Operating instructions
EN
Control
T 4.00 - AC/DC Comfort 2.0
099-00T400-EW501
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21.10.2016
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the location where the machine is operated.
• Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
• Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
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 the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of
liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Straße 8
56271 Mündersbach
Germany
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.
Contents
Notes on the use of these operating instructions
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1 Contents
1 Contents .................................................................................................................................................. 3
2 For your safety ....................................................................................................................................... 5
2.1 Notes on the use of these operating instructions .......................................................................... 5
2.1.1 Explanation of icons ....................................................................................................... 6
2.2 Part of the complete documentation .............................................................................................. 7
3 Machine control – Operating elements ................................................................................................ 8
3.1 Overview of control sections .......................................................................................................... 8
3.1.1 Control section A ............................................................................................................ 9
3.1.2 Control section B .......................................................................................................... 11
3.1.3 Control section C .......................................................................................................... 12
3.2 Machine display ........................................................................................................................... 13
3.2.1 Setting the welding current (absolute/percentage) ....................................................... 13
3.3 Operating the machine control ..................................................................................................... 14
3.3.1 Main screen .................................................................................................................. 14
3.3.2 Welding power setting .................................................................................................. 14
3.3.3 Welding parameter setting in the operation sequence ................................................. 14
3.3.4 Setting advanced welding parameters (Expert menu) ................................................. 14
3.3.5 Changing basic settings (machine configuration menu) .............................................. 14
4 Welding procedure ............................................................................................................................... 15
4.1 TIG welding .................................................................................................................................. 15
4.1.1 Setting the shielding gas volume (gas test)/rinse hose package ................................. 15
4.1.2 Welding task selection .................................................................................................. 16
4.1.2.1 Recurring welding tasks (JOB 1–7) .............................................................. 17
4.1.3 Tungsten balling function ............................................................................................. 18
4.1.4 AC balance (optimise cleaning effect and penetration characteristics) ....................... 19
4.1.5 AC amplitude balance .................................................................................................. 20
4.1.6 Arc ignition .................................................................................................................... 21
4.1.6.1 HF ignition ..................................................................................................... 21
4.1.6.2 Liftarc ............................................................................................................ 21
4.1.6.3 Automatic cut-out .......................................................................................... 21
4.1.7 Function sequences/operating modes ......................................................................... 22
4.1.7.1 Explanation of symbols ................................................................................. 22
4.1.7.2 Non-latched mode ......................................................................................... 23
4.1.7.3 Latched mode ............................................................................................... 24
4.1.7.4 spotArc .......................................................................................................... 25
4.1.7.5 spotmatic ....................................................................................................... 27
4.1.7.6 Non-latched operation, version C ................................................................. 29
4.1.8 TIG activArc welding ..................................................................................................... 30
4.1.9 TIG antistick .................................................................................................................. 30
4.1.10 Pulse welding ............................................................................................................... 31
4.1.10.1 Automated pulses ......................................................................................... 31
4.1.10.2 Thermal pulsing ............................................................................................. 32
4.1.10.3 Average value pulsing ................................................................................... 34
4.1.10.4 Metallurgical pulsing (kHz pulsing) ............................................................... 35
4.1.10.5 AC special ..................................................................................................... 37
4.1.11 Welding torch (operating variants) ............................................................................... 38
4.1.11.1 Tap torch trigger (tapping function) ............................................................... 38
4.1.12 Torch mode and up/down speed setting ...................................................................... 38
4.1.12.1 Standard TIG torch (5-pole) .......................................................................... 39
4.1.12.2 TIG up/down torch (8-pole) ........................................................................... 41
4.1.12.3 Potentiometer torch (8-pole) ......................................................................... 43
4.1.12.4 Configuring the TIG potentiometer torch connection .................................... 44
4.1.12.5 RETOX TIG torch (12-pole) .......................................................................... 45
4.1.13 Up/down operation in modes 4 and 14 ......................................................................... 46
4.1.14 Alternating current waveforms ...................................................................................... 47
4.1.15 Ramp function .............................................................................................................. 48
Contents
Notes on the use of these operating instructions
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4.1.15.1 Foot-operated remote control responsiveness.............................................. 48
4.1.15.2 RTF 1 foot-operated remote control .............................................................. 49
4.1.16 Automatic AC frequency ............................................................................................... 50
4.1.17 AC commutation optimisation ....................................................................................... 51
4.1.18 Simultaneous welding on both sides, synchronisation types ....................................... 51
4.1.19 Synchronisation via mains voltage (50Hz / 60Hz) ........................................................ 51
4.1.20 Expert menu (TIG) ........................................................................................................ 52
4.1.21 Aligning the cable resistance ........................................................................................ 54
4.2 MMA welding ................................................................................................................................ 56
4.2.1 Welding task selection .................................................................................................. 56
4.2.2 Hotstart ......................................................................................................................... 57
4.2.2.1 Hotstart current .............................................................................................. 57
4.2.2.2 Hotstart time .................................................................................................. 57
4.2.3 Arcforce ......................................................................................................................... 58
4.2.4 Antistick ......................................................................................................................... 58
4.2.5 Welding current polarity reversal (polarity reversal) ..................................................... 58
4.2.6 Pulse welding ................................................................................................................ 59
4.2.7 Average value pulse welding ........................................................................................ 60
4.3 Filler wire welding ......................................................................................................................... 61
4.3.1 Configuring the welding machine for mechanical arc fusion welding ........................... 61
4.3.1.1 Selecting a welding task by means of the JOB list ....................................... 61
4.3.1.2 Select wire speed operating mode (KORREKTUR / MANUELL).................. 61
4.3.1.3 Setting the welding current and wire speed .................................................. 61
4.3.2 Function sequences/operating modes .......................................................................... 62
4.3.2.1 Explanation of symbols ................................................................................. 62
4.3.2.2 Non-latched mode ......................................................................................... 63
4.3.2.3 3-cycle operation ........................................................................................... 64
4.3.2.4 Latched mode ................................................................................................ 64
4.4 Power-saving mode (Standby) ..................................................................................................... 65
4.5 Access control .............................................................................................................................. 65
4.6 Voltage reducing device ............................................................................................................... 65
4.7 Machine configuration menu ........................................................................................................ 65
4.7.1 Selecting, changing and saving parameters................................................................. 65
5 Rectifying faults .................................................................................................................................... 71
5.1 Warnings (power source) ............................................................................................................. 71
5.2 Error messages (power source) ................................................................................................... 72
5.3 Resetting welding parameters to the factory settings .................................................................. 74
5.4 Display machine control software version .................................................................................... 74
6 Appendix A ............................................................................................................................................ 75
6.1 Parameter overview – setting information .................................................................................... 75
6.1.1 TIG welding ................................................................................................................... 75
6.1.2 MMA welding ................................................................................................................ 76
7 Appendix B ............................................................................................................................................ 77
7.1 Overview of EWM branches......................................................................................................... 77
For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed 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.
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 with a general
warning symbol.
• The risk is explained using a symbol on the edge of the page.
Special technical points which users must observe.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.
For your safety
Notes on the use of these operating instructions
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2.1.1 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/tip
Switch 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 green
Exit menu
Signal light lights up in red
Time representation (e.g.: wait
4 s/activate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use
For your safety
Part of the complete documentation
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2.2 Part of the complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with all other parts of these instructions! Read and observe the operating
instructions for all system components, especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 2-1
Item
Documentation
A.1
Options conversion instructions
A.2
Power source
A.3
Cooling unit, voltage converter, tool box etc.
A.4
Transport cart
A.5
Welding torch
A.6
Remote control
A.7
Control
A
Complete documentation
Machine control – Operating elements
Overview of control sections
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3 Machine control – Operating elements
3.1 Overview of control sections
For description purposes, the machine control has been divided into three sections (A, B, C) to
ensure maximum clarity. The setting range for the parameter values are summarised in the
parameter overview section > see 6.1 chapter.
Figure 3-1
Item
Symbol
Description 0
1 Control section A
> see 3.1.1 chapter
2 Control section B
> see 3.1.2 chapter
3 Control section C
> see 3.1.3 chapter
Machine control – Operating elements
Overview of control sections
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3.1.1 Control section A
Figure 3-2
Item
Symbol
Description 0
1 Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 3.2 chapter
2 Push-button gas test / rinse hose package > see 4.1.1 chapter
3 Operating mode/power-saving mode push-button
--------- Latched > see 4.1.7.2 chapter
------- Non-latched > see 4.1.7.3 chapter
------ spotArc spot welding procedure – signal light turns
green > see 4.1.7.4 chapter
------ spotmatic spot welding procedure –signal light turns red > see 4.1.7.5 chapter
-------- Press button for long interval to put machine into power-saving
mode > see 4.4 chapter.
Activate one of the operating elements to reactivate.
