Page 1
Operating instructions
EN
Wire feed unit
Tetrix drive 4L
099-000094-EW501
Observe additional system documents!
18.07.2017
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Page 2
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the location where the machine is operated.
• Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
• Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on +49 2680 181-0.
A list of authorised sales partners can be found at www.ewm-group.com.
General instructions
Liability relating to the operation of this equipment is restricted solely to the function of the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of
liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Straße 8
56271 Mündersbach
Germany
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.
Page 3
Contents
Notes on the use of these operating instructions
099-000094-EW501
18.07.2017
3
1 Contents
1 Contents .................................................................................................................................................. 3
2 For your safety ....................................................................................................................................... 5
2.1 Notes on the use of these operating instructions .......................................................................... 5
2.2 Explanation of icons ....................................................................................................................... 6
2.3 Part of the complete documentation .............................................................................................. 7
3 Intended use ........................................................................................................................................... 8
3.1 Applications .................................................................................................................................... 8
3.1.1 Use and operation solely with the following machines ................................................... 8
3.2 Documents which also apply ......................................................................................................... 8
3.2.1 Warranty ......................................................................................................................... 8
3.2.2 Declaration of Conformity ............................................................................................... 8
3.2.3 Service documents (spare parts and circuit diagrams) .................................................. 8
3.2.4 Calibration/Validation...................................................................................................... 8
4 Machine description – quick overview ................................................................................................ 9
4.1 Front view ...................................................................................................................................... 9
4.2 Rear view ..................................................................................................................................... 10
4.3 Inside view ................................................................................................................................... 11
4.4 Machine control – Operating elements ........................................................................................ 12
5 Design and function ............................................................................................................................. 13
5.1 Ambient conditions ....................................................................................................................... 13
5.1.1 In operation ................................................................................................................... 13
5.1.2 Transport and storage .................................................................................................. 13
5.2 Transport and installation ............................................................................................................ 13
5.2.1 Connection plan ............................................................................................................ 14
5.2.2 Welding torch cooling system ....................................................................................... 16
5.2.3 Notes on the installation of welding current leads ........................................................ 17
5.2.4 Intermediate hose package connection ........................................................................ 19
5.2.5 Welding torch connection ............................................................................................. 20
5.3 Wire feed ...................................................................................................................................... 22
5.3.1 Open the protective flap of the wire feeder .................................................................. 22
5.4 Remote control ............................................................................................................................. 24
6 Maintenance, care and disposal ......................................................................................................... 26
6.1 General ........................................................................................................................................ 26
6.2 Cleaning ....................................................................................................................................... 26
6.2.1 Dirt filter ........................................................................................................................ 26
6.3 Maintenance work, intervals ........................................................................................................ 27
6.3.1 Daily maintenance tasks............................................................................................... 27
6.3.2 Monthly maintenance tasks .......................................................................................... 27
6.3.3 Annual test (inspection and testing during operation) .................................................. 27
6.4 Disposing of equipment ............................................................................................................... 28
6.5 Meeting the requirements of RoHS ............................................................................................. 28
7 Rectifying faults ................................................................................................................................... 29
7.1 Checklist for rectifying faults ........................................................................................................ 29
5.2.1.1 TIG hot wire welding ..................................................................................... 14
5.2.1.2 TIG cold wire welding .................................................................................... 15
5.2.1.3 Legend .......................................................................................................... 15
5.2.2.1 Approved coolants overview ......................................................................... 16
5.2.2.2 Maximal hose package length ...................................................................... 17
5.2.3.1 Stray welding currents................................................................................... 18
5.2.4.1 Connecting the shielding gas supply ............................................................ 20
5.2.5.1 Control cable pin configuration ..................................................................... 21
5.3.1.1 Inserting the wire spool ................................................................................. 22
5.3.1.2 Changing the wire feed rollers ...................................................................... 23
5.3.1.3 Inching the wire electrode ............................................................................. 23
5.3.1.4 Spool brake setting ....................................................................................... 24
Page 4
Contents
Notes on the use of these operating instructions
4
099-000094-EW501
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8 Technical data ....................................................................................................................................... 31
8.1 Tetrix drive 4L .............................................................................................................................. 31
9 Accessories .......................................................................................................................................... 32
9.1 General accessories .................................................................................................................... 32
9.2 Options ......................................................................................................................................... 32
9.3 Remote control / connection cable ............................................................................................... 32
10 Replaceable parts ................................................................................................................................. 33
10.1 Wire feed rollers ........................................................................................................................... 33
10.1.1 Wire feed rollers for steel wire ...................................................................................... 33
10.1.2 Wire feed rollers for aluminium wire ............................................................................. 33
10.1.3 Wire feed rollers for cored wire ..................................................................................... 33
10.1.4 Conversion kit ............................................................................................................... 33
11 Appendix A ............................................................................................................................................ 35
11.1 Overview of EWM branches......................................................................................................... 35
Page 5
For your safety
Notes on the use of these operating instructions
099-000094-EW501
18.07.2017
5
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
• The risk is explained using a symbol on the edge of the page.
