EWM Tetrix 351 AC/DC Synergic FW, Tetrix 501 AC/DC Synergic FW, Tetrix 551 AC/DC Synergic FW, Tetrix 451 AC/DC Synergic FW Operating Instructions Manual
Operating instructions
EN
Welding machine
Tetrix 351 AC/DC Synergic FW
Tetrix 451 AC/DC Synergic FW
Tetrix 501 AC/DC Synergic FW
Tetrix 551 AC/DC Synergic FW
099-000109-EW501
Observe additional system documents!
23.08.2018
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.
General instructions
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/en/specialist-dealers.
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
Tel.: +49 2680 181-0, Fax: -244
Email: info@ewm-group.com
www.ewm-group.com
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
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1 Contents
1 Contents .................................................................................................................................................. 3
2 For your safety ....................................................................................................................................... 7
2.1 Notes on the use of these operating instructions .......................................................................... 7
2.2 Explanation of icons ....................................................................................................................... 8
2.3 Part of the complete documentation .............................................................................................. 9
2.4 Safety instructions ........................................................................................................................ 10
2.5 Transport and installation ............................................................................................................ 13
3 Intended use ......................................................................................................................................... 15
3.1 Applications .................................................................................................................................. 15
3.2 Documents which also apply ....................................................................................................... 15
3.2.1 Warranty ....................................................................................................................... 15
3.2.2 Declaration of Conformity ............................................................................................. 15
3.2.3 Welding in environments with increased electrical hazards ......................................... 15
3.2.4 Service documents (spare parts and circuit diagrams) ................................................ 15
3.2.5 Calibration/Validation ................................................................................................... 15
4 Machine description – quick overview .............................................................................................. 16
4.1 Tetrix 351 AC/DC ......................................................................................................................... 16
4.1.1 Front view ..................................................................................................................... 16
4.1.2 Rear view ...................................................................................................................... 18
4.2 Tetrix 451-551 AC/DC ................................................................................................................. 20
4.2.1 Front view ..................................................................................................................... 20
4.2.2 Rear view ...................................................................................................................... 22
4.3 Machine control – Operating elements ........................................................................................ 24
4.3.1 Function sequence ....................................................................................................... 26
5 Design and function ............................................................................................................................. 28
5.1 Transport and installation ............................................................................................................ 28
5.1.1 Lifting by crane ............................................................................................................. 28
5.1.2 Ambient conditions ....................................................................................................... 28
5.1.3 Machine cooling ............................................................................................................ 29
5.1.4 Workpiece lead, general ............................................................................................... 29
5.1.5 Welding torch cooling system ....................................................................................... 29
5.1.6 Notes on the installation of welding current leads ........................................................ 31
5.1.7 Stray welding currents .................................................................................................. 32
5.1.8 Mains connection .......................................................................................................... 33
5.2 Welding data display .................................................................................................................... 34
5.2.1 Welding parameter setting ........................................................................................... 35
5.2.2 Setting the welding current (absolute/percentage) ....................................................... 35
5.3 TIG welding .................................................................................................................................. 36
5.3.1 Welding torch and workpiece line connection .............................................................. 36
5.3.2 Shielding gas supply (shielding gas cylinder for welding machine) ............................. 38
5.3.3 TIG Synergic operating principle .................................................................................. 39
5.3.4 Welding task selection .................................................................................................. 41
5.3.5 Gas test or "rinse hose package" ................................................................................. 41
5.3.6 Optimising the ignition characteristics for pure tungsten electrodes ............................ 43
5.1.2.1 In operation ................................................................................................... 29
5.1.2.2 Transport and storage ................................................................................... 29
5.1.5.1 Approved coolants overview ......................................................................... 30
5.1.5.2 Maximal hose package length ...................................................................... 30
5.1.5.3 Adding coolant .............................................................................................. 30
5.1.8.1 Mains configuration ....................................................................................... 34
5.3.1.1 Connection assignment, welding torch control cable .................................... 37
5.3.2.1 Connecting the shielding gas supply ............................................................ 38
5.3.3.1 Synergic parameter setting in the functional sequence ................................ 40
5.3.3.2 Conventional parameter setting in the functional sequence ......................... 40
5.3.3.3 Set the operating principle (conventional/synergic) ...................................... 40
5.3.5.1 Gas test ......................................................................................................... 42
5.3.5.2 “Purge hose package” function ..................................................................... 42
5.3.5.3 Automatic gas post-flow ................................................................................ 42
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5.3.7 Tungsten balling function .............................................................................................. 43
5.3.8 AC balance (optimise cleaning effect and penetration characteristics) ........................ 44
5.3.9 AC amplitude balance ................................................................................................... 44
5.3.10 Arc ignition .................................................................................................................... 45
5.3.10.1 HF ignition ..................................................................................................... 45
5.3.10.2 Liftarc ............................................................................................................. 45
5.3.10.3 Automatic cut-out .......................................................................................... 45
5.3.11 Operating modes (functional sequences) ..................................................................... 46
5.3.11.1 Explanation of symbols ................................................................................. 46
5.3.11.2 Non-latched mode ......................................................................................... 47
5.3.11.3 Latched mode ................................................................................................ 48
5.3.11.4 spotArc .......................................................................................................... 50
5.3.11.5 spotmatic ....................................................................................................... 51
5.3.11.6 Non-latched operation, version C .................................................................. 53
5.3.12 Alternating current waveforms ...................................................................................... 54
5.3.13 Pulse welding ................................................................................................................ 55
5.3.13.1 Automated pulses .......................................................................................... 55
5.3.13.2 Thermal pulsing ............................................................................................. 55
5.3.13.3 Metallurgical pulsing (kHz pulsing) ................................................................ 57
5.3.13.4 AC special ..................................................................................................... 59
5.3.14 TIG antistick .................................................................................................................. 59
5.3.15 activArc ......................................................................................................................... 60
5.3.16 Simultaneous welding on both sides, synchronisation types ....................................... 60
5.3.16.1 Synchronisation via mains voltage (50Hz / 60Hz) ........................................ 60
5.3.16.2 Synchronisation via cable (frequency 50Hz to 200Hz) ................................. 61
5.3.17 Expert menu (TIG) ........................................................................................................ 62
5.4 MMA welding ................................................................................................................................ 63
5.4.1 Connecting the electrode holder and workpiece lead .................................................. 63
5.4.2 Welding task selection .................................................................................................. 65
5.4.3 Welding current polarity reversal (polarity reversal) ..................................................... 65
5.4.3.1 Selection and adjustment .............................................................................. 65
5.4.4 Frequency and balance setting .................................................................................... 66
5.4.5 Hotstart ......................................................................................................................... 66
5.4.5.1 Hotstart current .............................................................................................. 67
5.4.5.2 Hotstart time .................................................................................................. 67
5.4.6 Arcforce......................................................................................................................... 68
5.4.7 Antistick......................................................................................................................... 68
5.4.8 Average value pulsing in the vertical-up position (PF) ................................................. 69
5.5 Organising welding tasks (Mode "JOB Manager") ....................................................................... 71
5.5.1 Explanation of symbols ................................................................................................. 71
5.5.2 Creating a new JOB in the memory or copying a JOB ................................................. 72
5.5.3 Loading an existing JOB from the free memory ........................................................... 73
5.5.4 Resetting an existing JOB to the factory setting (Reset JOB) ...................................... 73
5.5.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs) ..................................... 74
5.5.6 Exit JOB Manager without changes ............................................................................. 74
5.6 Welding programs ........................................................................................................................ 75
5.6.1 Selection and adjustment ............................................................................................. 75
5.6.2 Specifying max. no. of accessible programs ................................................................ 76
5.6.3 Example "Program with synergetic setting" .................................................................. 76
5.6.4 Example "Program with conventional setting" .............................................................. 76
5.6.5 Accessories for switching over programs ..................................................................... 76
5.7 Remote control ............................................................................................................................. 76
5.7.1 RT1 19POL ................................................................................................................... 76
5.7.2 RTG1 19POL ................................................................................................................ 77
5.7.3 RTP1 19POL ................................................................................................................ 77
5.7.4 RTP2 19POL ................................................................................................................ 77
5.7.5 RTP3 spotArc 19POL ................................................................................................... 77
5.7.6 RTAC1 19POL .............................................................................................................. 77
5.7.7 RT PWS1 19POL .......................................................................................................... 77
5.7.8 RTF1 19POL ................................................................................................................. 77
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5.7.8.1 RTF start ramp .............................................................................................. 78
5.7.8.2 RTF response ............................................................................................... 79
5.8 Welding torch (operating variants) ............................................................................................... 79
5.8.1 Tapping function (tap torch trigger) .............................................................................. 79
5.8.2 Torch mode setting ....................................................................................................... 79
5.8.3 Up/down speed ............................................................................................................. 80
5.8.4 Current jump ................................................................................................................. 80
5.8.5 Standard TIG torch (5-pole) ......................................................................................... 80
5.8.6 TIG up/down torch (8-pole) .......................................................................................... 83
5.8.7 Potentiometer torch (8-pole) ......................................................................................... 85
5.8.7.1 Configuring the TIG potentiometer torch connection .................................... 85
5.8.8 RETOX TIG torch (12-pole) .......................................................................................... 86
5.8.8.1 Specifying max. no. of accessible JOBs ....................................................... 88
5.9 Interfaces for automation ............................................................................................................. 88
5.9.1 Automation interface .................................................................................................... 88
5.9.2 Remote control connection socket, 19-pole ................................................................. 90
5.9.3 RINT X12 robot interface .............................................................................................. 90
5.9.4 BUSINT X11 Industrial bus interface ............................................................................ 90
5.10 PC interface ................................................................................................................................. 91
5.11 Power-saving mode (Standby) .................................................................................................... 91
5.12 Access control .............................................................................................................................. 91
5.13 Machine configuration menu ........................................................................................................ 92
5.13.1 Selecting, changing and saving parameters ................................................................ 92
5.13.2 Aligning the cable resistance ........................................................................................ 97
6 Maintenance, care and disposal ......................................................................................................... 99
6.1 General ........................................................................................................................................ 99
6.2 Cleaning ....................................................................................................................................... 99
6.2.1 Dirt filter ........................................................................................................................ 99
6.3 Maintenance work, intervals ...................................................................................................... 100
6.3.1 Daily maintenance tasks ............................................................................................ 100
6.3.2 Monthly maintenance tasks ........................................................................................ 100
6.3.3 Annual test (inspection and testing during operation) ................................................ 100
6.4 Disposing of equipment ............................................................................................................. 101
7 Rectifying faults ................................................................................................................................. 102
7.1 Checklist for rectifying faults ...................................................................................................... 102
7.2 Warnings .................................................................................................................................... 103
7.3 Error messages .......................................................................................................................... 104
7.4 Resetting welding parameters to the factory settings ................................................................ 105
7.5 Display machine control software version ................................................................................. 105
7.6 Vent coolant circuit ..................................................................................................................... 105
8 Technical data .................................................................................................................................... 106
8.1 Tetrix 351 AC/DC ....................................................................................................................... 106
8.2 Tetrix 451 AC/DC ....................................................................................................................... 107
8.3 Tetrix 501 AC/DC ....................................................................................................................... 108
8.4 Tetrix 551 AC/DC ....................................................................................................................... 109
9 Accessories ........................................................................................................................................ 110
9.1 Remote controls and accessories .............................................................................................. 110
9.2 Welding torch cooling system .................................................................................................... 110
9.3 Options ....................................................................................................................................... 110
9.3.1 Tetrix 351 AC/DC ....................................................................................................... 110
9.3.2 Tetrix 451-551 AC/DC ................................................................................................ 111
9.4 General accessories .................................................................................................................. 111
9.5 Simultaneous welding on both sides, synchronisation types .................................................... 111
9.5.1 Synchronisation via cable (frequency 50Hz to 200Hz) .............................................. 111
9.5.2 Synchronisation via mains voltage (50Hz / 60Hz) ...................................................... 111
9.6 Computer communication .......................................................................................................... 111
10 Appendix A ......................................................................................................................................... 112
10.1 JOB-List ..................................................................................................................................... 112
Contents
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11 Appendix B .......................................................................................................................................... 116
11.1 Parameter overview – setting ranges ........................................................................................ 116
11.1.1 TIG welding ................................................................................................................. 116
11.1.2 MMA welding .............................................................................................................. 116
12 Appendix C .......................................................................................................................................... 117
12.1 Searching for a dealer ................................................................................................................ 117
For your safety
Notes on the use of these operating instructions
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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.
