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Operating problems, causes and remedies

Error messages (power source)

Item No.: 099-004877-EWM01

81

9

Operating problems, causes and remedies

All machines are subject to rigorous production checks and final checks. If despite this, anything fails to
work at any time, please check the machine using the following chart. If none of the fault rectification
procedures described leads to the correct functioning of the machine, please inform your authorised
dealer.

9.1

Error messages (power source)

A welding machine error is indicated by the collective fault signal light (1) coming on and an error
code (see table) being displayed in the display of the machine controller (2).

In the event of a machine error, the power unit is shut down.
• If multiple errors occur, these are displayed in succession.
• Document machine errors and inform service staff as necessary.

Pos. Description

1

Collective interference signal light

2 Three-figure

LED

display

Figure 9-1

Error message

Possible cause

Remedy

Err 3

Speedometer error

Check wire guide / tube package

Err 4

Temperature error

Allow machine to cool down

Err 5

Excess voltage

Err 6

Undervoltage

Switch off the machine and check mains
voltages

Err 7

Coolant error (only if cooling module
connected)

Check coolant level and refill if necessary

Err 8

Gas error

Check gas supply

Err 9

Secondary excess voltage

Err 10

PE error

Err 11

FastStop

Switch the machine off and on again.
If the error persists, inform the service dept.

Err 32

Electronics error (I>0 error)

Err 33

Electronics error (Uactual error)

Err 34

Electronics error (A/D channel error)

Err 35

Electronics error (edge error)

Err 36

Electronics error (S sign)

Switch the machine off and on again.
If the error persists, inform the service dept.

Err 37

Electronics error (temperature error)

Allow machine to cool down.

Err 38

---

Err 39

Electronics error (secondary
overvoltage)

Switch the machine off and on again.
If the error persists, inform the service dept.

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Содержание TETRIX 270 AC/DC COMFORT activArc

Страница 1: ...e read before commissioning Failure to do so may be dangerous Machines may only be operated by personnel who are familiar with the appropriate safety regulations The machines bear the conformity mark...

Страница 2: ...ody future oriented advanced technology at the utmost level of quality Each of our products is carefully checked we guarantee that the material and processing of our products is faultless These operat...

Страница 3: ...ields CE EWM HIGHTEC WELDING GMBH D 56271 M NDERSBACH TYP ART SNR PROJ GEPR FT CONTROL Name of Customer company Adress Post code Place Country Stamp Signature of EWM distibutor Date of purchase Name o...

Страница 4: ...OB operation JOB 1 to 7 31 5 2 2 1 Displaying and changing the JOB number 31 5 2 3 Welding data display 32 5 2 3 1 Welding parameter setting 32 5 2 3 2 Machine configuration menu 32 5 3 TIG welding 33...

Страница 5: ...1 63 5 7 2 Manual remote control RT 1 63 5 7 3 Manual remote control RT AC 1 63 5 7 4 Manual remote control RTP 1 63 5 7 5 Manual remote control RTP 2 64 5 7 6 RTP 3 manual remote control 64 5 7 7 Ma...

Страница 6: ...ork 77 7 5 Disposing of equipment 78 7 5 1 Manufacturer s declaration to the end user 78 7 6 Meeting the requirements of RoHS 78 8 Warranty 79 8 1 General Validity 79 8 2 Warranty Declaration 80 9 Ope...

Страница 7: ...otective clothing e g gloves Protect eyes and face with protective visor Electric shocks can be fatal Do not touch any live parts in or on the machine The machine may only be connected to correctly ea...

Страница 8: ...Before beginning welding work ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source N...

Страница 9: ...ny risk of explosion exists The following conditions must be observed during operation Temperature range of the ambient air During welding 10 C to 40 C For transport and storage 25 C to 55 C Using the...

Страница 10: ...ch are graded as follows depending on their importance Please note Technical features which users must observe Warning Working and operating procedures which must be followed precisely to avoid damagi...

Страница 11: ...A DC 270 A 220 A 260 A 200 A 300 A 270 A 220 A 260 A 200 A Load alternation 10min 60 DC 6 min welding 4min break Open circuit voltage with AC and DC 93 V DC Mains voltage tolerances 3 x 400 V 25 20 3...

Страница 12: ...Load alternation 10min 60 DC 6 min welding 4min break Open circuit voltage with AC and DC 95 V Mains voltage tolerances 3 x 400 V 25 20 3 x 415 V 25 15 Frequency 50 60 Hz Mains fuse safety fuse slow...

