EWM Tetrix 230 Comfort 5P TM Operating Instructions Manual Download Page 79

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Accessories

Welding torch cooling system

099-000157-EW501

16.10.2014

Accessories

NOTE

Performance-dependent accessories like torches, workpiece leads, electrode holders or
intermediate hose packages are available from your authorised dealer.

9.1

Welding torch cooling system

Type

Designation

Item no.

cool40 U31

Cooling module

090-008593-00502

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

Type

Designation

Item no.

ON 12pol Retox TIG 190/230

Optional retrofit 12-pole connection socket, torch

092-002519-00000

ON Filter TIG 200/300-2

Retrofit option, dirt filter for air inlet

092-002551-00000

9.4

Remote controls and accessories

Type

Designation

Item no.

RT1 19POL

Remote control current

090-008097-00000

RTG1 19POL

Remote control, current

090-008106-00000

RTP1 19POL

Remote control spot welding / pulses

090-008098-00000

RTP2 19POL

Remote control spot welding / pulses

090-008099-00000

RTP3 spotArc 19POL

spotArc remote control for spot welding / pulses

090-008211-00000

RTF1 19POL 5 M

Foot-operated remote control current with
connection cable

094-006680-00000

RA5 19POL 5M

Remote control 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

9.5

General accessories

Type

Designation

Item no.

ADAP CEE16/SCHUKO

Earth contact coupling/CEE16A plug

092-000812-00000

DM AR D F1

Flowmeter pressure regulator

094-001980-00000

DMDIN TN 200B AR/MIX 35L Manometer pressure regulator

094-000009-00000

GH 2X1/4'' 2M

Gas hose

094-000010-00001

ADAP 8-5 POL

8 to 5-pole adapter

092-000940-00000

Summary of Contents for Tetrix 230 Comfort 5P TM

Page 1: ...s Welding machine Tetrix 230 Comfort 5P TM Tetrix 230 Comfort 8P TM 099 000157 EW501 16 10 2014 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warra...

Page 2: ...ment 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 monit...

Page 3: ...n and function 24 5 1 General 24 5 2 Workpiece lead general 24 5 3 Transport and installation 25 5 3 1 Adjusting the length of the carrying strap 25 5 4 Machine cooling 25 5 5 Notes on the installatio...

Page 4: ...l 60 5 10 1 Manual remote control RT1 19POL 60 5 10 2 RTG1 19POL manual remote control 60 5 10 3 Manual remote control RTP1 19POL 60 5 10 4 Manual remote control RTP2 19POL 60 5 10 5 RTP3 spotArc 19PO...

Page 5: ...4 7 3 Resetting welding parameters to the factory settings 75 7 4 Display machine control software version 76 7 5 Vent coolant circuit 77 8 Technical data 78 8 1 Tetrix 230 78 9 Accessories 79 9 1 Wel...

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: ...rong Press Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exit the menu 4 s Time display example...

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: ...cking in the molten pool and the tungsten inclusions are reduced This is particularly useful in tacking and in spot welding 3 1 1 2 spotArc This process is suitable for tack welding or joint welding o...

Page 15: ...d 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 electrical hazar...

Page 16: ...0157 EW501 16 10 2014 4 Machine description quick overview 4 1 Front view NOTE The maximum possible machine configuration is given in the text description If necessary the optional connection may need...

Page 17: ...r 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 C...

Page 18: ...Machine description quick overview Rear view 18 099 000157 EW501 16 10 2014 4 2 Rear view Figure 4 2...

Page 19: ...switch See 5 8 8 Arc ignition 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 Mains connection chapter 7...

Page 20: ...ic spot time setting range Non latched Latched Press for 3 s to put machine into power saving mode To reactivate activate one of the operating elements See 5 12 2 Power saving mode Standby chapter 3 T...

Page 21: ...0 6 Error status indicators Collective interference signal light see Rectifying faults chapter Water deficiency signal light welding torch cooling Excess temperature signal light 7 Display 3 digit 8...

Page 22: ...ranges 0 00 s to 5 0 s 0 1 s increments 5 sec Pulse time Pulse time setting range 0 01 sec to 9 99 sec 0 01s increments The pulse time applies to the main current phase AMP for pulses 6 AMP Main curre...

Page 23: ...rating elements 099 000157 EW501 16 10 2014 23 Item Symbol Description 0 13 Frequency TIG DC pulses 15 kHz Setting range 50 Hz to 15 kHz 14 activArc TIG welding process Switch activArc on or off Corre...

Page 24: ...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 25: ...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 26: ...in the arc flickering Lay the workpiece lead and hose package of 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 p...

Page 27: ...0 2014 27 NOTE Use an individual welding lead to the workpiece for each welding machine Figure 5 3 NOTE Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loop...

Page 28: ...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 configurati...

Page 29: ...accessory components Figure 5 6 Item Symbol Description 0 1 8 pole connection socket Cooling unit control lead 2 4 pole connection socket Cooling unit voltage supply 3 Cooling module Control and suppl...

Page 30: ...torch 2 Welding torch hose package 3 Connection socket welding current Welding current lead connection for TIG welding torch 4 G connecting nipple TIG welding torch shielding gas connection 5 Connect...

Page 31: ...ead 5 pole with standard torch 8 pole with up down or potentiometer torch and 12 pole with up down torch with LED display and tighten Insert the cable plug on the work piece lead into the welding curr...

Page 32: ...undamental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch being destroyed Always re fit the yellow protective cap when not using the...