Technical aspects which the user must observe to avoid material or equipment damage.
2 For your safety
2.1 Notes on the use of these operating instructions
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
Explanation of icons
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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 hold
Switch
Incorrect / Invalid
Turn
Correct / Valid
Numerical value – adjustable
Input
Signal light lights up in green
Navigation
Signal light flashes green
Output
Signal light lights up in red
Time representation (e.g.: wait 4 s /
actuate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use
2.2 Explanation of icons
For your safety
Part of the complete documentation
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Item
Documentation
A.1
Remote control
A.2
Control
A.3
Power source
A.4
Welding torch
A
Complete documentation
2.3 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
For your safety
Safety instructions
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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!
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low vol-
tages can cause a shock and lead to accidents.
• Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
• Always place torches and electrode holders on an insulated surface!
• Wear the full personal protective equipment (depending on the application)!
• The machine may only be opened by qualified personnel!
• The device must not be used to defrost pipes!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a techni-
cal specialist may interconnect the sources as per standard IEC 60974-9:2010: Installa-
tion and use and German Accident Prevention Regulation BVG D1 (formerly VBG 15) or
country-specific regulations.
Before commencing arc welding, a test must verify that the equipment cannot exceed
the maximum permitted open circuit voltage.
• Only qualified personnel may connect the machine.
• When taking individual power sources out of operation, all mains and welding current leads
must be safely disconnected from the welding system as a whole. (Hazard due to reverse
polarity voltage!)
• Do not interconnect welding machines with pole reversing switch (PWS series) or machines
for AC welding since a minor error in operation can cause the welding voltages to be combined, which is not permitted.
Risk of injury due to improper clothing!
During arc welding, radiation, heat and voltage are sources of risk that cannot be
avoided. The user has to be equipped with the complete personal protective equipment
at all times. The protective equipment has to include:
• Respiratory protection against hazardous substances and mixtures (fumes and vapours);
otherwise implement suitable measures such as extraction facilities.
• Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and
heat.
• Dry welding clothing (shoes, gloves and body protection) to protect against warm environments with conditions comparable to ambient temperatures of 100 °C or higher and arcing
and work on live components.
• Hearing protection against harming noise.
Risk of injury due to radiation or heat!
Arc radiation can lead to skin and eye injuries.
Contact with hot workpieces and sparks can lead to burns.
• Use hand shield or welding helmet with the appropriate safety level (depends on the application).
• Wear dry protective clothing (e.g. hand shield, gloves, etc.) in accordance with
the applicable regulations of your country.
• Persons who are not directly involved should be protected with a welding curtain or suitable
safety screen against radiation and the risk of blinding!
2.4 Safety instructions
For your safety
Safety instructions
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WARNING
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during
welding, there is a risk of flames.
• Be watchful of potential sources of fire in the working area!
• Do not carry any easily inflammable objects, e.g. matches or lighters.
• Ensure suitable fire extinguishers are available in the working area!
• Thoroughly remove any residue of flammable materials from the workpiece prior to starting
to weld.
• Only further process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!
CAUTION
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent
vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to
the ultraviolet radiation of the arc!
• Ensure that there is sufficient fresh air!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
For your safety
Safety instructions
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CAUTION
According to IEC 60974-10, welding machines are divided into two classes of
electromagnetic compatibility (the EMC class can be found in the Technical data) > see 8 chapter:
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas, including residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the
surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding system
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
• Observe the maintenance instructions > see 6.3 chapter!
• Unwind welding leads completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if nec-
essary).
Obligations of the operator!
The respective national directives and laws must be complied with when operating the
machine!
• Implementation of national legislation relating to framework directive 89/391/EEC on the
introduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
• In particular, directive 89/655/EEC concerning the minimum safety and health requirements
for the use of work equipment by workers at work.
• The regulations applicable to occupational safety and accident prevention in the country
concerned.
• Setting up and operating the machine as per IEC 60974.-9.
• Brief the user on safety-conscious work practices on a regular basis.
• Regularly inspect the machine as per IEC 60974.-4.
For your safety
Transport and installation
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The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause seri-
ous injuries!
• Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air!
• Do not attach any element to the shielding gas cylinder valve!
• Prevent the shielding gas cylinder from heating up.
CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
• Disconnect all supply lines before transport!
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10° (according to IEC 60974-1).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Risk of accidents due to incorrectly installed leads!
Incorrectly installed leads (mains, control and welding leads or intermediate hose pack-
ages ) can present a tripping hazard.
• Lay the supply lines flat on the floor (avoid loops).
• Avoid laying the leads on passage ways.
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of the
operator, where necessary in consultation with the mains network operator, to ensure that the
2.5 Transport and installation
machine can be connected.
For your safety
Transport and installation
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The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant accessory components.
• Accessory components are detected automatically after the power source is switched on.
Protective dust caps protect the connection sockets and therefore the machine against dirt and
damage.
• The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
• The cap must be replaced if faulty or if lost!
Intended use
Applications
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WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
• The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
The labelled product complies with the following EC directives in terms of its design and
construction:
• Low Voltage Directive (LVD)
• Electromagnetic Compatibility Directive (EMC)
• Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment – Inspection and Testing during Operation," and/or prohibited modifications which
have not been explicitly authorised by the manufacturer, this declaration shall be voided. An original
document of the specific declaration of conformity is included with every product.
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in environments with an increased electrical hazard.
WARNING
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
3 Intended use
3.1 Applications
Arc welding machine for TIG DC and AC welding with lift arc (touch starting) or HF ignition (contactless)
and MMA welding as secondary process. It may be possible to expand the functionality by using accessories (see the documentation in the relevant chapter).
3.2 Documents which also apply
3.2.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information regarding
3.2.2 Declaration of Conformity
warranty, maintenance and testing at www.ewm-group.com!
3.2.3 Welding in environments with increased electrical hazards
3.2.4 Service documents (spare parts and circuit diagrams)
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.2.5 Calibration/Validation
We hereby confirm that this product was tested with calibrated measuring equipment according to the applicable standards IEC/EN 60974, ISO/EN 17662, EN 50504 and complies with the permissible tolerances. Recommended calibration interval: 12 months.
Machine description – quick overview
Tetrix 351 AC/DC
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4 Machine description – quick overview
4.1 Tetrix 351 AC/DC
4.1.1 Front view
Figure 4-1
Machine description – quick overview
Tetrix 351 AC/DC
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Item
Symbol
Description 0
1
Lifting lug > see 5.1.1 chapter
2
Main switch, machine on/off
3
Machine control > see 4.3 chapter
4
Carrying handle
5
Automatic cut-out of coolant pump key button
press to reset a triggered fuse
6
Quick connect coupling (red)
Coolant return from welding torch
7
Quick connect coupling (blue)
Coolant forward flow to the welding torch
8
Wheels, guide castors
9
Coolant tank > see 5.1.5 chapter
10
Coolant tank cap
11
Connection socket, welding torch control cable > see 5.3.1.1 chapter
12
Cooling air inlet
13
G¼” connecting nipple, “-” welding current
Shielding gas connection (with yellow insulating cap) for TIG welding torch
14
Connection socket, “-” welding current
TIG welding torch connection
15
Connection socket, “+” welding current
Connection for workpiece lead
16
Key switch to protect against unauthorised use (retrofitting option)
Position 1: changes possible.
Position 0: no changes possible.
> see 5.12 chapter.
17
Connection socket, 19-pole
Remote control connection
18
Connection socket, “-” welding current
Electrode holder connection
19
Operating state signal lamp
Lights up when the machine is ready for use.
Machine description – quick overview
Tetrix 351 AC/DC
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4.1.2 Rear view
Figure 4-2
Machine description – quick overview
Tetrix 351 AC/DC
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Item
Symbol
Description 0
1
Connection socket, 7-pole (digital)
To connect digital accessories
Retrofitting option > see 9 chapter
2
PC interface, serial (D-Sub connection socket, 9-pole)
3
Automation interface 19-pin (analogue)
Option for retrofitting > see 5.9.1 chapter
4
Ignition type changeover switch > see 5.3.10 chapter
= ------ Liftarc (contact ignition)
= ------ HF ignition
5
Securing elements for shielding gas cylinder (strap/chain)
6
Mains connection cable > see 5.1.8 chapter
7
Cooling air outlet
8
Shielding gas connection (inlet)
Connecting nipple, G¼”
9
Quick connect coupling (red)
Coolant return from welding torch
10
Quick connect coupling (blue)
Coolant forward flow to the welding torch
11
Bracket for shielding gas cylinder
12
Wheels, fixed castors
Machine description – quick overview
Tetrix 451-551 AC/DC
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4.2 Tetrix 451-551 AC/DC
4.2.1 Front view
Figure 4-3
Machine description – quick overview
Tetrix 451-551 AC/DC
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Item
Symbol
Description 0
1
Lifting lug > see 5.1.1 chapter
2
Main switch, machine on/off
3
Machine control > see 4.3 chapter
4
Carrying handle
5
Automatic cut-out of coolant pump key button
press to reset a triggered fuse
6
Quick connect coupling (red)
Coolant return from welding torch
7
Quick connect coupling (blue)
Coolant forward flow to the welding torch
8
Wheels, guide castors
9
Coolant tank > see 5.1.5 chapter
10
Coolant tank cap
11
Connection socket, welding torch control cable > see 5.3.1.1 chapter
12
Cooling air inlet
13
G¼“ connecting nipple, welding current "-" (with DC- polarity)
Shielding gas connection (with yellow insulating cap) for TIG welding torch
14
Connection socket, welding current “-” (with DC- polarity)
connection TIG welding torch
15
Connection socket, welding current “+” (with DC- polarity)
Connection for workpiece lead
16
Key switch to protect against unauthorised use (retrofitting option)
Position 1: changes possible.
