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Contents

Notes on the use of these operating instructions

099-000124-EW501

29.07.2011

Contents

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

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

2.1

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

2.2

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

2.3

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

2.4

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

2.5

Ambient conditions....................................................................................................................... 13

2.5.1

In operation................................................................................................................... 13

2.5.2

Transport and storage .................................................................................................. 13

Intended use ......................................................................................................................................... 14

3.1

Applications.................................................................................................................................. 14

3.1.1

TIG welding .................................................................................................................. 14

3.1.2

MMA welding ................................................................................................................ 14

3.2

Documents which also apply ....................................................................................................... 15

3.2.1

Warranty ....................................................................................................................... 15

3.2.2

Declaration of Conformity ............................................................................................. 15

3.2.3

Welding in environments with increased electrical hazards......................................... 15

3.2.4

Service documents (spare parts and circuit diagrams) ................................................ 15

Machine description ............................................................................................................................ 16

4.1

Front view .................................................................................................................................... 16

4.2

Rear view ..................................................................................................................................... 17

4.3

Machine control – Operating elements ........................................................................................ 18

Design and function............................................................................................................................. 20

5.1

General ........................................................................................................................................ 20

5.2

Workpiece lead, general .............................................................................................................. 20

5.3

Transport and installation ............................................................................................................ 21

5.3.1

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

5.4

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

5.5

Mains connection ......................................................................................................................... 22

5.5.1

Mains configuration ...................................................................................................... 22

5.6

TIG welding.................................................................................................................................. 23

5.6.1

Welding torch and workpiece line connection .............................................................. 23

5.6.2

Torch connection options and pin assignments ........................................................... 24

5.6.3

Shielding gas supply (shielding gas cylinder for welding machine) ............................. 24

5.6.3.1

Connecting the shielding gas supply ............................................................ 25

5.6.3.2

Setting the shielding gas quantity ................................................................. 26

5.6.4

Select welding task....................................................................................................... 27

5.6.5

Welding data display .................................................................................................... 27

5.6.6

Arc ignition.................................................................................................................... 28

5.6.6.1

HF ignition ..................................................................................................... 28

5.6.6.2

Liftarc ignition ................................................................................................ 28

5.6.7

Automatic cut-out.......................................................................................................... 28

5.6.8

Function sequences/operating modes ......................................................................... 29

5.6.8.1

Explanation of symbols ................................................................................. 29

5.6.8.2

Non-latched mode......................................................................................... 30

5.6.8.3

Latched mode ............................................................................................... 31

5.6.8.4

SpotArc ......................................................................................................... 32

5.6.8.5

Spotmatic ...................................................................................................... 33

5.6.8.6

Non-latched operation, version C ................................................................. 34

5.6.8.7

Automated pulses ......................................................................................... 35

5.6.9

TIG activArc welding..................................................................................................... 36

5.6.10

Welding torch (operating variants) ............................................................................... 37

5.6.10.1

Tap torch trigger (tapping function)............................................................... 37

Содержание Tetrix 180 Smart TGD

Страница 1: ...g instructions Welding machine GB Tetrix 180 Smart TGD 099 000124 EW501 29 07 2011 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warranty www ewm g...

Страница 2: ...ther 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 whethe...

Страница 3: ...ce lead general 20 5 3 Transport and installation 21 5 3 1 Adjusting the length of the carrying strap 21 5 4 Machine cooling 21 5 5 Mains connection 22 5 5 1 Mains configuration 22 5 6 TIG welding 23...

Страница 4: ...11 3 Configuring the TIG potentiometer torch connection 54 5 11 4 Welding current display ignition secondary end and hotstart currents 55 5 11 5 Ramp function foot operated remote control RTF 1 56 5 1...

Страница 5: ...Contents Notes on the use of these operating instructions 099 000124 EW501 29 07 2011 5...

Страница 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...

Страница 7: ...scription Press Do not press Turn Switch 0 1 Switch off machine 0 1 Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display example wait 4s press Inter...

Страница 8: ...s 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 Switchin...

Страница 9: ...ith flammable material Connect welding leads correctly Risk of accidents if these safety instructions are not observed Non observance of these safety instructions is potentially fatal Carefully read t...

Страница 10: ...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 grinders etc on...

Страница 11: ...he 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...

Страница 12: ...ble 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 duri...

Страница 13: ...s 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 ambient...

Страница 14: ...rrectly No liability is accepted for any damages arising from improper usage The equipment must only be used in line with proper usage and by trained or expert staff Do not modify or convert the equip...

Страница 15: ...ted conversion work not specifically authorised by the manufacturer The original copy of the declaration of conformity is enclosed with the unit 3 2 3 Welding in environments with increased electrical...

