optimum spherical cup formation in the tungsten electrode depend on the electrode diameter being used The set value should correspond to the diameter of the tungsten electrode The value can of course be adjusted in line with different requirements 5 10 4 1 Manual standard operation JOB 0 Figure 5 14 5 10 4 2 JOB operation JOB 1 to 7 EXIT 3s Figure 5 ...

Page 33: ...isite for optimum tungsten balling is a sharpened electrode approx 15 25 Tungsten balling should be performed on a test component as surplus tungsten may be melted and this may lead to impurities on the weld seam Balling Figure 5 16 Turn balance setting in JOB 0 to the left stop position positive Ignite arc with HF start no contact and form required tungsten balling for the application in question...

Page 34: ...EXIT 2s Figure 5 17 Display Setting selection AC frequency AC Automatic frequency Function enabled Setting via potentiometer Function disabled The AC frequency rotary knob is now without function If it is turned nevertheless the alternate flashing of parameters FrE and AUt on the control display shows the active function To deactivate the AC frequency automatic turn the rotary knob to Pot ...

Page 35: ...tion Shielding gas supply shielding gas cylinder for welding machine 099 000159 EW501 16 08 2016 35 5 10 6 2 JOB operation JOB 1 to 7 EXIT 3s Figure 5 18 Display Setting selection Automatic frequency Function enabled ...

Page 36: ...20 The arc is ignited on contact with the workpiece a Carefully place the torch gas nozzle and 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 approx 2 3 mm between the electrode tip and the workpiece The arc ignites and the welding current is increased...

Page 37: ...operating modes 5 10 8 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 I Current t Time Gas pre flows Ignition current Up slope time Spot time AMP Main current minimum to maximum current AMP Secondary current Pulse time Pulse pause time Down slope time End crater current Gas post flows Balance Frequency ...

Page 38: ...sed together with torch trigger 1 during the main current phase the welding current decreases to the secondary current AMP If torch trigger 2 is released the welding current increases again to the main current AMP 2nd cycle Release torch trigger 1 The main current falls to the end crater current minimum current in the set down slope time If the 1st torch trigger is pressed during the down slope ti...

Page 39: ... 2 or Tap torch trigger 1 torch modes 1 4 3rd cycle Press torch trigger 1 The main current decreases to the end crater current within the set down slope time 4th cycle Release torch trigger 1 arc is extinguished Set gas post flow time runs Ending the welding process immediately without a down slope or end crater current Press the 1st torch trigger briefly 3rd and 4th cycles torch modes 11 14 Curre...

Page 40: ...rent thicknesses can also be welded on top of one another As this is a one sided process it is also possible to weld metal sheets onto tubular sections such as round or square pipes In arc spot welding the arc melts through the upper metal sheet and the lower metal sheet is melted onto it This produces flat fine textured welding tacks which require little or no post weld work even in visible areas...

Page 41: ...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 of the ignition current HF switches off The welding current ramps up to the main current AMP in the selected up slope time The process ends when the set spotArc time elapses or by releasing the torch trigger When switching on the spotArc function...

Page 42: ...n and adjustment are made in the same way as with spotArc operating mode see 5 10 8 4 chapter I t 6 4 3 2 1 5 Figure 5 25 As an example the process is shown with HF ignition Arc ignition with lift arc is also possible however see 5 10 7 chapter Selecting the process activation type for the welding process see 5 15 chapter Up slope and down slope times possible for long spot time setting range 0 01...

Page 43: ...ere per volt A V and vice versa This helps 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 Selection EXIT 3s Figure 5 26 Setting 2s EXIT 2s Figure 5 27 5 10 10 TIG antistick The function prevents uncontrolled re ignition following the sticking of the tungsten electrode in the weld pool by...

Page 44: ... AC special TIG AC 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 5 10 11 1Thermal pulsing The operation sequences with thermal pulses basically match the standard welding sequences but there is an additional switching back and forth between pulse and pause currents at the relev...

