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Functional characteristics

Filler wire welding

54

099-00T401-EW501

01.02.2022

5.3.3 Select wire speed operating mode (KORREKTUR / MANUELL)

The wire speed can be set in two different operating modes:
MANUAL:

The wire speed can be selected on the wire feed unit as an absolute value across the

entire setting range.

CORRETION: The wire speed is approximately specified by the welding machine control and can be

corrected as a percentage on the wire feed unit

In the wire feed unit underneath the cap is a switch for selecting the operating mode.

5.3.4 Setting the welding current and wire speed

Operating ele-

ment

Action

Result

Set welding current on the welding machine

Set wire speed

MANUAL operating mode (outer scale):

The wire speed can be selected on the wire feed unit as an absolute

value across the entire setting range.
CORRECTION operating mode (inner scale):

The wire speed is specified largely by the welding machine control and

can be corrected as a percentage on the wire feed unit

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Содержание T 4.01

Страница 1: ...Operating instructions EN Control T4 01 Tetrix DC Comfort 2 0 T4 09 Tetrix DC Comfort 2 0 T4 12 Tetrix DC Comfort 2 0 099 00T401 EW501 Observe additional system documents 01 02 2022...

Страница 2: ...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 ac...

Страница 3: ...TIG welding 20 5 1 1 Setting the shielding gas volume gas test rinse hose package 20 5 1 1 1 Automatic gas post flow 20 5 1 2 Welding task selection 21 5 1 2 1 Recurring welding tasks JOB 1 100 22 5...

Страница 4: ...by means of the JOB list 53 5 3 3 Select wire speed operating mode KORREKTUR MANUELL 54 5 3 4 Setting the welding current and wire speed 54 5 3 5 Operating modes functional sequences 55 5 3 5 1 Explan...

Страница 5: ...s and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning sym bol The hazard is also highlighted using a symbol in the page margin CAUTION Working or ope...

Страница 6: ...tch off machine Release Switch on machine Press and hold Switch Incorrect Invalid Turn Correct Valid Numerical value adjustable Input Signal light lights up in green Navigation Signal light flashes gr...

Страница 7: ...cal specialist may interconnect the sources as per standard IEC 60974 9 2010 Installa tion and use and German Accident Prevention Regulation BVG D1 formerly VBG 15 or country specific regulations Befo...

Страница 8: ...temperatures of 100 C or higher and arcing and work on live components Hearing protection against harming noise Explosion risk Apparently harmless substances in closed containers may generate excessi...

Страница 9: ...s specified in the 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 use...

Страница 10: ...placement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the ma chine is switched off Requirements for connection to the public...

Страница 11: ...on or connection points can heat up significantly during operation water cooled version When opening the coolant circuit escaping coolant may cause scalding Open the coolant circuit only when the powe...

Страница 12: ...correctly No liability is accepted for any damages arising from improper usage The equipment must only be used in line with its designated purpose and by trained or expert personnel Do not improperly...

Страница 13: ...combination with all other parts of these instructions Read and observe the operating instructions for all system components especially the safety instructions The illustration shows a general exampl...

Страница 14: ...control sections For description purposes the machine control has been divided into two sections A B to ensure maximum clarity The setting ranges for the parameter values are summarised in the paramet...

Страница 15: ...tivate 4 Pulsing push button see 5 1 7 chapter Automated pulsing frequency and balance Signal light turns green Thermal pulsed TIG welding MMA pulse welding Signal light turns red Metallurgical pulsed...

Страница 16: ...light see 5 6 chapter 13 Hold Signal light Status display After each completed welding task the last values used in the welding process for the welding current and welding voltage are shown on the dis...

Страница 17: ...Signal light activArc see 5 1 5 chapter 7 Signal light two colour Green Pulse frequency MMA Red Pulse frequency TIG average value pulsing 8 Parameter selection push button left The welding sequence pa...

Страница 18: ...that if no pulse variant was selected for example no pulse parameters will be available to set in the function sequence 4 2 1 Setting the welding current absolute percentage The welding current can be...

Страница 19: ...settings Factory setting example value 20 Parameter is set to optimum value Decrease the parameter value To return to the factory settings 4 3 4 Setting advanced welding parameters Expert menu The Exp...

Страница 20: ...just the shielding gas quantity to suit the welding task Setting instructions Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11 5 l min MIG brazing Wire diameter x 11 5...

Страница 21: ...can also be set to meet individual requirements e g for thin panels a smaller diameter is recommended to reduce the ignition energy The electrode diameter setting determines the minimum current limit...

Страница 22: ...individually for latched and non latched operation Selection Figure 5 2 When one or more of the recurring welding tasks has been selected the JOB signal light comes on 5 1 3 Arc ignition To change the...