4 Pulsing push-button > see 4.1.10 chapter
------ Automated pulsing (frequency and balance)
------- Signal light turns green: Thermal pulsed TIG welding/MMA pulse welding
------- Signal light turns red: Metallurgical pulsed TIG welding (kHz pulsing)/average
value pulsing
--- Special TIG AC
5
Welding current polarity/tungsten balling push-button
---- Signal light turns green: DC welding with negative polarity on the electrode
holder or welding torch.
---- Signal light turns red: MMA DC welding with positive polarity on the electrode
holder > see 4.2.5 chapter.
---- Alternating current welding/alternating current forms > see 4.1.14 chapter
- Tungsten balling current > see 4.1.3 chapter
Machine control – Operating elements
Overview of control sections
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Item
Symbol
Description 0
6 Welding procedure push-button
--------- TIG welding
---- MMA welding (signal light turns green)
---- Arcforce setting (signal light turns red)
7 Display switching push-button
kW ------- Welding power display
V --------- Welding voltage display
JOB ----- Display and setting of the JOB number with the control button
8 Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 3.2 chapter
9 Filler wire welding signal light
For machines with filler wire only (AW) > see 4.3 chapter
10 TIG ignition type signal light
Signal light on: Lift arc ignition active/HF start off. You can switch the ignition type in the
Expert menu (TIG) > see 4.1.20 chapter.
11 Character function signal light
Indicates that it is possible to weld in an environment with major electric hazards, such
as in boilers. Service must be informed if this signal light is not on.
12 Coolant fault signal light
Comes on when pressure is lost in the coolant circuit. Check coolant level and ensure
that coolant circuit is leak-tight.
13
VRD
Voltage reduction device (VRD) signal light
The VRD signal light is illuminated when the voltage reduction device is operating
without fault and the output voltage is reduced to a value specified in the relevant
standard (see technical data) > see 4.6 chapter. The voltage reduction device is only
active on VRD machine versions.
14
Hold
Signal light Status display
After each completed welding task, the last values used in the welding process for the
welding current and welding voltage are shown on the displays, and the signal light will
be on
15 Excess temperature signal light
In case of excess temperature, temperature monitors de-activate the power unit, and
the excess temperature control lamp comes on. Once the machine has cooled down,
welding can continue without any further measures.
16 Access control active signal light
Signal light is on when access control is active on the machine
control > see 4.5 chapter.
17 Simultaneous AC welding on both sides, signal light
This signal light indicates that the function is active > see 4.1.18 chapter.
18 Automatic AC frequency > see 4.1.16 chapter
Machine control – Operating elements
Overview of control sections
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3.1.2 Control section B
Figure 3-3
Item
Symbol
Description 0
1 Parameter selection push-button, left
The welding sequence parameters are selected one after another in an anti-clockwise
direction.
2 Control button
Central control button to be pressed or turned > see 3.2 chapter.
3 Parameter selection push-button, right
The welding sequence parameters are selected one after another in a clockwise
direction.
4 Balance signal light
DC balance (JOBs 0–7)
AC balance (JOBs 1–7), pulse balance, AC amplitude balance (JOBs 0–7)
5 Electrode diameter signal light
Ignition optimisation (TIG)/tungsten balling basic setting
6
Gas post-flow time
7
AMP%
Signal light, two colour
Red: End current
Green: End current time > see 4.1.20 chapter
8
sec
Down-slope time signal light
9
AMP%
sec
Signal light, two colour
Red: Secondary or pulse pause current (% of AMP)
Green: Pulse pause time /slope time (Expert menu)
10
AMP
sec
Signal light, two colour
Red: Main or pulse current
Green: Pulse time /slope time (AMP to AMP%, Expert menu)
11
sec
Signal light
Up-slope time (TIG)/hot start time (MMA)
12
AMP%
Signal light, two colour
Red: Ignition current (TIG)/hot start current (MMA)
Green: Ignition current time (TIG, Expert menu)
Machine control – Operating elements
Overview of control sections
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Item
Symbol
Description 0
13 Gas pre-flow time signal light
14 activArc TIG welding process
• Switch activArc <>
• Correct the activArc characteristic > see 4.1.20 chapter
15 Signal light, two colour
Green: AC frequency (TIG)/pulse frequency (MMA)
Red: Pulse frequency (TIG, kHz pulsing)
3.1.3 Control section C
Figure 3-4
Item
Symbol
Description 0
1 AC frequency rotary knob (JOB 0)
2
Balance
AC balance rotary knob (JOB 0)
3 Tungsten electrode diameter rotary knob (JOB 0)
Machine control – Operating elements
Machine display
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3.2 Machine display
The following welding parameters can be displayed before (nominal values), during (actual values) or
after welding (hold values):
"left display"
Parameter
Before welding
(nominal values)
During welding
(actual values)
After welding
(hold values)
Welding current
Parameter times
Parameter currents
Frequency, balance
JOB number
"right display"
Welding power
Welding voltage
When the hold values are displayed after welding and the settings are then changed (e.g. welding
current), the display will switch to the relevant nominal values.
possible
not possible
The parameters that can be set in the function sequence of the machine control depend on the selected
welding task. This means that if for example you have not selected a pulse variant, then you cannot set
any pulse times in the function sequence.
3.2.1 Setting the welding current (absolute/percentage)
The welding current for the ignition, secondary, end and hot start current can be set as a percentage of
the main current AMP or as an absolute value. To select, use the parameter <dg in the configuration
menu_ref_source_inline>Gerätekonfigurationsmenü</dg_ref_source_inline>.
> see 4.7 chapter
Machine control – Operating elements
Operating the machine control
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3.3 Operating the machine control
3.3.1 Main screen
The machine control switches to the main screen after it has been turned on or a setting has been
completed. This means that the previously selected settings (indicated by signal lights where applicable)
and the nominal value for the current (A) are displayed in the left-hand welding data display. Depending
on the selection, the right-hand display shows the welding voltage (V) nominal value or the welding power
(kW) actual value. The control always switches back to the main screen after 4 sec. of inactivity.
3.3.2 Welding power setting
The welding power is set using the control button. You can also adjust the parameters in the operation
sequence or settings in the different machine menus.
3.3.3 Welding parameter setting in the operation sequence
A welding parameter can be set in two ways in the operation sequence.
1. Push the "left" or "right" arrow keys (flashing signal light will indicate your selection). Turn the control
button to set the parameter value.
2. Press briefly on the control button (operation sequence selection) and then turn the button (navigate to
the required parameter). Press again to apply the selected parameter as the setting (corresponding
signal light flashes). Turn the button to set the parameter value.
The welding parameter setting is shown on the left-hand display while it is being set. A parameter
abbreviation or a deviation in the specified parameter value upwards or downwards is shown on the righthand display:
Display
Meaning
Increase the parameter value
To return to the factory settings.
Factory setting (example value = 20)
Parameter is set to optimum value
Decrease the parameter value
To return to the factory settings.
3.3.4 Setting advanced welding parameters (Expert menu)
The Expert menu contains functions and parameters which cannot be set directly in the machine control
or which do not need to be et on a regular basis. The number and display of these parameters depends
on the previously selected welding procedure or the functions.
To select them hold the control button for more than 2 sec. Select the required parameter/menu item by
turning (navigate) and pressing (confirm) the control button.
You can also or alternatively use the push-buttons to the left and right of the control button to navigate.
3.3.5 Changing basic settings (machine configuration menu)
The basic welding system functions can be adjusted in the machine configuration menu. Only
experienced users should change the settings > see 4.7 chapter.
Welding procedure
TIG welding
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4 Welding procedure
4.1 TIG welding
4.1.1 Setting the shielding gas volume (gas test)/rinse hose package
• Slowly open the gas cylinder valve.
• Open the pressure regulator.
• Switch on the power source at the main switch.
• Set the relevant gas quantity for the application on the pressure regulator.
• The gas test can be activated at the machine control by pressing the "Gas test/purge " push-
button > see 3.1.1 chapter.
Setting the shielding gas quantity (gas test)
• Shielding gas flows for approx. 20 seconds or until the push-button is pressed again.
Purging long hose packages (purging)
• Press push-button for about 5 sec. Shielding gas flows continuously until the push-button is pressed
again.
If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause
pores to form. Adjust the shielding gas quantity to suit the welding task!
Setting instructions
Welding process
Recommended shielding gas quantity
MAG welding
Wire diameter x 11.5 = l/min
MIG brazing
Wire diameter x 11.5 = l/min
MIG welding (aluminium)
Wire diameter x 13.5 = l/min (100 % argon)
TIG
Gas nozzle diameter in mm corresponds to l/min gas throughput
Helium-rich gas mixtures require a higher gas volume!
The table below can be used to correct the gas volume calculated where necessary:
Shielding gas
Factor
75% Ar/25% He
1.14
50% Ar/50% He
1.35
25% Ar/75% He
1.75
100% He
3.16
For connecting the shielding gas supply and handling the shielding gas cylinder refer to the
power source operating instructions.