Страница 13: ...n 60 DC 6 min welding 4min break Open circuit voltage with AC and DC 79 V at 400 V 91 V at 460 V Mains voltage tolerances 3 x 400 V 25 20 3 x 415 V 25 15 3 x 460 V 25 10 Frequency 50 60 Hz Mains fuse...

Страница 14: ...Machine description TETRIX 270 300 AC DC COMFORT activArc 14 Item No 099 004877 EWM01 4 Machine description 4 1 TETRIX 270 300 AC DC COMFORT activArc 4 1 1 Front view Figure 4 1...

Страница 15: ...DC polarity Connection for workpiece lead 7 0 1 Key switch for locking the control option Position 1 changes possible Position 0 changes not possible 8 Connection socket 8 pole 12 pole 8 pole TIG Up D...

Страница 16: ...Machine description TETRIX 270 300 AC DC COMFORT activArc 16 Item No 099 004877 EWM01 4 1 2 Rear view Figure 4 2...

Страница 17: ...ole connection socket Cooling unit voltage supply 7 8 pole connection socket Cooling unit control lead 8 42V 4A Automatic circuit breaker key button fuse protection Ignition unit Gas valve Peripheral...

Страница 18: ...Machine description TETRIX 350 AC DC COMFORT activArc 18 Item No 099 004877 EWM01 4 2 TETRIX 350 AC DC COMFORT activArc 4 2 1 Front view Figure 4 3...

Страница 19: ...control lead 5 Cooling air inlet 6 Rubber feet 7 0 1 Key switch for locking the control option Position 1 changes possible Position 0 changes not possible 8 Connection socket 19 pole Remote control c...

Страница 20: ...Machine description TETRIX 350 AC DC COMFORT activArc 20 Item No 099 004877 EWM01 4 2 2 Rear view Figure 4 4...

Страница 21: ...e Interface set SECINTX10 DSUB required observe installation instructions 5 G connecting nipple Shielding gas connection on the pressure reducer 6 8 pole connection socket Cooling unit control lead 7...

Страница 22: ...Machine description TETRIX 500 AC DC COMFORT activArc 22 Item No 099 004877 EWM01 4 3 TETRIX 500 AC DC COMFORT activArc 4 3 1 Front view Figure 4 5...

Страница 23: ...ing elements see chapter Function specification 7 0 1 Key switch for locking the control option Position 1 changes possible Position 0 changes not possible 8 Connection socket 19 pole Remote control c...

Страница 24: ...Machine description TETRIX 500 AC DC COMFORT activArc 24 Item No 099 004877 EWM01 4 3 2 Rear view Figure 4 6...

Страница 25: ...ions 4 8 pole connection socket Cooling unit control lead 5 analog 19 pole connection socket option Analogue interface for mechanised welding 6 G connecting nipple Shielding gas connection on the pres...

Страница 26: ...ge optimise all parameters directly in machine control see chapter Operating concepts Figure 5 1 Item Symbol Description 0 1 Welding process button MMA welding lights up in green arcforce setting ligh...

Страница 27: ...Welding current display Welding voltage display JOB number display 6 Alternating current frequency TIG AC rotary dial 50 Hz to 200 Hz 1 Hz increments 7 Alternating current balance TIG AC rotary dial M...

Страница 28: ...tting range 1 to 200 1 increments 4 sec Up slope time TIG Setting ranges 0 00 sec to 20 0 sec 0 1 sec increments The up slope time can be set separately for non latched and latched Hotstart time MMA S...

Страница 29: ...c increments 12 Tungsten electrode diameter Ignition optimisation LED Infinitely adjustable from 1 mm to 4 mm or greater Alternating current balance TIG AC Max setting range 30 to 30 1 increments The...

Страница 30: ...ent welding with positive polarity at the electrode holder MMA only DC welding with negative polarity at the torch or electrode holder with respect to the workpiece AC welding with rectangular current...

Страница 31: ...switchover is pressed or if there is no keyboard input for 5 seconds the new JOB will be active JOB number The procedure for setting welding tasks is the same as described under Manual standard operat...

Страница 32: ...riant then you cannot set any pulse times in the function sequence 5 2 3 2 Machine configuration menu If the machine configuration is changed then the parameter and its value are shown alternately in...