Special technical points which users must observe.
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.
Page 6
For your safety
Explanation of icons
6
099-000094-EW501
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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 keep pressed
Switch
Wrong
Turn
Correct
Numerical value – adjustable
Menu entry
Signal light lights up in green
Navigating the menu
Signal light flashes green
Exit menu
Signal light lights up in red
Time representation (e.g.: wait
4 s/activate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use
2.2 Explanation of icons
Page 7
For your safety
Part of the complete documentation
099-000094-EW501
18.07.2017
7
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!
Item
Operating instructions
A.1
Wire feeder
A.2
Options xxx conversion instructions
A.3
Power source
A.4
Welding torch
A.5
Control
A.6
Remote control
A
Complete documentation
2.3 Part of the complete documentation
The illustration shows a general example of a welding system.
Figure 2-1
Page 8
Intended use
Applications
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099-000094-EW501
18.07.2017
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!
A suitable power source (system component) is required in order to operate the wire feed unit!
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
The labelled machine 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 EWM, this declaration shall be voided. An original document of the
specific declaration of conformity is included with every product.
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
Wire feeder to feed welding consumables for MMA welding.
3.1.1 Use and operation solely with the following machines
A cold/hot wire Tetrix power source (AW) is required for operation.
For hot wire welding, an additional hot wire power source is required for pre-warming the wire.
• Tetrix 351, 451, 551 AW FWD
• Tetrix 351, 451, 551 AC/DC AW FWD
• Tetrix 270 Hotwire
3.2 Documents which also apply
3.2.1 Warranty
3.2.2 Declaration of Conformity
3.2.3 Service documents (spare parts and circuit diagrams)
Original copies of the circuit diagrams are enclosed with the unit.
3.2.4 Calibration/Validation
Spare parts can be obtained from the relevant authorised dealer.
We hereby confirm that this machine has been tested using calibrated measuring equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months
Page 9
Machine description – quick overview
Front view
099-000094-EW501
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9
Item
Symbol
Description 0
1
Carrying handle
2
Slide latch, lock for the protective cap
3
Wire electrode connection
Welding torch wire feed
4
Quick connect coupling (red)
coolant return
5
Quick connect coupling (blue)
coolant supply
6
Connection socket, welding torch control cable > see 5.2.5.1 chapter
7
Connection socket (TIG)
Welding current, minus potential
8
Machine control > see 4.4 chapter
9
Connection socket (TIG hot wire)
Hot wire power, minus potential
10
Quick connect coupling
Shielding gas
4 Machine description – quick overview
4.1 Front view
Figure 4-1
Page 10
Machine description – quick overview
Rear view
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Item
Symbol
Description 0
1
Connection socket, 19-pole
Remote control connection
2
Connector plug (TIG hot wire)
Welding current, minus potential
3
Connecting thread (G¼")
Shielding gas
4
X2
Connection socket (28-pole)
Control lead
5
Connector plug (TIG)
Welding current, minus potential
6
Machine feet
7
Intermediate hose package strain relief
8
Quick connect coupling (red)
coolant return
9
Quick connect coupling (blue)
coolant supply
4.2 Rear view
Figure 4-2
Page 11
Machine description – quick overview
Inside view
099-000094-EW501
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11
Item
Symbol
Description 0
1
Cover of the wire spool
2
Wire spool holder
3
Protective cap
Cover for the wire feed mechanism and other operating elements.