Welding procedure
TIG welding
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4.1.2 Welding task selection
The setting of the tungsten electrode diameter has a direct influence on the machine functionality, TIG
ignition behaviour and minimum current limits. The ignition energy is controlled by the set electrode
diameter. Smaller electrode diameters requires less ignition current and less ignition current time than
greater electrode diameters. The set value should correspond to the tungsten electrode diameter. The
value can also be set to meet individual requirements, e.g. for thin panels a smaller diameter is
recommended to reduce the ignition energy.
The electrode diameter setting determines the minimum current limit, which in turn affects the ignition,
main and secondary current. The minimum current limits have a positive effect on the ignition behaviour
and ensure a very high arc stability for each electrode diameter selected. The minimum current limit
function is enabled ex works, but can be disabled with parameter in the machine configuration
menu > see 4.7 chapter.
For foot-operated remote control mode, minimum current limits are disabled by default.
The following welding task is an example of use:
EXIT
4s
mm
inch
?
Figure 4-1
Welding procedure
TIG welding
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4.1.2.1 Recurring welding tasks (JOB 1–7)
The user has 7 more memory locations at their disposal to save recurring or different welding tasks on a
permanent basis. To do so, simply select the required memory location (JOB 1–7) and the welding task is
set as described previously.
The three rotary knobs for AC frequency, AC balance and the tungsten electrode diameter are
exceptions. These settings are made in the operation sequence (signal lights with same name).
Switching a JOB is only possible if no welding current flows. Up-slope and down-slope times can be set
individually for latched and non-latched operation.
Selection
Figure 4-2
When one or more of the recurring welding tasks (JOB 1–7) has been selected the JOB signal light
comes on.
Welding procedure
TIG welding
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4.1.3 Tungsten balling function
The tungsten balling function provides optimum tungsten balling, ensuring that the best ignition and
welding results are achieved during AC welding.
Optimum tungsten balling requires a sharpened electrode (about 15–25°) and the set electrode diameter
on the machine control. The set electrode diameter affects the current for tungsten balling and,
consequently, also the ball size.
Press the tungsten balling push-button to activate the function. If required, this current can be adjusted on
an individual basis using the parameter (+/- 30 A). The user presses the torch trigger and the function
is started by non-contact ignition (HF start). The balled end is formed and the function then ends.
Tungsten balling should be performed on a test component as surplus tungsten may be melted and this
may lead to impurities on the weld seam.
Balling
mm
inch
Figure 4-3
Welding procedure
TIG welding
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4.1.4 AC balance (optimise cleaning effect and penetration characteristics)
To weld aluminium and aluminium alloys, AC welding is used in combination with a continuous change in
polarity of the tungsten electrode. The process encompasses two phases (half-waves): a positive and a
negative one. The positive phase cracks the aluminium oxide layer on the material surface (so called
cleaning effect).
At the same time, tungsten balling occurs at the tip of the tungsten electrode. The size of this balled end
depends on the length of the positive phase. Please note that an excessively big balled end will cause the
arc to become unstable and diffuse, with low penetration. In the negative phase, the tungsten electrode is
cooled and the required penetration is realised. Make sure to select the correct durations (balance) for
positive phase (cleaning effect, balled end size) and negative phase (penetration depth) by setting the AC
balance. The default (zero setting) balance setting is 65%, referring to the duration of the negative halfwave.
Figure 4-4
Welding procedure
TIG welding
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4.1.5 AC amplitude balance
As with AC balance, durations (balance) for positive phase and negative phase are set for AC amplitude
balance. The balance changes in terms of the current amplitude.
Figure 4-5
Increasing the current amplitude in the positive half-wave facilitates the cleaning effect and the
cracking of the oxide layer.
Raising the negative current amplitude increases the penetration.
Welding procedure
TIG welding
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4.1.6 Arc ignition
4.1.6.1 HF ignition
Figure 4-6
The arc is started without contact from high-voltage ignition pulses.
a) Position the welding torch in welding position over the workpiece (distance between the electrode tip
and workpiece should be approx. 2-3mm).
b) Press the torch trigger (high voltage ignition pulses ignite the arc).
c) Ignition current flows, and the welding process is continued depending on the operating mode
selected.
End the welding process: Release or press the torch trigger depending on the operating mode
selected.
4.1.6.2 Liftarc
Figure 4-7
The arc is ignited on contact with the workpiece:
a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch
trigger (liftarc current flowing, regardless of the main current set).
b) Incline the torch over the torch gas nozzle to produce a gap of approx. 2-3 mm between the electrode
tip and the workpiece. The arc ignites and the welding current is increased, depending on the
operating mode set, to the ignition or main current set.
c) Lift off the torch and swivel to the normal position.
Ending the welding process: Release or press the torch trigger depending on the operating mode
selected.
4.1.6.3 Automatic cut-out
The automatic cut-out function will be triggered by two conditions during the welding process:
• During the ignition phase (ignition fault) If there is no welding current within 3s after starting
the welding.
• During the welding phase (arc interruption) If the arc is interrupted for longer than 3s.
In both cases, the welding machine ends the ignition or welding process immediately.
Welding procedure
TIG welding
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4.1.7 Function sequences/operating modes
4.1.7.1 Explanation of symbols
Symbol
Meaning
Press torch trigger 1
Release torch trigger 1
I
Current
t
Time
Gas pre-flow
Ignition current
Up-slope time
Spot time
AMP
Main current (minimum to maximum current)
AMP%
Secondary current
Pulse time
Pulse pause time
Pulse current
Pulsed TIG welding: Slope time from main current (AMP) to secondary current (AMP%)
Pulsed TIG welding: Slope time from secondary current (AMP%) to main current (AMP%)
Down-slope time
End-crater current
Gas post-flow
Balance
Frequency
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4.1.7.2 Non-latched mode
Figure 4-8
1st cycle:
• Press torch trigger 1 and hold down.
• Gas pre-flow time elapses.
• HF ignition pulses jump from the electrode to the workpiece. The arc ignites.
• The welding current flows and immediately assumes the value of the ignition current .
• HF switches off.
• The welding current ramps up to the main current (AMP) in the selected up-slope time .
If torch trigger 2 is pressed together with torch trigger 1 during the main current phase, the welding
current 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 parameters and can be set in the Expert menu (TIG) > see 4.1.20 chapter.
2nd cycle:
• Release torch trigger 1.
• The main current falls to the end-crater current (minimum current) in the set down-slope time .
If the 1st torch trigger is pressed during the down-slope time,
the welding current returns to the set main current AMP
• Main current reaches the end-crater current ; the arc is extinguished.
• Set gas post-flow time elapses.
When the foot-operated remote control RTF is connected, the machine switches automatically to
non-latched operation.
The up- and down-slopes are switched off.
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4.1.7.3 Latched mode
Figure 4-9
1st cycle
• Press torch trigger 1; gas pre-flow time elapses.
• HF ignition pulses jump from the electrode to the workpiece. The arc ignites.
• Welding current flows and immediately assumes the set ignition current (search arc at minimum
setting). HF switches off.
2nd cycle
• Release torch trigger 1.
• The welding current ramps up to the main current (AMP) in the selected up-slope time .
Switching from the main current AMP to secondary current (AMP%):
• Press torch trigger 2 or
• Tap torch trigger 1 (torch modes 1–6).
The slope times and can be set > see 4.1.20 chapter.
3rd cycle
• Press torch trigger 1.
• The main current decreases to the end-crater current within the set down-slope time .
4th cycle
• Release torch trigger 1; arc is extinguished.
• Set gas post-flow time runs.
Ending the welding process immediately without a down-slope or end-crater current:
• Press the 1st torch trigger briefly > 3rd and 4th cycles (torch modes 11–16).
Current drops to zero and the gas post-flow time begins.
When the foot-operated remote control RTF is connected, the machine switches automatically to
non-latched operation.
The up- and down-slopes are switched off.
A double-digit torch mode (11-x) needs to be set at the welding machine control to use the
alternative welding start (tapping start). The number of torch modes available depends on the
machine type.
From mode 11 upwards, the tapping start function can also be deactivated when required
(welding stop by tapping remains active). To do so, the parameter must be switched to in
the machine configuration menu > see 4.7 chapter.
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4.1.7.4 spotArc
This process is suitable for tack welding or 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-sided process, it is also possible to weld metal sheets onto tubular
sections such as round or square pipes. In arc spot welding, the arc melts through the upper metal sheet
and the lower metal sheet is melted onto it. This produces flat, fine-textured welding tacks which require
little or no post weld work, even in visible areas.
?
EXIT
4s
?
Figure 4-10
The up-slope and down-slope times should be set to “0” to achieve an effective result.
Welding procedure
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Figure 4-11
As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible,
however > see 4.1.6.2 chapter.
Sequence:
• Press torch trigger and hold down.
• The gas pre-flow time elapses.
• HF ignition pulses jump from the electrode to the workpiece. The arc ignites.
The welding current flows and immediately assumes the value of the ignition current
• HF switches off.