Position 0: no changes possible.
> see 5.12 chapter.
17
Connection socket, 19-pole
Remote control connection
18
Connection socket, welding current “-” (with DC- polarity)
connection for Electrode holder
19
Operating state signal lamp
Lights up when the machine is ready for use.
Machine description – quick overview
Tetrix 451-551 AC/DC
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4.2.2 Rear view
Figure 4-4
Machine description – quick overview
Tetrix 451-551 AC/DC
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Item
Symbol
Description 0
1
Connection socket, 7-pole (digital)
To connect digital accessories
Retrofitting option > see 9 chapter
2
PC interface, serial (D-Sub connection socket, 9-pole)
3
Automation interface 19-pin (analogue)
Option for retrofitting > see 5.9.1 chapter
4
Ignition type changeover switch > see 5.3.10 chapter
= ------ Liftarc (contact ignition)
= ------ HF ignition
5
Securing elements for shielding gas cylinder (strap/chain)
6
Mains connection cable > see 5.1.8 chapter
7
Cooling air outlet
8
Shielding gas connection (inlet)
Connecting nipple, G¼”
9
Quick connect coupling (red)
Coolant return from welding torch
10
Quick connect coupling (blue)
Coolant forward flow to the welding torch
11
Bracket for shielding gas cylinder
12
Wheels, fixed castors
Machine description – quick overview
Machine control – Operating elements
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Item
Symbol
Description 0
1
Polarity changeover (TIG manual) button
Select material type (TIG
Synergic) key button
DC welding with positive polarity on the
electrode holder in relation to the workpiece (pole reversing switch, MMA only).
Chrome/nickel alloys / iron /
steel alloys
DC welding with negative polarity at the
torch (or electrode holder) with respect
to the workpiece.
Copper / copper alloys
(bronzes) / copper/zinc alloys
(brass)
AC welding with rectangular current
output wave form. Maximum power loading and safe welding.
Aluminium/magnesium alloys
AC welding with trapezoidal current output wave form. An all-rounder, suitable
for most applications.
Aluminium/silicon alloys
AC welding with sinusoidal current output wave form. Low noise level.
99% aluminium
2
"Welding process" button
MMA welding, lights up in green / arcforce setting, lights up in red
TIG synergic welding (synergic parameter setting)
TIG manual welding (manual parameter setting)
3
Tungsten electrode diameter push-button > see 5.3.4 chapter
Ignition optimisation > see 5.3.6 chapter
Tungsten balling > see 5.3.7 chapter
4.3 Machine control – Operating elements
Figure 4-5
Machine description – quick overview
Machine control – Operating elements
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Item
Symbol
Description 0
4
Select seam type button
------- Fillet weld
-------- Butt joint
------- Fillet weld - lap joint
--------- Vertical-down
5
Operating mode / Power-saving mode button
-- spotArc / spotmatic (spot time setting range)
--------- Non-latched
------ Latched
Press for 3 s to put machine into power-saving mode. To reactivate, activate one of the
operating elements > see 5.11 chapter.
6
Pulsing push-button > see 5.3.13 chapter
------ Automated pulsing (frequency and balance)
-------- Signal light turns green: Thermal pulsed TIG welding/MMA pulsing/average
value pulses
-------- Signal light turns red: Metallurgical pulsed TIG welding (kHz pulsing)/average
value pulses
--- Special TIG AC
7
Synchronisation types key button (two-sided, simultaneous welding)
Synchronisation via mains voltage
Synchronisation via cable
8
Gas test/rinse hose package button
> see 5.3.2 chapter
9
Error/status indicators
------- Collective interference signal light
--------- Water deficiency signal light (welding torch cooling)
---------- Excess temperature signal light
--------- S safety sign signal light
10
Display switching button
------- Material thickness display
VOLT --- Welding voltage display
JOB ----- JOB number display
PROG --- Program number display
11
Welding parameter setting rotary transducer
Setting of all parameters such as welding current, sheet metal thickness, gas pre-flow
time, etc.
12
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 5.2 chapter
13
Status displays
--- 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
-- Direct current welding
-- Alternating current welding
and simultaneously: Alternating current welding, AC special
14
Functional sequence > see 4.3.1 chapter
Machine description – quick overview
Machine control – Operating elements
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Item
Symbol
Description 0
1
Select welding parameters button
This button is used to select the welding parameters depending on the welding process
and operating mode used.
2
Gas pre-flow time signal light
3
AMP%
Signal light
Ignition current (TIG)/hot start current (MMA)
4
sec
Signal light
Up-slope time (TIG)/hot start time (MMA)
5
AMP
Main current (TIG) / pulse current
I min to I max (1 A increments)
Main current (MMA)
I min to I max (1 A increments)
6
sec
Pulse break time/slope time from AMP to AMP%
• Pulse break setting range: 0.01 sec to 20.0 sec
(0.01 sec increments < 0.5 sec; 0.1 sec increments > 0.5 sec)
• Slope time (tS1) setting range: 0.0 sec to 20.0 sec > see 5.3.13 chapter
TIG pulses: The pulse break time applies to the secondary current phase (AMP%)
TIG AC Special: The pulse break time applies to the DC phase with AC special.
7
AMP%
Secondary current / pulse pause current
8
sec
Pulse time / slope time from AMP% to AMP
• Pulse time setting range: 0.01 s to 20.0 s
(0.01 s increments < 0.5 s; 0.1 s increments > 0.5 s)
• Slope time (tS2) setting range: 0.0 s to 20.0 s > see 5.3.13 chapter
TIG pulses
The pulse time applies to the main current
phase (AMP) for pulses.
TIG AC Special
The pulse time applies to the AC phase for
AC special.
9
sec
Down-slope time (TIG)
10
AMP%
End-crater current signal light
11
Signal light, gas post-flow time
12
Balance signal light
AC balance (TIG)/pulse balance (TIG DC – kHz pulses)/pulse balance (MMA)
4.3.1 Function sequence
Figure 4-6
Machine description – quick overview
Machine control – Operating elements
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Item
Symbol
Description 0
13
Frequency signal light
AC frequency (TIG)/pulse frequency (TIG DC – kHz pulses)/pulse frequency (MMA)
14
AC/DC
Welding current polarity, MMA
> see 5.4.3 chapter
15
Signal light activArc > see 5.3.15 chapter
Design and function
Transport and installation
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WARNING
Risk of injury from electrical voltage!
Contact with live parts, e.g. power connections, can be fatal!
• Observe the safety information on the first pages of the operating instructions!
• Commissioning must be carried out by persons who are specifically trained in handling
power sources!
• Connect connection or power cables while the machine is switched off!
CAUTION
Risk from electrical current!
If welding is carried out alternately using different methods and if a welding torch and
an electrode holder remain connected to the machine, the open-circuit/welding voltage
is applied simultaneously on all cables.
• The torch and the electrode holder should therefore always be placed on an insulated
surface before starting work and during breaks.
WARNING
Risk of injury during lifting by crane!
When lifting the machine by crane, persons may be severely injured by falling machines
or mount-on components.
• Simultaneous lifting of system components such as power source, wire
feeder or cooling unit without suitable crane components is not allowed. Each system component has to be lifted separately!
• Remove any supply leads and accessories before lifting by crane (e.g.
hose package, wire spool, shielding gas cylinder, toolbox, wire feeder,
remote control,etc.)!)
• Properly close and lock all casing covers and protective caps before
lifting by crane!
• Use the correct number of hoisting equipment of the right size in the
correct position! Observe craning principle (see figure)!
• For machines with lifting eyes: always lift all lifting eyes simultaneously!
• When using retrofitted craning frames etc.: always use at least two
lifting points positioned as far apart as possible – observe option
description.
• Avoid any jerky movements!
• Ensure that the load is distributed evenly! • Use chain hoists and
chain slings of the same length only!
• Stay outside the danger zone underneath the machine!
• Observe the regulations regarding occupational safety and accident
prevention for the respective country.
Craning principle
T he machine must not be operated in the open air and must only be set up and operated on a
suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient lighting
for the place of work.
• Safe operation of the machine must be guaranteed at all times.
5 Design and function
Read and observe the documentation to all system and accessory components!
5.1 Transport and installation
5.1.1 Lifting by crane
5.1.2 Ambient conditions
Design and function
Transport and installation
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Equipment damage due to contamination!
Unusually high amounts of dust, acids, corrosive gases or substances can damage the machine
(observe maintenance intervals > see 6.3 chapter).
• Avoid large amounts of smoke, steam, oily fumes, grinding dust and corrosive ambient air!
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!
CAUTION
Risk of burning due to incorrect welding current connection!
If the welding current plugs (machine connections) are not locked or if the workpiece
connection is contaminated (paint, corrosion), these connections and leads can heat up
and cause burns when touched!
• Check welding current connections on a daily basis and lock by turning to the right when
necessary.
• Clean workpiece connection thoroughly and secure properly. Do not use structural parts of
the workpiece as welding current return lead!
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch > see 5.1.5.1 chapter.
Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the
frost protection is adequate to prevent damage to the machine or the accessory components.
• The coolant must be checked for adequate frost protection with the TYP 1 frost protection
tester .
• Replace coolant as necessary if frost protection is inadequate!
Coolant mixtures!
Mixtures with other liquids or the use of unsuitable coolants result in material damage and ren-
ders the manufacturer's warranty void!
• Only use the coolant described in this manual (overview of coolants).
• Do not mix different coolants.
• When changing the coolant, the entire volume of liquid must be changed.
5.1.2.1 In operation Temperature range of the ambient air:
• -25 °C to +40 °C (-13 °F to 104 °F)
Relative humidity:
• up to 50 % at 40 °C (104 °F)
• up to 90 % at 20 °C (68 °F)
5.1.2.2 Transport and storage Storage in a closed room, temperature range of the ambient air:
• -30 °C to +70 °C (-22 °F to 158 °F)
Relative humidity
5.1.3 Machine cooling
• up to 90 % at 20 °C (68 °F)
5.1.4 Workpiece lead, general
5.1.5 Welding torch cooling system
Dispose of the coolant in accordance with local regulations and the material safety data sheets.