Страница 23: ...ing on the operat ing mode set to the ignition or main current set c Lift off the torch and swivel to the normal position Ending the welding process Release the torch trigger or press and release depe...

Страница 24: ...n current minimum to maximum current AMP Secondary current Pulse time Pulse pause time Pulse current Latched operating mode Slope time from main current AMP to secondary current AMP TIG thermal pulsin...

Страница 25: ...welding cur rent decreases to the secondary current AMP in the set slope time If torch trigger 2 is released the welding current increases again to the main current AMP in the set slope time The param...

Страница 26: ...Functional characteristics TIG welding 26 099 00T401 EW501 01 02 2022 5 1 4 3 Latched mode Selection Figure 5 7 Sequence Figure 5 8...

Страница 27: ...third cycle will be omitted 4th cycle Release torch trigger 1 arc is extinguished Set gas post flow time runs When the foot operated remote control is connected the machine switches automatically to n...

Страница 28: ...jump from the electrode to the workpiece The arc ignites The welding current flows and immediately assumes the value of the start current HF switches off The welding current ramps up to the main curr...

Страница 29: ...torch trigger Process activation is automatically terminated after 30 s of inactivity Permanent process activation The welding process is activated by pressing the torch trigger once The following ar...

Страница 30: ...ess and release the torch trigger tap to reactivate the welding process only for separate process activation Touching the welding torch with the tungsten electrode tip against the workpiece again will...

Страница 31: ...vents the tungsten electrode sticking in the molten pool and the tungsten inclusions are reduced Selection 4s Figure 5 14 Setting Parameter setting The activArc parameter control can be adjusted speci...

Страница 32: ...the weld pool that have a positive effect on the gap bridging The required pulse parameters are automatically defined by the machine control If required the function can be disabled by pressing the pu...

Страница 33: ...se setting 4s Figure 5 19 Pulse edge setting The and pulse edges can be set in the Expert menu TIG see 5 1 11 chapter 5 1 7 3 Pulsed welding in the upslope and downslope phases The pulse function can...

Страница 34: ...the plasma force arc force occurring at high currents which al lows you to achieve a constricted arc with concentrated heat input Unlike thermal pulsing no times are set a frequency and the balance ar...

Страница 35: ...ctivated the red signal lights for the main current AMP and secondary current AMP light up at the same time Average value pulse welding means that the system switches between two currents periodically...

Страница 36: ...he secondary current The functionality of the individual modes can be found in the corresponding torch type tables The torch modes are set using the torch configuration parameters in the machine confi...

Страница 37: ...ts Welding current on off 1 ex works Secondary current latched operation Standard torch with two torch triggers Figure Operating ele ments Explanation of symbols BRT1 torch trigger 1 BRT2 torch trigge...

Страница 38: ...rch trigger 2 Functions Mode Operating ele ments Welding current on off 1 ex works Secondary current Secondary current tapping function 1 latched operating mode Welding current on off 2 Secondary curr...

Страница 39: ...perating ele ments Welding current on off 1 ex works Secondary current tapping function 1 latched operating mode Increase welding current up function2 Decrease welding current down function2 Welding c...

Страница 40: ...condary current Secondary current tapping function 1 latched operating mode Increase welding current up function2 Decrease welding current down function2 Modes 2 and 3 are not used with this type of t...

Страница 41: ...bols BRT 1 torch trigger 1 Functions Mode Operating ele ments Welding current on off 3 Secondary current tapping function1 Increase welding current Decrease welding current Potentiometer torch with tw...

Страница 42: ...be repaired or modified by specialist skilled persons The warranty becomes null and void in the event of unauthorised interference Appoint only skilled persons for repair work trained service personn...

Страница 43: ...g Increase JOB number BRT 3 Decrease JOB number BRT 4 Gas test BRT 2 3 s Welding current on off 6 BRT 1 Secondary current BRT 2 Secondary current tapping function BRT 1 tapping Increase welding curren...

Страница 44: ...The user sets the main current at the welding machine to 200 A The user presses the remote control pe dal very quickly down by approx 50 of the pedal travel RTF start ramp switched on The welding curr...

Страница 45: ...choose between linear and logarithmic response The logarithmic setting is especially suited for welding with low currents e g for thin panels as the logarithmic response enables a better control of th...

Страница 46: ...ored that don t require regular setting The number of pa rameters shown may be limited e g if a function is deactivated Figure 5 30 Display Setting selection Expert menu Start time duration of start c...

Страница 47: ...can be disabled during pulse pauses not the case for automated pul sing or kHz pulsing Function disabled Function enabled ex works Filler wire diameter manual setting Setting the wire diameter betwee...