• The welding current ramps up to the main current (AMP) in the selected up-slope time.
The process ends when the set spotArc.time elapses or by releasing the torch trigger.
When switching on the spotArc function, Automatic pulsing is switched on as well. Any other
pulsing variant can be selected as well, or no pulsing at all.
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4.1.7.5 spotmatic
In contrast to spotArc operating mode, the arc is not ignited by pressing the torch trigger as is usual, but
by briefly touching the tungsten electrode against the workpiece. The torch trigger is used for welding
process activation. The process can be activated separately for each spot or also on a permanent basis.
The setting is controlled using the process activation parameter in the configuration
menu > see 4.7 chapter:
• Separate process activation ( > ):
The welding process has to be reactivated for every arc ignition by pressing the torch trigger.
• Permanent process activation ( > ):
The welding process is activated by pressing the torch trigger once. The following arc ignitions are
initiated by briefly touching the tungsten electrode against the workpiece.
For spotmatic the separate process activation and the short spot time setting range are enabled by
default.
Ignition by touching the tungsten electrode against the workpiece can be disabled in the machine
configuration menu with parameter . In this case the function works as with spotArc, but the spot time
setting range can be selected in the machine configuration menu.
The duration is set in the machine configuration menu using parameter > see 4.7 chapter
EXIT
4s
Figure 4-12
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Figure 4-13
As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible,
however > see 4.1.6.2 chapter.
Selecting the process activation type for the welding process > see 4.7 chapter.
Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 sec) only.
Press and release torch trigger (tap) to activate the welding process.
Touch the torch gas nozzle and tungsten electrode tip carefully against the workpiece.
Incline 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 the previously set ignition current flows.
The main current phase ends when the set spotArc time elapses.
The welding current decreases to the end current level within the set down-slope time .
The gas post-flow time elapses and the welding process ends.
Press and release the torch trigger (tap) to reactivate the welding process (only for separate
process activation). Touching the welding torch with the tungsten electrode tip again against the
workpiece will initiate the next welding processes.
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4.1.7.6 Non-latched operation, version C
Figure 4-14
1st cycle
• Press torch trigger 1 , the gas pre-flow time elapses.
• HF ignition pulses jump from the electrode to the workpiece. The arc ignites.
• Welding current flows and immediately assumes the set ignition current (search arc at minimum
setting). HF switches off.
2nd cycle
• Release torch trigger 1.
• The welding current 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 from the secondary current AMP% and
back to the main current AMP. This process can be repeated as frequently as required.
The welding process is ended by arc interruption in the secondary current (remove the welding
torch from the workpiece until the arc is extinguished).
The slope times and can be set in the Expert menu > see 4.1.20 chapter.
This operating mode must be enabled (parameter ) > see 4.7 chapter.
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4.1.8 TIG activArc welding
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 between the welding torch and
the weld pool, e.g. during manual welding. Voltage losses as a result of a shortening of the distance
between the torch and molten pool are compensated by a current rise (ampere per volt - A/V), and vice
versa. This helps prevents the tungsten electrode sticking in the molten pool and the tungsten inclusions
are reduced. This is particularly useful in tacking and in spot welding.
Selection
EXIT
4s
Figure 4-15
Setting
Parameter setting
The activArc parameter (control) can be adjusted specifically for the welding task (panel
thickness) > see 4.1.20 chapter.
4.1.9 TIG antistick
The function prevents uncontrolled re-ignition following the sticking of the tungsten electrode in the weld
pool by switching off the welding current. In addition, wear at the tungsten electrode is reduced.
After triggering 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
(parameter ) > see 4.7 chapter.
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4.1.10 Pulse welding
The following pulse types can be selected:
• Automated pulsing (TIG DC)
• Thermal pulsing (TIG AC or TIG DC)
• Average value pulsing (TIG AC or TIG DC)
• Metallurgical pulsing (TIG DC)
• AC special (TIG AC)
4.1.10.1 Automated pulses
The automated pulses are used with tacking and spot welding of workpieces in particular.
An oscillation in the molten pool is produced by the current-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 4-16
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4.1.10.2 Thermal pulsing
The operation sequences basically match the standard welding sequences, but there is an additional
switching back and forth between the main current AMP (pulse current) and the secondary current AMP%
(pulse pause current) at the set times. Pulse and pause times and the pulse edges ( and ) are
entered in seconds on the control.
Figure 4-17
The pulse function can also be deactivated if necessary during the up-slope and down-slope
phases (parameter ) > see 4.7 chapter.
Figure 4-18
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Selection
Figure 4-19
Pulse time setting
EXIT
4s
Figure 4-20
Pulse pause setting
EXIT
4s
Figure 4-21
Pulse edge setting
The and pulse edges can be set in the Expert menu (TIG) > see 4.1.20 chapter.
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4.1.10.3 Average value pulsing
Average value pulsing is a variant of pulsing, with the particularity that the power source will always
maintain the preset average value. This makes this method especially suitable for welding according to
welding procedure specifications.
The parameter must be switched to in the machine configuration menu to enable this pulse
variant. See the "Metallurgical pulsing" pulse variant for other parameter settings.
Once the function is activated, the red signal lights for the main current AMP and secondary current
AMP% light up at the same time.
Average value pulse welding means that the system switches between two currents periodically, an
average current value (AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been
defined first. The predefined ampere current average value is decisive, the pulse current (Ipuls) is defined
by the parameter as a percentage of the average current value (AMP).
The pulse pause current (IPP) is not set; the machine control calculates the value instead to ensure that
the average value of the welding current (AMP) is maintained. For average value pulsing, the current
is the secondary current only, activated with the torch trigger.
Figure 4-22
AMP = main current (average value), e.g. 100 A
Ipuls = pulse current = x AMP, e.g. 140% x 100 A = 140 A
IPP = pulse pause current
Tpuls = duration of one pulse cycle = 1/ , e.g. 1/100 Hz = 10 ms
= balance = x Tpuls, e.g. 30% x 1 s = 0.3 s
Selection
Figure 4-23
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4.1.10.4 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 with concentrated heat input. Unlike thermal pulsing, no times are
set; a frequency and the balance are set instead. The pulsing process also occurs during the upslope and down-slope phase.
Figure 4-24
Selection
Figure 4-25
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Balance setting
EXIT
4s
Figure 4-26
Frequency setting
EXIT
4s
Figure 4-27
Welding procedure
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4.1.10.5 AC special
Is e.g. used to join metal sheets of different thickness.
Figure 4-28
Figure 4-29
The and pulse edges can be set in the Expert menu (TIG) > see 4.1.20 chapter.
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4.1.11 Welding torch (operating variants)
Different torch versions can be used with this machine.
Functions on the operating elements, such as torch triggers (TT), rockers or potentiometers, can be
modified individually via torch modes.
Explanation of symbols for operating elements:
Symbol
Description
Press torch trigger
Tap torch trigger
Tap and press torch trigger
4.1.11.1 Tap torch trigger (tapping function)
Swiftly tap the torch trigger to change the function.
The torch mode set determines the operating mode of the tapping function.
4.1.12 Torch mode and up/down speed setting
Modes 1 to 6 and 11 to 16 are available to the user. Modes 11 to 16 feature the same function options as
1 to 6, but without the tapping function for the secondary current.
The function options of the individual modes can be found in the corresponding torch type tables.
The torch modes are set using the torch configuration parameters " " in the machine configuration
menu > torch mode " " > see 4.7 chapter.
Only the modes listed are suitable for the corresponding torch types.
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4.1.12.1 Standard TIG torch (5-pole)
Standard torch with one torch trigger:
Diagram
Operating
elements
Explanation of symbols
BRT1 = Torch trigger 1 (welding current on/off; secondary
current via tapping function)
Functions
mode
Operating
elements
Welding current On/Off
1
(factory-set)
Secondary current (Latched mode)
Standard torch with two torch triggers:
Diagram
Operating
elements
Explanation of symbols
BRT1 = torch trigger 1
BRT2 = torch trigger 2
Functions
mode
Operating
elements
Welding current On/Off
1
(factory-set)
Secondary current
Secondary current (tapping mode) / (latched mode)
Welding current On/Off
3
Secondary current (tapping mode) / (latched mode)
Up function
Down function
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Standard torch with one rocker (MG rocker, two torch triggers)
Diagram
Operating
elements
Explanation of symbols
BRT 1 = torch trigger 1
BRT 2 = torch trigger 2
Functions
mode
Operating
elements
Welding current On/Off
1
(factory-set)
Secondary current
Secondary current (tapping mode) / (latched mode)
Welding current On/Off
2
Secondary current (tapping mode)
Up function
Down function
Welding current On/Off
3
Secondary current (tapping mode) / (latched mode)
Up function
Down function
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4.1.12.2 TIG up/down torch (8-pole)
Up/down torch with one torch trigger
Diagram
Operating
elements
Explanation of symbols
TT 1 = torch trigger 1
Functions
Mode
Operating
elements
Welding current on/off
1
(factory-
set)
Secondary current (tapping mode) / (latched mode)
Increase welding current, infinite adjustment (up function)
Reduce welding current, infinite adjustment (down function)
Welding current on/off
2
Secondary current (tapping mode)
Welding current on/off
4
Secondary current (tapping mode) / (Latched mode)
Increase welding current by an increment *
Reduce welding current by an increment *
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Up/down torch with two torch triggers
Diagram
Operating
elements
Explanation of symbols
TT 1 = torch trigger 1 (left)
TT 2 = torch trigger 2 (right)
Functions
Mode
Operating
elements
Welding current on/off
1
(factory-
set)
Secondary current
Secondary current (tapping mode) / (latched mode)
Increase welding current, infinite adjustment (up function)
Reduce welding current, infinite adjustment (down function)
Welding current on/off
2
Secondary current
Secondary current (tapping mode)
Welding current on/off
4
Secondary current
Secondary current (tapping mode)
Increase welding current by an increment *
Reduce welding current by an increment *
Gas test
4
>
3 s
* > see 4.1.13 chapter
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4.1.12.3 Potentiometer torch (8-pole)
The welding machine needs to be configured for operation with a potentiometer
torch > see 4.1.12.4 chapter.