Design and function
Transport and installation
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Coolant
Temperature range
KF 23E (Standard)
-10 °C up to +40 °C (14 °F up to +104 °F)
KF 37E
-20 °C up to +30 °C (-4 °F up to +86 °F)
--------------------------------------------------------------------------------------------------------------------- ►
Power source
Hose package
Wire feeder
miniDrive
Welding torch
Max.
Compact
(25 m / 82 ft.)
(5 m / 16 ft.)
30 m
98 ft.
(20 m / 65 ft.)
(5 m / 16 ft.)
Decompact
(25 m / 82 ft.)
(5 m / 16 ft.)
(15 m / 49 ft.)
(10 m / 32 ft.)
(5 m / 16 ft.)
--------------------------------------------------------------------------------------------------------------------- ►
Power source
Hose package
Wire feeder
miniDrive
Welding torch
Max.
Compact
(25 m / 82 ft.)
(5 m / 16 ft.)
30 m
98 ft.
(30 m / 98 ft.)
(5 m / 16 ft.)
40 m
131 ft.
Decompact
(40 m / 131 ft.)
(5 m / 16 ft.)
45 m
147 ft.
(40 m / 131 ft.)
(25 m / 82 ft.)
(5 m / 16 ft.)
70 m
229 ft.
Item
Symbol
Description 0
1
Coolant tank cap
5.1.5.1 Approved coolants overview
5.1.5.2 Maximal hose package length
All information relates to the total hose package length of the complete welding system and presents
exemplary configurations (of components of the EWM product portfolio with standard lengths). A straight
kink-free installation is to be ensured, taking into account the max. delivery height.
Pump: Pmax = 3,5 bar (0.35 MPa)
Pump: Pmax = 4.5 bar (0.45 MPa)
5.1.5.3 Adding coolant
The unit is supplied ex works with a minimum level of coolant.
Figure 5-1
Design and function
Transport and installation
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Item
Symbol
Description 0
2
Coolant filter sieve
3
Coolant tank > see 5.1.5 chapter
4
"Min" mark
Minimum coolant level
If the cooling system is empty or only insufficiently filled with coolant, the coolant pump is automatically switched off after approx. one minute (protection against destruction). At the same time, the welding data display signals the lack of coolant or low coolant level.
• Reset the coolant error, fill coolant and repeat the operation.
The level of coolant must never fall below the “min” mark.
• Unscrew and remove the coolant tank sealing cover.
• Check filter sieve insert for dirt, clean if necessary and reinsert into position.
• Top up coolant to the filter sieve insert, close sealing cover again.
If there is less coolant in the coolant tank than the minimum required you may need to vent the
coolant circuit. In this case the welding machine will automatically shut down the coolant pump
and signal an error, > see 7.6 chapter.
5.1.6 Notes on the installation of welding current leads
• Incorrectly installed welding current leads can cause faults in the arc (flickering).
• Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for
as long and as close as possible in parallel.
• Lay the workpiece lead and hose package of power sources with HF igniter (TIG) for as long as
possible in parallel with a distance of 20 cm to avoid HF sparkover.
• Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences
• Always keep leads as short as possible! For optimum welding results max. 30 m (welding lead
+ intermediate hose package + torch lead).
Figure 5-2
Design and function
Transport and installation
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WARNING
Risk of injury due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage machines and
electronic devices and cause overheating of components, leading to fire.
• Check that all welding current connections are firmly secured and electrical connections are
in perfect condition.
• Set up, attach or suspend all conductive power source components such as casing, transport vehicles and crane frames so they are insulated.
• Do not place any other electronic devices such as drills or angle grinders on the power
source, transport vehicle or crane frames unless they are insulated.
• Always put welding torches and electrode holders on an insulated surface when they are
not in use.
Use an individual welding lead to the workpiece for each welding machine!
Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid
loops!
Always keep leads as short as possible!
Lay any excess cable lengths in meanders.
5.1.7 Stray welding currents
Figure 5-3
Figure 5-4
Design and function
Transport and installation
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DANGER
Hazards caused by improper mains connection!
An improper mains connection can cause injuries or damage property!
• The connection (mains plug or cable), the repair or voltage adjustment of the device must
be carried out by a qualified electrician in accordance with the respective local laws or national regulations!
• The mains voltage indicated on the rating plate must match the supply voltage.
• Only operate machine using a socket that has correctly fitted protective earth.
• Mains plug, socket and lead must be checked by a qualified electrician on a regular basis!
• When operating the generator, always ensure it is earthed as stipulated in the operating
instructions. The network created must be suitable for operating machines according to protection class I.
5.1.8 Mains connection
Figure 5-5
Design and function
Welding data display
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Item
Designation
Colour code
L1
Outer conductor 1
brown
L2
Outer conductor 2
black
L3
Outer conductor 3
grey
N
Neutral conductor
blue
PE
Protective conductor
green-yellow
left-hand display
Parameter
Before welding
(nominal values)
During welding
(actual values)
After welding
(hold values)
Welding current
Parameter times
Parameter currents
right-hand display
Material thickness
Welding voltage
JOB number
Program number
5.1.8.1 Mains configuration The machine may be connected to:
• a three-phase system with four conductors and an earthed neutral conductor
• a three-phase system with three conductors of which any one can be earthed,
e.g. the outer conductor
Legend
Figure 5-6
• Insert mains plug of the switched-off machine into the appropriate socket.
5.2 Welding data display
The following welding parameters can be displayed before (nominal values), during (actual values) or after welding (hold values):
When the settings are changed (e.g. welding current) after welding when the hold values are displayed,
the display will be switched to the relevant nominal values.
If the "Program number" signal light is on in addition to the "Material thickness" signal light, the user is in
program mode (programs 1-15, , > see 5.6 chapter).
If the "JOB-number" signal light is on in addition to the "Material thickness" light, the user is in a JOB in
the free memory (JOB 128 to 256, > see 5.5.2 chapter).
Design and function
TIG welding
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Display
Meaning of the symbols shown in the right-hand display
Increase parameter value To restore the factory settings.
Factory setting Parameter value is on the optimum setting
Reduce parameter value To restore the factory settings.
5.2.1 Welding parameter setting
During the welding parameter setting process, the parameter value being set is displayed on the left-hand
display. The right-hand display shows the “Factory setting” or a variation of it upwards or downwards.
Displays, e.g. when setting the ignition current, and their meanings:
5.2.2 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 the display use the parameter in the configuration menu <dg _ref_source_inline>Gerätekonfigurationsmenü</dg_ref_source_inline>.
> see 5.13 chapter
Design and function
TIG welding
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Equipment damage due to improperly connected coolant pipes!
If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant
circuit is interrupted and equipment damage can occur.
• Connect all coolant pipes correctly!
• Completely unroll the hose package and the torch hose package!
• Observe maximal hose package length > see 5.1.5.2 chapter.
• When using a gas-cooled welding torch, use a hose bridge to establish the coolant
cuit > see 9 chapter.
Item
Symbol
Description 0
1
Welding torch
2
Welding torch hose package
3
Connection socket, welding torch control cable > see 5.3.1.1 chapter
4
G¼” connecting nipple, “-” welding current
Shielding gas connection (with yellow insulating cap) for TIG welding torch
5.3 TIG welding
5.3.1 Welding torch and workpiece line connection
Prepare welding torch according to the welding task in hand (see operating instructions for the torch).
Figure 5-7
Design and function
TIG welding
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Item
Symbol
Description 0
5
Connection socket, “-” welding current
TIG welding torch connection
6
Quick connect coupling (red)
Coolant return from welding torch
7
Quick connect coupling (blue)
Coolant forward flow to the welding torch
8
Workpiece
9
Connection socket, “+” welding current
Connection for workpiece lead
TIG standard torch
TIG up/down or
potentiometer torch
TIG up/down torch with display
• Insert the welding current plug on the welding torch into the welding current connection socket and
lock by turning to the right.
• Screw welding torch shielding gas connection tightly onto the G¼" connection nipple, welding current
“-”.
• Plug the welding torch control cable plug into the welding torch control cable connection socket and
secure.
• Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings:
Return line red to quick connect coupling, red (coolant return) and
supply line blue to quick connect coupling, blue (coolant supply).
• Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by
turning to the right.
5.3.1.1 Connection assignment, welding torch control cable
TIG welding machines are equipped ex works with a dedicated connection socket for the welding torch
control cable (5- or 8-pole). As mobile machines offer more free space, they may even feature two control
cable connection sockets. The functionality increases with the number of poles. One of these connection
sockets may be converted or retrofitted > see 9 chapter.
Figure 5-8
Design and function
TIG welding
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WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders
can cause serious injuries!
• Place shielding gas cylinder into the designated holder and secure with
fastening elements (chain/belt)!
• Attach the fastening elements within the upper half of the shielding gas
cylinder!
• The fastening elements must tightly enclose the shielding gas cylinder!
An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results. In addition, a blocked shielding gas supply
may result in the welding torch being destroyed.
• Always re-fit the yellow protective cap when not using the shielding gas connection.
• All shielding gas connections must be gas tight.
Item
Symbol
Description 0
1
Pressure regulator
2
Shielding gas cylinder
3
Output side of the pressure regulator
4
Cylinder valve
5.3.2 Shielding gas supply (shielding gas cylinder for welding machine)
5.3.2.1 Connecting the shielding gas supply
Figure 5-9
• Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow
out any dirt.
• Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.
• Screw gas hose connection crown nut onto the output side of the pressure regulator.
• Install gas hose with G1/4" crown nut at the correct welding machine connection so that it is gas-
tight.
Design and function
TIG welding
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5.3.3 TIG Synergic operating principle
Figure 5-10
The machine is operated according to the TIG Synergic operating principle:
In a similar way to the MIG machines with Synergic operation, three basic parameters –
• Tungsten electrode diameter (A),
• Material type (B) and
• Seam type (C)
are used to select the welding task (JOB).
All welding parameters specified here are the optimum settings for a variety of applications, but they can
also be modified individually.
The required welding current can be set as the sheet metal thickness or conventionally as the welding
current (D).
The parameters and functions described here can also be programmed by PC using the
Tetrix PC300.NET welding parameter software.
The Tetrix machine range has been designed to be very easy and quick to operate, whilst still providing
all the functions one could ever need.
Design and function
TIG welding
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5.3.3.1 Synergic parameter setting in the functional sequence
When setting the welding current, all the necessary welding parameters are adjusted automatically during
the functional sequence > see 4.3.1 chapter with the exception of the gas pre-flow time. These welding
parameters can also be set in the conventional way if required (regardless of the welding
rent) > see 5.6.4 chapter.
