Operating instructions

Transcription

1 EWM HIGHTEC WELDING GmbH Dr. Günter - Henle - Straße 8 D-57 Mündersbach Phone: Fax: info@ewm.de GB Operating instructions Welding machines for TIG and MMA welding TETRIX 70, 00, 50, 500 AC/DC COMFORT activarc N. B. These operating instructions must be read before commissioning. Failure to do so may be dangerous. Machines may only be operated by personnel who are familiar with the appropriate safety regulations. The machines bear the conformity mark and thus comply with the EC Low Voltage Directive (00/95/ EG) EC EMC Directive (00/08/ EG) In compliance with IEC 097, EN 097, VDE 05 the machines can be used in environments with an increased electrical hazard. 008 Subject to alteration. Item No.: EWM0 Revised:.0.008

2 Dear customer, Congratulations! You have chosen a quality product from EWM HIGHTEC WELDING GmbH. EWM machines provide results of the highest perfection thanks to their PREMIUM quality. Therefore we are happy to provide you with a full -year warranty according to our operating instructions. We develop and produce quality! From individual components to the final product, we retain sole responsibility for our machines. In all their high-tech components, our welding machines embody future-oriented advanced technology at the utmost level of quality. Each of our products is carefully checked; we guarantee that the material and processing of our products is faultless. These operating instructions contain everything about commissioning the machine, notes regarding safety, maintenance and care, technical data as well as information regarding the warranty. Please heed all these notes to ensure many years of safe operation of the machine. Thank you for the trust that you have placed in us. We look forward to a long-term partnership with you in the spirit of OE EWM ALWAYS EWM. Yours sincerely, EWM HIGHTEC WELDING GmbH Bernd Szczesny Executive management

3 Machine and Company Data Please enter the EWM machine data and your company s data in the appropriate fields. TYP: EWM HIGHTEC WELDING GMBH D-57 MÜNDERSBACH SNR: ART: GEPRÜFT/CONTROL: PROJ: CE Name of Customer / company Name of Customer / company Adress Adress Post code / Place Post code / Place Country Country Stamp / Signature of EWM-distibutor Date of purchase Stamp / Signature of EWM-distibutor Date of purchase

4 Contents For your safety Contents Contents... Safety instructions...7. For your safety...7. Transport and installation Ambient conditions...9. Notes on the use of these operating instructions...0 Technical data.... TETRIX 70; 00 AC/DC COMFORT activarc.... TETRIX 50 AC/DC COMFORT activarc.... TETRIX 500 AC/DC COMFORT activarc... Machine description.... TETRIX 70; 00 AC/DC COMFORT activarc..... Front view..... Rear view.... TETRIX 50 AC/DC COMFORT activarc Front view Rear view...0. TETRIX 500 AC/DC COMFORT activarc..... Front view..... Rear view... 5 Functional characteristics Machine control Operating elements Function sequence Operating concepts Manual, standard operation (JOB 0) JOB operation (JOB to 7) Displaying and changing the JOB number Welding data display Welding parameter setting Machine configuration menu TIG welding Arc ignition HF ignition Liftarc Optimising the ignition characteristics for pure tungsten electrodes Manual, standard operation (JOB 0) JOB operation (JOB to 7) TIG automatic cut-out Tapping operating mode Optimal and fast spherical cup formation TIG function sequences / operating modes Explanation of symbols TIG non-latched operation TIG latched operation TIG spotarc TIG non-latched operation, C version TIG pulses, function sequences TIG pulses non-latched operation TIG pulses - latched operation TIG pulse variants Pulses (thermal pulses) KHz pulses (metallurgic pulses) Automated pulses AC special... Item No.: EWM0

5 Contents For your safety 5..9 TIG activarc welding TIG shielding gas setting Gas test TIG welding torch (operating variants) Torch mode and up/down speed setting Standard TIG torch (5-pole) TIG up/down torch (8-pole) Potentiometer torch (8-pole) RETOX TIG torch (-pole) Setting the first increment MMA welding Selection and adjustment Hotstart Hotstart current Hotstart time Arcforcing Antistick Key switch Advanced settings Setting slope times for secondary current AMP% or pulse edges TIG non-latched operating mode, C version Configuring the TIG potentiometer torch connection Switching between percentage and absolute welding currents Selection and adjustment Remote control Foot-operated remote control RTF Manual remote control RT Manual remote control RT AC Manual remote control RTP Manual remote control RTP RTP manual remote control Manual remote control RT PWS Interfaces for automation TIG interface for mechanised welding Remote control connection socket, 9-pole... Commissioning...7. General...7. Area of application proper usage...7. Installation...7. Mains connection Machine cooling Workpiece lead, general...7 TIG welding Welding torch connection Torch connection options and pin assignments Connection for workpiece lead Shielding gas supply (shielding gas cylinder for welding machine) Connecting the shielding gas supply Setting the shielding gas quantity MMA welding Electrode holder connection Connection for workpiece lead Cooling unit function specification Coolant error Simultaneous welding on both sides, synchronisation types Synchronisation via mains voltage Selection and adjustment...7. PC interface...7 Item No.: EWM0 5