Potentiometer torch with one torch trigger:
Diagram
Operating
elements
Explanation of symbols
BRT 1 = torch trigger 1
Functions
Mode
Operating
elements
Welding current On/Off
3
Secondary current (tapping mode)
Increase welding current, infinite adjustment
Reduce welding current, infinite adjustment
Potentiometer torch with two torch triggers:
Diagram
Operating
elements
Explanation of symbols
BRT 1 = torch trigger 1
BRT 2 = torch trigger 2
Functions
Mode
Operating
elements
Welding current On/Off
3
Secondary current
Secondary current (tapping mode)
Increase welding current, infinite adjustment
Reduce welding current, infinite adjustment
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4.1.12.4 Configuring the TIG potentiometer torch connection
DANGER
Risk of injury due to electrical voltage after switching off!
Working on an open machine can lead to fatal injuries!
Capacitors are loaded with electrical voltage during operation. Voltage remains present
for up to four minutes after the mains plug is removed.
1. Switch off machine.
2. Remove the mains plug.
3. Wait for at last 4 minutes until the capacitors have discharged!
WARNING
Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
• Carefully read the safety instructions in this manual!
• Observe the accident prevention regulations and any regional regulations!
• Inform persons in the working area that they must comply with the regulations!
Test!
Before re-commissioning, it is essential that an "inspection and test during operation" is carried
out conforming to IEC / DIN EN 60974-4 "Arc welding devices - inspection and testing during
operation"!
• For detailed instructions, please see the standard operating instructions for the welding
machine.
When connecting a potentiometer torch, jumper JP27 on PCB T320/1 inside the welding machine
should be unplugged.
Welding torch configuration
Setting
Prepared for TIG standard or up/down torch (factory setting)
JP27
Prepared for potentiometer torches
JP27
Figure 4-30
For this torch type the welding machine has to be set to torch mode 3 > see 4.1.12 chapter.
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4.1.12.5 RETOX TIG torch (12-pole)
For machines with 12-pole torch connection socket only.
Diagram
Operating elements
Explanation of symbols
TT= torch trigger
Functions
Mode
Operating
elements
Welding current on/off
1
(ex works)
TT 1
Secondary current
TT 2
Secondary current (tapping function)
TT 1 (tapping)
Increase welding current (up function)
TT 3
Reduce welding current (down function)
TT 4
Modes 2 and 3 are not used 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 the first increment)
TT 3
Decrease welding current in stages (setting the first decrement)
TT 4
Switchover between Up-Down and JOB changeover
TT 2 (tapping)
Increase JOB number
TT 3
Decrease JOB number
TT 4
Gas test
TT 2 (3 s)
Welding current on/off
6
TT 1
Secondary current
TT 2
Secondary current (tapping function)
TT 1 (tapping)
Increase welding current, infinite adjustment (up function)
TT 3
Reduce welding current, infinite adjustment (down function)
TT 4
Switchover between Up-Down and JOB changeover
TT 2 (tapping)
Increase JOB number
TT 3
Decrease JOB number
TT 4
Gas test
TT 2 (3 s)
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4.1.13 Up/down operation in modes 4 and 14
By tapping the relevant torch trigger the current can be roughly adjusted. Holding the torch trigger will
cause an infinite adjustment of the welding current.
This function is only available when using up/down torches in modes 4 and 14!
Figure 4-31
The parameter for setting the reach can be found in the machine configuration
menu > see 4.7 chapter.
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4.1.14 Alternating current waveforms
Selection
EXIT
4s
Figure 4-32
Display
Setting/selection
Alternating current waveforms
------- Rectangular (ex works)
------- Trapezoidal
------- Sine
AC welding with rectangular current waveform (ex works)
Highest energy input
Alternating current welding with trapezoidal current waveform
An all-rounder, suitable for most applications
Alternating current welding with sinusoidal current waveform
Low noise level
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4.1.15 Ramp function
4.1.15.1 Foot-operated remote control responsiveness
With the foot-operated remote control the welding current can be infinitely adjusted during the welding
process. The maximum main current has to be set at the machine before starting to weld. Within the
preset range the main current can be set by adjusting the pressure on the pedal.
Linear responsiveness (ex works)
Welding current changes linearly.
Figure 4-33
Logarithmic responsiveness
Welding current changes logarithmically.
This setting is especially suited for welding with low currents, e.g. for thin panels. The logarithmic
responsiveness enables a more precise dosing.
Figure 4-34
The logarithmic responsiveness is set in the machine configuration menu. The parameter must be set
to > see 4.7 chapter.
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4.1.15.2 RTF 1 foot-operated remote control
Figure 4-35
Symbol
Meaning
Actuate foot-operated remote control (start welding process)
Operate foot-operated remote control (set welding current according to application)
Release foot-operated remote control (end welding process)
The parameter can be changed in the machine configuration menu > see 4.7 chapter.
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4.1.16 Automatic AC frequency
Automatic AC frequency can be selected for JOBs 1–7 only. The left stop in the frequency functional
sequence is used for activation, displayed as .
The signal light comes on when the function is activated.
The machine control adjusts or sets the AC frequency in relation to the set main current. The lower the
welding current, the higher the frequency and vice versa. This ensures a concentrated, directionally
stable arc is achieved when welding currents are low. The load from the tungsten electrode is minimised
when the welding currents are high, ensuring a higher service life.
The use of a foot-operated remote control reduces manual intervention by the user during the welding
process to a minimum.
Figure 4-36
Selection
<
Figure 4-37
Welding procedure
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4.1.17 AC commutation optimisation
The AC commutation assistance function can help to increase process stability when welding materials
such as pure aluminium. If half-wave failures should occur during the welding process, the parameter can
be increased, counteracting half-wave failures.
The parameter must first be switched on in the machine configuration menu > see 4.7 chapter. The
parameter value can then be selected and set in the Expert menu > see 4.1.20 chapter.
4.1.18 Simultaneous welding on both sides, synchronisation types
This function is important, if two power sources are used to simultaneously weld on both sides, as is
sometimes required for welding thick aluminium materials in the PF position. This ensures that, with
alternating currents, the positive and negative pole phases are present on both power sources
simultaneously, thus avoiding the arcs negatively influencing each other.
4.1.19 Synchronisation via mains voltage (50Hz / 60Hz)
Phase sequences and rotating magnetic fields in the supply voltages must be the same for both welding
machines. If this is not the case, the energy input into the weld pool will be negatively affected.
Some machine types can be optionally retrofitted with a rotary switch to set the phase position (ON
NETSYNCHRON). Use this rotary switch to correct the phase difference in increments of 60° (0°, 60°,
120°, 180°, 240° and 300°). Optimum phase correction will directly achieve better welding results.
The synchronisation via mains voltage function is enabled in the Expert menu (TIG). The parameter
must be set to (signal light Netsync lights up) > see 4.1.20 chapter.
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4.1.20 Expert menu (TIG)
The expert menu includes functions and parameters which are either not set on the machine control, or
which do not require regular setting.
ENTER (Enter the menu)
• Keep the control button pressed for 2 s.
NAVIGATION (Navigate the menu)
• Parameters are selected by turning the main control button or pressing the "Parameter
selection left/right" push-button.
• Change parameters by pressing (parameter selection) and turning (parameter setting) the
main control button.
EXIT (Exit the menu)
• The machine will return automatically to the ready-to-operate status after 4 sec.
ENTER
4s
NAVIGATION
A
A
B
A
B
A
B B
A
A
A
B
B
A
A
A
B
A
B
B
B
A
B
A
A
B
A
B
A
A
A
B
A
A
A
B
B
EXIT
4s
A
A
A
A
A
A
A
B
A
A
Figure 4-38
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Display
Setting/selection
Expert menu
Slope time (main current to secondary current)
Slope time (main current to secondary current)
Slope time (main current to secondary current)
Slope time (main current to secondary current)
Amplitude balance
activArc parameter
Parameter also adjustable after TIG activArc welding is activated.