Figure 5-11
5.3.3.2 Conventional parameter setting in the functional sequence
All welding parameters in the functional sequence can also be adjusted, regardless of the welding current
set. This means that if the welding current is changed, the values for the down slope time or gas post-flow
time remain unchanged, for example. The welding task still needs to be selected as before using the
three basic parameters of tungsten electrode diameter, material type and seam type.
Figure 5-12
The parameters for the ignition, secondary and end currents can be set and displayed as
percentage values or absolute values > see 5.13 chapter.
5.3.3.3 Set the operating principle (conventional/synergic) The settings are defined in the machine configuration menu > see 5.13 chapter.
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EXIT
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5.3.4 Welding task selection
The following welding task selection is an example of use. In general, the selection process always has
the same sequence. Signal lights (LED) will show the selected combination.
5.3.5 Gas test or "rinse hose package"
Rule of thumb for the gas flow rate:
Diameter of gas nozzle in mm corresponds to gas flow in l/min.
Example: 7mm gas nozzle corresponds to 7l/min gas flow.
If the shielding gas setting is 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!
• Slowly open the gas cylinder valve. Conduct a gas test > see 5.3.5.1 chapter
• Set the required amount of shielding gas on the pressure reducer, about 4 - 15 l/min depending on the
current strength and the material.
Figure 5-13
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20s
EXIT
EXIT
5.3.5.1 Gas test
Figure 5-14
• Set the required shielding gas quantity at the pressure regulator.
5.3.5.2 “Purge hose package” function
Figure 5-15
If the "Rinse hose package" function is not ended by pressing the "Gas and current parameters"
button again, shielding gas will flow until the gas cylinder is empty!
5.3.5.3 Automatic gas post-flow
If the function is active, the gas post-flow time is defined by the machine control unit in dependence on
power output. The defined gas post-flow time can also be adjusted if required. This value is then saved
for the current welding task. The automatic gas post-flow function can be activated or deactivated in the
machine configuration menu > see 5.13 chapter.
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EXIT
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Balling
EXIT
5.3.6 Optimising the ignition characteristics for pure tungsten electrodes
The best ignition and stabilisation of the arc (DC, AC) and optimum spherical cup formation in the tungsten electrode depend on the electrode diameter being used.
The set value should correspond to the diameter of the tungsten electrode. The value can of course be
adjusted in line with different requirements.
Figure 5-16
5.3.7 Tungsten balling function
Tungsten balling ensures optimum ignition and welding results for 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.
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.
Figure 5-17
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5.3.8 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.
5.3.9 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.
The AC amplitude balance can be set in the Expert menu (TIG) using parameter
> see 5.3.17 chapter.
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.
Figure 5-18
Figure 5-19
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5.3.10 Arc ignition
5.3.10.1 HF ignition
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 select-
ed.
End the welding process: Release or press the torch trigger depending on the operating mode
5.3.10.2 Liftarc
selected.
Figure 5-20
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 operat-
ing 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.
5.3.10.3 Automatic cut-out
Once the fault periods have elapsed, the automatic cut-out stops the welding process when it has been
triggered by one of two states:
• During ignition
3 s after the start of the welding process, no welding current flows (ignition error).
• During welding
The arc is interrupted for more than 3 s (arc interruption). You can disable or set the time for re-ignition
after an arc interruption in the machine configuration menu > see 5.13 chapter (parameter ).
Figure 5-21
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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
Down-slope time
End-crater current
Gas post-flow
Balance
Frequency
5.3.11 Operating modes (functional sequences)
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.
5.3.11.1 Explanation of symbols
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5.3.11.2 Non-latched mode Selection
Sequence
Figure 5-22
Figure 5-23
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 5.3.17 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 is connected, the machine switches automatically to non-latched
operation. The up- and down-slopes are switched off.
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5.3.11.3 Latched mode Selection
Sequence
Figure 5-24
Figure 5-25
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1st cycle
• Press torch trigger 1 , the gas pre-flow time elapses.
• HF start 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.
• Ignition current flows at least for the start time or as long as the torch trigger is held.
2nd cycle
• Release torch trigger 1.
• The welding current ramps up to the main current (AMP) in the selected upslope time .
Switching from the main current AMP to secondary current (AMP%):
• Press torch trigger 2 or
• Tap torch trigger 1 (torch modes 1–6).
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 .
Once 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 5.3.17 chapter.
3rd cycle
• Press torch trigger 1.
• The main current decreases to the end-crater current within the set down-slope time .
Once the main current phase AMP has been reached, you can shorten the welding sequence by tapping torch trigger 1 (third cycle will be omitted).
4th cycle
• Release torch trigger 1; arc is extinguished.
• Set gas post-flow time runs.
When the foot-operated remote control is connected, the machine switches automatically to non-latched
operation. The up- and down-slopes are switched off.
Alternative welding start (tapping start):
For the alternative welding start, the durations of the first and second cycle are defined by the set process
times only (tapping the torch trigger in the gas pre-low phase ).
To activate this function, set a two-digit torch mode (11-1x) at the machine control. This function can also
be deactivated completely when required (welding stop by tapping remains active). To do so, the parameter must be switched to in the machine configuration menu > see 5.13 chapter.
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Interval
Setting range
Up-/down-slope
Pulsing
AC
Display
Display
Long
0.01–20.0 s (10 ms)
Yes
Yes
Yes
Short
5–999 ms (1 ms)
No
No
No
EXIT
3s
5.3.11.4 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.
The spot welding operating modes (spotArc/Spotmatic) can be used with two different intervals, i.e. a
"long" or "short" interval, which are defined as follows:
When selecting the spotArc operating mode, the long interval is automatically preselected. When selecting the Spotmatic operating mode, the short interval is automatically preselected. The user can change
the interval in the Configuration menu > see 5.13 chapter.
Figure 5-26
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The up-slope and down-slope times should be set to “0” to achieve an effective result.
As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 5.3.10.2 chapter.
Sequence:
• Press and hold torch trigger 1.
• 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 set for the ignition current .
• HF is switched off.
• The welding current increases in the adjusted up-slope time to the main current .
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.
5.3.11.5 spotmatic
In contrast to the 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. Activation is indicated by flashing of the spotArc/spotmatic signal light. The process
can be activated separately for each spot or also on a permanent basis. The setting is controlled using
the process activation parameter in the configuration menu > see 5.13 chapter:
• Separate process activation ( > ):
The welding process has to be reactivated for every arc ignition by pressing the torch trigger. Process
activation is automatically terminated after 30 s of inactivity.
• Permanent process activation ( > ):
The welding process is activated by pressing the torch trigger once. The following arc ignitions are initiated by shortly touching the tungsten electrode against the workpiece. Process activation is terminated either by pressing the torch trigger again or automatically after 30 s of inactivity.
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 5.13 chapter
Figure 5-27
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Figure 5-28
As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 5.3.10.2 chapter.
Selecting the process activation type for the welding process > see 5.13 chapter.
Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) 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 spot time elapses.
For long-time spot welding only (parameter = ):
The welding current decreases to the end-crater current 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 against the
workpiece again will initiate the next welding processes.
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5.3.11.6 Non-latched operation, version C
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 stopped by interrupting the arc in the secondary current (remove the welding torch
from the workpiece until the arc is extinguished, no re-ignition).
The slope times and can be set in the Expert menu > see 5.3.17 chapter.
This operating mode must be enabled (parameter ) > see 5.13 chapter.
Figure 5-29
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Waveform
Description, areas of application
Name
Symbol
Square
Maximum energy input and safe welding (aluminium/magnesium alloys)
Trapezoidal
An all-rounder, suitable for most applications (aluminium/silicum alloys)
Sine
Low noise level (aluminium 99%)
5.3.12 Alternating current waveforms
Figure 5-30
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5.3.13 Pulse welding
The following pulse types can be selected:
• Automated pulsing (TIG DC)
• Thermal pulsing (TIG AC or TIG DC)
• Metallurgical pulsing (TIG DC)
• AC special (TIG AC)
5.3.13.1 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.
5.3.13.2 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 5-31
Figure 5-32
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The pulse function can also be deactivated if necessary during the up-slope and down-slope
phases (parameter ) > see 5.13 chapter.
Figure 5-33
Selection
Figure 5-34
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Pulse time setting
Figure 5-35
Pulse pause setting
Pulse edge setting
The and pulse edges can be set in the Expert menu (TIG) > see 5.3.17 chapter.
5.3.13.3 Metallurgical pulsing (kHz pulsing)
Metallurgical pulsing (kHz pulsing) uses the plasma force (arc force) occurring at high currents which allows you to achieve a constricted arc 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 5-36
Figure 5-37
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EXIT
4s
EXIT
4s
Selection
Figure 5-38
Balance setting
Figure 5-39
Frequency setting
Figure 5-40
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5.3.13.4 AC special
Is e.g. used to join metal sheets of different thickness.
Selection
Figure 5-41
5.3.14 TIG antistick
Figure 5-42
The and pulse edges can be set in the Expert menu (TIG) > see 5.3.17 chapter.
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 5.13 chapter.
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EXITENTER
4s
5.3.15 activArc
The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power supplied is kept virtually constant in the event of changes in the distance 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.
Figure 5-43
Parameter setting
The activArc parameter (control) can be adjusted specifically for the welding task (panel thickness) > see 5.3.17 chapter.
5.3.16 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.
5.3.16.1 Synchronisation via mains voltage (50Hz / 60Hz) This application relates to two types of synchronisation:
• Synchronisation between a Tetrix series machine and a competitor machine.
• Synchronisation between two Tetrix series machines.
Phase sequences and rotating fields of the supply voltages must be identical for both welding
machines.
If this is not the case, the energy input into the weld pool will be negatively affected.
Use the "Phase sequence changeover“ rotary switch to correct the phase difference in steps of
60° (0°, 60°, 120°, 180°, 240° and 300°).
An optimum phase correction will directly achieve better welding results.
Figure 5-44
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5.3.16.2 Synchronisation via cable (frequency 50Hz to 200Hz) This application describes synchronisation (master/slave operation) with two machines in the
Tetrix series. The following components are required:
• The synchronisation interface SYNINT X10
• Control lead (connecting cable) of the relevant length
• Both welding machines must be fitted with the 19-pole TIG interface for mechanised welding
(optional)
• Connect the SYNINT X10 synchronisation interface connector plug to the 19-pole TIG interface for
mechanised welding on the rear of a welding machine from the TETRIX series (master).
The machine connected to the synchronisation interface using the short connection cable is
designated the "master" welding machine. The TIG AC frequencies are set on this welding
machine and transferred to the second welding machine (slave).
