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Operating instructions

Welding machines and accessories

Tetrix 351 AW FW
Tetrix 451 AW FW
Tetrix 551 AW FW

099-000118-EW501

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24.11.2017

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Содержание Tetrix 351 AW FW

Страница 1: ...nd accessories Tetrix 351 AW FW Tetrix 451 AW FW Tetrix 551 AW FW 099 000118 EW501 Observe additional system documents 24 11 2017 Register now and benefit Jetzt Registrieren und Profitieren www ewm gr...

Страница 2: ...ervice department on 49 2680 181 0 A list of authorised sales partners can be found at www ewm group com Liability relating to the operation of this equipment is restricted solely to the function of t...

Страница 3: ...3 5 1 4 Workpiece lead general 23 5 1 5 Welding torch cooling system 24 5 1 5 1 Approved coolants overview 24 5 1 5 2 Maximal hose package length 24 5 1 5 3 Adding coolant 25 5 1 6 Notes on the instal...

Страница 4: ...ymbols 53 5 9 12 2 Non latched mode 53 5 9 12 3 Latched mode 54 5 9 12 4 spotArc 56 5 9 12 5 spotmatic 57 5 9 12 6 Non latched operation version C 59 5 9 13 Pulse welding 60 5 9 13 1 Automated pulses...

Страница 5: ...ustrial bus interface 92 5 15 PC interface 93 5 16 Power saving mode Standby 93 5 17 Access control 94 5 18 Machine configuration menu 95 5 18 1 Selecting changing and saving parameters 95 5 19 Aligni...

Страница 6: ...se of these operating instructions 6 099 000118 EW501 24 11 2017 11 Appendix B 119 11 1 Parameter overview setting ranges 119 11 1 1 TIG welding 119 11 1 2 MMA welding 119 12 Appendix C 120 12 1 Overv...

Страница 7: ...erved to prevent serious and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning symbol The hazard is also highlighted using a symbol in the page margin...

Страница 8: ...off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Correct Numerical value adjustable Menu entry Signal light lights up in green Navigating the menu Signal light flashes gr...

Страница 9: ...ws a general example of a welding system Figure 2 1 Item Operating instructions A 1 Wire feeder A 2 Options conversion instructions A 3 Power source A 4 Welding torch A 5 Control A 6 Remote control A...

Страница 10: ...cause the welding voltages to be combined which is not permitted Risk of injury due to improper clothing During arc welding radiation heat and voltage are sources of risk that cannot be avoided The us...

Страница 11: ...magnetic compatibility of class A machines difficulties can arise in these areas due to interference not only in the supply lines but also in the form of radiated interference Class B machines fulfil...

Страница 12: ...The regulations applicable to occupational safety and accident prevention in the country concerned Setting up and operating the machine as per IEC 60974 9 Brief the user on safety conscious work prac...

Страница 13: ...sport the machine on level solid ground Secure add on parts using suitable equipment Risk of accidents due to incorrectly installed leads Incorrectly installed leads mains control and welding leads or...

Страница 14: ...ms of its design and construction Low Voltage Directive LVD Electromagnetic Compatibility Directive EMC Restriction of Hazardous Substance RoHS In case of unauthorised changes improper repairs non com...

Страница 15: ...view Front view 099 000118 EW501 24 11 2017 15 4 Machine description quick overview 4 1 Front view Figure 4 1 Item Symbol Description 0 1 Lifting lug 2 Main switch machine on off 3 Machine control see...

Страница 16: ...g nipple welding current Shielding gas connection with yellow insulating cap for TIG welding torch 14 Connection socket welding current TIG welding torch connection 15 Connection socket welding curren...

Страница 17: ...elements for shielding gas cylinder strap chain 3 Mains connection cable see 5 5 3 chapter 4 G connecting nipple Shielding gas connection on the pressure regulator 5 Connector plug TIG hot wire Weldi...