AC commutation optimisation > see 4.1.17 chapter
------- Function enabled
------- Function disabled (ex works)
Filler wire process (cold/hot wire)
------ filler wire activated
------ filler wire deactivated (factory setting)
Hot wire process (start signal for hot wire power source)
------- Function enabled
------- Function disabled (ex works)
Wire/pulse function (wire feeding behaviour when using pulsed TIG welding)
Wire feeding can be disabled during pulse pauses (not the case for automated
pulsing or kHz pulsing).
------- Function disabled
------- Function enabled (ex works)
Filler wire diameter (manual setting)
Setting the wire diameter between 0.6 mm to 1.6 mm.
The character "d" preceding the wire diameter on the display (d0.8) indicates a preprogrammed characteristics (correction operating mode "KORREKTUR”).
If there is no characteristics for the selected wire diameter, the parameters have to be set
manually (manual operating mode “MANUELL“).
To select the operating mode > see 4.3.1.2 chapter.
Wire return
• Increase value = more wire return
• Decrease value = less wire return
Simultaneous AC welding on both sides, synchronisation types
------- Function disabled (ex works)
------- Synchronisation via mains voltage (50 Hz/60 Hz)
Ignition type (TIG)
------- HF start active (ex works)
------- Lift arc ignition active
Welding procedure
TIG welding
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4.1.21 Aligning the cable resistance
To ensure optimum welding properties, the electric cable resistance should be aligned again whenever an
accessory component such as the welding 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 is set to the optimum values. To optimise the welding properties for
other cable lengths, an alignment process (voltage correction) is necessary.
2
3
4
1
l0l
0
+
+
Tetrix
Classic
Tetrix
Smart
Comfort
Synergic
B
A
+
Tetrix
Comfort 2.0
RT50 7POL
Figure 4-39
Welding procedure
TIG welding
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1 Preparation
• Switch off the welding machine.
• Unscrew the gas nozzle from the welding torch.
• Unfasten the tungsten electrode and extract.
2 Configuration
• Activate the rotary knob while switching on the welding machine at the same time.
• Release rotary knob.
• You can now use the rotary knob (rotate and press) to select the parameter rL > see 4.7 chapter.
3 Alignment/measurement
• Applying slight pressure, 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 is used to determine and display the cable resistance. The value can be between 0 mΩ
and 60 mΩ. 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 must be repeated.
4 Restoring welding standby mode
• Switch off the welding machine.
• Lock the tungsten electrode in the collet again.
• Screw the gas nozzle onto the welding torch.
• Switch on the welding machine.
Welding procedure
MMA welding
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4.2 MMA welding
4.2.1 Welding task selection
It is only possible to change the basic parameters when no welding current is flowing and any
possible access control is disabled > see 4.5 chapter.
The welding task is selected using the buttons on the machine control on the welding machine.
Signal lights (LED) display the welding parameter selection.
Set the welding task in the following order:
Figure 4-40
Welding procedure
MMA welding
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4.2.2 Hotstart
The hot start device ensures that stick electrodes ignite more effectively thanks to a greater hot start
current. After selecting the stick electrode, the arc ignites with the hot start current for the preset hot
start time and then reverts to the main current (AMP).
The parameter values for hot start current and time can be optimised for the electrode types used.
Figure 4-41
4.2.2.1 Hotstart current
EXIT
4s
Figure 4-42
4.2.2.2 Hotstart time
EXIT
4s
Figure 4-43
Welding procedure
MMA welding
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4.2.3 Arcforce
During the welding process, arcforce prevents the electrode sticking in the 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 4-44
4.2.4 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 minimum current within about 1
second to prevent the electrode from overheating. Check the welding
current setting and correct according to the welding task!
Figure 4-45
4.2.5 Welding current polarity reversal (polarity reversal)
This function can be used to reverse the welding current polarity electronically.
For example, when welding with different electrode types for which different polarities are stipulated by
the manufacturer, the welding current polarity can be switched easily on the control.
-
+
~
Figure 4-46
Welding procedure
MMA welding
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4.2.6 Pulse welding
Pulse welding means that the system switches between two currents periodically with a pulse current
(Ipuls), a pulse pause current (IPP), a balance ( ) and a frequency ( ) having been defined first.
Figure 4-47
AMP = main current, e.g. 100 A
Ipuls = pulse current = x AMP, e.g. 140% x 100 A = 140 A
IPP = pulse pause current = 1–200% of AMP
Tpuls = duration of one pulse cycle = 1/ , e.g. 1/100 Hz = 10 ms
= balance = x Tpuls, e.g. 30% x 1 s = 0.3 s
Selection
Figure 4-48
The machine function is enabled in the machine configuration menu. The parameter must be set to
> see 4.7 chapter.
Welding procedure
MMA welding
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4.2.7 Average value pulse welding
Average value pulsing is a variant of pulsing, with the particularity that the power source will always
maintain the preset average value. This makes this method especially suitable for welding according to
welding procedure specifications.
Average value pulse welding means that two currents are switched periodically, a current average value
(AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The
predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the
parameter as a percentage of the current average value (AMP). The pulse pause current (IPP) requires
no setting. This value is calculated by the machine control, so that the welding current average value
(AMP) is maintained at all times.
Figure 4-49
AMP = Main current; e.g. 100 A
IPL = Pulse current = IP1 x AMP; e.g. 170% x 100 A = 170 A
IPP = Pulse pause current
Tpuls = Duration of one pulse cycle = 1/FrE; e.g. 1/1 Hz = 1 s
bAL = Balance = bAL x Tpuls; e.g. 30% x 1 s = 0.3 s
Selection
Figure 4-50
Welding procedure
Filler wire welding
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4.3 Filler wire welding
4.3.1 Configuring the welding machine for mechanical arc fusion welding
Before the welding machine is commissioned it has to be configured for mechanical arc fusion welding
(cold or hot wire welding). The following basic settings are made in the Expert menu:
1. Activate filler wire process (AW = on).
2. Hot wire or cold wire selection (HW = on/off)
In addition, wire diameter and wire return can be adjusted if required.
Read and observe the documentation to all system and accessory components!
4.3.1.1 Selecting a welding task by means of the JOB list
• Select material, tungsten electrode and seam position on the welding machine controls.
The welding task number (JOB number) results from the chosen basic parameters. If no wire
speed is assigned to this JOB-number ( > see 4.3.1.2 chapter), wire feeding will not take place. In
order to carry out the chosen welding task, the wire feed unit must be switched to the MANUELL
operating mode .
4.3.1.2 Select wire speed operating mode (KORREKTUR / MANUELL)
The wire speed can be set in two different operating modes:
MANUAL: The wire speed can be selected on the wire feed unit as an absolute value across the
entire setting range.
CORRETION: The wire speed is approximately specified by the welding machine control and can be
corrected as a percentage on the wire feed unit
In the wire feed unit underneath the cap is a switch for selecting the operating mode.
4.3.1.3 Setting the welding current and wire speed
Operating
element
Action
Result
Set welding current on the welding machine
Set wire speed
MANUAL operating mode (outer scale):
The wire speed can be selected on the wire feed unit as an absolute
value across the entire setting range.
CORRECTION operating mode (inner scale):
The wire speed is specified largely by the welding machine control and
can be corrected as a percentage on the wire feed unit
Welding procedure
Filler wire welding
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4.3.2 Function sequences/operating modes
The welding current operating mode must be set to latched on the welding machine. The welding
current is infinitely adjustable by means of torch triggers 3 and 4 (BRT 3 and BRT 4). Torch
trigger 2 (BRT 2) switches the 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 4-51
4.3.2.1 Explanation of symbols
Symbol
Meaning
Press torch trigger
Release torch trigger
Tap torch trigger (press briefly and release)
Shielding gas flowing
I
Welding output
Gas pre-flows
Gas post-flows
Non-latched
Latched
t
Time
P
START
Ignition program
PA
Main program
PB
Reduced main program
P
END
End program
tS1
Slope duration from PSTART to PA
Wire feed
Welding procedure
Filler wire welding
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4.3.2.2 Non-latched mode
Figure 4-52
1st cycle (current)
• Press torch trigger 2 (BRT 2), the gas pre-flow time elapses.
• HF ignition pulses jump from the tungsten electrode to the workpiece. The arc ignites.
• Welding current flows and immediately assumes the set ignition current AMP%
(search arc at minimum setting). HF switches off.
2nd cycle (current)
• Release BRT 2.
• The welding current ramps up to the 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 BRT 2.
• The main current ramps down to the end-crater current I
end
(AMP%) in the selected down-slope time.
4th cycle (current)
• Release BRT 2. Arc extinguishes.
• Shielding gas continues to flow for the selected gas post-flow time.