• Connect the extension cable RA (5 m, 10 m or 20 m) between the interface and the 19-pole TIG inter-
face for mechanised welding on the second welding machine.
Figure 5-45
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ENTER
4s
EXIT
4s
Display
Setting/selection
Expert menu
Slope time (main current to secondary current)
Slope time (main current to secondary current)
Amplitude balance > see 5.3.9 chapter
activArc parameter
Parameter also adjustable after TIG activArc welding is activated.
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)
5.3.17 Expert menu (TIG)
The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa-
rameters shown may be limited, e.g. if a function is deactivated.
Figure 5-46
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Display
Setting/selection
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 pre-
programmed 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.
Wire return
• Increase value = more wire return
• Decrease value = less wire return
CAUTION
Risk of crushing and burns!
When changing stick electrodes there is a risk of crushing and burns!
• Wear appropriate and dry protective gloves.
• Use an insulated pair of tongs to remove the used stick electrode or to move welded work-
pieces.
Electrical voltage at the shielding gas connection!
During MMA welding open circuit voltage is applied at the shielding gas connection
(G¼" connecting nipple).
• Place yellow insulating cap on the G¼" connection nipple (protects against electrical voltage and dirt).
5.4 MMA welding
5.4.1 Connecting the electrode holder and workpiece lead
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Item
Symbol
Description 0
1
Workpiece
2
Connection socket, “+” welding current
Connection for workpiece lead
3
Electrode holder
4
Connection socket, “-” welding current
Electrode holder connection
5
G¼" connecting nipple
Shielding gas connection (with yellow insulating cap) for TIG welding torch
Figure 5-47
Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.
• Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and
lock by turning to the right.
• Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and
lock by turning to the right.
• Fit yellow protective cap onto G¼" connecting nipple.
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EXIT
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Display
Setting/selection
Negative welding current polarity during the ignition phase
Positive welding current polarity during the ignition phase
MMA AC welding
5.4.2 Welding task selection
The following welding task selection is an example of use. In general, the selection process always has
the same sequence. Signal lights (LED) will show the selected combination.
Figure 5-48
5.4.3 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.
5.4.3.1 Selection and adjustment
Figure 5-49
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A = Hot start current
B = Hot start time
C = Main current
I = Current
t = Time
5.4.4 Frequency and balance setting
Balance setting
Frequency setting
Figure 5-50
5.4.5 Hotstart
The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent
metal at the beginning of the welding process. The ignition takes place here with increased current (hot
start current) over a certain time (hot start time).
Figure 5-51
Figure 5-52
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EXIT
4s
EXIT
4s
5.4.5.1 Hotstart current
5.4.5.2 Hotstart time
Figure 5-53
Figure 5-54
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The Antistick feature prevents the electrode from annealing.
Should the electrode stick despite the Arcforce feature, the machine
automatically switches to the minimum current within approx. one second. This prevents the electrode from annealing. Check the welding
current setting and correct for the welding task in hand.
5.4.6 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.
5.4.7 Antistick
Figure 5-55
Figure 5-56
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AMP = main current
AMP% = pulse current
AMP% = pulse pause current
= frequency
= duty cycle
5.4.8 Average value pulsing in the vertical-up position (PF)
Welding characteristics:
• Especially suitable for root welding
• Fine-flaked weld surface with a TIG look for final passes
• Less finishing work thanks to less spatter
• Highly suitable for difficult electrodes
• Outstanding gap bridging with no sagging of the root side
• Less distortion thanks to controlled heat input
Figure 5-57
Selection
Pulse current setting
Figure 5-58
Figure 5-59
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Pulse pause current setting
Figure 5-60
Balance setting
Figure 5-61
Frequency setting
Figure 5-62
The default pulse parameters are pre-set in such a way that the welding current average value
corresponds to the pre-selected main current AMP.
Changes in the pulse parameters result in changes to welding current average value AMP.
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Display
Meaning
Load JOB
Copy JOB
Reset JOB
Reset all JOBs
5.5 Organising welding tasks (Mode "JOB Manager")
After carrying out any of the actions described, the machine switches back to the default
parameters such as current and voltage.
To ensure that all the changes are active, the welding machine should only be switched off after 5
seconds have elapsed.
The JOB Manager can be used to load, copy or save JOBs.
A JOB is a welding task defined using the 4 main welding parameters
• welding process,
• material type,
• electrode diameter and
• seam type.
One program sequence can be defined in each JOB.
Up to 16 programs (P0 to P15) can be set in each program sequence.
The user has a total of 249 JOBs available. 121 of these JOBs are pre-programmed. A further 128 JOBs
can be freely defined.
A distinction is made between two memory sectors:
• 121 factory-set, pre-programmed, permanent JOBs. Permanent JOBs are not loaded but are defined
by the welding task (each welding task is permanently assigned a JOB number).
• 128 freely definable JOBs (JOBs 129 to 256)
5.5.1 Explanation of symbols
Design and function
Organising welding tasks (Mode "JOB Manager")
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EXIT
5.5.2 Creating a new JOB in the memory or copying a JOB
Copying a pre-defined welding task from the fixed memory (JOBs 1 to 128) to the free memory
(JOBs 129-256):
It is normally possible to adjust all 256 JOBs individually. However, it is a good idea to assign
specific JOB numbers in the free memory (JOB 128 to 256) for specific welding tasks.
Figure 5-63
Design and function
Organising welding tasks (Mode "JOB Manager")
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EXIT
5.5.3 Loading an existing JOB from the free memory
Figure 5-64
5.5.4 Resetting an existing JOB to the factory setting (Reset JOB)
Figure 5-65
Design and function
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EXIT
5.5.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs)
5.5.6 Exit JOB Manager without changes
Figure 5-66
Figure 5-67
Design and function
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Program number
Welding current
Operating mode
Pulse function
1
80A
Non-latched
Pulses on
2
70A
Latched
Pulses off
5.6 Welding programs
Changes made to the other welding parameters during the course of the program have the
equivalent effect on all programs.
The change to the welding parameters is saved immediately in the JOB.
The welding machine has 16 programs, which you can change during welding.
In each selected welding task (JOB), > see 5.3.4 chapter, 16 programs can be set, saved and called up.
In program “0” (default setting) the welding current can be infinitely adjusted across the entire range. In
programs 1-15, 15 different welding currents (incl. operating mode and pulse function) are defined.
Example:
The operating mode cannot be changed during the welding process. If welding is started with program 1
(non-latched operating mode), program 2 controls the setting of ignition program 1 despite the latched
setting and is implemented to the end of the welding process.
The pulse function (pulses off, pulses on) and the welding currents are transferred from the correspond-
5.6.1 Selection and adjustment
ing programs.
Figure 5-68
When connecting a potentiometer torch or up/down torch or operating a standard torch in
up/down mode, the program changeover to the welding machine control is blocked!
Design and function
Remote control
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Programs
Component
create and change
call up
Welding machine control
16
16
PC with PC 300 welding parameter software
16
16
Tetrix RINT X11, -X12 robot interface
-
16
BUSINT X11 industrial bus interface
-
16
Functions
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
5.6.2 Specifying max. no. of accessible programs
This function can be used to specify the maximum number of programs which can be called up
(only applies to the welding torch). According to the factory setting, all 16 programs can be called
up. If necessary these can be limited to a specific number.
To limit the number of programs, the welding current needs to be set to 0A for the next, unused
program. For example, if only programs 0 to 3 are being used, the welding current is set to 0A in
program 4. A maximum of programs 0 to 3 can then be called up on the welding torch.
5.6.3 Example "Program with synergetic setting"
Figure 5-69
5.6.4 Example "Program with conventional setting"
5.6.5 Accessories for switching over programs
Figure 5-70
The user can change, retrieve and save programs using the following components.
5.7 Remote control
5.7.1 RT1 19POL
The remote controls are operated on the 19-pole remote control connection socket (analogue).
Design and function
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Functions
• Infinite setting of the welding current (0% to 100%) depending on the main current
preselected at the welding machine
Functions
• TIG/MMA
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Pulse/spot/normal
• Pulse, spot and break times are infinitely adjustable.
Functions
• TIG/MMA.
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Pulse/spot/normal
• Frequency and spot times infinitely adjustable.
• Coarse adjustment of the cycle frequency.
• Pulse/pause ratio (balance) adjustable from 10% to 90%.
Functions
• TIG / MMA.
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Pulse / SpotArc spots / normal
• Frequency and spot time infinitely adjustable.
• Coarse adjustment of the pulse frequency.
• Pulse/pause ratio (balance) adjustable from 10% to 90%.
Functions
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• AC frequency of welding current infinitely adjustable.
• AC balance (positive/negative half-wave ratio) can be set from +15% to -15%.
Functions
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current at the welding machine
• Pole reversing switch, suitable for machines with PWS function
Functions
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Start/stop welding operation (TIG)
5.7.2 RTG1 19POL
5.7.3 RTP1 19POL
5.7.4 RTP2 19POL
5.7.5 RTP3 spotArc 19POL
5.7.6 RTAC1 19POL
5.7.7 RT PWS1 19POL
5.7.8 RTF1 19POL
ActivArc welding is not possible in combination with the foot-operated remote control.
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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)
Display
Setting/selection
RTF start ramp > see 5.7.8.1 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
Gas pre-flow time
Ignition current (as percentage, dependent on main current)
End-crater current
Setting range in percent: depending on main current
Setting range, absolute: Imin to Imax.
Gas post-flow time
5.7.8.1 RTF start ramp
The RTF start ramp function prevents the energy input at the start of welding from being too high and too
fast should the user press the remote control pedal too fast and too strongly.
Example:
The user sets the main current at the welding machine to 200 A. The user presses the remote control pedal very quickly down by approx. 50% of the pedal travel.
• RTF switched on: The welding current increases in a linear (slow )ramp to approx. 100 A.
• RTF switched off: The welding current immediately jumps to approx. 100 A.
The RTF start ramp function is activated/deactivated by the parameter in the machine configuration
menu > see 5.13 chapter.
Figure 5-71
Design and function
Welding torch (operating variants)
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Symbol
Description
Press torch trigger
Tap torch trigger
Tap and press torch trigger
5.7.8.2 RTF response
This function controls the current response during the main current phase. The user can choose between
linear and logarithmic response. The logarithmic setting is especially suited for welding with low currents,
e.g. for thin panels, as the logarithmic response enables a better control of the welding current.
In the machine configuration menu, the RTF response function can be toggled between linear
response and logarithmic response (ex works) > see 5.13 chapter.
Figure 5-72
5.8 Welding torch (operating variants)
Different torch versions can be used with this machine.
Functions on the operating elements, such as torch triggers (BRT), rockers or potentiometers, can be
modified individually via torch modes.
