EWM Tetrix 300 Comfort TM Operating Instructions Manual Download Page 28

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Design and function

Notes on the installation of welding current leads

099-000099-EW501

29.08.2014

NOTE

Use an individual welding lead to the workpiece for each welding machine!

Figure 5-4

NOTE

Fully unroll welding current leads, torch hose packages and intermediate hose
packages. Avoid loops!

Always keep leads as short as possible!

Lay any excess cable lengths in meanders.

Figure 5-5

Summary of Contents for Tetrix 300 Comfort TM

Page 1: ...ons Welding machine Tetrix 300 Comfort TM Tetrix 400 2 Comfort TM 099 000099 EW501 29 08 2014 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warrant...

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 sequence 22 5 Design 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 26 5 5 Wel...

Page 4: ...3 5 9 5 Hotstart 64 5 9 5 1 Hotstart current 64 5 9 5 2 Hotstart time 64 5 10 Remote control 65 5 10 1 Manual remote control RT1 19POL 65 5 10 2 RTG1 19POL manual remote control 65 5 10 3 Manual remot...

Page 5: ...l operating problems 81 7 5 1 Interface for automated welding 81 7 6 Vent coolant circuit 82 8 Technical data 83 8 1 Tetrix 300 Comfort 83 8 2 Tetrix 400 2 Comfort 84 9 Accessories 85 9 1 General acce...

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: ...ess 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 wait 4s...

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: ...0099 EW501 29 08 2014 4 Machine description quick overview NOTE The maximum possible machine configuration is given in the text description If necessary the optional connection may need to be retrofit...

Page 17: ...down or potentiometer torch 12 pole Control cable TIG up down torch with LED display option 6 Connection socket 5 pole Standard TIG torch control lead 7 G connecting nipple welding current with DC pol...

Page 18: ...Machine description quick overview Rear view 18 099 000099 EW501 29 08 2014 4 2 Rear view Figure 4 2...

Page 19: ...uit breaker key button fuse protection Ignition unit Gas valve Peripheral devices on the 7 pole digital interfaces rear of the machine Reset triggered automatic cutout by pressing 5 Ignition type chan...

Page 20: ...tic spot time setting range Non latched Latched 3 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 balanc...

Page 21: ...s 099 000099 EW501 29 08 2014 21 Item Symbol Description 0 7 Error status indicators Collective interference signal light Water deficiency signal light welding torch cooling Excess temperature signal...

Page 22: ...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 Pulsz...

Page 23: ...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 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: ...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 operator must ensu...

Page 26: ...to get into the machine 5 5 Welding torch cooling system 5 5 1 Cooling module connection NOTE Please note the relevant documentation of the accessory components Figure 5 2 Item Symbol Description 0 1...

Page 27: ...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 28: ...9 08 2014 NOTE Use an individual welding lead to the workpiece for each welding machine Figure 5 4 NOTE Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loop...

Page 29: ...ions The resulting network has to be suitable for operating devices according to protection class 1 5 7 1 Mains configuration NOTE The machine may be connected to a three phase system with four conduc...

Page 30: ...gas connection 6 Connection socket welding current Welding current lead connection for TIG welding torch 7 Workpiece 8 Connection socket for welding current Workpiece lead connection Insert the weldin...

Page 31: ...tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant return and supply line blue to quick connect coupling blue coolant supply NOTE Please note t...

Page 32: ...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 shielding...

Page 33: ...tion 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 gas tight Sc...

Page 34: ...setting 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 8 2 3 Gas test Operating element Action...

Page 35: ...set to 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 setting...

Page 36: ...e 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 be ac...

Page 37: ...ans that if for example you have not selected a pulse variant then you cannot set any pulse times in the function sequence 5 8 3 6 Welding current display ignition secondary end and hotstart currents...

Page 38: ...welding 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...

Page 39: ...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 40: ...as welding current sheet metal thickness gas pre flow time etc 5 8 6 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 I Current t Time Gas pre flows Istart Igniti...

Page 41: ...rrent 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 curr...

Page 42: ...er 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 extinguishes The set gas post...

Page 43: ...eselected The user can change the interval in the Configuration menu See 5 13 Machine configuration menu chapter Selecting and setting TIG spotArc Operating element Action Result Signal light comes on...

Page 44: ...o 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 slop...