Страница 33: ...Release or press the torch trigger depending on the operating mode selected 5 3 1 2 Liftarc a b c Figure 5 4 The arc is ignited on contact with the workpiece a Carefully place the torch gas nozzle an...

Страница 34: ...n JOB 1 to 7 Operating element Action Result Display x x Select ignition characteristics parameter Press until signal light comes on Set diameter of tungsten electrode Increase parameter value more ig...

Страница 35: ...rm Trapezoidal current output wave form Sinusoidal current output wave form Balance setting in JOB 0 Turn rotary dial to the left as far as it will go positive Form spherical cups on the tungsten elec...

Страница 36: ...r setting rotary dial Figure 5 5 5 3 6 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 I Current t Time Gas pre flows Istart Ignition current tUp Up slope time tP...

Страница 37: ...e 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 slope ti...

Страница 38: ...er 1 The welding current increases with the set up slope time to the main current AMP Switching from main current AMP to secondary current AMP Press torch trigger 2 or Tap torch trigger 1 for tapping...

Страница 39: ...play Signal light comes on The spot time can be set for approx 4 sec using the Welding parameter setting rotary dial spot time setting range 0 01 sec to 20 0 sec Afterwards the display switches back t...

Страница 40: ...ed off The welding current increases in the adjusted up slope time to the main current AMP The process ends when the set SpotArc time elapses or if the torch trigger is released prematurely spotArc pu...

Страница 41: ...2 5kHz with activArc 0 5s 250A 0 3s 1mm Automated pulses with activArc 0 4s 200A 0 1s 1mm Fast pulsing 2 5kHz 0 4s 200A 0 1s Lap weld 2mm Fast pulsing 2 5kHz with activArc 0 5s 270A 0 5s spotArc setti...

Страница 42: ...at minimum setting HF is switched off 2nd cycle Release torch trigger 1 The welding current increases in the set up slope time to the main current AMP Pressing torch trigger 1 starts the slope tS1 fro...

Страница 43: ...sequences in pulses basically behave in the same way as in standard welding but during the main current phase there is a continual switching back and forth between the pulse and pause currents at the...

Страница 44: ...pause times frequency up to 200 Hz and the pulse edges ts1 and ts2 are entered in seconds on the control Figure 5 12 Operating element Action Result Display Select TIG pulses function Signal light li...

Страница 45: ...ct kHz pulses Press the TIG pulses button until the signal light lights up in red Select balance Setting range 1 to 99 1 increments Select frequency Setting range 50 Hz to 2 5 kHz 0 01 kHz increments...

Страница 46: ...tion Result Select TIG AC special Press the TIG pulses button until the AC special signal light comes on AMP AMP tpause tpuls AMP t AMP AC current phase pulse current AMP DC phase pulse pause current...

Страница 47: ...in tacking and in spot welding TIG activArc combined with pulse variant TIG automated pulses or kHz pulses metallurgic pulses improves the positive properties of the process further depending on the...

Страница 48: ...ows for approx 20 sec 5 3 11 TIG welding torch operating variants There is the option of connecting various operating and display elements to the welding torch The functions of the torch triggers TT a...

Страница 49: ...ed on and off in all modes using torch trigger 1 TT 1 Operating element Action Result Display 0 1 Switch off the welding machine Press and hold key button Switch on the welding machine Select Torch mo...

Страница 50: ...Off BRT 1 Secondary current 1 factory set BRT 1 Further modes are not relevant for this torch type Standard torch with two torch triggers Diagram Operating elements Explanation of symbols BRT1 torch...

Страница 51: ...r 2 Functions mode Operating elements Welding current On Off BRT 1 Secondary current BRT 2 Secondary current tapping mode 1 factory set BRT 1 Welding current On Off BRT 1 BRT 2 Secondary current tappi...

Страница 52: ...pping 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...

Страница 53: ...T 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 BRT 2 Seconda...

Страница 54: ...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 55: ...ding gas flows for approx 20 secondsFehler Es wurde kein Textmarkenname vergeben Select secondary current via TT 2 Tapping function switched on Mode 1 6 tapping function switched off Modes 11 16 Basic...

Страница 56: ...tton Switch on welding machine Select Torch mode menu item trd The parameter that can be changed and the associated value blink alternately in the display 1 x Hold until menu item tod torch mode is di...