Страница 18: ...out Wire feed motor supply voltage fuse press to reset a triggered fuse 13 Mains connection hot wire power source Power supply for hot wire power source 14 Ignition type changeover switch see 5 9 11 c...

Страница 19: ...r push button see 5 9 6 chapter Ignition optimisation TIG see 5 9 9 chapter 3 Select material type button CrNi Chrome nickel alloys FeSt Iron and steel alloys Cu Copper or copper alloys bronzes CuZn C...

Страница 20: ...itching button Material thickness display VOLT Welding voltage display JOB JOB number display PROG Program number display 10 Welding parameter setting rotary dial Setting currents times and parameters...

Страница 21: ...TIG pulse current I min to I max 1 A increments Main current MMA I min to I max 1 A increments 6 sec Pulse time slope time from AMP to AMP Spot time 7 AMP Secondary current TIG 8 sec Pulse pause time...

Страница 22: ...fting by crane When lifting the machine by crane persons may be severely injured by falling machines or mount on components Simultaneous lifting of system components such as power source wire feeder o...

Страница 23: ...90 at 20 C 5 1 2 2 Transport and storage Storage in an enclosed space temperature range of the ambient air 30 C to 70 C Relative air humidity Up to 90 at 20 C 5 1 3 Machine cooling Insufficient venti...

Страница 24: ...erview of coolants Do not mix different coolants When changing the coolant the entire volume of liquid must be changed Dispose of the coolant in accordance with local regulations and the material safe...

Страница 25: ...sieve insert close sealing cover again If the cooling system is empty or only insufficiently filled with coolant the coolant pump is automatically switched off after approx one minute protection again...

Страница 26: ...with HF igniter TIG for as long as possible 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 A...

Страница 27: ...transport vehicle or crane frames unless they are insulated Always put welding torches and electrode holders on an insulated surface when they are not in use Figure 5 5 5 1 7 Mains connection DANGER...

Страница 28: ...earthed neutral conductor a three phase system with three conductors of which any one can be earthed e g the outer conductor Figure 5 6 Legend Item Designation Colour code L1 Outer conductor 1 brown L...

Страница 29: ...and function TIG cold wire welding 099 000118 EW501 24 11 2017 29 5 2 TIG cold wire welding 5 2 1 Connection plan Tetrix AW 3 AC Tetrix drive 4L TIG 450 WD CW AC HW X2 X2 hotwire HW TP TP RT AW 1 Figu...

Страница 30: ...colour X2 Control lead 28 pole TP Hose package TP tube package HW Welding current minus potential TIG hot wire Welding current plus potential workpiece hotwire Control lead hot wire signal input 4 pol...

Страница 31: ...g for the place of work Safe operation of the machine must be guaranteed at all times In a TIG cold wire welding system the wire feed unit is placed onto the casing cover of the TIG power source 5 3 1...

Страница 32: ...nto the connection socket TIG and lock by turning to the right Insert cable plug on the control lead into the connection socket 28 pole and secure with crown nut the plug can only be inserted into the...

Страница 33: ...ot wire welding 099 000118 EW501 24 11 2017 33 5 4 TIG hot wire welding 5 4 1 Connection plan Tetrix AW 3 AC Tetrix Hotwire Tetrix drive 4L TIG 450W HW 12POL AC HW X2 X2 hotwire hotwire HW HW HW 3 AC...

Страница 34: ...colour X2 Control lead 28 pole TP Hose package TP tube package HW Welding current minus potential TIG hot wire Welding current plus potential workpiece hotwire Control lead hot wire signal input 4 pol...

Страница 35: ...placed on the support it can fall down and cause injuries The inner feet of the machine have to be properly inserted into the recesses The wire feeder has to be level with the outer support frame Chec...

Страница 36: ...filler wire The machine may only be mounted and operated on the carrier platform for the hot wire power source Safe operation of the machine must be guaranteed at all times Figure 5 11 Item Symbol De...

Страница 37: ...to the primary power source Tetrix series via the connection intended for this power source Mains plug socket and lead must be checked regularly by an electrician Figure 5 12 Item Symbol Description...