Страница 48: ...rch or the intermediate hose package AW has been chan ged The resistance value of the cables can be set directly or can be aligned by the power source In the delivery state the cable resistance is set...

Страница 49: ...fly which is used to determine and display the cable resistance The value can be between 0 m and 60 m The new value is immediately saved without requiring further confirmation If no value is shown on...

Страница 50: ...ufficient heating to the still cold parent metal at the beginning of the welding process The ignition takes place here with increased current hot start current over a certain time hot start time A Hot...

Страница 51: ...lting electrode types at low current strengths with a short arc in particular 4s Figure 5 36 5 2 4 Antistick The Antistick feature prevents the electrode from annealing Should the electrode stick desp...

Страница 52: ...current e g 100 A Ipuls pulse current x AMP e g 140 x 100 A 140 A IPP pulse pause current 1 200 of AMP Tpuls duration of one pulse cycle 1 e g 1 100 Hz 10 ms Balance Selection Figure 5 39 With manual...

Страница 53: ...t the welding current average value AMP is maintained at all times Figure 5 40 AMP Main current e g 100 A Ipuls Pulse current x AMP e g 140 x 100 A 140 A IPP Pulse pause current Tpuls Duration of one...

Страница 54: ...and can be corrected as a percentage on the wire feed unit In the wire feed unit underneath the cap is a switch for selecting the operating mode 5 3 4 Setting the welding current and wire speed Opera...

Страница 55: ...elding current on or off Torch trigger 1 BRT 1 switches the wire feed on or off The operator can choose between three operating modes see following function sequences Figure 5 42 5 3 5 1 Explanation o...

Страница 56: ...he selected up slope time 1st cycle wire Press torch trigger 1 BRT 1 Wire electrode is advanced 2nd cycle wire Release BRT 1 Wire electrode advance stops 3rd cycle current Press BRT 2 The main current...

Страница 57: ...tapping the BRT 1 By pressing and releasing tapping the BRT 1 again wire feeding will stop It is not necessary to keep the torch trigger pressed This is especially helpful with long welding seams 5 4...

Страница 58: ...s block activation is indicated by the Access block active signal light see 4 chapter Disabling access block Enter the access code for the access block Select parameter and enter the previously select...

Страница 59: ...u Basic machine settings are defined in the machine configuration menu 5 7 1 Selecting changing and saving parameters l 0 A A B A A A A A B B B B B B B B B B B B B B B B B B B B B B B B B B A B B B B...

Страница 60: ...ion secondary end and hot start cur rent see 4 2 1 chapter Welding current setting absolute Welding current setting as a percentage of the main current ex works Non latched operation version C see 5 1...

Страница 61: ...Welding current polarity switching 1 polarity switching at the RT PWS 1 19POL remote control ex works polarity switching at the welding machine control spotmatic operating mode see 5 1 4 5 chapter Ig...

Страница 62: ...ic AVC Arc voltage control connection Gas monitoring Depending on where the gas sensor is situated the use of a pilot static tube and the welding process monitoring phase Function disabled ex works Mo...

Страница 63: ...nual rC on off operating mode 3 Select machine function control with external control voltages signals with machine control Software version query System bus ID and version number are separated by a d...

Страница 64: ...service personnel if required Warning code Possible cause Remedy 1 Machine excess temperature Allow the machine to cool down 2 Half wave failures Check process parameters 3 Welding torch cooling warn...

Страница 65: ...up if necessary 8 Gas error Check the gas supply 9 Secondary overvoltage Switch the machine off and on If the error persists no tify Service 10 PE error 11 FastStop position Slope Acknowledge error si...

Страница 66: ...lding process 49 Arc interruption Inform service 51 Error in the emergency stop circuit interface for automated welding Check the external shutdown devices Check jumper JP 1 on PCB T320 1 57 Auxiliary...

Страница 67: ...es Observe the maintenance instructions In the event that the provisions of one of the below stated tests are not met the machine must not be operated again until it has been repaired and a new test h...

Страница 68: ...tem separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private households can be disposed of free of...

Страница 69: ...s 0 00 20 0 Down slope time 1 0 s 0 0 20 0 End current percentage of AMP 20 1 200 End current absolute depending on power source A End current time 0 01 s 0 01 20 0 Gas post flow time 8 s 0 0 40 0 Ele...

Страница 70: ...current AMP depending on power source A Hot start current percentage of AMP 120 1 200 Hot start current percentage of AMP 1 150 1 150 Hot start current absolute depending on power source A Hot start...

Страница 71: ...Appendix Searching for a dealer 099 00T401 EW501 01 02 2022 71 8 2 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide...

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