Depending on the machine series, additional stickers with information on the
replacement parts will be located on the inside.
4
Wire feed unit
5
Operating mode changeover switch
• Position KORREKTUR
• Position MANUELL
The setting determines the wire speed operating mode at the wire speed rotary dial.
6
Changeover switch, remote control on/off
ON Set the welding performance via the remote control
OFF Set the welding performance via the machine control
4.3 Inside view
Figure 4-3
Page 12
Machine description – quick overview
Machine control – Operating elements
12
099-000094-EW501
18.07.2017
Item
Symbol
Description 0
1
Gas test button
Shielding gas setting/tube package Rinse.
(See the operating instructions for the power source, chapter “Gas test”)
2
Wire inching button
To inch the wire electrode when changing wire spools
3
Wire return button
The welding wire is retracted to the wire spool.
4
Wire speed rotary dial
Parameters can be set in two operating modes:
• Operating mode KORREKTUR (inner scale):
The wire speed is specified primarily by the welding machine control and can be
corrected on the wire feed unit by +/- 40%.
• Operating mode MANUELL (outer scale):
The wire speed is set on the wire feed unit as an absolute value in the range from
0.2 to 10 m/min.
The operating mode is set with the operating mode changeover switch (above the wire
feed unit, under the cover).
4.4 Machine control – Operating elements
Figure 4-4
Page 13
Design and function
Ambient conditions
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13
WARNING
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
• Follow safety instructions on the opening pages of the operating instructions.
• Commissioning may only be carried out by persons who have the relevant expertise of
working with arc welding machines!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
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.
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
WARNING
Risk of accident due to improper transport of machines that must not be lifted!
Do not lift or suspend the machine! The machine can drop and cause injuries! The
handles, straps or brackets are suitable for transport by hand only!
• The machine must not be suspended or lifted using a crane.
5 Design and function
5.1 Ambient conditions
5.1.1 In operation
Temperature range of the ambient air:
• -25 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
5.1.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -30 °C to +70 °C
Relative air humidity
5.2 Transport and installation
• Up to 90% at 20 °C
Page 14
Design and function
Transport and installation
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099-000094-EW501
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Tetrix AW
3~
AC
Tetrix Hotwire
Tetrix drive 4L TIG 450W HW 12POL
AC
HW
X2
X2
hotwire
hotwire
HW
HW HW
3~
AC
TP
TP
RT AW 1
5.2.1 Connection plan
5.2.1.1 TIG hot wire welding
Figure 5-1
Page 15
Design and function
Transport and installation
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15
Tetrix AW
3~
AC
Tetrix drive 4L TIG 450 WD CW
AC
HW
X2
X2
hotwire
HW
TP
TP
RT AW 1
Shielding gas
Welding current(minus potential)
Coolant input (marked in colour)
5.2.1.2 TIG cold wire welding
5.2.1.3 Legend
Figure 5-2
Page 16
Design and function
Transport and installation
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Coolant output (marked in colour)
X2
Control lead (28-pole)
TP
Hose package (TP = tube package)
HW
Welding current (minus potential, TIG hot wire)
Welding current (plus potential, workpiece)
hotwire
Control lead, hot wire (signal input, 4-pole)
3~
AC
Connection, supply voltage (3-phase)
Supply voltage, hot wire power source
hotwire
Control lead, hot wire (signal output, 4-pole)
Control lead, welding torch (12-pole)
Remote control connection
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch > see 5.2.2.1 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
renders 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.
Dispose of the coolant in accordance with local regulations and the material safety data sheets
(German waste code number: 70104).
May not be disposed of in household waste.