Страница 38: ...13 Item Symbol Description 0 1 Wire feed unit 2 Intermediate hose package 3 Intermediate hose package strain relief 4 X2 Connection socket 28 pole Control lead 5 Connecting thread G Shielding gas 6 Co...

Страница 39: ...rrents right hand display Material thickness Welding voltage JOB number Program number When the settings are changed e g welding current after welding when the hold values are displayed the display wi...

Страница 40: ...t take place In order to carry out the chosen welding task the wire feed unit must be switched to the MANUELL operating mode see 5 8 2 chapter 5 8 2 Select wire speed operating mode KORREKTUR MANUELL...

Страница 41: ...welding current on or off Torch trigger 1 BRT 1 switches the wire feed on or off The operator can choose between three operating modes see following function sequences Figure 5 14 5 8 4 1 Explanation...

Страница 42: ...main current AMP in the selected up slope time 1st cycle wire Press torch trigger 1 BRT 1 Wire electrode is advanced 2nd cycle wire Release BRT 1 Wire electrode advance stops 3rd cycle current Press B...

Страница 43: ...has started the wire electrode is fed corresponding to the welding current until the welding process ends 5 8 4 4 Latched mode Figure 5 17 This operating mode differs from non latched operation in the...

Страница 44: ...oolant circuit is interrupted and equipment damage can occur Connect all coolant pipes correctly Completely unroll the hose package and the torch hose package Observe maximal hose package length see 5...

Страница 45: ...ock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant return and supply line blue to quick connect coup...

Страница 46: ...a fundamental 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...

Страница 47: ...select the welding task JOB All welding parameters specified here are the optimum settings for a variety of applications but they can also be modified individually The required welding current can be...

Страница 48: ...functional sequence All welding parameters in the functional sequence can also be adjusted regardless of the welding current set This means that if the welding current is changed the values for the d...

Страница 49: ...nse hose package Rule of thumb for the gas flow rate Diameter of gas nozzle in mm corresponds to gas flow in l min Example 7mm gas nozzle corresponds to 7l min gas flow If the shielding gas setting is...

Страница 50: ...igure 5 26 Set the required shielding gas quantity at the pressure regulator 5 9 8 2 Purge hose package function EXIT Figure 5 27 If the Rinse hose package function is not ended by pressing the Gas an...

Страница 51: ...f course be adjusted in line with different requirements EXIT 3s Figure 5 28 5 9 10 Tungsten balling function Tungsten balling ensures optimum ignition and welding results for AC welding Optimum tungs...

Страница 52: ...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 th...

Страница 53: ...not selected a pulse variant then you cannot set any pulse times in the function sequence 5 9 12 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 I Current t Time...

Страница 54: ...rent 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 parameters and can be set in the Expert menu TIG see...

Страница 55: ...time The parameters and can be set in the Expert menu TIG see 5 9 16 chapter 3 rd cycle Press torch trigger 1 The main current decreases to the end crater current within the set down slope time Once t...

Страница 56: ...produces flat fine textured welding tacks which require little or no post weld work even in visible areas The spot welding operating modes spotArc Spotmatic can be used with two different intervals i...

Страница 57: ...ion 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 is controlled using the process activa...

Страница 58: ...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 ignites and...

Страница 59: ...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 the slope...

Страница 60: ...rent dependent pulse frequency and balance which positively influences the ability to bridge the air gap The pulse parameters required are automatically specified by the machine control Figure 5 40 5...

Страница 61: ...function TIG welding 099 000118 EW501 24 11 2017 61 The pulse function can also be deactivated if necessary during the up slope and down slope phases parameter see 5 18 chapter Figure 5 42 Selection F...

Страница 62: ...see 5 9 16 chapter 5 9 13 3 Metallurgical pulsing kHz pulsing Metallurgical pulsing kHz pulsing uses the plasma force arc force occurring at high currents which allows you to achieve a constricted arc...