5.8.1 Tapping function (tap torch trigger)
5.8.2 Torch mode setting
Explanation of symbols for operating elements:
Tapping function: Swiftly tap the torch trigger to change the function. The set torch mode determines the
operating mode.
Modes 1 to 6 and 11 to 16 are available to the user. Modes 11 to 16 feature the same functionality as 1 to
6, but without the tapping function > see 5.13 chapter for the secondary current.
The functionality 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 5.8.1 chapter.
Only the modes listed are suitable for the corresponding torch types.
Design and function
Welding torch (operating variants)
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Figure
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
(ex works)
Secondary current (latched operation)
5.8.3 Up/down speed
Functionality
Press and hold the up push-button:
Increase current up to the maximum value (main current) set in the power source.
Press and hold the down push-button:
Decrease current to the minimum value.
Use the machine configuration menu > see 5.13 chapter to set the up/down speed parameter which
determines the speed with which a current change becomes effective.
5.8.4 Current jump
By tapping the corresponding torch trigger the welding current can be determined in an adjustable jump
range. Each tap will cause the welding current to jump up or down by the defined value.
The “current jump” parameter is set in the machine configuration menu > see 5.13 chapter.
5.8.5 Standard TIG torch (5-pole)
Standard torch with one torch trigger
Design and function
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Figure
Operating elements
Explanation of symbols
BRT1 = torch trigger 1
BRT2 = torch trigger 2
Functions
Mode
Operating elements
Welding current on/off
1
(ex works)
Secondary current
Secondary current (tapping function)1)/(latched operating mode)
Welding current on/off
3
Secondary current (tapping function)1)/(latched operating mode)
Up function2
Down function2
Standard torch with two torch triggers
1
> see 5.8.1 chapter
2
> see 5.8.3 chapter
Design and function
Welding torch (operating variants)
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Figure
Operating elements
Explanation of symbols
BRT 1 = torch trigger 1
BRT 2 = torch trigger 2
Functions
Mode
Operating elements
Welding current on/off
1
(ex works)
Secondary current
Secondary current (tapping function)1)/(latched operating mode)
Welding current on/off
2
Secondary current (tapping function1)
Up function2
Down function2
Welding current on/off
3
Secondary current (tapping function)1)/(latched operating mode)
Up function2
Down function2
Standard torch with one rocker (rocker, two torch triggers)
1
> see 5.8.1 chapter
2
> see 5.8.3 chapter
Design and function
Welding torch (operating variants)
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Image
Operating elements
Explanation of symbols
BRT 1 = torch trigger 1
Functions
Mode
Operating elements
Welding current on/off
1
(ex works)
Secondary current (tapping function)1)/(latched operating mode)
Increase welding current (up function2)
Decrease welding current (down function2)
Welding current on/off
2
Secondary current
Secondary current (tapping function1)
Program selection upwards
Program selection downwards
Welding current on/off
4
Secondary current (tapping function)1)/(latched operating mode)
Increase welding current via current jump3
Decrease welding current via current jump3
5.8.6 TIG up/down torch (8-pole)
Up/down torch with one torch trigger
1
> see 5.8.1 chapter
2
> see 5.8.3 chapter
3
> see 5.8.4 chapter
Design and function
Welding torch (operating variants)
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Figure
Operating elements
Explanation of symbols
BRT 1 = torch trigger 1 (left)
BRT 2 = torch trigger 2 (right)
Functions
Mode
Operating elements
Welding current on/off
1
(ex works)
Secondary current
Secondary current (tapping function)1/(latched operation)
Increase welding current (up function2)
Decrease welding current (down function2)
Welding current on/off
2
Secondary current
Secondary current (tapping function1)
Program selection upwards
Program selection downwards
Welding current on/off
4
Secondary current
Secondary current (tapping function1)
Increase welding current via current jump3
Decrease welding current via current jump3
Gas test
4
> 3 s
Up/down torch with two torch triggers
1
> see 5.8.1 chapter
2
> see 5.8.3 chapter
3
> see 5.8.4 chapter
Design and function
Welding torch (operating variants)
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85
Figure
Operating elements
Explanation of symbols
BRT 1 = torch trigger 1
Functions
Mode
Operating elements
Welding current on/off
3
Secondary current (tapping function1)
Increase welding current
Decrease welding current
Figure
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 function1)
Increase welding current
Decrease welding current
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!
5.8.7 Potentiometer torch (8-pole)
The welding machine needs to be configured for operation with a potentiometer
torch > see 5.8.7.1 chapter.
Potentiometer torch with one torch trigger
Potentiometer torch with two torch triggers
1
5.8.7.1 Configuring the TIG potentiometer torch connection
> see 5.8.1 chapter
Design and function
Welding torch (operating variants)
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WARNING
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Dangers resulting from failure to perform test after conversion!
Before reconnection, “Inspection and Testing during Operation” according to
IEC/BS EN 60974-4 “Arc welding systems – Inspection and Testing during Operation”
has to be performed!
• Perform test to IEC / DIN EN 60974-4!
Welding torch configuration
Setting
Prepared for TIG standard or up/down torch (factory setting)
JP27
Prepared for potentiometer torches
JP27
Diagram
Operating elements
Explanation of symbols
TT= torch trigger
When connecting a potentiometer torch, jumper JP27 on PCB T320/1 inside the welding machine
should be unplugged.
This torch type requires the welding machine to be set to torch mode 3 > see 5.8.2 chapter.
5.8.8 RETOX TIG torch (12-pole)
For operation with this welding torch, the welding machine must be equipped with the retrofit
option "ON 12POL RETOX TIG" (12-pole torch connection socket)!
Figure 5-73
Design and function
Welding torch (operating variants)
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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
5
TT 1
Secondary current
TT 2
Secondary current (tapping function)
TT 1 (tapping)
Increase program number
TT 3
Decrease program number
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)
Design and function
Interfaces for automation
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Display
Setting/selection
Start JOB
Set first JOB to get (setting: 129 to 256, factory setting 129).
Get JOB number
Set maximum selectable jobs (setting: 1 to 128, factory setting 10).
Additional parameter after activating the BLOCK JOB function.
WARNING
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Damage to the machine due to improper connection!
Unsuitable control leads or incorrect connection of input and output signals can cause damage
to the machine.
• Only use shielded control leads!
• If the machine is to be operated with control voltages connection via suitable isolation amplifi-
ers is required!
• To control the main or secondary current via control voltages, the relevant inputs must be
enabled (see specification for activation of control voltage).
WARNING
No function of the external interrupt equipment (emergency stop switch)!
If the emergency stop circuit has been set up using an external interrupt equipment
connected to the interface for automated welding, the machine must be configured for
this setup. If this is not observed, the power source will ignore the external interrupt
equipment and will not shut down!
• Remove jumper 1 on the corresponding control board (to be done only by qualified service
personnel)!
5.8.8.1 Specifying max. no. of accessible JOBs
This function can be used to specify the maximum number of JOBs which can be retrieved from the free
memory. The factory setting is for 10 JOBs to be accessible on the welding machine, but this figure can
be increased to up to 128 if required.
The first JOB in the free memory is JOB 129. With the factory setting of 10 JOBs, this equates to JOB
numbers 129 to 138. The first JOB can be set as required.
The following graphic gives an example with the settings for max. JOBs available = 5 and first available
JOB = 145. This gives the available JOBs 145 to 150.
Figure 5-74
The settings are defined in the machine configuration menu > see 5.13 chapter.
The setting of the max. number of JOBs is intended solely for torch modes 4, 5 and 6 or 14, 15 and
5.9 Interfaces for automation
5.9.1 Automation interface
16 (no tapping function).
Design and function
Interfaces for automation
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Pin
Signal
shape
Designation
Diagram
A
Output
PE Connection for cable screen
B
Output
REGaus For servicing purposes only
C
Input
SYN_E Synchronisation for master/slave operation
D
Input
(no c.)
IGRO Current flows signal I>0 (maximum load 20mA
/ 15V)
0V = welding current flowing
E
+
R
Input
Output
Not/Aus Emergency stop for higher level shut-down of
the power source.
To use this function, jumper 1 must be unplugged on
PCB T320/1 in the welding machine. Contact open
welding current off
F
Output
0V Reference potential
G
-
NC Not assigned
H
Output
Uist Actual welding voltage, measured on pin F, 010V (0V = 0V, 10V = 100V)
J
Vschweiss Reserved for special purposes
K
Input
SYN_A Synchronisation for master/slave operation
L
Input
Str/Stp Start / stop welding current, same as torch
trigger.
Only available in non-latched operating mode. +15V =
start, 0V stop
M
Output
+15V Voltage supply
+15V, max. 75mA
N
Output
-15V Voltage supply
-15V, max. 25mA
P
-
NC Not assigned
S
Output
0V Reference potential
T
Output
Iist Actual welding current, measured on pin F;
0-10V (0V = 0A, 10V = 1000A)
U
NC
V
Output
SYN_A 0V Synchronisation for master/slave
operation
These accessory components can be retrofitted as an option > see 9 chapter.
Design and function
Interfaces for automation
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Pos.
Pin
Signal shape
Designation
1 A Output
Connection for cable screen (PE)
2
B/L
Output
Current flows signal I>0, galvanically isolated (max. +- 15V/100mA)
3 F Output
Reference voltage for potentiometer 10V (max. 10mA)
4 C Input
Control value specification for main current, 0-10V (0V = I
min
, 10V =
I
max
)
5 D Input
Control value specification for secondary current, 0-10V (0V = I
min
, 10V
= I
max
)
6
J/U
Output
Reference 0V
7 K Output
Power supply +15V, max. 75mA
8 V Output
Power supply -15V, max. 25mA
9 R Input
Start/Stop welding current
10 H Input
Switching between main and secondary welding currents (pulses)
11
M/N/P
Input
Activation of control voltage specification
Set all 3 signals to reference potential 0V to activate external control
voltage specification for main and secondary currents
12 G Output
Measured value I
SETPOINT
(1V = 100A)
5.9.2 Remote control connection socket, 19-pole
Figure 5-75
5.9.3 RINT X12 robot interface
The standard digital interface for mechanised applications
(optional, retrofitting on the machine or external fitting by the customer)
Functions and signals:
• Digital inputs: start/stop, operating modes, JOB and program selection, inching, gas test
• Analogue inputs: control voltages, e.g. for welding performance, welding current, etc.
• Relay outputs: process signal, ready for welding, system composite fault, etc.
5.9.4 BUSINT X11 Industrial bus interface
The solution for easy integration with automated production with e.g.
• Profinet/Profibus
• EnthernetIP/DeviceNet
• EtherCAT
etc.