Prevent entry into sewers.
Absorb with liquid-binding material (sand, gravel, acid-binding agents, universal binding agents,
sawdust).
Coolant
Temperature range
KF 23E (Standard)
-10 °C to +40 °C
KF 37E
-20 °C to +10 °C
5.2.2 Welding torch cooling system
5.2.2.1 Approved coolants overview
Page 17
Design and function
Transport and installation
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17
Pump 3.5 bar
Pump 4.5 bar
Machines with or without separate wire feeder
30 m
60 m
Compact machines with additional intermediate
drive (example. miniDrive)
20 m
30 m
Machines with separate wire feeder and additional
intermediate drive (example: miniDrive)
20 m
60 m
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).
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!
5.2.2.2 Maximal hose package length
Data as a rule refer to the entire hose package length
including welding torch. The pump output is shown on the type plate (parameter: Pmax).
Pump 3.5 bar: Pmax = 0.35 MPa (3.5 bar)
5.2.3 Notes on the installation of welding current leads
Pump 4.5 bar: Pmax = 0.45 MPa (4.5 bar)
Figure 5-4
Figure 5-3
Page 18
Design and function
Transport and installation
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Always keep leads as short as possible!
Lay any excess cable lengths in meanders.
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.
5.2.3.1 Stray welding currents
Figure 5-5
Figure 5-6
Page 19
Design and function
Transport and installation
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19
Item
Symbol
Description 0
1
Power source
2
Intermediate hose package
3
Quick connect coupling (blue)
coolant supply
4
Connector plug (TIG hot wire)
Welding current, minus potential
5
Connecting thread (G¼")
Shielding gas
6
X2
Connection socket (28-pole)
Control lead
7
Connector plug (TIG)
Welding current, minus potential
8
Quick connect coupling (red)
coolant return
9
Intermediate hose package strain relief
5.2.4 Intermediate hose package connection
Figure 5-7
• Insert the end of the hose package through the strain relief of the hose package and lock by turning to
the right.
• Push the cable socket for the welding current (TIG) onto the connector plug (TIG) and lock by turnng
to the right.
• 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 cable plug on the control lead into the connection socket (28-pole) and secure with crown nut
(the plug can only be inserted into the connection socket in one position).
• Screw the crown nut on the shielding gas lead gastight to the connecting thread (G¼").
Where applicable:
• Push the cable socket for the welding current (TIG hot wire) onto the connector plug (TIG hot wire)
and lock by turnng to the right.
Page 20
Design and function
Transport and installation
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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.
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 5.2.2.2 chapter.
• When using a gas-cooled welding torch, use a hose bridge to establish the coolant
circuit > see 9 chapter.
Item
Symbol
Description 0
1
Welding torch
Observe additional system documents!
5.2.4.1 Connecting the shielding gas supply
5.2.5 Welding torch connection
Prepare welding torch according to the welding task in hand (see operating instructions for the torch).
Figure 5-8
Page 21
Design and function
Transport and installation
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21
Item
Symbol
Description 0
2
Welding torch hose package
3
Wire electrode connection
Welding torch wire feed
4
Quick connect coupling
Shielding gas
5
Connection socket (TIG hot wire)
Hot wire power, minus potential
6
Connection socket, welding torch control cable > see 5.2.5.1 chapter
7
Connection socket (TIG)
Welding current, minus potential
8
Quick connect coupling (blue)
coolant supply
9
Quick connect coupling (red)
coolant return
• Extend and lay out the torch hose package.
• Insert the wire feed plug of the welding torch into the wire electrode connector and lock by turning to
the right.
• Push the cable socket for the welding current (TIG) onto the connector plug (TIG) and lock by turnng
to the right.
• Insert shielding gas rapid-action closure nipple in the quick connect coupling and engage.
• Insert welding torch control lead into the 12-pole connection socket and secure with the crown nut.
• 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).
If fitted:
• Push the cable socket for the welding current (TIG hot wire) onto the connector plug (TIG hot wire)
and lock by turnng to the right.