Page 45: ...process activation The process can be activated separately for each spot or permanently See 5 13 Machine configuration menu chapter Separate process activation The welding process has to be reactivat...

Page 46: ...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 47: ...nt increases in the set up slope time to 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 s...

Page 48: ...welding 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 necess...

Page 49: ...ermal 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 pulse...

Page 50: ...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 Hz...

Page 51: ...revents 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 52: ...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 53: ...vidual 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 Fig...

Page 54: ...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 55: ...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 56: ...ory 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...

Page 57: ...ondary 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 Se...

Page 58: ...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 59: ...y information in this manual Observe the accident prevention regulations in your country Inform persons in the working area that they must observe the regulations CAUTION Test Before re commissioning...

Page 60: ...with this type of torch or respectively are not appropriate Welding current on off 4 TT 1 Secondary current TT 2 Secondary current tapping function TT 1 tapping Raise welding current in stages settin...

Page 61: ...ent Figure 5 28 ENTER EXIT NAVIGATION l 0 Figure 5 29 Display Setting selection Exit the menu Exit Torch configuration menu Set welding torch functions Setting the first increment Setting 1 to 20 fact...

Page 62: ...ring MMA welding open circuit voltage is applied at the shielding gas connection G connecting nipple Place yellow insulating cap on the G connection nipple protects against electrical voltage and dirt...

Page 63: ...osition 1 Operating element Action Result Select MMA welding process The signal light lights up in green Set welding current 5 9 3 Arcforce Shortly before the electrode threatens to stick the arcforci...

Page 64: ...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 65: ...rrent 0 to 100 depending on the preselected main current on the welding machine Pulse spot normal Pulse spot and break times are infinitely adjustable 5 10 4 Manual remote control RTP2 19POL Functions...

Page 66: ...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 67: ...ENTER EXIT NAVIGATION l 0 Figure 5 33 Display Setting selection Exit the menu Exit Machine configuration part two Settings for machine functions and parameter display Ramp function Remote control RTF...

Page 68: ...ation for master slave operation D Input no c IGRO Current flows signal I 0 maximum load 20mA 15V 0V welding current flowing E R Input Output Not Aus Emergency stop for higher level shut down of the p...

Page 69: ...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 70: ...e relevant documentation of the accessory components 5 13 Machine configuration menu The machine menu includes basic functions such as torch modes display settings and the service menu 5 13 1 Selectin...

Page 71: ...Design and function Machine configuration menu 099 000099 EW501 29 08 2014 71 EXIT NAVIGATION ENTER l 0 Figure 5 35...

Page 72: ...e upslope and downslope phases The function can be switched on or off Machine configuration part two Settings for machine functions and parameter display Ramp function Remote control RTF 1 The ramp fu...

Page 73: ...unction off factory setting Orbital welding off off ex works on on Orbital welding Correction value for orbital current Service menu Modifications to the service menu may only be carried out by author...

Page 74: ...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 75: ...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 76: ...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 See 7 6 Ven...

Page 77: ...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 78: ...ltage 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 availabl...

Page 79: ...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 80: ...menu 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 ma...

Page 81: ...version query example 07 System bus ID 0340 Version number System bus ID and version number are separated by a dot 7 5 General operating problems 7 5 1 Interface for automated welding WARNING No func...

Page 82: ...t circuit 82 099 000099 EW501 29 08 2014 7 6 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 83: ...e at 40 C 300 A 60 DC 250 A 100 DC Load alternation 10 min 60 DC 6 min welding 4 min break Open circuit voltage 98 V Mains voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fu...

Page 84: ...n 60 DC 6 min welding 4 min break Open circuit voltage 102 V Mains voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 16 A Mains connection lead H07RN F4G2 5...

Page 85: ...KF 37E 10 Coolant 20 C 9 3 l 094 006256 00000 KF 37E 200 Coolant 20 C 200 l 094 006256 00001 TYP 1 Frost protection tester 094 014499 00000 9 3 Remote controls and accessories Type Designation Item n...

Page 86: ...ions Type Designation Item no ON 12pol Retox Tetrix 300 400 401 351 451 551 Optional 12 pole retrofit connection socket 092 001807 00000 ON 19POL Tetrix 300 351 Optional 19 pole retrofit connection so...

Page 87: ...Appendix A Overview of EWM branches 099 000099 EW501 29 08 2014 87 10 Appendix A 10 1 Overview of EWM branches...

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