Страница 63: ...Design and function TIG welding 099 000118 EW501 24 11 2017 63 Selection Figure 5 47 Balance setting EXIT 4s Figure 5 48 Frequency setting EXIT 4s Figure 5 49...

Страница 64: ...5 18 chapter 5 9 15 activArc The EWM activArc process thanks to the highly dynamic controller system ensures that the power supplied is kept virtually constant in the event of changes in the distance...

Страница 65: ...y current Slope time main current to secondary current activArc parameter Parameter also adjustable after TIG activArc welding is activated Filler wire process cold hot wire filler wire activated fill...

Страница 66: ...ter d preceding the wire diameter on the display d0 8 indicates a pre programmed characteristics correction operating mode KORREKTUR If there is no characteristics for the selected wire diameter the p...

Страница 67: ...air of tongs to remove the used stick electrode or to move welded workpieces Shielding gas connection During MMA welding open circuit voltage is applied at the shielding gas connection G connecting ni...

Страница 68: ...urning to the right Fit yellow protective cap onto G connecting nipple 5 10 2 Welding task selection The following welding task selection is an example of use In general the selection process always h...

Страница 69: ...Design and function MMA welding 099 000118 EW501 24 11 2017 69 5 10 3 1 Hotstart current EXIT 4s Figure 5 55 5 10 3 2 Hotstart time EXIT 4s Figure 5 56...

Страница 70: ...electrode types at low current strengths with a short arc in particular EXIT 4s Figure 5 57 5 10 5 Antistick The Antistick feature prevents the electrode from annealing Should the electrode stick desp...

Страница 71: ...laked weld surface with a TIG look for final passes Less finishing work thanks to less spatter Highly suitable for difficult electrodes Outstanding gap bridging with no sagging of the root side Less d...

Страница 72: ...nt setting Figure 5 62 Balance setting Figure 5 63 Frequency setting Figure 5 64 The default pulse parameters are pre set in such a way that the welding current average value corresponds to the pre se...

Страница 73: ...ng the 4 main welding parameters welding process material type electrode diameter and seam type One program sequence can be defined in each JOB Up to 16 programs P0 to P15 can be set in each program s...

Страница 74: ...e memory or copying a JOB Copying a pre defined welding task from the fixed memory JOBs 1 to 128 to the free memory JOBs 129 256 It is normally possible to adjust all 256 JOBs individually However it...

Страница 75: ...Organising welding tasks Mode JOB Manager 099 000118 EW501 24 11 2017 75 5 11 3 Loading an existing JOB from the free memory EXIT Figure 5 66 5 11 4 Resetting an existing JOB to the factory setting Re...

Страница 76: ...ction Organising welding tasks Mode JOB Manager 76 099 000118 EW501 24 11 2017 5 11 5 Resetting JOBs 1 128 to the factory setting Reset All JOBs Figure 5 68 5 11 6 Exit JOB Manager without changes EXI...

Страница 77: ...Example Program number Welding current Operating mode Pulse function 1 80A Non latched Pulses on 2 70A Latched Pulses off The operating mode cannot be changed during the welding process If welding is...

Страница 78: ...12 3 Example Program with synergetic setting Figure 5 71 5 12 4 Example Program with conventional setting Figure 5 72 5 12 5 Accessories for switching over programs The user can change retrieve and s...

Страница 79: ...he welding machine Pulse spot normal Frequency and spot times infinitely adjustable Coarse adjustment of the cycle frequency Pulse pause ratio balance adjustable from 10 to 90 5 13 5 RTP3 spotArc 19PO...

Страница 80: ...o approx 100 A The RTF start ramp function is activated deactivated by the parameter in the machine configuration menu see 5 18 chapter Figure 5 73 Symbol Meaning Actuate foot operated remote control...

Страница 81: ...s torch triggers BRT 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 a...