5.2.5.1 Control cable pin configuration
Figure 5-9
Page 22
Design and function
Wire feed
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CAUTION
Risk of injury due to moving parts!
The wire feeders are equipped with moving parts, which can trap hands, hair, clothing
or tools and thus injure persons!
• Do not reach into rotating or moving parts or drive components!
• Keep casing covers or protective caps closed during operation!
Risk of injury due to welding wire escaping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may
escape in an uncontrolled manner and injure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the
welding torch!
• Check wire guide at regular intervals!
• Keep all casing covers or protective caps closed during operation!
To perform the following steps, the protective flap of the wire feeder needs to be opened. Make
sure to close the protective flap again before starting to work.
CAUTION
Risk of injury due to incorrectly secured wire spool.
If the wire spool is not secured properly, it may come loose from the wire spool support
and fall to the ground, causing damage to the machine and injuries.
• Make sure to correctly fasten the wire spool to the wire spool support.
• Before you start working, always check the wire spool is securely fastened.
Standard D300 wire spool holder can be used. Adapters are required when using standardised
basket coils (DIN 8559) > see 9 chapter.
Item
Symbol
Description 0
1
Carrier pin
For fixing the wire spool
2
Knurled nut
For fixing the wire spool
5.3 Wire feed
5.3.1 Open the protective flap of the wire feeder
5.3.1.1 Inserting the wire spool
• Unlock and open protective flap.
Figure 5-10
• Loosen knurled nut from spool holder.
• Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore.
• Fasten wire spool using knurled nut.
Page 23
Design and function
Wire feed
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23
Unsatisfactory welding results due to faulty wire feeding! Wire feed rollers must be suitable for
the diameter of the wire and the material.
• Check the roller label to verify that the rollers are suitable for the wire diameter.
Turn or change if necessary!
• use V-groove rollers with for steel wires and other hard wires,
• use U-groove rollers for aluminium wires and other soft, alloyed wires.
CAUTION
Risk of injury due to welding wire escaping from the welding torch!
The welding wire can escape from the welding torch at high speed and cause bodily
injury including injuries to the face and eyes!
• Never direct the welding torch towards your own body or towards other persons!
Incorrect contact pressure will cause extensive wear of the wire feed rollers!
• With the adjusting nuts of the pressure units set the contact pressure so that the wire
electrode is conveyed but will still slip through if the wire spool jams.
• Set the contact pressure of the front rollers (in wire feed direction) to a higher value!
The inching speed is infinitely adjustable by simultaneously pressing the wire inching pushbutton and turning the wire speed rotary knob. The left display shows the wire feed speed
selected, the right display shows the current motor current of the wire feed mechanism.
Item
Symbol
Description 0
1
Adjusting nut
5.3.1.2 Changing the wire feed rollers
• Slide new drive rollers into place so that the diameter of the wire used is visible on the drive roller.
• Screw the drive rollers in place with knurled screws.
5.3.1.3 Inching the wire electrode
Figure 5-11
Figure 5-12
Page 24
Design and function
Remote control
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Item
Symbol
Description 0
2
Feed roll tensioner
Fixing the clamping unit and setting the pressure.
3
Clamping unit
4
Knurled screw
5
Pressure roller
6
Drive roller
7
Wire feed nipple
8
Guide tube
Item
Symbol
Description 0
1
Allen screw
Securing the wire spool retainer and adjustment of the spool brake
Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but
without it jamming during operation!
These accessory components can be retrofitted as an option > see 9 chapter.
The remote controls are operated on the 19-pole remote control connection socket (analogue).
The remote control On/Off changeover switch (above the wire feed mechanism, below the cover)
has to be set to ON.
• Extend and lay out the torch hose package.
• Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip
upwards).
• Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the
drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe.
• Press the clamping element with the pressure roller back downwards and fold the wire units back up
again (wire electrode should be in the groove on the drive roller).
• Set the contact pressure with the adjusting nuts of the pressure unit.
• Press the wire inching button until the wire electrode projects out of the welding torch.