Страница 57: ...The signal light lights up in green Display shows the last current value used for welding Set welding current Welding current is displayed 5 4 2 Hotstart The hotstart device improves the ignition of...

Страница 58: ...rrent increase aggressive arc 5 4 4 Antistick Anti stick prevents the electrode from annealing If the electrode sticks in spite of the Arcforce device the machine automatically switches over to the mi...

Страница 59: ...mes for secondary current AMP or pulse edges Figure 5 15 Operating element Action Result Display 2 sec Select slope time tS1 Set slope time tS1 from main current AMP to secondary current AMP 1 x Selec...

Страница 60: ...e welding machine Select Configuration menu item cFG The parameter that can be changed and the associated value blink alternately in the display Hold until menu item 2tc TIG non latched C version is d...

Страница 61: ...k must be completed by electrical engineers in accordance with the relevant VDE regulations Disconnect from the mains before opening Switching off is not sufficient Wait for 2 minutes until the capaci...

Страница 62: ...Select Configuration menu item cFG The parameter that can be changed and the associated value blink alternately in the display 1 x Hold until SEt menu item is displayed Select the operating mode Pro p...

Страница 63: ...remote control is connected to the 19 pole remote control connection socket on the welding machine via a 19 pole extension cable 5 7 3 Manual remote control RT AC 1 Functions Infinitely adjustable we...

Страница 64: ...initely adjustable welding current 0 to 100 depending on the preselected main current on the welding machine Pulse SpotArc spots normal Frequency and spot time infinitely adjustable Coarse adjustment...

Страница 65: ...on for master slave operation D Output no c IGRO Current flows signal I 0 maximum load 20mA 15V 0V welding current flowing E R Input Not Aus Emergency stop for higher level shut down of the power sour...

Страница 66: ...ax 15V 100mA 3 F Output Reference voltage for potentiometer 10V max 10mA 4 C Input Control value specification for main current 0 10V 0V Imin 10V Imax 5 D Input Control value specification for seconda...

Страница 67: ...for the relevant machine Set up the machine so that there is sufficient room to adjust the operating elements 6 4 Mains connection The operating voltage shown on the rating plate must match the mains...

Страница 68: ...welding and if a welding torch and an electrode holder are connected to the machine the open circuit or welding voltage is applied simultaneously to both The torch and the electrode holder should ther...

Страница 69: ...corresponding rapid action closure couplings Return line red to rapid action coupling red coolant return line and supply line blue to rapid action coupling blue coolant supply line Please note the rel...

Страница 70: ...the pressure reducer Place shielding gas cylinder in the retainer provided for it and secure with chains Before connecting the pressure reducer to the gas cylinder open the cylinder valve briefly to...

Страница 71: ...isk of being crushed or burnt When replacing spent or new stick electrodes Switch off machine at the main switch Wear appropriate safety gloves Use insulated tongs to remove spent stick electrodes or...

Страница 72: ...and Remedies 6 9 1 Coolant error If the coolant pressure drops during the welding process e g due to insufficient coolant pump failure or defective hose the welding process is terminated deliberately...

Страница 73: ...Trapezoidal current output wave form Sinusoidal current output wave form Turn the Alternating current frequency TIG AC rotary dial to the left as far as it will go Signal light Netsyn comes on 6 11 P...

Страница 74: ...ng on the amount of dust blow out using oil and moisture free compressed air Electronics Do not blast electronic components or circuit boards with compressed air but instead use suction from a vacuum...

Страница 75: ...lding current sockets The voltmeter must display mean values and have an internal resistance 1 M In the case of step switch controlled devices set the maximum output voltage step switch Adjust the pot...

Страница 76: ...uctor current 5mA 2 Leakage current from the welding sockets separately to PE 10mA 7 3 7 Measurement of protective conductor resistance Measure between the plug earthed contact and accessible live par...

Страница 77: ...g an order please quote the type designation and item number as well as the type serial number and item number of the relevant equipment We hereby confirm that the servicing and maintenance instructio...

Страница 78: ...eeled bins indicates the requirement to separate this waste Help to protect the environment and ensure that this equipment when you no longer want to use it is disposed of in the relevant system of se...

Страница 79: ...ll additional parts used by EWM but manufactured by other companies e g motors pumps fans torches etc Non reproducible software errors and parts subject to mechanical ageing are excluded from the warr...

Страница 80: ...remote control remote control extension cable coolant etc The warranty does not apply to products that are damaged due to accidents misuse improper operation incorrect installation use of force disre...