Страница 82: ...nge becomes effective 5 13 7 4 Current jump By tapping the corresponding torch trigger the welding current can be determined in an adjustable jump range Each tap will cause the welding current to jump...

Страница 83: ...ls BRT1 torch trigger 1 BRT2 torch trigger 2 Functions Mode Operating elements Welding current on off 1 ex works Secondary current Secondary current tapping function 1 latched operating mode Welding c...

Страница 84: ...rigger 2 Functions Mode Operating elements Welding current on off 1 ex works Secondary current Secondary current tapping function 1 latched operating mode Welding current on off 2 Secondary current ta...

Страница 85: ...pping function 1 latched operating mode Increase welding current up function 2 Decrease welding current down function 2 Welding current on off 2 Secondary current Secondary current tapping function 1...

Страница 86: ...rent tapping function 1 latched operation Increase welding current up function 2 Decrease welding current down function 2 Welding current on off 2 Secondary current Secondary current tapping function...

Страница 87: ...ols BRT 1 torch trigger 1 Functions Mode Operating elements Welding current on off 3 Secondary current tapping function 1 Increase welding current Decrease welding current Potentiometer torch with two...

Страница 88: ...injury and equipment damage the unit must only be repaired or modified by specialist skilled persons The warranty becomes null and void in the event of unauthorised interference Appoint only skilled...

Страница 89: ...with this type of torch or respectively are not appropriate Welding current on off 4 TT 1 Secondary current TT 2 Secondary current tapping function TT 1 tapping Raise welding current in stages setting...

Страница 90: ...itional parameter after activating the BLOCK JOB function The settings are defined in the machine configuration menu see 5 18 chapter The setting of the max number of JOBs is intended solely for torch...

Страница 91: ...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 power sourc...

Страница 92: ...een main and secondary welding currents pulses 11 M N P Input Activation of control voltage specification Set all 3 signals to reference potential 0V to activate external control voltage specification...

Страница 93: ...quipment damage or faults may occur if the PC is connected incorrectly Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission The PC may be destroyed due to...

Страница 94: ...ntentional adjustment of the welding parameters on the machine the control input can be locked with the aid of a key switch Key position 1 All parameters can be set Key position 0 Only the following o...

Страница 95: ...chine settings are defined in the machine configuration menu 5 18 1 Selecting changing and saving parameters ENTER l 0 A A B A A A A EXIT NAVIGATION 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 A...

Страница 96: ...ameter setting factory setting conventional parameter setting Absolute value setting ignition secondary end and hot start current see 5 7 2 chapter Welding current setting absolute Welding current set...

Страница 97: ...g old variant Function enabled Function disabled ex works Welding current polarity switching 1 polarity switching at the RT PWS 1 19POL remote control ex works polarity switching at the welding machin...

Страница 98: ...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 disabled ex works Monitorin...

Страница 99: ...us ID 03c0 version number System bus ID and version number are separated by a dot Cable resistance alignment see 5 19 chapter Only qualified service personnel may change the parameters TIG HF start so...

Страница 100: ...ing torch or the intermediate hose package AW has been changed The resistance value of the cables can be set directly or can be aligned by the power source In the delivery state the cable resistance i...

Страница 101: ...ressure press the welding torch with the collet against a clean purged location on the workpiece and then press the torch trigger for approx 2 seconds A short circuit current will flow briefly which i...

Страница 102: ...nder warranty is void In all service matters always consult the dealer who supplied the machine Return deliveries of defective equipment subject to warranty may only be made through your dealer When r...

Страница 103: ...ly tighten if necessary Remove any spatter Clean the wire feed rollers on a regular basis depending on the degree of soiling 6 3 2 Monthly maintenance tasks Visual inspection Casing damage front rear...

Страница 104: ...r on wheels indicates that the equipment must be collected separately This machine has to be disposed of or recycled in accordance with the waste separation systems in use According to German law law...

Страница 105: ...machines with access block Entry level is blocked disable access lock see 5 17 chapter All machine control signal lights are illuminated after switching on No machine control signal light is illuminat...