Automatic inching stop
Touch the welding torch against the workpiece during inching. Inching of the welding wire will stop as
soon it touches the workpiece.
5.3.1.4 Spool brake setting
• Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect.
5.4 Remote control
Figure 5-13
Page 25
Design and function
Remote control
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25
Item
Symbol
Description 0
1
19-pole connection socket (analogue)
For connecting the control lead.
2
Wire inching button
Inching the wire electrode when changing the wire spool. (The welding wire is inched
loosely into the hose package, without gas being expelled.)
3
Wire return button
The welding wire is retracted to the wire spool.
4
Wire speed rotary dial
Parameters can be set in two operating modes:
• Operating mode KORREKTUR (inner scale):
The wire speed is specified primarily by the welding machine control and can be
corrected on the wire feed unit by +/- 40%.
• Operating mode MANUELL (outer scale):
The wire speed is set on the wire feed unit as an absolute value in the range from
0.2 to 10 m/min.
The operating mode is set with the operating mode changeover switch (above the wire
feed unit, under the cover).
5
3-step changeover switch, current and wire control
---------- Welding current (start/stop)
--------- Wire control (start/stop)
The operating modes for welding current and wire have to be set as follows: latched for
welding current, non-latched for welding wire.
Figure 5-14
Page 26
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.
• Check the coolant for contaminants and replace, if necessary.
6.2.1 Dirt filter
The duty cycle of the welding machine decreases as an effect of the reduced cooling air volume.
Depending on the amount of dirt building up (at least every two months), the dirt filter has to be
uninstalled and cleaned regularly (e.g. by purging with compressed air).
Page 27
Maintenance, care and disposal
Maintenance work, intervals
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For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
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
necessary.
• 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.
Page 28
Maintenance, care and disposal
Disposing of equipment
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Proper disposal!
The machine contains valuable raw materials, which should be recycled, and electronic
components, which must be disposed of.
• Do not dispose of in household waste!
• Observe the local regulations regarding disposal!
6.4 Disposing of equipment
• According to European provisions (guideline 2012/19/EU of the European Parliament and the Council
of Juli, 4th 2021), used electric and electronic equipment may no longer be placed in unsorted
municipal waste. It must be collected separately. The symbol depicting a waste container on wheels
indicates that the equipment must be collected separately.
This machine is to be placed for disposal or recycling in the waste separation systems provided for
this purpose.
• According to German law (law governing the distribution, taking back and environmentally correct
disposal of electric and electronic equipment (ElektroG) from 16.03.2005), used machines are to be
placed in a collection system separate from unsorted municipal waste. The public waste management
utilities (communities) have created collection points at which used equipment from private
households can be disposed of free of charge.
• Information about giving back used equipment or about collections can be obtained from the
respective municipal administration office.
• EWM participates in an approved waste disposal and recycling system and is registered in the Used
Electrical Equipment Register (EAR) under number WEEE DE 57686922.
• In addition to this, returns are also possible throughout Europe via EWM sales partners.
6.5 Meeting the requirements of RoHS
We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and
that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives
on the Declaration of Conformity on your machine).
Page 29
Rectifying faults
Checklist for rectifying faults
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The correct machine equipment for the material and process gas in use is a fundamental
requirement for perfect operation!
Legend
Symbol
Description
Fault/Cause
Remedy
7 Rectifying faults
All products are subject to rigorous production checks and final checks. If, despite this, something fails to
work at any time, please check the product using the following flowchart. If none of the fault rectification
procedures described leads to the correct functioning of the product, please inform your authorised
dealer.
7.1 Checklist for rectifying faults
Mains fuse triggers
Unsuitable mains fuse
Set up recommended mains fuse > see 8 chapter.
Coolant error/no coolant flowing
Insufficient coolant flow
Check coolant level and refill if necessary
Eliminate kinks in conduit system (hose packages)
Reset automatic cutout of the coolant pump by activating
Air in the coolant circuit
Vent coolant circuit
Functional errors
All machine control signal lights are illuminated after switching on
No machine control signal light is illuminated after switching on
No welding power
Phase failure > check mains connection (fuses)
Several parameters cannot be set (machines with access block)
Entry level is blocked, disable access lock
Connection problems
Make control lead connections and check that they are fitted correctly.