Page 45: ...Design and function Shielding gas supply shielding gas cylinder for welding machine 099 000159 EW501 16 08 2016 45 TIG pulses latched operation Figure 5 30 Selection Figure 5 31 ...

Page 46: ...r welding machine 46 099 000159 EW501 16 08 2016 Pulse time setting EXIT 3s Figure 5 32 Pulse pause setting EXIT 3s Figure 5 33 The pulse function can also be deactivated if necessary during the up slope and down slope phases parameter see 5 15 chapter I t Figure 5 34 ...

Page 47: ... Metallurgical pulsing kHz pulsing uses the plasma force arc force occurring at high currents which allows you to achieve a constricted arc with concentrated heat input Unlike thermal pulsing no times are set a frequency and the balance are set instead The pulsing process also occurs during the up slope and down slope phase Figure 5 35 Selection Figure 5 36 ...

Page 48: ...Design and function Shielding gas supply shielding gas cylinder for welding machine 48 099 000159 EW501 16 08 2016 Balance setting EXIT 3s Figure 5 37 Frequency setting EXIT 3s Figure 5 38 ...

Page 49: ...ular An oscillation in the molten pool is produced by the current dependent pulse frequency and balance which positively influences the ability to bridge the air gap The pulse parameters required are automatically specified by the machine control Figure 5 39 5 10 11 4AC pulses Figure 5 40 AMP pulse current AMP pulse pause current basic current tpuls pulse time tpause pulse pause time Figure 5 41 t...

Page 50: ...9 EW501 16 08 2016 5 10 11 5AC special Figure 5 42 Application e g for welding thick metal sheets onto thin metal sheets AMP AC current phase pulse current AMP DC phase pulse pause current tpulse Pulse time AC phase time tbreak Pulse break time DC phase time Figure 5 43 AMP AMP tpause tpuls AMP t ...

Page 51: ... 12 1Tap torch trigger tapping function Swiftly tap the torch trigger to change the function The torch mode set determines the operating mode of the tapping function 5 10 13 Torch mode and up down speed setting Modes 1 to 4 and 11 to 14 are available to the user Modes 11 to 14 feature the same function options as 1 to 4 but without the tapping function for the secondary current The function option...

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 torch trigger 1 BRT2 torch trigger 2 Functions mode Operating elements Welding current On Off 1 factory set Secondary current Secondary current tapping mode latched mode Welding current On Off 3 Secon...

Page 53: ...T 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 current On Off 2 Secondary current tapping mode Up function Down function Welding current On Off 3 Secondary current tapping mode latched mode Up function Down function BRT 1 BRT 2 BRT 1 BRT 1 BRT 2 BRT 1 BRT 2 BRT 1 ...

Page 54: ...f symbols TT 1 torch trigger 1 Functions Mode Operating elements Welding current on off 1 factory set Secondary current tapping mode Latched mode Increase welding current infinite adjustment up function Reduce welding current infinite adjustment down function Welding current on off 2 Secondary current tapping mode Welding current on off 4 Secondary current tapping mode Latched mode BRT 1 BRT 1 Up ...

Page 55: ... Functions Mode Operating elements Welding current on off 1 factory set Secondary current Secondary current tapping mode Latched mode Increase welding current infinite adjustment up function Reduce welding current infinite adjustment down function Welding current on off 2 Secondary current Secondary current tapping mode Welding current on off 4 Secondary current Secondary current tapping mode BRT ...

Page 56: ...torch trigger 1 Functions Mode Operating elements Welding current On Off 3 Secondary current tapping mode Increase welding current infinite adjustment Reduce welding current infinite adjustment Potentiometer torch with two torch triggers Diagram Operating elements Explanation of symbols BRT 1 torch trigger 1 BRT 2 torch trigger 2 Functions Mode Operating elements Welding current On Off 3 Secondary...

Page 57: ...specialist skilled persons The warranty becomes null and void in the event of unauthorised interference Appoint only skilled persons for repair work trained service personnel Test Before re commissioning it is essential that an inspection and test during operation is carried out conforming to IEC DIN EN 60974 4 Arc welding devices inspection and testing during operation For detailed instructions p...