6 Contents For your safety 7 Maintenance and testing General Cleaning Test Test equipment Scope of the test Visual inspection Measuring the open circuit voltage Measurement of insulation resistance Measuring the leakage current (protective conductor and contact current) Measurement of protective conductor resistance Functional test of the welding machine Documentation of the test Repair Work Disposing of equipment Manufacturer's declaration to the end user Meeting the requirements of RoHS Warranty General Validity Warranty Declaration Operating problems, causes and remedies Error messages (power source) Accessories, options General accessories Remote control / connection cable Options TIG welding torch Transport vehicle Cooling units Synchronisation...8 Circuit diagrams...8. TETRIX 70 AC/DC COMFORT activarc...8. TETRIX 00 AC/DC COMFORT activarc...8. TETRIX 50 AC/DC COMFORT activarc TETRIX 500 AC/DC COMFORT activarc...90 Appendix A...9. Declaration of Conformity...9 Item No.: EWM0

7 Safety instructions For your safety Safety instructions. For your safety Observe accident prevention regulations! Ignoring the following safety procedures can be fatal! Proper usage This machine has been manufactured according to the latest developments in technology and current regulations and standards. It is to be operated only for the use for which it was designed (see chapter Commissioning/Area of application). Improper usage However, this machine may be a hazard to persons, animals and property if it is not used as directed used by unskilled persons who have not been trained modified or converted improperly Our operating instructions will provide you with an introduction into the safe use of the machine. Therefore please read them carefully and only start work when you are familiar with them. Any person involved in the operation, maintenance and repair of this machine must read and follow these operating instructions, especially the safety precautions. Where appropriate, this should be confirmed by signature. Furthermore, the relevant accident prevention regulations, generally accepted safety regulations, local regulations, etc. must be observed. Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves. Protect eyes and face with protective visor. Electric shocks can be fatal! Do not touch any live parts in or on the machine! The machine may only be connected to correctly earthed sockets. Only operate with intact connection lead including protective conductor and safety plug. An improperly repaired plug or damaged mains cable insulation can cause electric shocks. The machine may only be opened by qualified and authorised specialist staff. Disconnect from the mains before opening. Switching off is not sufficient. Wait for minutes until the capacitors have discharged. Always put down welding torch, stick electrode holder in an insulated condition. The machine must not be used to defrost pipes! Even touching low voltages can cause you to get a shock and lead to accidents, so: Protect yourself from falling before working on platforms or scaffolding. During welding ensure that you operate earth tongs, torch and workpiece correctly, and not in ways for which they are not intended. Do not touch live parts with bare skin. Only replace electrodes when wearing dry gloves. Never use torches or earth cables with damaged insulation. Smoke and gases can lead to breathing difficulties and poisoning. Do not breathe in smoke and gases. Ensure that there is sufficient fresh air. Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can be converted into poisonous phosgene by ultraviolet radiation. Item No.: EWM0 7

