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Contents

Notes on the use of these operating instructions

099-000120-EW501

26.07.2011

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 – quick overview .............................................................................................. 16

4.1

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

4.2

Rear view ..................................................................................................................................... 18

4.3

Machine control – Operating elements ........................................................................................ 20

4.3.1

Function sequence ....................................................................................................... 22

Design and function............................................................................................................................. 24

5.1

General ........................................................................................................................................ 24

5.2

Transport and installation ............................................................................................................ 25

5.3

Machine cooling ........................................................................................................................... 25

5.4

Workpiece lead, general .............................................................................................................. 25

5.5

Mains connection ......................................................................................................................... 26

5.5.1

Mains configuration ...................................................................................................... 26

5.6

TIG welding.................................................................................................................................. 27

5.6.1

Welding torch and workpiece line connection .............................................................. 27

5.6.2

Torch connection options and pin assignments ........................................................... 28

5.6.3

Shielding gas supply (shielding gas cylinder for welding machine) ............................. 28

5.6.3.1

Connecting the shielding gas supply ............................................................ 29

5.6.3.2

Setting the shielding gas quantity ................................................................. 30

5.6.3.3

Gas test......................................................................................................... 30

5.6.4

Select welding task....................................................................................................... 31

5.6.4.1

Manual, standard operation (JOB 0)............................................................. 31

5.6.4.2

Save welding tasks (JOBs)

........................................................................... 32

5.6.5

Welding data display .................................................................................................... 32

5.6.5.1

Welding parameter setting ............................................................................ 32

5.6.6

Arc ignition.................................................................................................................... 33

5.6.6.1

HF ignition ..................................................................................................... 33

5.6.6.2

Liftarc ignition ................................................................................................ 33

5.6.7

Automatic cut-out.......................................................................................................... 33

5.6.8

Optimising the ignition characteristics for pure tungsten electrodes............................ 34

5.6.8.1

Manual, standard operation (JOB 0)............................................................. 34

5.6.8.2

JOB operation (JOB 1 to 7)........................................................................... 34

5.6.9

Optimal and fast spherical cup formation ..................................................................... 35

5.6.10

Function sequences/operating modes ......................................................................... 36

5.6.10.1

Explanation of symbols ................................................................................. 36

5.6.10.2

SpotArc ......................................................................................................... 39

5.6.10.3

Spotmatic ...................................................................................................... 41

5.6.10.4

Non-latched operation, version C ................................................................. 42

Содержание TETRIX 300 AC/DC COMFORT activArc

Страница 1: ...instructions Welding machine GB Tetrix 300 AC DC Comfort 099 000120 EW501 26 07 2011 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warranty www ewm...

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: ...Machine cooling 25 5 4 Workpiece lead general 25 5 5 Mains connection 26 5 5 1 Mains configuration 26 5 6 TIG welding 27 5 6 1 Welding torch and workpiece line connection 27 5 6 2 Torch connection opt...

Страница 4: ...ing parameters from unauthorised access 60 5 9 Remote control 61 5 9 1 Manual remote control RT 1 61 5 9 2 RTG1 19POL manual remote control 61 5 9 3 Manual remote control RTP 1 61 5 9 4 Manual remote...

Страница 5: ...77 6 5 Meeting the requirements of RoHS 77 7 Rectifying faults 78 7 1 Customer checklist 78 7 2 Machine faults error messages 80 7 3 Resetting welding parameters to the factory settings 81 7 4 Displa...

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: ...ccepted 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 equipment improperly 3 1 Appli...

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: ...00120 EW501 26 07 2011 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 retrofi...

Страница 17: ...y switch for protection against unauthorised use Position 1 changes possible Position 0 changes not possible Please take note of chapter Protecting welding parameters from unauthorised access 8 Connec...

Страница 18: ...Machine description quick overview Rear view 18 099 000120 EW501 26 07 2011 4 2 Rear view Figure 4 2...