Страница 16: ...apter 3 Connection socket welding current Connection for workpiece lead 4 Connection socket 5 pole 8 pole 5 pole Standard TIG torch control lead 8 pole TIG Up Down or potentiometer torch control lead...

Страница 17: ...switch machine on off 2 HF HF Ignition type changeover switch HF Liftarc contact ignition HF HF ignition 3 COM PC interface serial D Sub connection socket 9 pole 4 G connecting nipple Shielding gas co...

Страница 18: ...a display 3 Welding process button MMA welding lights up in green arcforce setting lights up in red TIG welding 4 Operating mode button spotArc spot time setting range 0 01 sec to 20 0 sec Non latched...

Страница 19: ...own slope time can be set separately for non latched and latched 10 sec Gas post flow time TIG Setting ranges 0 00 sec to 40 0 sec 0 1 sec increments 11 Select welding parameters button This button is...

Страница 20: ...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...

Страница 21: ...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...

Страница 22: ...g the generator always ensure it is earthed as stated in the operating instructions The resulting network has to be suitable for operating devices according to protection class 1 5 5 1 Mains configura...

Страница 23: ...orch control lead 8 pole TIG Up Down or potentiometer torch control lead 6 Workpiece 7 Connection socket for welding current Workpiece lead connection Insert the welding current plug on the welding to...

Страница 24: ...levant regulations concerning the use of compressed air Place shielding gas cylinders in the holders provided for them and secure with fixing devices Avoid heating the shielding gas cylinder CAUTION F...

Страница 25: ...linder 3 Output side of the pressure regulator 4 Cylinder valve NOTE Before connecting the pressure regulator to the gas cylinder open the cylinder valve briefly to expel any dirt Tighten the pressure...

Страница 26: ...y 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 NOTE Rule of thumb f...

Страница 27: ...Operating mode button spotArc spot time setting range 0 01 sec to 20 0 sec Non latched Latched TIG pulse welding TIG automated pulses frequency and balance Select welding parameters button This butto...

Страница 28: ...sten 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...

Страница 29: ...elding process and operating mode used 2 Welding parameter setting rotary transducer Setting flows times and parameters 5 6 8 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torc...

Страница 30: ...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...

Страница 31: ...see chapter Advanced settings section Setting slope times for secondary current AMP or pulse edges Step 3 Press torch trigger 1 The main current drops with the set down slope time to the end crater c...

Страница 32: ...potArc process is switched on with the pulse variant TIG automated pulses by default TIG automated pulses frequency and balance NOTE The up slope and down slope times should be set to 0 to achieve an...

Страница 33: ...ter entitled Arc ignition The torch trigger must first be pressed once to activate the function The spotArc signal light starts to flash rapidly The user must now start the welding process within 30 s...

Страница 34: ...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 slope tS2 from the secondary current AMP back...

Страница 35: ...utomated pulses are used with tacking and spot welding of workpieces in particular An oscillation in the molten pool is produced by the current dependent pulse frequency and balance which positively i...

Страница 36: ...sa 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 Operating element Action Re...

Страница 37: ...orch modes Explanation of symbols for operating elements Symbol Description BRT 1 Press torch trigger BRT 1 Tap torch trigger BRT 2 Tap and press torch trigger 5 6 10 1 Tap torch trigger tapping funct...

Страница 38: ...or the corresponding torch types The welding process can of course be switched on and off in all modes using torch trigger 1 TT 1 0 1 0 1 Figure 5 16 Display Setting selection Exit the menu Exit Torch...

Страница 39: ...g elements Welding current On Off BRT 1 Secondary current Latched mode 1 factory set BRT 1 Standard torch with two torch triggers Diagram Operating elements Explanation of symbols BRT1 torch trigger 1...

Страница 40: ...orch trigger 2 Functions mode Operating elements Welding current On Off BRT 1 Secondary current BRT 2 Secondary current tapping mode Latched mode 1 factory set BRT 1 Welding current On Off BRT 1 BRT 2...

Страница 41: ...hed mode BRT 1 Increase welding current infinite adjustment up function Up Reduce welding current infinite adjustment down function 1 factory set Down Welding current on off BRT 1 Secondary current ta...

Страница 42: ...crease welding current infinite adjustment up function Up Reduce welding current infinite adjustment down function 1 factory set Down Welding current on off BRT 1 Secondary current BRT 2 Secondary cur...

Страница 43: ...1 Functions Mode Operating elements Welding current On Off BRT 1 Secondary current tapping mode BRT 1 Increase welding current infinite adjustment Reduce welding current infinite adjustment 3 Potenti...

Страница 44: ...t increment Figure 5 17 0 1 0 1 Figure 5 18 Display Setting selection Exit the menu Exit Torch configuration menu Set welding torch functions Setting the first increment Setting 1 to 20 factory settin...