8 Safety instructions For your safety Workpiece, flying sparks and droplets are hot! Keep children and animals well away from the working area. Their behaviour is unpredictable. Move containers with inflammable or explosive liquids away from the working area. There is a danger of fire and explosion. Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of explosions when apparently harmless substances develop high pressures in enclosed containers by heating. Take care to avoid fire hazards Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when parts are glowing or hot slag is present. A constant check must be kept on whether fire hazards have arisen in the working area. Highly inflammable objects, such as matches and cigarette lighters for example, must not be carried in trouser pockets. You must ensure that fire extinguishing equipment - appropriate for the welding process - is available close to the welding work area and that this equipment can be accessed easily. Containers in which fuels or lubricants have been present must be thoroughly cleaned before welding begins. It is not sufficient simply for the receptacle to be empty. After a workpiece has been welded, it must only be touched or brought into contact with inflammable material when it has cooled down sufficiently. Loose welding connections can completely destroy protective conductor systems of interior installations and cause fires. Before beginning welding work, ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source. Noise exceeding 70 dba can cause permanent hearing damage! Wear suitable earmuffs or plugs. Ensure that other people who spend time in the working area are not inconvenienced by the noise. Interference by electrical and electromagnetic fields is possible e.g. from the welding machine or from the high-voltage pulses of the ignition unit. As laid down in Electromagnetic Compatibility Standard EN 5099, the machines are intended for use in industrial areas; if they are operated in residential environments, for example, problems may occur in ensuring electromagnetic compatibility. The functioning of heart pacemakers can be adversely affected when you are standing near the welding machine. It is possible that electronic equipment (e.g. EDP, C equipment) in the vicinity of the welding site could malfunction. Other mains supply leads, control leads, signal and telecommunications leads above, under and near the welding device may be subject to interference. Electromagnetic interference must be reduced to a level that no longer constitutes interference. Possible reduction measures: Welding machines must be serviced regularly. (see Chap. Maintenance and care) Welding leads should be as short as possible and run closely together on or near to the ground. Selective shielding of other leads and equipment in the environment can reduce radiation. Repair and modifications may only carried out by authorised, trained, specialist staff. The warranty becomes null and void in the event of unauthorised interference. 8 Item No.: EWM0

9 Safety instructions Transport and installation. Transport and installation The machines may only be transported and operated in an upright position. Before carrying away or moving, pull out mains plug and place on the machine. When setting up the machine, resistance to tilting is only guaranteed up to an angle of 0 (as specified in EN 097-). Secure the gas cylinder! Place shielding gas cylinders in the holders provided for them and secure with safety chains. Take care when handling cylinders; do not throw or heat, guard against them toppling over. When moving by crane, take off the gas cylinder from the welding machine... Ambient conditions This machine must not be operated in any area where any risk of explosion exists. The following conditions must be observed during operation: Temperature range of the ambient air During welding: -0 C to +0 C *), For transport and storage: -5 C to +55 C *) *) Using the appropriate coolant. Relative air humidity up to 50% at 0 C up to 90% at 0 C The ambient air must be free of unusual amounts of dust, acids, corrosive gases or substances, etc., assuming these are not produced by the welding process. Examples of unusual operating conditions: unusual corrosive smoke, vapour, excessive oil vapour, unusual vibrations or jolts, excessive quantities of dust such as grinding dust etc., severe weather conditions, unusual conditions near the coast or on board ship. When setting up the machine, ensure a free inlet and outlet of air. The machine is tested to protection class IP, i.e.: Protection against penetration of solid foreign bodies > mm, Protection against water spray up to an angle of 0 to the vertical. Item No.: EWM0 9

10 Safety instructions Notes on the use of these operating instructions. Notes on the use of these operating instructions These operating instructions are arranged into chapters. To help you find your way around more quickly, in the margins you will occasionally see symbols along with the sub-headings. These symbols refer to particularly important passages of text which are graded as follows depending on their importance: Please note: Technical features which users must observe. Warning: Working and operating procedures which must be followed precisely to avoid damaging or destroying the machine. Caution: Working and operating procedures which must be followed precisely to avoid risk to persons and includes the "Warning" symbol. Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet points, e.g.: Insert the welding current lead socket into the relevant socket and lock. Symbol Description Press Do not press Turn Switch 0 Item No.: EWM0

11 Technical data. TETRIX 70; 00 AC/DC COMFORT activarc Technical data TETRIX 70; 00 AC/DC COMFORT activarc TETRIX 70 AC/DC 00 AC/DC Setting range: Welding current / welding voltage TIG (DC) TIG (AC) MMA 5A - 00 A / 0, V,0 V 5A - 70 A / 0, V 0,8 V 5A - 70 A / 0, V 0,8 V Max. welding current at TIG MMA TIG MMA 0ºC ambient temperature: 5%DC 5%DC 00%DC 0ºC ambient temperature: 0%DC 0%DC 00%DC Load alternation Open circuit voltage (with AC and DC) 00 A (DC) 70 A 0 A 00 A (DC) 70 A 0 A - 0 A 0 A - 0 A 00 A 00 A 70 A 0 A 00 A 70 A 0 A 0min (0% DC min. welding, min. break) 9 V (DC) Mains voltage (tolerances) x 00 V -5 %; +0 % x 5 V -5 %; +5 % Frequency 50/0 Hz Mains fuse (safety fuse, slow-blow) x A Mains connection lead H07RN-FG,5 Max. connected power, kva Recommended generator rating 8,7 kva cosϕ / efficiency 0,99 / 85 % Insulation class / protection F / IP classification Ambient temperature -0 C bis +0 C Machine cooling / torch cooling Fan / gas or water Workpiece lead 5 mm Dimensions L x W x H [mm] 50 x 0 x 550 mm Weight,5 kg Constructed to standards IEC 097 / EN 097 / VDE 05 EN 5099 / VDE 05 Teil 0 / - 0 A 0 A - 0 A 00 A Item No.: EWM0