Page 33: ...d to electric shocks and burning on contact Keep the welding torch electrically insulated from persons animals or equipment during the setting procedure Press the torch trigger and set the shielding g...

Page 34: ...de spotArc spot time setting range 0 01 sec to 20 0 sec Non latched Latched Select and display pulse procedure TIG automated pulses frequency and balance TIG pulses Select welding parameter in the fun...

Page 35: ...hed on You change JOBs by pressing the Switch display JOB number button until the respective signal lamp lights You can choose between 8 JOBs JOB 0 to 7 with the welding parameter rotary dial The para...

Page 36: ...n 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 m...

Page 37: ...used to select the welding parameters depending on the welding process and operating mode used 2 Welding parameter setting rotary dial Setting currents times and parameters 5 8 9 1 Explanation of sym...

Page 38: ...n current AMP Switching from main current AMP to secondary current AMP Press torch trigger 2 or Tap torch trigger 1 2nd cycle Release torch trigger 1 The main current falls in the set down slope time...

Page 39: ...er 2 or Tap torch trigger 1 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 Release torch trigger 1 the arc extin...

Page 40: ...d The user can change the interval in the Configuration menu See 5 12 8 spotarc Spotmatic configuration chapter Selecting and setting TIG spotArc Operating element Action Result Signal light comes on...

Page 41: ...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 i...

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: ...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 relevant times 5...

Page 45: ...he pulse current main current and pause current secondary current 5 8 11 1 Pulses thermal pulses Figure 5 21 Operating element Action Result Select TIG pulses function Signal light lights up in green...

Page 46: ...lect 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 15 kHz 0 01 kHz increments 5 8...

Page 47: ...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 O...

Page 48: ...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 Tap...

Page 49: ...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 Figure 5 24 Display Setting selection Lock JOB...

Page 50: ...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 51: ...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 52: ...bols 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 Re...

Page 53: ...ight 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 Reduc...

Page 54: ...f symbols BRT 1 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 a...

Page 55: ...p to four minutes after the mains plug is removed 1 Switch off machine 2 Remove the mains plug 3 Wait for at last 4 minutes until the capacitors have discharged CAUTION Test Before re commissioning it...

Page 56: ...ion TT 1 tapping Increase welding current 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 tappin...

Page 57: ...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 58: ...ing 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 connecti...

Page 59: ...ter Press until hotstart current signal light AMP comes on Set hotstart current The factory setting is a value as a percentage of the selected main current See 5 12 Machine configuration menu chapter...

Page 60: ...0 4 Manual remote control RTP2 19POL 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 s...

Page 61: ...ltage Figure 5 27 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 f...

Page 62: ...ied machine changes to the ready to operate status 5 12 2 Power saving mode Standby The power saving function can be activated either by pressing the button for a longer time See 4 3 Machine control O...

Page 63: ...at the machine controls so that you can check that it is working correctly ENTER EXIT NAVIGATION l 0 Figure 5 29 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised a...

Page 64: ...machine to 10A in order to avoid triggering the fuse This restricts the welding machine s power input The maximum welding performance cannot be achieved when the current is limited to 10A ENTER EXIT N...

Page 65: ...de If the access lock is active only the following parameters can be changed Welding current within a previously defined range ENTER EXIT NAVIGATION 3 s l 0 Figure 5 31 Display Setting selection Lock...

Page 66: ...ating and deactivating the access lock ENTER EXIT NAVIGATION 3 s 3 s l 0 Figure 5 32 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Machine code Confirming...

Page 67: ...in percentage display mode only the respective AMP signal light is lit ENTER EXIT NAVIGATION l 0 Figure 5 33 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised acces...

Page 68: ...in current phase of the latched operating mode See 5 8 9 3 Latched mode chapter The 3rd and 4th cycle are omitted and the welder starts the new process with the 1st cycle The user can switch the funct...

Page 69: ...Function switched on Exit the menu Exit Setting spot time on Short spot time 5 ms 999 ms 1 ms steps off long spot time 0 01 s 20 0 s 10 ms steps Long spot time Setting of 0 01 20 0 s 10 ms steps Separ...

Page 70: ...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 71: ...ment 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 waste contai...

Page 72: ...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 See 7 5 Vent coolant cir...

Page 73: ...sary 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...

Page 74: ...ult 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 t...

Page 75: ...16 10 2014 75 7 3 Resetting welding parameters to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings RESET AM P VOLT JOB l 0 Figure 7...

Page 76: ...he query of the software versions only serves to inform the authorised service staff ENTER EXIT NAVIGATION l 0 Figure 7 2 Display Setting selection Lock JOB menu Protect welding parameters from unauth...

Page 77: ...t circuit 099 000157 EW501 16 10 2014 77 7 5 Vent coolant circuit NOTE To vent the cooling system always use the blue coolant connection which is located as deep as possible inside the system close to...

Page 78: ...80 A 60 DC 200 A 150 A 100 DC 170 A 120 A Load alternation 10 min 60 DC 6 min welding 4 min pause Open circuit voltage DC 90 V Mains voltage tolerances 1 x 230 V 40 to 15 Frequency 50 60 Hz Mains fuse...

Page 79: ...19POL Remote control current 090 008097 00000 RTG1 19POL Remote control current 090 008106 00000 RTP1 19POL Remote control spot welding pulses 090 008098 00000 RTP2 19POL Remote control spot welding p...

Page 80: ...Appendix A Overview of EWM branches 80 099 000157 EW501 16 10 2014 10 Appendix A 10 1 Overview of EWM branches...

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