Ending the welding process without down-slope time and end-crater current:
• Tap BRT 2 (tapping function).
Shielding gas continues to flow for the selected gas post-flow time.
Swiftly tap the torch trigger to change the function.
The torch mode set determines the operating mode of the tapping function.
Welding procedure
Filler wire welding
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4.3.2.3 3-cycle operation
Figure 4-53
This operating mode differs from non-latched operation in the following ways:
• Once the third cycle (current) has started, the wire electrode is fed, corresponding to the welding
current, until the welding process ends.
4.3.2.4 Latched mode
Figure 4-54
This operating mode differs from non-latched operation in the following ways:
• Wire feeding is started by pressing and releasing (tapping) the BRT 1.
• By pressing and releasing (tapping) the BRT 1 again, wire feeding will stop. (It is not necessary to
keep the torch trigger pressed. This is especially helpful with long welding seams.)
Welding procedure
Power-saving mode (Standby)
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4.4 Power-saving mode (Standby)
You can activate the power-saving mode by either pressing the push-button > see 3 chapter for a
prolonged time or by setting a parameter in the machine configuration menu (time-controlled powersaving mode ) > see 4.7 chapter.
When power-saving mode is activated, the machine displays show the horizontal digit in the
centre of the display only.
Pressing any operating element (e.g. tapping the torch trigger) deactivates power-saving mode and the
machine is ready for welding again.
4.5 Access control
The machine control can be locked to secure it against unauthorised or unintentional adjustment. The
access block has the following effect:
• The parameters and their settings in the machine configuration menu, Expert menu and operation
sequence can only be viewed but not changed.
• Welding procedure and welding current polarity cannot be changed.
The parameters for setting the access block are configured in the machine configuration
menu > see 4.7 chapter.
Enabling access block
• Assign the access code for the access block: Select parameter and select a number code (0–
999).
• Enable access block: Set parameter to access block enabled .
The access block activation is indicated by the "Access block active" signal light > see 3.1.1 chapter.
Disabling access block
• Enter the access code for the access block: Select parameter and enter the previously selected
number code (0–999).
• Disable access block: Set parameter to access block disabled . The only way to disable the
access block is to enter the selected number code.
4.6 Voltage reducing device
The machine can be equipped with a VRD(Voltage-reducing device) to increase safety, particularly in
hazardous environments such as those in shipbuilding, pipe construction or mining (identified with name
prefix "VRD").
The VRD signal light comes on when the voltage reduction device is operating perfectly and the output
voltage is reduced to the value specified in the relevant technical standard..
4.7 Machine configuration menu
Basic machine settings are defined in the machine configuration menu.
4.7.1 Selecting, changing and saving parameters
ENTER (Enter the menu)
• Switch off the machine at the main switch.
• Press and hold the control button while switching the machine on again at the same time.
NAVIGATION (Navigate the menu)
• Parameters are selected by pressing the control button.
• Set or change the parameters by turning the control button.
EXIT (Exit the menu)
• Select menu item .
• Press control button (settings will be applied, machine changes to the ready-to-operate
status).
Welding procedure
Machine configuration menu
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ENTER
+
l
0
NAVIGATION
A
A
A
A A
B
B
B
B B B B B B B
A
A
A
A
A A A A
A A A A A A A A A
A
B B B B B B B B
B
B B B B
B
B
A A A
A
A A
A A A A A
A
B
B
B
B B
B B B B B
A
A
A
B
A
A
A
A
B B B
A A
B
A
B
A A
B
A
B
B
B B
A
B
B
A
B B
A
B
A
B
A
B
EXIT
Figure 4-55
Welding procedure
Machine configuration menu
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Display
Setting/selection
Exit the menu
Torch configuration menu
Set welding torch functions
Torch mode (ex works 1) > see 4.1.12 chapter
Alternative welding start – tapping start
Available from torch mode 11 (welding stop by tapping remains active).
------- Function enabled (ex works)
------- Function disabled
Up/down speed
Numerical setting 1–100 (ex works 10).
Increase value > rapid current change
Decrease value > slow current change
Setting the first increment
Numerical setting 1–20 (ex works 1)
Machine configuration
Settings for machine functions and parameter display
Absolute value setting (ignition, secondary, end and hot start
current) > see 3.2.1 chapter
------- Welding current setting, absolute
------- Welding current setting, as a percentage of the main current
Non-latched operation (version C) > see 4.1.7.6 chapter
------- Function enabled
------- Function disabled (ex works)
Current display switching (MMA)
------- Actual value display
------- Nominal value display (ex works)
Pulsed TIG welding (thermic) in the upslope and downslope phases
------- Function enabled (ex works)
------- Function disabled
MMA pulse shape
------- Average value MMA pulse welding (ex works)
------- MMA pulse welding
TIG average value pulsing
------- Average value pulsing enabled
------- Average value pulsing disabled (ex works)
Filler wire welding, operating mode
------- Filler wire operation for automated applications,
wire is fed when current flows
------- Non-latched operating mode (ex works)
------- 3rd cycle operating mode
------- Latched operating mode
TIG antistick > see 4.1.9 chapter
------- function active (factory setting).
------- function inactive.
Show warnings > see 5.1 chapter
------- Function disabled (ex works)
------- Function enabled
Welding procedure
Machine configuration menu
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Display
Setting/selection
Setting the system of units
------- Units of length in mm, m/min. (metric system)
------- Unit of length in inches, ipm (imperial system)
Machine configuration (second part)
Settings for machine functions and parameter display
Foot-operated remote control ramp function > see 4.1.15 chapter
------- Welding current rises to the specified main current level in a ramp function (ex
works)
------- Welding current immediately jumps to the specified main current level
Foot-operated remote control responsiveness > see 4.1.15.1 chapter
------- Linear responsiveness (ex works)
------- Logarithmic responsiveness (better control of lower welding currents)
Tungsten balling with RT AC remote control
------- Function disabled
------ Function enabled (in addition, the "AC balance" rotary knob at the RT
AC remote control has to be turned to the left stop) (ex works)
Tungsten balling (old variant)
------- Function enabled
------- Function disabled (ex works)
Welding current polarity switching
------- polarity switching at the RT PWS 1 19POL remote control (ex works)
------- polarity switching at the welding machine control
spotmatic operating mode > see 4.1.7.5 chapter
Ignition by contact with the workpiece
------- Function enabled (ex works)
------- Function disabled
Spot time setting > see 4.1.7.5 chapter
------- Short spot time, setting range 5 ms to 999 ms, increments of 1 ms (ex works)
------- Long spot time, setting range 0.01 s to 20.0 s, increments of 10 ms (ex works)
Process activation setting > see 4.1.7.5 chapter
------- Separate process activation
------- Permanent process activation (ex works)
Torch cooling mode
------- Automatic operation (ex works)
------- Permanently enabled
------- Permanently disabled
Welding torch cooling, post-flow time
Setting 1–60 min. (ex works 5 min.)
Time-controlled power-saving mode > see 4.4 chapter
• ---------- 5 min.–60 min. = time until activation of power-saving mode when inactive.
• ---------- off = switched off
Expert menu
AC average value controller
------- Function enabled (ex works)
------- Function disabled
Welding procedure
Machine configuration menu
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Display
Setting/selection
Welding current polarity switch (dc+) with TIG DC
------- Polarity switch released
------- Polarity switch blocked;
protects the tungsten electrode from being permanently damaged (ex works).
Reconditioning pulse (tungsten ball stability)
Cleaning effect of the tungsten ball at the end of welding.
------- Function enabled (ex works)
------- Function disabled
activArc voltage measuring
------- Function enabled (ex works)
------- Function disabled
Error output to interface for automated welding, contact SYN_A
------- AC synchronisation or hot wire (ex works)
------- Error signal, negative logic
------- Error 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 disabled (ex works).
------- Monitoring during the welding process. Gas sensor between gas valve and
welding torch (with pilot static tube).
------- Monitoring prior to the welding process. Gas sensor between gas valve and
welding torch (without pilot static tube).
------- Permanent monitoring Gas sensor between gas cylinder and gas valve (with
pilot static tube).
AC commutation optimisation > see 4.1.17 chapter
------- Function enabled
------- Function disabled (ex works)
Minimum current limit > see 4.1.2 chapter
Depending on the set electrode diameter
------- Function disabled
------- Function enabled (ex works)
Access control – access code
Setting: 000 to 999 (000 ex works)
Access control > see 4.5 chapter
------- Function enabled
------- Function disabled (ex works)
Automation menu
Fast take-over of control voltage (automation)
------- Function enabled
------- Function disabled (ex works)
Orbital welding
------- Function disabled (ex works)
------- Function enabled
Orbital welding
Correction value for orbital current
Welding procedure
Machine configuration menu
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Display
Setting/selection
Service menu
Any changes to the service menu should be agreed with the authorised service
personnel.