12 Technical data TETRIX 50 AC/DC COMFORT activarc. TETRIX 50 AC/DC COMFORT activarc TETRIX 50 AC/DC Setting range: Welding current / welding voltage TIG MMA 5 A - 50 A / 0. V.0 V 5 A - 50 A / 0. V.0 V Max. welding current at TIG MMA 0ºC ambient temperature: 5%DC 0%DC 00%DC 0ºC ambient temperature: 5%DC 0%DC 0%DC 00%DC Load alternation Open circuit voltage (with AC and DC) - 50 A 0 A - 50 A 5 A 0 A 50 A 0 A 50 A 50 A - 90 A 0 A 0min (0 % DC min welding, min break) 95 V Mains voltage (tolerances) x 00 V (-5 %; +0 %) x 5 V (-5 %; +5 %) Frequency 50/0 Hz Mains fuse (safety fuse, slow-blow) x 5 A Mains connection lead H07RN-FG.5 Max. connected power 7,7 kva Recommended generator rating,9 kva cosϕ / efficiency 0,99 / 85 % Insulation class / protection classification F / IP Ambient temperature -0 C to +0 C Machine cooling / torch cooling Fan / gas or water Workpiece lead 50 mm Dimensions L x W x H [mm] 05 x 5 x 50 Weight 5 kg Constructed to standards EN 097 / IEC 097 / VDE 05 EN 5099 / VDE 05 Part 0 / Item No.: EWM0

13 . TETRIX 500 AC/DC COMFORT activarc TETRIX 500 AC/DC Setting range: Welding current / welding voltage TIG MMA Technical data TETRIX 500 AC/DC COMFORT activarc 5A A / 0, V 0,0 V 5A A / 0, V 0,0 V Max. welding current at TIG MMA 0ºC ambient temperature: 0%DC 0%DC 00%DC 0ºC ambient temperature: 5%DC 0%DC 00%DC Load alternation Open circuit voltage (with AC and DC) 500 A 75 A 90 A 500 A 75 A 90 A 500 A 50 A 0 A 500 A 0 A 50 A 0min (0% DC min. welding, min. break) 79 V at 00 V 9 V at 0 V Mains voltage (tolerances) x 00 V -5 %; +0 % x 5 V -5 %; +5 % x 0 V -5 %; +0 % Frequency 50/0 Hz Mains fuse (safety fuse, slow-blow) x 5 A Mains connection lead H07RN-FG Max. connected power 9 kva Recommended generator rating 9. kva cosϕ / efficiency 0,99 / 85 % Insulation class / protection classification F / IP Ambient temperature -0 C to +0 C Machine cooling / torch cooling Fan / gas or water Workpiece lead 95 mm Dimensions L x W x H [mm] 0 x 50 x 850 mm Weight 0.5 kg Constructed to standards EN 097 / IEC 097 / VDE 05 EN 5099 / VDE 05 Part 0 / Item No.: EWM0

14 Machine description TETRIX 70; 00 AC/DC COMFORT activarc Machine description. TETRIX 70; 00 AC/DC COMFORT activarc.. Front view Figure - Item No.: EWM0

15 Machine description TETRIX 70; 00 AC/DC COMFORT activarc Item Symbol Description 0 Carrying handle Control / Operating elements (see chapter Function specification) Connection socket, 9-pole Remote control connection Cooling air inlet 5 Connection socket, welding current - (with DC- polarity) connection for Electrode holder Connection socket, welding current + (with DC- polarity) Connection for workpiece lead 7 0 Key switch for locking the control (option) Position > changes possible, Position 0 > changes not possible. 8 Connection socket, 8-pole / -pole 8-pole: TIG Up/Down or potentiometer torch control lead -pole: Control lead for TIG up/down torch with LED display (option) 9 Connection socket, 5-pole Standard TIG torch control lead 0 Connection socket, welding current - (with DC- polarity) connection TIG welding torch G¼ connecting nipple, welding current "-" (with DC- polarity) Shielding gas connection (with yellow insulating cap) for TIG welding torch Rubber feet Item No.: EWM0 5