Page 58: ...nt up function TT 3 Reduce welding current down function TT 4 Welding current on off 2 TT 1 Secondary current TT 2 Secondary current tapping function TT 1 tapping Increase JOB number TT 3 Decrease JOB number TT 4 Welding current on off 3 TT 1 Secondary current TT 2 Secondary current tapping function TT 1 tapping Welding current on off 4 TT 1 Secondary current TT 2 Secondary current tapping functio...

Page 59: ...st electrical voltage and dirt 5 11 1 Connecting the electrode holder and workpiece lead Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging Figure 5 45 Item Symbol Description 0 1 Electrode holder 2 Connection socket welding current Workpiece lead or electrode holder connection 3 Workpiece 4 Connection socket for welding current Electrode holder o...

Page 60: ... the basic parameters when no welding current is flowing and any possible access control is disabled see 5 14 chapter 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 Figure 5 46 ...

Page 61: ...er hot start current After selecting the stick electrode the arc ignites with the hot start current for the preset hot start time and then reverts to the main current AMP The parameter values for hot start current and time can be optimised for the electrode types used I t Figure 5 47 5 11 3 1 Hotstart current EXIT 4s Figure 5 48 5 11 3 2 Hotstart time EXIT 4s Figure 5 49 ...

Page 62: ... weld surface with a TIG look for final passes Less finishing work thanks to less spatter Highly suitable for difficult electrodes Outstanding gap bridging with no sagging of the root side Less distortion thanks to controlled heat input I A I A AMP Ipuls AMP Ipuls IPP IPP t s t s Tpuls Tpuls 100 100 Figure 5 50 AMP Main current e g 100 A IPL Pulse current IP1 x AMP e g 170 x 100 A 170 A IPP Pulse ...

Page 63: ...Design and function MMA welding 099 000159 EW501 16 08 2016 63 EXIT 3s 2s Figure 5 51 ...

Page 64: ...TP 2 RTP2 Functions TIG MMA Infinitely adjustable welding current 0 to 100 depending on the preselected main current on the welding machine Pulse spot normal Frequency and spot times infinitely adjustable Coarse adjustment of the cycle frequency Pulse pause ratio balance adjustable from 10 to 90 5 12 5 RTP3 spotArc 19POL RTP2 Functions TIG MMA Infinitely adjustable welding current 0 to 100 dependi...

Page 65: ...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 52 Item Pin Signal shape Designation 1 A Output Connection for cable screen PE 2 B L Output Current flowing signal I 0 galvanically isolated max 15V 100mA 3 F Output Reference voltage for potentiometer 10V max 10mA 4 C Input Control voltage specification for main current 0 10V 0V Imin 10V Im...

Page 66: ...nabling the access block Assign the access code for the access block Select parameter and select a number code 0 999 Enable access block Set parameter to function Disabling the access block Enter the access code for the access block Select parameter and enter the number code 0 999 Disable access block Set parameter to The only way to disable the access block is to enter the selected number code Ch...

Page 67: ...Design and function Machine configuration menu 099 000159 EW501 16 08 2016 67 l 0 3s 3s 3s Figure 5 53 ...

Page 68: ...ults in an absolute secondary current of 60A Welding current display absolute Absolute representation of all welding currents in amperes TIG antistick see 5 10 10 chapter function active factory setting function inactive Time based power saving mode see 5 13 2 chapter 5 min 60 min Time to activation of power saving mode in case of inactivity inactivated TIG HF start soft hard switching soft igniti...

Page 69: ...oftware version of the machine control Version display example 014 version 14 Mains current limit Mains current limited to 16A Mains current limit Mains current limited to 10A Machine code Confirming the old machine code entering the new machine code Error Error message after entering an incorrect machine code New machine code Machine code entered correctly Prompt for entering the new machine code...

Page 70: ... who is able to implement the required safety procedures In the event of failure of any one of the following tests the machine must not be operated again until it has been repaired and a new test has been carried out Repair and maintenance work may only be performed by qualified authorised personnel otherwise the right to claim under warranty is void In all service matters always consult the deale...