Welding torch overheated
Loose welding current connections
Tighten power connections on the torch and/or on the workpiece
Tighten contact tip correctly
Overload
Check and correct welding current setting
Use a more powerful welding torch
Unstable arc
Unsuitable or worn welding torch equipment
Adjust contact tip to wire diameter and -material and replace if necessary
Adjust wire guide to material in use, blow through and replace if necessary
Material inclusions in the tungsten electrode due to contact with filler material or workpiece
Regrind or replace the tungsten electrode
Incompatible parameter settings
Check settings and correct if necessary
Page 30
Rectifying faults
Checklist for rectifying faults
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Wire feed problems
Unsuitable or worn welding torch equipment
Adjust contact tip (cold wire/hot wire) to wire diameter, blow through and replace if necessary
Adjust wire guide to material in use, blow through and replace if necessary
Contact tip blocked
Clean, spray with anti-spatter spray and replace if necessary
Worn wire rolls
Check and replace if necessary
Wire feed motor without supply voltage (automatic cutout triggered by overloading)
Reset triggered fuse (rear of the power source) by pressing the key button
Kinked hose packages
Extend and lay out the torch hose package
Incompatible parameter settings
Check settings and correct if necessary
Arc between gas nozzle and workpiece (metal vapour on the gas nozzle)
Replace gas nozzle
Pore formation
Inadequate or missing gas shielding
Check shielding gas setting and replace shielding gas cylinder if necessary
Shield welding site with protective screens (draughts affect the welding result)
Use gas lens for aluminium applications and high-alloy steels
Unsuitable or worn welding torch equipment
Check size of gas nozzle and replace if necessary
Condensation (hydrogen) in the gas tube
Purge hose package with gas or replace
Page 31
Technical data
Tetrix drive 4L
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Performance specifications and guarantee only in connection with original spare and
replacement parts!
Supply voltage
42 VAC/60 VDC
Max. welding current at 60% DC
550 A
Max. welding current at 100% DC
420 A
Wire feed speed
0.2 m/min. to 10 m/min.
Standard WF roll equipment
1.0 + 1.2 mm (for steel wire)
Drive
4-roll (37 mm)
Torch connector
Decentral
Protection classification
IP 23
Ambient temperature
–25 C to +40 C
Wire spool diameter
Standardised wire spools up to 300 mm
Dimensions L x W x H
690 x 300 x 410 mm
27.17 x 11.81 x 16.14 inch
Weight without accessories
13.7 kg
30.2 lb
EMC class
A
Safety identification
/
Harmonised standards used
see declaration of conformity (machine documentation)
8 Technical data
8.1 Tetrix drive 4L
Page 32
Accessories
General accessories
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Performance-dependent accessories like torches, workpiece leads, electrode holders or
intermediate hose packages are available from your authorised dealer.
Type
Designation
Item no.
AK300
Wire spool adapter K300
094-001803-00001
DM 842 Ar/CO2 230bar 30l D
Pressure regulator with manometer
394-002910-00030
HOSE BRIDGE UNI
Tube bridge
092-007843-00000
Type
Designation
Item no.
ON TB drive 4L/HW
Transport bracket for Tetrix drive 4L and Tetrix 270
Hotwire
092-000038-00000
ON PS drive 4L T/P
Pivot support
092-002112-00000
ON WAKD2 4L/41L
Optional wheel assembly retrofit kit for drive 4L
090-008151-00000
ON CMF drive 4L
Optional retrofit crane suspension for drive 4L
092-002483-00000
ON WAKD 4L/41L
Wheel assembly kit for drive 4L
090-008169-00000
Type
Designation
Item no.