Страница 45: ...cap on the G connection nipple protects against electrical voltage and dirt 5 7 1 Connecting the electrode holder and workpiece lead NOTE Polarity depends on the instructions from the electrode manufa...

Страница 46: ...7 3 Hotstart current and Hotstart time The hotstart device improves the ignition of the stick electrodes using an increased ignition current a Hotstart time b Hotstart current I Welding current t Time...

Страница 47: ...parameter The signal light lights up in red Set arcforcing 40 low current increase soft arc 0 default setting 40 high current increase aggressive arc 5 7 5 Antistick Anti stick prevents the electrode...

Страница 48: ...pending on the preselected main current on the welding machine Pulse spot normal Pulse spot and break times are infinitely adjustable 5 8 4 Manual remote control RTP 2 RTP2 Functions TIG MMA Infinitel...

Страница 49: ...I start I FFr on FFr off end I t Figure 5 21 Symbol Meaning Actuate foot operated remote control start welding process Operate foot operated remote control set welding current according to application...

Страница 50: ...0V 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 22 Pos Pin Signal shape Designation 1 A Output Connection for cable screen PE 2 B L Outpu...

Страница 51: ...interface results in equipment damage or faults in signal transmission The PC may be destroyed due to high frequency ignition pulses Interface SECINT X10USB must be connected between the PC and the w...

Страница 52: ...lope times for secondary current AMP or pulse edges Figure 5 23 Figure 5 24 Display Setting selection Expert menu Slope time tS1 main current to secondary current Setting 0 00 s to 20 0 s factory sett...

Страница 53: ...7 2011 53 5 11 2 TIG non latched operating mode C version 0 1 0 1 Figure 5 25 Display Setting selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display No...

Страница 54: ...the accident prevention regulations in your country Inform persons in the working area that they must observe the regulations CAUTION Test Before re commissioning it is essential that an inspection a...

Страница 55: ...ert menu can be displayed as percentages factory setting or absolute values on the machine display 0 1 0 1 Figure 5 27 Display Setting selection Exit the menu Exit Machine configuration Settings for m...

Страница 56: ...ntrol RTF 1 0 1 0 1 Figure 5 28 Display Setting selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display Ramp function Remote control RTF 1 The ramp func...

Страница 57: ...n once 5 12 2 Expert menu MMA Figure 5 29 Display Setting selection Hotstart current Hotstart current setting Hotstart time Hotstart time setting NOTE ENTER enter the menu Keep the welding parameters...

Страница 58: ...Ignition current Setting range in percent depending on main current Setting range absolute Imin to Imax Upslope time to main current Setting 0 0 sec to 20 0 sec factory setting 1 0 sec Slope time tS1...

Страница 59: ...d hold the welding parameters button and switch the machine on again at the same time NAVIGATION navigating in the menu Parameters are selected by pressing the welding parameters button Set or change...

Страница 60: ...tion C version on on off off factory setting Power display switching MMA on actual value display off setpoint value display factory setting spotMatic Variation of operation mode spotArc ignition with...

Страница 61: ...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 machine configuration menu CPL Complete res...

Страница 62: ...ey are fitted correctly and secured Gas tubes and their switching equipment solenoid valve Operating message safety and adjustment devices Functional test Other general condition 6 2 2 Monthly mainten...

Страница 63: ...pean provisions guideline 2002 96 EG of the European Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must...

Страница 64: ...heck mains connection fuses a Various parameters cannot be set Entry level is blocked disable access lock see chapter entitled Lock welding parameters against unauthorised access a Connection problems...

Страница 65: ...d correct if necessary Pore formation a Inadequate or missing gas shielding Check shielding gas setting and replace shielding gas cylinder if necessary Shield welding site with protective screens drau...

Страница 66: ...ion menu off status Connect wire feed unit Temperature error Allow machine to cool down Err 4 Error in emergency stop circuit interface for mechanised welding Check the external shut down equipment Ch...

Страница 67: ...t 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 machine con...

Страница 68: ...oftware versions only serves to inform the authorised service staff 0 1 0 1 Figure 7 2 Display Setting selection Exit the menu Exit Service menu Modifications to the service menu may only be carried o...

Страница 69: ...e at 40 C 35 DC 180 A 150 A 60 DC 150 A 120 A 100 DC 120 A 100 A Load alternation 10 min 60 DC 6 min welding 4 min pause Open circuit voltage 90 V Mains voltage tolerances 1 x 230 V 40 to 15 Frequency...

Страница 70: ...cable 092 000857 00000 9 2 Options Type Designation Item no ON 8POL 02 TETRIX 180 Optional retrofit 8 pole torch connection socket for TETRIX 180 up to serial no 196718 092 002464 00000 ON 8POL 03 TET...

Страница 71: ...Appendix A Overview of EWM branches 099 000124 EW501 29 07 2011 71 10 Appendix A 10 1 Overview of EWM branches...

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