Reset (to factory setting)
------- Disabled (ex works)
------- Reset the values in the machine configuration menu
------ Complete reset of all values and settings
Resetting is performed when exiting the menu ( ).
Software version query (example)
07.= ------ system bus ID
03c0= --- version number
System bus ID and version number are separated by a dot.
Only qualified service personnel may change the parameters!
Only qualified service personnel may change the parameters!
Soft ignition
------- Function enabled (ex works)
------- Function disabled
Ignition pulse limit
Setting 0 ms–15 ms (increments of 1 ms)
PCB state – qualified service personnel only!
Rectifying faults
Warnings (power source)
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5 Rectifying faults
All products are subject to rigorous production checks and final checks. If, despite this, something fails to
work at any time, please check the product using the following flowchart. If none of the fault rectification
procedures described leads to the correct functioning of the product, please inform your authorised
dealer.
5.1 Warnings (power source)
A warning is denoted by the letter A on the machine display, or Att in case of multiple 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 case of multiple warnings, these are displayed in sequence.
• Document machine warning and inform service personnel, if required.
Warning code
Possible cause
Remedy
1
Machine excess temperature
Allow the machine to cool down
2
Half-wave failures
Check process parameters
3
Welding torch cooling warning
Check coolant level and refill if necessary
4
Gas warning
Check gas supply
5
See warning number 3
-
6
Welding consumable (wire electrode)
fault
Check wire feeding (with machines with filler
wire)
7
CAN bus failure
Inform service
32
Encoder malfunction, drive
Inform service
33
Drive is operating under overload
conditions
Adjust mechanical load
34
JOB unknown
Select alternative JOB
The warnings can be reset by pressing a push-button (see table):
Welding machine
control
Smart
Classic
Comfort
Comfort 2
Synergic
Push-button
Rectifying faults
Error messages (power source)
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5.2 Error messages (power source)
A welding machine error is indicated by the collective fault signal lamp (A1) lighting up and an
error code (see table) being displayed in the machine control display. In the event of a machine
error, the power unit shuts down.
The display of possible error numbers depends on the machine version (interfaces/functions).
• If multiple errors occur, these are displayed in succession.
• Document machine errors and inform service staff as necessary.
Error message
Possible cause
Remedy
Err 3
Speedometer error
Check wire guide/hose package
Wire feeder is not connected
• Switch off cold wire mode in the device
configuration menu (off status)
• Connect the wire feeder
Err 4
Temperature error
Allow the machine to cool down
Error in emergency stop circuit
(interface for automated welding)
• Check the external interrupt equipment
• Check jumper JP 1 on PCB T320/1
Err 5
Overvoltage
Switch off machine and check the mains
voltage
Err 6
Low voltage
Err 7
Coolant error (with connected cooling
unit only)
Check coolant level and refill if necessary
Err 8
Gas error
Check gas supply
Err 9
Secondary overvoltage
Switch machine off and on again,
inform the service department if the error
continues
Err 10
PE error
Err 11
FastStop position
Edge 'Acknowledge error' signal (0 to 1) via
robot interface (if available)
Err 12
VRD error
Switch the machine off and on again.
If the error persists, inform the service dept.
Err 16
Pilot arc current
Check welding torch
Err 17
Cold wire error
Excess current limit of a motor control
card has been triggered
Cold wire error – a permanent deviation
between wire nominal value and actual
value or a blocked drive has been
detected in the process
Inspect the wire feed system (drives, tube
packages, torch):
• Check cold wire on the torch / work piece
(moved against work piece?)
• Check relation of process wire feed
speed to robot travel speed, and correct
if necessary
• Check wire feed for stiffness with wire
inching function (resolve by checking
wire guides section by section)
Reset error via robot interface (reset error)
Err 18
Plasma gas error
Nominal value significantly different
from actual value -> No plasma gas?
• Check plasma gas supply; use the
plasma gas test function on "cold wire
feed unit" if necessary
• Check guiding / connections of the gas
supply hose for leaks / kinks
• Check that the gas supply lead of the
plasma torch is not blocked
Reset error via robot interface (reset error)
Err 19
Shielding gas
Nominal value significantly different
from actual value -> No shielding gas?
Rectifying faults
Error messages (power source)
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Error message
Possible cause
Remedy
Err 20
Coolant
The flow quantity of the torch coolant
has fallen below the permissible
minimum -> the coolant flow is dirty or
cut off because the tube package has
been unsuitably installed
The flow quantity of the torch coolant
has fallen below the permissible level
Check coolant level and refill if necessary
• Check coolant level in the reverse cooler
• Check coolant lines for leaks and kinks
• Check that the coolant inlet and outlet on
the plasma torch is not blocked
Reset error via robot interface (reset error)
Err 22
Excess temperature in coolant circuit
Coolant temperature exceeded
The temperature of the coolant is too
high
• Check coolant level in the reverse cooler
• Check temperature nominal value on the
cooling unit
Reset error via robot interface (reset error)
Err 23
HF choke excess temperature
High frequency blocking inductor
excess temperature
The excess temperature of the high
frequency blocking inductor has
triggered
• Allow equipment to cool down
• Adjust processing cycle times if
necessary
Reset error via robot interface (reset error)
Err 24
Pilot arc ignition error
Check plasma torch replacement parts
Err 32
Electronics error (I>0 error)
Switch the machine off and on again.
If the error persists, inform the service dept.
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)
Err 37
Electronics error (temperature error)
Allow machine to cool down.
Err 38
---
Switch the machine off and on again.
If the error persists, inform the service dept.
Err 39
Electronics error (secondary
overvoltage)
Err 40
Electronic error (I>0 error)
Inform service
Err 48
Ignition error
Check welding process
Err 49
Arc interruption
Inform the Service department
Err 51
Error in emergency stop circuit
(interface for automated welding)
• Check the external interrupt equipment
• Check jumper JP 1 on PCB T320/1
Err 57
Auxiliary drive error, tacho error
Check auxiliary drive
No signal from tachometer.
M3.51 defective > Inform service
Rectifying faults
Resetting welding parameters to the factory settings
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5.3 Resetting welding parameters to the factory settings
All customised welding parameters that are stored will be replaced by the factory settings.
To reset the welding parameters or machine settings to the factory settings, select parameter in the
service menu > see 4.7 chapter.
5.4 Display machine control software version
The query of the software versions only serves to inform the authorised service staff. It is available in the
machine configuration menu > see 4.7 chapter.
Appendix A
Parameter overview – setting information
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6 Appendix A
6.1 Parameter overview – setting information
6.1.1 TIG welding
Parameter
TIG/plasma
Display
Setting range
Comment
Code
Unit
Standard
Min. Max.
Main current
A 5 - 300
Gas pre-flow time
s
0,5
0 - 20
Ignition current AMP%
%
20
1 - 200
% of main current AMP
Start time
s
0,01
0,00 - 20,0
Up-slope time
s
1,0
0,0 - 20,0
Pulse current
%
140
1 200
Pulse time
s
0,01
0,00 - 20,0
Slope time
s
0,00
0,00 - 20,0
Time from main current AMP to
secondary current AMP%
Secondary current AMP%
%
50
1 200
% of main current AMP
Pulse pause time
s
0,01
0,00 - 20,0
Slope time
s
0,00
0,00 - 20,0
Time from main current AMP to
secondary current AMP%
Down-slope time
s
1,0
0,0 - 20,0
End current AMP%
%
20
1 - 200
% of main current AMP
End current time
s
0,01
0,00 - 20,0
Gas post-flow time
s 8 0,0 - 40,0
Electrode diameter, metric
mm
2,4
1,0 - 4,0
Electrode diameter, imperial
mil
92
40 - 160
spotArc time
s 2 0,01 - 20,0
spotmatic time ( > )
ms
200
5 - 999
spotmatic time ( > )
s 2 0,01 - 20,0
AC balance (JOB 0)
% -30 - +30
Rotary knob
AC balance (JOB 1-7)
% 1 - 99
AC commutation
optimisation
5 - 375
Pulse balance
% 1 - 99
Pulsing, metallurgical
Pulse frequency
Hz
50
5 - 15000
Pulsing, metallurgical
AC frequency (JOB 0)
Hz - 30 - 300
AC frequency (JOB 1-7)
Hz
50
30 - 300
activArc
0 - 100
Amplitude balance
70 - 130
Appendix A
Parameter overview – setting information
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6.1.2 MMA welding
Parameter
MMA
Display
Setting range
Comment
Code
Unit
Standard
Min. Max.
Main current
A 5 - 300
Hot start current
%
120
1 - 200
% of main current AMP (parameter
to setting )
Hot start time
s
0.5
0.0 - 10.0
Arcforce
0 -40 - 40
Pulse pause current
%
50
1 - 200
Pulse current
142
1 - 200
Pulse frequency
Hz
1.2
0.2 - 500
Pulse balance
30
1 - 99
Appendix B
Overview of EWM branches
099-00T400-EW501
21.10.2016
77
7 Appendix B
7.1 Overview of EWM branches
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