Design and function
PC interface
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Item
Symbol
Description 0
1
PC interface, serial (D-Sub connection socket, 9-pole)
2
Connection cable, 9-pole, serial
3
SECINT X10 USB
4
USB connection
5
Windows PC
Equipment damage or faults may occur if the PC is connected incorrectly!
Not using the SECINT X10USB interface results in equipment damage or faults in signal trans-
mission. The PC may be destroyed due to high frequency ignition pulses.
• Interface SECINT X10USB must be connected between the PC and the welding machine!
• The connection must only be made using the cables supplied (do not use any additional ex-
tension cables)!
When power-saving mode is activated, the machine displays show the horizontal digit in the
centre of the display only.
Key position 1 =
All parameters can be set
Key position 0 =
Only the following operating elements are functional:
• “Operating mode” button
• “Welding parameter setting” rotary transducer
• “Display switching” button
• “TIG pulse welding” button
• “Select welding parameters” button
• “Gas test” button
5.10 PC interface
PC 300 welding parameter software
Set all welding parameters on the PC and simply transfer to one or more welding machines (accessory,
set consisting of software, interface, connection leads)
• Manage up to 510 JOBs
• Exchange JOBs with the welding machine
• Online data communication
• Default settings for welding data monitoring
• Always up-to-date thanks to standard update function for new welding parameters
• Data backup by easy communication between power source and PC
Figure 5-76
5.11 Power-saving mode (Standby)
You can activate the power-saving mode by either pressing the push-button > see 4.3 chapter for a pro-
longed time or by setting a parameter in the machine configuration menu (time-controlled power-saving
mode ) > see 5.13 chapter.
Pressing any operating element (e.g. turning a rotary knob) deactivates power-saving mode and the machine is ready for welding again.
5.12 Access control
These accessory components can be retrofitted as an option > see 9 chapter.
To protect against unauthorised or unintentional adjustment of the welding parameters on the machine,
the control input can be locked with the aid of a key switch.
Design and function
Machine configuration menu
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ENTER
+
l
0
A
B
A
A
A
A
EXIT NAVIGATION
A
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
A
B B
B
B
B
B
B
B B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
Display
Setting/selection
Exit the menu
Exit
5.13 Machine configuration menu
Basic machine settings are defined in the machine configuration menu.
5.13.1 Selecting, changing and saving parameters
Figure 5-77
Design and function
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Display
Setting/selection
Torch configuration menu
Set welding torch functions
Torch mode (ex works 1) > see 5.8.2 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 > see 5.8.3 chapter
Increase value > rapid current change
Decrease value > slow current change
Current jump > see 5.8.4 chapter
Current jump setting in ampere
Get JOB number
Set maximum selectable jobs (setting: 1 to 128, factory setting 10).
Additional parameter after activating the BLOCK JOB function.
Start JOB
Set first JOB to get (setting: 129 to 256, factory setting 129).
Machine configuration
Settings for machine functions and parameter display
Operating principle
------ synergic parameter setting (factory setting)
------ conventional parameter setting
Absolute value setting (ignition, secondary, end and hot start current) > see 5.2.2 chapter
------- Welding current setting, absolute
------- Welding current setting, as a percentage of the main current (ex works)
Non-latched operation (version C) > see 5.3.11.6 chapter
------- Function enabled
------- Function disabled (ex works)
Setting for the primary setpoint value display
Defines the priority display for setpoint values:
------panel thickness
------welding voltage (factory setting)
RINT X12, JOB control for automation solutions
------ on
------ off (factory setting)
Current display switching (MMA)
------- Actual value display
------- Nominal value display (ex works)
Pulsed welding in the upslope and downslope phases > see 5.3.13 chapter
------- Function enabled (ex works)
------- Function disabled
Filler wire welding, operating mode 2
------- 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 5.3.14 chapter
------- function active (factory setting).
------- function inactive.
Design and function
Machine configuration menu
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Display
Setting/selection
Program 0 block
With machines with access block, program 0 can be disabled. When the access block
has been enabled, programs 1–x only can be switched.
------- All programs can be selected (ex works)
------- Programs 1–x can be selected (program 0 disabled)
Show warnings > see 7.2 chapter
------- Function disabled (ex works)
------- Function enabled
Machine configuration (second part)
Settings for machine functions and parameter display
RTF start ramp > see 5.7.8.1 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
RTF response<dg_ref_source_inline>Ansprechverhalten Fußfernsteller</dg_ref_source_inline>
------- Linear response
------- Logarithmic responsive (ex works)
Tungsten balling with RT AC remote control 1
------- 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 1
------- polarity switching at the RT PWS 1 19POL remote control (ex works)
------- polarity switching at the welding machine control
spotmatic operating mode > see 5.3.11.5 chapter
Ignition by contact with the workpiece
------- Function enabled (ex works)
------- Function disabled
Spot time setting <dg_ref_source_inline>spotmatic</dg_ref_source_inline>
------- 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 5.3.11.5 chapter
------- Separate process activation (ex works)
------- Permanent process activation
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-based power-saving mode > see 5.11 chapter
Time to activation of the power-saving mode in case of inactivity.
Setting = disabled or numerical value 5– 60 min. (ex works: 20).
Operating mode switching via interface for automated welding
------ Non-latched
------- Special non-latched
Re-ignition after arc interruption > see 5.3.10.3 chapter
------- Function disabled or numerical value 0.1 s–5.0 s (ex works: 3 s).
Design and function
Machine configuration menu
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Display
Setting/selection
Expert menu
AC average value controller 1
------- Function enabled (ex works)
------- Function disabled
Welding current polarity switch (dc+) with TIG DC 1
------- Polarity switch released
------- Polarity switch blocked;
protects the tungsten electrode from being permanently damaged (ex works).
Reconditioning pulse (tungsten ball stability) 1
Cleaning effect of the tungsten ball at the end of welding.
------- Function enabled (ex works)
------- Function disabled
Automatic gas post-flow > see 5.3.5.3 chapter
------- function on (factory setting)
------- function off
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).
Automation menu 3
Fast take-over of control voltage (automation) 3
------- Function enabled
------- Function disabled (ex works)
Orbital welding 3
------- Function disabled (ex works)
------- Function enabled
Orbital welding 3
Correction value for orbital current
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 ( ).
Design and function
Machine configuration menu
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Display
Setting/selection
Automated/Manual (rC on/off) operating mode 3
Select machine/function control
------with external control voltages/signals
------with machine control
Software version query (example)
07.= ------ system bus ID
03c0= --- version number
System bus ID and version number are separated by a dot.
Cable resistance alignment > see 5.13.2 chapter
Only qualified service personnel may change the parameters!
TIG HF start (soft/hard) switching
------- soft ignition (factory setting).
------- hard ignition.
Ignition pulse limit
Setting 0 ms–15 ms (increments of 1 ms)
PCB state – qualified service personnel only!
1
for AC welding machines only.
2
For machines with filler wire (AW) only.
3
for components for automated welding (RC) only.
Design and function
Machine configuration menu
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1
2
3
4
l0l
0
+
+
Tetrix
Classic
Tetrix
Smart
Comfort
Synergic
B
A
+
Tetrix
Comfort 2.0
Smart 2.0
RT50 7POL
5.13.2 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.
Figure 5-78
Design and function
Machine configuration menu
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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
• Press the or (Tetrix Classic) push-button while simultaneously switching on the welding machi-
ne.
• Release push-button.
• The required parameter can now be selected using the rotary knob.
3 Adjustment/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
Maintenance, care and disposal
General
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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
Incorrect maintenance, testing and repair!
Maintenance, testing and repair of the machine may only be carried out by skilled and
qualified personnel. A qualified person is one who, because of his or her training, knowledge and experience, is able to recognise the dangers that can occur while testing
welding power sources as well as possible subsequent damage, and who is able to implement the required safety procedures.
Observe the maintenance instructions > see 6.3 chapter.
• In the event that the provisions of one of the below-stated tests are not met, the machine
must not be operated again until it has been repaired and a new test has been carried out!
6 Maintenance, care and disposal
6.1 General
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service matters, always consult the dealer who supplied the
machine. Return deliveries of defective equipment subject to warranty may only be made through your
dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the
machine type, serial number and item number of the machine, as well as the type designation and item
number of the spare part.
Under the specified ambient conditions and normal working conditions this machine is essentially maintenance-free and requires just a minimum of care.
Contamination of the machine may impair service life and duty cycle. The cleaning intervals depend on
the ambient conditions and the resulting contamination of the machine. The minimum interval is every six
months.
6.2 Cleaning
• Clean the outer surfaces with a moist cloth (no aggressive cleaning agents).
• Purge the machine venting channel and cooling fins (if present) with oil- and water-free compressed
air. Compressed air may overspeed and destroy the machine fans. Never direct the compressed air
directly at the machine fans. Mechanically block the fans, if required.
6.2.1 Dirt filter
• Check the coolant for contaminants and replace, if necessary.
The duty cycle of the welding machine decreases as an effect of the reduced cooling air volume. The dirt
filter must be remove at regular intervals and cleaned by blowing out with compressed air (depending on
the level of soiling).
Maintenance, care and disposal
Maintenance work, intervals
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6.3 Maintenance work, intervals
6.3.1 Daily maintenance tasks
Visual inspection
• Mains supply lead and its strain relief
• Gas cylinder securing elements
• Check hose package and power connections for exterior damage and replace or have repaired by
specialist staff as necessary!
• Gas tubes and their switching equipment (solenoid valve)
• Check that all connections and wearing parts are hand-tight and tighten if necessary.
• Check correct mounting of the wire spool.
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
6.3.2 Monthly maintenance tasks
6.3.3 Annual test (inspection and testing during operation)
• Other, general condition
Functional test
• Operating, message, safety and adjustment devices (Functional test)
• Welding current cables (check that they are fitted correctly and secured)
• Gas tubes and their switching equipment (solenoid valve)
• Gas cylinder securing elements
• Check correct mounting of the wire spool.
• Check that all screw and plug connections and replaceable parts are secured correctly, tighten if ne-
cessary.
• Remove any spatter.
• Clean the wire feed rollers on a regular basis (depending on the degree of soiling).
Visual inspection
• Casing damage (front, rear and side walls)
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
• Check coolant tubes and their connections for impurities
Functional test
• Selector switches, command devices, emergency stop devices, voltage reducing devices, message
and control lamps
• Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
• Check coolant tubes and their connections for impurities
• Check and clean the welding torch. Deposits in the torch can cause short circuits and have a negative
impact on the welding result, ultimately causing damage to the torch.
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition
to the regulations on testing given here, the relevant local laws and regulations must also be observed.
For more information refer to the "Warranty registration" brochure supplied and our information regarding
warranty, maintenance and testing at www.ewm-group.com!
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