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Machine description – quick overview

Front view / rear view

099-000125-EW501

29.9.2022

Item Symbol Description

Carrying handle

Machine control

> see 4.2 chapter

Cooling air inlet

Connection socket, 19-pole

Remote control connection

Connection socket (welding torch control cable)

> see 5.2.1.1 chapter

G¼“ connecting nipple, welding current "-" (with DC- polarity)

Shielding gas connection (with yellow insulating cap) for TIG welding torch

19-pole mechanised welding interface (analogue)

> see 5.6.1 chapter

Connection thread - G¼"

Shielding gas connection (inlet)

Push-button of automatic circuit-breaker for control electronics

Press to reset tripped fuse

Ignition type changeover switch

> see 5.2.3 chapter

= HF ignition

= Liftarc (contact ignition)

Cooling air outlet

Machine feet

4-pole connection socket

Cooling unit voltage supply

Mains connection cable

> see 5.1.8 chapter

8-pole connection socket

Cooling unit control lead

Main Switch

Switching the machine on or off.

Connection socket (9-pole) - D-Sub

PC interface

> see 5.5 chapter

Connection socket, “+” welding current

Connection for workpiece lead

Connection socket, “-” welding current

TIG welding torch connection

Connection socket, welding current “–”

Connection of the electrode holder

Содержание Tetrix 300 Smart TM

Страница 1: ...Operating instructions EN Welding machine Tetrix 300 Smart TM 099 000125 EW501 Observe additional system documents 29 9 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: ...1 4 Transport belt 19 5 1 4 1 Adjusting the lengthof thecarrying strap 19 5 1 5 Welding torch cooling system 20 5 1 5 1 Cooling unit connection 20 5 1 6 Notes on the installation of welding current le...

Страница 4: ...6 2 Responsiveness 52 5 5 PC interface 52 5 5 1 Connection 52 5 6 Interfaces for automation 53 5 6 1 Automation interface 54 5 6 2 Remotecontrol connectionsocket 19 pole 55 5 6 3 RINT X12 robot interf...

Страница 5: ...5 EW501 29 9 2022 5 9 2 Welding torch cooling system 71 9 2 1 Coolant typeblueCool 71 9 2 2 Coolant type KF 71 9 3 Remotecontrols and accessories 71 9 4 Options 71 9 5 Transport system 72 9 6 Computer...

Страница 6: ...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 oper...

Страница 7: ...on machine Press and hold Incorrect Invalid Switch Correct Valid Turn Input Numerical value adjustable Navigation Signal light lights up in green Output Signal light flashes green Time representation...

Страница 8: ...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 9: ...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 excessiv...

Страница 10: ...ts 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 us...

Страница 11: ...lacement 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 12: ...n 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 power...

Страница 13: ...anty maintenanceand testing at www ewm group com 3 3 2 Declaration of Conformity This product corresponds in its design and construction to theEU directives listed in the decla ration The product come...

Страница 14: ...Machine description quick overview Front view rear view 14 099 000125 EW501 29 9 2022 4 Machine description quick overview 4 1 Front view rear view Figure 4 1...

Страница 15: ...Shielding gas connection inlet 9 Push button of automatic circuit breaker for control electronics Press to reset tripped fuse 10 Ignition type changeover switch see 5 2 3 chapter HF ignition Liftarc c...

Страница 16: ...gnal light S safety sign signal light 3 Functional sequence see 4 2 1 chapter 4 Welding parameter setting rotary dial Setting currents times and parameters 5 Pulsing push button TIG automated pulses p...

Страница 17: ...g process and operating mode used 5 sec Down slope time TIG 6 AMP Secondary current pulse pause current 4 2 2 Welding data display The following welding parameters can be displayed before nominal valu...

Страница 18: ...t must not be lifted Do not lift or suspend the machine The machine can drop and causeinjuries The handles straps or brackets are suitable for transport by hand only The machine must not be suspended...

Страница 19: ...plugs machine connections are not locked or if the workpiece connection is contaminated paint corrosion these connections and leads can heat up and cause burns when touched Check welding current conne...

Страница 20: ...omponents Figure 5 2 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 Insert and lock the 8 pole c...