ON ASM FR AW 1
Connection capability for remote control for filler
wire
092-008765-00000
FR AW 1
Remote control for filler wire
090-008765-00000
RA5 19POL 5M
Remote control e.g. connection cable
092-001470-00005
RA10 19POL 10M
Remote control e.g. connection cable
092-001470-00010
RA20 19POL 20M
Remote control e.g. connection cable
092-001470-00020
9 Accessories
9.1 General accessories
9.2 Options
9.3 Remote control / connection cable
Page 33
Replaceable parts
Wire feed rollers
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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.
Type
Designation
Item no.
FE 2DR4R 0,6+0,8
Drive rollers, 37 mm, steel
092-000839-00000
FE 2DR4R 0,8+1,0
Drive rollers, 37 mm, steel
092-000840-00000
FE 2DR4R 0,9+1,2
Drive rollers, 37 mm, steel
092-000841-00000
FE 2DR4R 1,0+1,2
Drive rollers, 37 mm, steel
092-000842-00000
FE 2DR4R 1,2+1,6
Drive rollers, 37 mm, steel
092-000843-00000
FE/AL 2GR4R SF
Pressure rollers, smooth, 37 mm
092-000414-00000
Type
Designation
Item no.
AL 4ZR4R 0,8+1,0
Twin rollers, 37 mm, for aluminium
092-000869-00000
AL 4ZR4R 1,0+1,2
Twin rollers, 37 mm, for aluminium
092-000848-00000
AL 4ZR4R 1,2+1,6
Twin rollers, 37 mm, for aluminium
092-000849-00000
AL 4ZR4R 2,4+3,2
Twin rollers, 37 mm, for aluminium
092-000870-00000
Type
Designation
Item no.
ROE 2DR4R 0,8/0,9+0,8/0,9
Drive rollers, 37 mm, cored wire
092-000834-00000
ROE 2DR4R 1,0/1,2+1,4/1,6
Drive rollers, 37 mm, cored wire
092-000835-00000
ROE 2DR4R 1,4/1,6+2,0/2,4
Drive rollers, 37 mm, cored wire
092-000836-00000
ROE 2DR4R 2,8+3,2
Drive rollers, 37 mm, cored wire
092-000837-00000
ROE 2GR4R
Pressure rollers, knurled, 37mm
092-000838-00000
Type
Designation
Item no.
URUE VERZ>UNVERZ FE/AL
4R SF
Conversion kit, 37mm, 4-roller drive on non-toothed
rollers (steel/aluminium)
092-000415-00000
URUE ROE 2DR4R
0,8/0,9+0,8/0,9 SF
Conversion kit, 37 mm, 4-roller drive for cored wire
092-000410-00000
URUE ROE 2DR4R
1,0/1,2+1,4/1,6 SF
Conversion kit, 37 mm, 4-roller drive for cored wire
092-000411-00000
URUE ROE 2DR4R
1,4/1,6+2,0/2,4 SF
Conversion kit, 37 mm, 4-roller drive for cored wire
092-000412-00000
URUE ROE 2DR4R 2,8+3,2
SF
Conversion kit, 37 mm, 4-roller drive for cored wire
092-000413-00000
URUE AL 4ZR4R 0,8+1,0 SF
Conversion kit, 37 mm, 4-roller drive for aluminium
092-002268-00000
URUE AL 4ZR4R 1,0+1,2 SF
Conversion kit, 37 mm, 4-roller drive for aluminium
092-002266-00000
URUE AL 4ZR4R 1,2+1,6 SF
Conversion kit, 37 mm, 4-roller drive for aluminium
092-002269-00000
URUE AL 4ZR4R 2,4+3,2 SF
Conversion kit, 37 mm, 4-roller drive for aluminium
092-002270-00000
10 Replaceable parts
10.1 Wire feed rollers
10.1.1 Wire feed rollers for steel wire
10.1.2 Wire feed rollers for aluminium wire
10.1.3 Wire feed rollers for cored wire
10.1.4 Conversion kit
Page 34
Replaceable parts
Wire feed rollers
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Figure 10-1
Page 35
Appendix A
Overview of EWM branches
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11 Appendix A
11.1 Overview of EWM branches
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