Страница 81: ...1 Collective interference signal light 2 Three figure LED display Figure 9 1 Error message Possible cause Remedy Err 3 Speedometer error Check wire guide tube package Err 4 Temperature error Allow mac...

Страница 82: ...10 19POLE 20M Connection cable e g for remote control 092 001470 00020 RTF1 19POLE 5M Foot operated remote control for current with connection cable 094 006680 00000 RV5M19 19POLE 5M Extension cable 0...

Страница 83: ...trifugal pump and reinforced cooling 090 008220 00102 10 7 Synchronisation Type Designation Item number ON NETSYNCHRON Optional retrofit set for phase sequence switching for synchronous welding 090 00...

Страница 84: ...VAC X2 1 X2 2 X2 3 X2 4 X2 X1 1 X1 2 X1 X4 1 X4 2 X4 3 X4 4 X3 1 X3 2 X4 X3 HF DC1 T A7 1 15V 3 HF 1 Coil 2 Coil 2 42VAC 4 0VAC WIG EL W A E HF Drossel L2 22nF PE 2x2n2F PE 1 P E 1 T P E 2 1 P E 4 3 A...

Страница 85: ...X20 9 X20 10 X21 X21 1 X21 2 X21 3 X21 4 X21 5 X21 6 X21 7 X21 8 X21 9 X21 10 D Sub 15polig X12 Fernregler X PE X12 10 X12 11 X12 12 X12 13 X12 14 X12 15 X12 16 X12 17 X12 18 X12 1 X12 2 X12 3 X12 4 X...

Страница 86: ...X1 2 X1 X4 1 X4 2 X4 3 X4 4 X3 1 X3 2 X4 X3 HF DC1 T A7 1 15V 3 HF 1 Coil 2 Coil 2 42VAC 4 0VAC WIG EL W A E HF Drossel L2 22nF PE 2x2n2F PE 1 PE1 T PE2 1 PE4 3 A 2 3 B 2 3 C 2 3 D 2 X8 2 X8 1 15polig...

Страница 87: ...20 8 X20 9 X20 10 X21 X21 1 X21 2 X21 3 X21 4 X21 5 X21 6 X21 7 X21 8 X21 9 X21 10 D Sub 15polig X12 Fernregler X PE X12 10 X12 11 X12 12 X12 13 X12 14 X12 15 X12 16 X12 17 X12 18 X12 1 X12 2 X12 3 X1...

Страница 88: ...6 X1 7 X1 8 T2 4AT F1 T1 12V W K 6 A6 X9 1 X9 2 X2 1 X2 2 X2 3 X2 4 X7 X6 X5 X4 E 5 2 8 PE 1 P E 1 1 42VAC 2 0VAC 5 42VAC 6 0VAC 1 Absicherung 2 Absicherung A 42V B 0V B 3 2 A 3 2 X2 1 X2 2 X2 3 X2 4...

Страница 89: ...2 3 X22 2 X22 1 X22 10 X14 Peripherie X14 12 X14 11 X14 10 X14 9 X14 8 X14 7 X14 6 X14 5 X14 4 X14 3 X14 2 X14 1 D Sub 15polig X11 1 X11 2 X11 3 X11 4 X11 5 X11 6 X11 7 X11 8 X11 9 X11 10 X11 11 X11 1...

Страница 90: ...g D SUB Stecker X3 Schirm 0V RS 12V TXD RXD RSGND 42V X1 7 X1 6 X1 5 X1 4 X1 3 X1 2 X1 1 Schirm 0V RS 12V RSGND 42V X2 7 X2 6 X2 5 X2 4 X2 3 X2 2 X2 1 RXD TXD VP5 2D 2x2n2F A11 X2 1 X2 2 X2 3 X2 4 X2...

Страница 91: ...X22 5 X22 4 X22 3 X22 2 X22 1 X22 10 X14 Peripherie X14 12 X14 11 X14 10 X14 9 X14 8 X14 7 X14 6 X14 5 X14 4 X14 3 X14 2 X14 1 D Sub 15polig X11 1 X11 2 X11 3 X11 4 X11 5 X11 6 X11 7 X11 8 X11 9 X11...

Страница 92: ...he event of unau thorised modifications improperly con ducted repairs non observance of the deadlines for the repetition test and or non permitted conversion work not specifically authorised by EWM Pa...

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