Page 71: ... Wheels and their securing elements Transport elements strap lifting lugs handle Other general condition 6 3 1 2 Functional test Operating message safety and adjustment devices Functional test Welding current cables check that they are fitted correctly and secured Gas tubes and their switching equipment solenoid valve Gas cylinder securing elements Check correct mounting of the wire spool Check th...

Page 72: ...opean Parliament and the Council of Juli 4th 2021 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be collected separately The symbol depicting a waste container on wheels indicates that the equipment must be collected separately This machine is to be placed for disposal or recycling in the waste separation systems provided for this purpose Accordi...

Page 73: ...ion Fault Cause Remedy Functional errors Insufficient coolant flow Check coolant level and refill if necessary Eliminate kinks in conduit system hose packages Reset automatic cutout of the coolant pump by activating Air in the coolant circuit Vent coolant circuit see 7 4 chapter All machine control signal lights are illuminated after switching on No machine control signal light is illuminated afte...

Page 74: ...sten electrode diameter Ignition optimisation rotary dial and increase if necessary higher ignition energy 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 ...

Page 75: ...lt persists inform the service department E4 see E3 see E3 E5 see E3 see E3 E6 Balancing error in voltage recording Switch machine off place the torch on an insulated surface and switch on again If the fault persists inform the service department E7 Balancing error in current recording Switch machine off place the torch on an insulated surface and switch on again If the fault persists inform the s...

Page 76: ...000159 EW501 16 08 2016 7 3 Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by the factory settings RESET l 0 Figure 7 1 Display Setting selection Input confirmation User entries are applied release button s ...

Page 77: ... 7 4 Vent coolant circuit 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 max 1 2 ca 5s 3 4 7 6 5 KLICK CLICK KLICK CLICK 092 007861 00000 blau blue l 0 l 0 l 0 Figure 7 2 ...

Page 78: ...cycle 10 min 60 DC 6 min welding 4 min pause Open circuit voltage 45 V Mains voltage tolerances 1 x 230 V 40 to 15 Frequency 50 60 Hz Mains fuse 1 x 16 A safety fuse slow blow Mains connection lead H07RN F3G2 5 Max connected load 5 5 kVA 6 kVA Recommended generator rating 8 1 kVA Noise level 70 dB A cos efficiency 1 0 85 Insulation class protection classification H IP 23 Ambient temperature 25 C t...

Page 79: ...ol e g connection cable 092 001470 00005 RA10 19POL 10M Remote control e g connection cable 092 001470 00010 RA20 19POL 20M Remote control e g connection cable 092 001470 00020 RV5M19 19POLE 5M Extension cable 092 000857 00000 9 2 Transport vehicle Type Designation Item no Trolly 35 2 2 Transport vehicle 090 008296 00000 Trolly 38 2 E Transport vehicle long wheelbase 090 008270 00000 9 3 Options T...

Page 80: ...0 0 20 0 Pulse time s 0 1 0 01 9 99 Secondary current AMP 50 1 200 of main current AMP Pulse pause time s 0 1 0 01 9 99 Down slope time s 0 1 0 0 20 0 Down slope time s 5 0 0 0 20 0 End current AMP 20 1 200 of main current AMP Gas post flow time s 8 0 1 20 0 Electrode diameter mm 1 6 1 0 4 0 spotArc time s 2 0 0 01 20 0 AC balance JOB 0 30 30 Rotary knob AC balance JOB 1 7 0 30 30 Pulse balance 50...

Page 81: ...W501 16 08 2016 81 10 1 2 MMA welding Parameter MMA Display Setting range Comment Code Unit Standard Min Max Main current A 5 180 Hot start current 150 1 150 Hot start time s 0 1 0 1 5 0 Pulse current 142 1 200 Pulse frequency Hz 1 2 0 2 500 Pulse balance 30 1 99 ...

Page 82: ...Appendix B Overview of EWM branches 82 099 000159 EW501 16 08 2016 11 Appendix B 11 1 Overview of EWM branches ...

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