Страница 19: ...pressure regulator 4 Main switch machine on off 5 Mains connection cable 6 4 pole connection socket Cooling unit voltage supply 7 8 pole connection socket Cooling unit control lead 8 42V 4A Automatic...

Страница 20: ...red light TIG AC special 4 Welding current polarity button Direct current welding with positive polarity on the electrode holder in relation to the workpiece pole reversal switch MMA only DC welding...

Страница 21: ...trode diameter Ignition optimisation rotary dial Infinitely adjustable from 1 mm to 4 mm or greater 9 Welding parameter setting rotary transducer Setting flows times and parameters 10 Three figure LED...

Страница 22: ...for non latched and latched Hotstart time MMA Setting ranges 0 00 s to 20 0 s 0 1 s increments Pulse time slope time from AMP to AMP Pulse time setting range 0 01 s to 20 0 s 0 01 s increments 0 5 s 0...

Страница 23: ...to 4 mm or greater 0 1 mm increments Alternating current balance TIG AC Max setting range 30 to 30 1 increments The setting range may also be lower depending on the factory setting Optimisation of cl...

Страница 24: ...e not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by turning in clockwise direction if necessary Risk from electrical c...

Страница 25: ...ng for the place of work Safe operation of the machine must be guaranteed at all times 5 3 Machine cooling To obtain an optimal duty cycle from the power components the following precautions should be...

Страница 26: ...ctions The resulting network has to be suitable for operating devices according to protection class 1 5 5 1 Mains configuration NOTE The machine may be connected to a three phase system with four cond...

Страница 27: ...torch control lead 7 Connection socket welding current Welding current lead connection for TIG welding torch 8 G connecting nipple TIG welding torch shielding gas connection Insert the welding current...

Страница 28: ...in serious and even fatal injury Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air Place shielding gas cylinders in the holders pr...

Страница 29: ...ymbol Description 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...

Страница 30: ...his can introduce air to the weld pool and may cause pores to form Adjust the shielding gas quantity to suit the welding task 5 6 3 3 Gas test Operating element Action Result x x Press the Select weld...

Страница 31: ...ollowing order Item Symbol Description 0 1 Welding process button MMA welding lights up in green arcforce setting lights up in red TIG welding 2 Welding current polarity button Direct current welding...

Страница 32: ...ndard operation JOB 0 The Alternating current balance TIG AC and Tungsten electrode diameter Ignition optimisation rotary dials are the exception These welding parameters are set in JOB 1 to 7 in the...

Страница 33: ...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 34: ...ungsten electrode The value can of course be adjusted in line with different requirements 5 6 8 1 Manual standard operation JOB 0 Operating element Action Result Set diameter of tungsten electrode Inc...

Страница 35: ...use refer to the table of guideline values for spherical cup formation depending on welding current Select AC type Square current output wave form Trapezoidal current output wave form Sinusoidal curre...

Страница 36: ...d operating mode used 2 Welding parameter setting rotary transducer Setting flows times and parameters 5 6 10 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 I Cu...

Страница 37: ...t 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 current...

Страница 38: ...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 curre...

Страница 39: ...s using the Welding parameter setting rotary dial spot time setting range 0 01 s to 20 0 s Set spot time tP The TIG spotArc process is switched on with the pulse variant TIG automated pulses by defaul...

Страница 40: ...ematurely spotArc pulse variants table Process Pulse variants Automated pulses factory setting lights up in green Pulses thermal pulses lights up in red kHz pulse metallurgic pulses TIG DC No pulses l...

Страница 41: ...pter 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...

Страница 42: ...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 43: ...ng 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 necessary during the up...

Страница 44: ...e and pause times frequency up to 200 Hz and the pulse edges ts1 and ts2 are entered in seconds on the control Figure 5 16 Operating element Action Result Select TIG pulses function Signal light light...

Страница 45: ...element Action Result Display Select 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...