Страница 106: ...machine displays The possible cause of the warning is signalled by the respective warning code see table The display of possible warning numbers depends on the machine version interfaces functions In...

Страница 107: ...error via robot interface if available Err 12 VRD error Switch the machine off and on again If the error persists contact service Err 16 Pilot arc current Check welding torch Err 17 Filler wire error...

Страница 108: ...interrupt equipment Check jumper JP 1 on PCB T320 1 Err 57 Auxiliary drive error tacho error Check the auxiliary drive tacho no signal M3 51 defective inform service Err 59 Incompatible component Repl...

Страница 109: ...nt circuit Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling To vent the cooling system always use the blue coolant connection which i...

Страница 110: ...n lead H07RN F4G6 Max connected load 10 9 kVA 15 4 kVA Recommended generator rating 20 8 kVA cos efficiency 0 99 90 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C...

Страница 111: ...A Recommended generator rating 29 7 kVA cos efficiency 0 99 90 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C 1 Machine torch cooling Fan gas or water Noise level...

Страница 112: ...A Recommended generator rating 39 8 kVA cos efficiency 0 99 90 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C 1 Machine torch cooling Fan gas or water Noise level...

Страница 113: ...lant 10 C 200 litres 094 000530 00001 KF 37E 10 Coolant 20 C 9 3 l 094 006256 00000 KF 37E 200 Coolant 20 C 200 l 094 006256 00001 TYP 1 Frost protection tester 094 014499 00000 HOSE BRIDGE UNI Tube b...

Страница 114: ...d SECINT X10 USB interface 090 008777 00000 9 6 System components Type Designation Item no Tetrix drive 4L TIG wire feed unit cooling water conduit 090 000094 00502 Tetrix 270 Hotwire TIG constant pow...

Страница 115: ...down weld 0 6 0 8 1 0 1 2 1 6 1 Reserved 2 CrNi 1 3 CrNi 1 6 4 CrNi 2 5 CrNi 2 4 6 CrNi 3 2 7 CrNi 3 2 8 CrNi 1 9 CrNi 1 6 10 CrNi 2 11 CrNi 2 4 12 CrNi 3 2 13 CrNi 3 2 14 CrNi 1 15 CrNi 1 6 16 CrNi...

Страница 116: ...0 8 1 0 1 2 1 6 36 Fe St 3 2 37 Fe St 3 2 38 Fe St 1 39 Fe St 1 6 40 Fe St 2 41 Fe St 2 4 42 Fe St 3 2 43 Fe St 3 2 44 Fe St 1 45 Fe St 1 6 46 Fe St 2 47 Fe St 2 4 48 Fe St 3 2 49 Fe St 3 2 50 Cu 1 51...

Страница 117: ...Zn 2 77 CuZn 2 4 78 CuZn 3 2 79 CuZn 3 2 80 CuZn 1 81 CuZn 1 6 82 CuZn 2 83 CuZn 2 4 84 CuZn 3 2 85 CuZn 3 2 86 CuZn 1 87 CuZn 1 6 88 CuZn 2 89 CuZn 2 4 90 CuZn 3 2 91 CuZn 3 2 92 CuZn 1 93 CuZn 1 6 9...

Страница 118: ...3 2 121 Special 3 2 122 TIG manual TIG classic 123 Classic electrode 124 Reserved 125 Reserved 126 Reserved 127 Electrode JOB 128 Reserved 129 179 Free JOBs or SCO e g plasma 180 CrNi 2 4 181 CrNi 3 2...

Страница 119: ...0 00 20 0 Slope time s 0 10 0 00 20 0 Period from secondary current AMP to main current AMP Down slope time s 1 0 0 0 20 0 End current AMP 20 1 200 of main current AMP Gas post flow time s 8 0 0 40 0...

Страница 120: ...Appendix C Overview of EWM branches 120 099 000118 EW501 24 11 2017 12 Appendix C 12 1 Overview of EWM branches...

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