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Design and function

Notes on the installation of welding current leads

099-000157-EW501

16.10.2014

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 loops!

Always keep leads as short as possible!

Lay any excess cable lengths in meanders.

Figure 5-4

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Содержание Tetrix 230 Comfort 5P TM

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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