Страница 46: ...se pulse pause time Figure 5 18 5 6 12 5 AC special Application e g for welding thick metal sheets onto thin metal sheets Operating element Action Result Select TIG AC special Press the TIG pulses but...

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 t...

Страница 48: ...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 14 1 Tap torch trigger tapping funct...

Страница 49: ...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 20 Display Setting selection Exit the menu Exit Torch...

Страница 50: ...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 51: ...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 52: ...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 53: ...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 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: ...3 are not used with this type of torch or respectively are not appropriate Welding current on off TT 1 Secondary current TT 2 Secondary current tapping function TT 1 tapping Raise welding current in...

Страница 56: ...t increment Figure 5 21 0 1 0 1 Figure 5 22 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 57: ...During 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 di...

Страница 58: ...urrent polarity button Direct current welding with positive polarity on the electrode holder in relation to the workpiece pole reversal switch MMA only DC welding with negative polarity on the torch o...

Страница 59: ...ated articles for welding can be welded and cleaned perfectly at a higher frequency Frequency fast TIG DC pulses Setting range 50 Hz to 15 kHz 5 7 3 Hotstart current and Hotstart time The hotstart dev...

Страница 60: ...Result Displays 1 x Select arcforcing welding 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...

Страница 61: ...anual remote control RTP 2 RTP2 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 spot t...

Страница 62: ...ding operation TIG ActivArc welding is not possible in combination with the RTF 1 foot operated remote control I start I FFr on FFr off end I t Figure 5 25 Symbol Meaning Actuate foot operated remote...

Страница 63: ...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 64: ...competitor machine Synchronisation between two Tetrix series machines Phase sequences and rotating fields of the supply voltages must be identical for both welding machines If this is not the case the...

Страница 65: ...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...

Страница 66: ...ted max 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 se...

Страница 67: ...lope times for secondary current AMP or pulse edges Figure 5 27 Figure 5 28 Display Setting selection Expert menu Slope time tS1 main current to secondary current Setting 0 00 s to 20 0 s factory sett...

Страница 68: ...6 07 2011 5 13 2 TIG non latched operating mode C version 0 1 0 1 Figure 5 29 Display Setting selection Exit the menu Exit Machine configuration Settings for machine functions and parameter display No...

Страница 69: ...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 70: ...ert menu can be displayed as percentages factory setting or absolute values on the machine display 0 1 0 1 Figure 5 31 Display Setting selection Exit the menu Exit Machine configuration Settings for m...

Страница 71: ...ntrol RTF 1 0 1 0 1 Figure 5 32 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 72: ...s to 20 0 s factory setting 0 01 s Slope time tS2 secondary current to main current Setting 0 00 s to 20 0 s factory setting 0 01 s Wire return Increase value more wire return Reduce value less wire...

Страница 73: ...arameters 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 the parameters by tu...

Страница 74: ...on 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 wo...

Страница 75: ...utomation on function on off function 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...

Страница 76: ...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 77: ...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 78: ...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 79: ...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 80: ...0 1 Err 5 Overvoltage 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 erro...

Страница 81: ...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 82: ...re version query example 07 System bus ID 02c0 Version number System bus ID and version number are separated by a dot 7 5 General operating problems 7 5 1 Interface for mechanised welding WARNING No f...

Страница 83: ...65 DC 100 DC 300 A DC 270 A 220 A 300 A DC 270 A 210 A 260 A 210 A 260 A 200 A Load alternation 10 min 60 DC 6 min welding 4 min break No load DC voltage 98 V DC Mains voltage tolerances 3 x 400 V 25...

Страница 84: ...092 001470 00020 RV5M19 19POLE 5M Extension cable 092 000857 00000 9 2 Welding torch cooling system Type Designation Item no cool35 U31 Air cooling unit 090 008235 00502 9 3 Transportsysteme Type Des...

Страница 85: ...Appendix A Overview of EWM branches 099 000120 EW501 26 07 2011 85 10 Appendix A 10 1 Overview of EWM branches...

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