Страница 21: ...th HF igniter TIG for as long as pos sible in parallel with a distance of 20 cm to avoid HF sparkover Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences Al...

Страница 22: ...heck that all welding current connections are firmly secured and electrical connections are in perfect condition Set up attach or suspend all conductive power source components such as casing trans po...

Страница 23: ...s plug socket and lead must be checked by a qualified electrician on a regular basis When operating the generator always ensure it is earthed as stipulated in the operating in structions The network c...

Страница 24: ...the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch being destroyed Alw...

Страница 25: ...ircuit vol tage are applied at the welding torch these can lead to electric shocks and burning on contact Keep the welding torch electrically insulated from persons animals or equipment during the set...

Страница 26: ...lead connection Insert the welding current plug on the welding torch into the welding current connectionsocket and lock by turning to the right Remove yellow protective cap on G connecting nipple Scre...

Страница 27: ...1 29 9 2022 27 5 2 2 Welding task selection The following welding task selection is an example of use In general the selection process always has the same sequence Signal lights LED will show the sele...

Страница 28: ...e 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 mm between the electrode tip and t...

Страница 29: ...g the function the machine immediately switches to the gas post flow process phase The welder starts the new process again at the first cycle The user can switch the function on or off parame ter see...

Страница 30: ...torch trigger Tap torch trigger Tap and press torch trigger 5 2 7 1 Welding torch mode Modes 1 to 6 and 11 to 16 are available to the user Modes 11 to 16 feature thesame functionality as 1 to 6 but wi...

Страница 31: ...elding 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 trigger 2...

Страница 32: ...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 current...

Страница 33: ...ting 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 curre...

Страница 34: ...ary 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 torch...

Страница 35: ...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 two to...

Страница 36: ...e to perform test after conversion Before reconnection Inspection and Testing during Operation according to IEC BS EN 60974 4 Arc welding systems Inspection and Testing during Operation has to be perf...

Страница 37: ...et in the machine control function sequence are dependent on the welding task selected This means that if no pulse variant was selected for example no pulseparameters will be available to set in the f...

Страница 38: ...lding 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 paramet...

Страница 39: ...igger 1 The welding current increases in the up slope time to the main current During the main current phase you can switch to the secondary current in two ways Either tap torch trigger 1 or press and...

Страница 40: ...joint welding of metal sheets made from steel and CrNi alloys up to a thickness of approximately 2 5 mm Metal sheets of different thicknesses can also be welded on top of one another As this is a one...

Страница 41: ...for welding process activation Activation is indicated by flashing of the spotArc spotmatic signal light The process can be activated separately for each spot or also on a permanent basis The setting...

Страница 42: ...the welding 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 during the set gas pre flow time The arc igni tes and...

Страница 43: ...ent ramps up to the main current AMP in the selected up slope time Pressing torch trigger 1 starts the slope from main current AMP to secondary current AMP Releasing the torch trigger starts theslope...

Страница 44: ...iew section EXIT ENTER 4s 4s Figure 5 26 Display Setting selection Expert menu Gas pre flow time Start current as percentage dependent on main current Upslope time to main current Slope time main curr...

Страница 45: ...ng nipple Place yellow insulating cap on the G connection nipple protects against electrical vol tage and dirt Figure 5 27 Item Symbol Description 0 1 Electrode holder 2 Connection socket welding curr...

Страница 46: ...weld pool with increases in current This makes it easier to weld large drop melting electrode types at low current strengths with a short arc in particular EXIT 4s Figure 5 29 5 3 4 Hotstart The funct...

Страница 47: ...vents the electrode from annealing Should the electrode stick despite the Arcforce feature themachine au tomatically switches to the minimum current within approx one second This prevents the electrod...

Страница 48: ...method especially suitable for welding according to welding procedure specifications Figure 5 32 AMP main current e g 100 A Ipuls pulse current x AMP e g 140 x 100 A 140 A IPP pulse pause current 1 2...

Страница 49: ...IT ENTER 4s 4s Figure 5 34 Display Setting selection Expert menu Hotstart current Hotstart time Pulse current see 5 3 7 chapter Pulse balance Pulse frequency 5 4 Remote control The remote controls are...

Страница 50: ...y adjustable Coarse adjustment of the cycle frequency Pulse pause ratio balance adjustable from 10 to 90 5 4 5 RTP3 spotArc 19POL Functions TIG MMA Infinitely adjustable welding current 0 to 100 depen...

Страница 51: ...current immediately jumps to approx 100 A The start ramp function is switched on or off with the parameter in the machine configuration menu see 5 8 chapter Figure 5 35 Symbol Meaning Actuate foot op...

Страница 52: ...on the PC and simply transfer to one or more welding machines accessory set consisting of software interface connection leads Data exchange between power source and PC Welding task administration JOB...

Страница 53: ...e Unauthorised manipulations will invalidate the warranty Instruct competent personnel authorised service personnel to repair the machine Damage to the machine due to improper connection Unsuitable co...

Страница 54: ..._E Synchronisation 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...

Страница 55: ...supply 15V max 25mA 9 R Input Start Stop welding current 10 H Input Switching between main and secondary welding currents pulses 11 M N P Input Activation of control voltage specification Set all 3 si...

Страница 56: ...sistance should bealigned again whenever an accessory component suchas the welding torch or the intermediate hose package AW has been chan ged The resistance value of the cables can beset directly or...

Страница 57: ...e The value can bebetween 0 m and 60 m The new value is immediately saved without requiring further confirmation If no value is shown on the right hand display then measurement failed The measurement...

Страница 58: ...machine configuration menu 5 8 1 Selecting changing and saving parameters ENTER l 0 B EXIT NAVIGATION A A A A A A B B B B B B B B B B B 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 Fi...

Страница 59: ...value display see 4 2 2 chapter Actual value display Nominal value display TIG antistick see 5 2 5 chapter function active factory setting function inactive Show warnings see 7 2 chapter Function disa...

Страница 60: ...r signal positive logic 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...

Страница 61: ...re separated by a dot Example 07 0040 07 system bus ID 0 0 4 0 version number Cable resistance alignment see 5 6 5 chapter Only qualified service personnel may change the parameters TIG HF start soft...

Страница 62: ...e dealer who supplied the machine Return deliveries of defective equipment subject to warranty may only bemade through your dealer When replacing parts use only original spare parts When ordering spar...

Страница 63: ...rollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks Visual inspection Casing damage front rear and side walls Wheels and their securing elements Transport el...

Страница 64: ...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 c...

Страница 65: ...everal parameters cannot beset machines with access block Entry level is blocked disable access lock All machine control signal lights are illuminated after switching on No machine control signal ligh...

Страница 66: ...um applications and high alloy steels Unsuitable or worn welding torch equipment Check size of gas nozzle and replace if necessary Condensation in the gas tube Purge hose package with gas or replace 7...

Страница 67: ...drive Inform service 33 Drive is operating under overload con ditions Adjust mechanical load 34 JOB unknown Select alternatives JOB The warnings can be reset by pressing a push button see table Machi...

Страница 68: ...r Target value specification deviates significantly from the actual value Check plasma gas supply leak tightness kinks guide connections closure 20 Coolant flow Coolant flow rate too low Check cooling...

Страница 69: ...ly serves to inform the authorised service staff It is available in the machine configuration menu see 5 8 chapter 7 6 Vent coolant circuit Figure 7 1 Switch off the machine and fill the coolant tank...

Страница 70: ...A Cos efficiency 0 99 88 Protection class Overvoltage category Contamination level 3 Insulation class protection classification H IP 23 Residual current circuit breaker Type B recommended Noise level...

Страница 71: ...0 C 14 F 5 l 094 000530 00005 KF 23E 200 Coolant 10 C 200 litres 094 000530 00001 KF 37E 5 Coolant up to 20 C 4 F 5 l 094 006256 00005 KF 37E 200 Coolant 20 C 200 l 094 006256 00001 TYP1 Frost protect...

Страница 72: ...nation Item no Trolly 35 2 2 Transport vehicle 090 008296 00000 Trolly 38 2 E Transport vehicle long wheelbase 090 008270 00000 9 6 Computer communication Type Designation Item no PC300 XQ Set PC300 N...

Страница 73: ...ndix Searching for a dealer 099 000125 EW501 29 9 2022 73 10 Appendix 10 1 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldw...

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