16 Machine description TETRIX 70; 00 AC/DC COMFORT activarc.. Rear view Figure - Item No.: EWM0

17 Machine description TETRIX 70; 00 AC/DC COMFORT activarc Item Symbol Description 0 analog digital 9-pole connection socket (option) Analogue interface for mechanised welding 7-pole connection socket (option) Wire feed unit connection (cold wire); RINT; Q-DOC, etc. G¼ connecting nipple Shielding gas connection on the pressure reducer Main switch, machine on/off 5 Strain relief with mains connection cable -pole connection socket Cooling unit voltage supply 7 8-pole connection socket Cooling unit control lead V/A PC INT digital HF HF "Automatic circuit-breaker" key button; fuse protection: Ignition unit Gas valve Peripheral devices on the 7-pole, digital interfaces (rear of the machine) Reset triggered automatic cutout by pressing 9-pole D-SUB connection socket, serial PC interface Interface set SECINTX0 DSUB required (observe installation instructions) 7-pole connection socket (option) Wire feed unit connection (cold wire); RINT; Q-DOC, etc. Ignition type changeover switch HF= HF ignition HF = Liftarc (contact ignition) Cooling air outlet Item No.: EWM0 7

18 Machine description TETRIX 50 AC/DC COMFORT activarc. TETRIX 50 AC/DC COMFORT activarc.. Front view Figure - 8 Item No.: EWM0

19 Machine description TETRIX 50 AC/DC COMFORT activarc Item Symbol Description 0 Carrying handle Control / Operating elements (see chapter Function specification) Connection socket, 8-pole / -pole 8-pole: TIG Up/Down or potentiometer torch control lead -pole: Control lead for TIG up/down torch with LED display (option) Connection socket, 5-pole Standard TIG torch control lead 5 Cooling air inlet Rubber feet 7 0 Key switch for locking the control (option) Position > changes possible, Position 0 > changes not possible. 8 Connection socket, 9-pole Remote control connection 9 G¼ connecting nipple, welding current "-" (with DC- polarity) Shielding gas connection (with yellow insulating cap) for TIG welding torch 0 Connection socket, welding current - (with DC- polarity) connection TIG welding torch Connection socket, welding current - (with DC- polarity) connection for Electrode holder Connection socket, welding current + (with DC- polarity) Connection for workpiece lead Item No.: EWM0 9

20 Machine description TETRIX 50 AC/DC COMFORT activarc.. Rear view Figure - 0 Item No.: EWM0

21 Machine description TETRIX 50 AC/DC COMFORT activarc Item Symbol Description 0 analog digital digital PC INT 9-pole connection socket (option) Analogue interface for mechanised welding 7-pole connection socket (option) Wire feed unit connection (cold wire); RINT; Q-DOC, etc. 7-pole connection socket (option) Wire feed unit connection (cold wire); RINT; Q-DOC, etc. 9-pole D-SUB connection socket, serial PC interface Interface set SECINTX0 DSUB required (observe installation instructions) 5 G¼ connecting nipple Shielding gas connection on the pressure reducer 8-pole connection socket Cooling unit control lead 7 Main switch, machine on/off 8 HF HF Ignition type changeover switch HF= HF ignition HF = Liftarc (contact ignition) 9 Strain relief with mains connection cable 0 -pole connection socket Cooling unit voltage supply "Automatic circuit-breaker" key button; fuse protection: Ignition unit V/A Gas valve Peripheral devices on the 7-pole, digital interfaces (rear of the machine) Reset triggered automatic cutout by pressing Cooling air outlet Item No.: EWM0

22 Machine description TETRIX 500 AC/DC COMFORT activarc. TETRIX 500 AC/DC COMFORT activarc.. Front view Figure -5 Item No.: EWM0

23 Machine description TETRIX 500 AC/DC COMFORT activarc Item Symbol Description 0 Carrying handle Main switch, machine on/off Connection socket, 8-pole / -pole 8-pole: TIG Up/Down or potentiometer torch control lead -pole: Control lead for TIG up/down torch with LED display (option) Connection socket, 5-pole Standard TIG torch control lead 5 Cooling air inlet Control / Operating elements (see chapter Function specification) 7 0 Key switch for locking the control (option) Position > changes possible, Position 0 > changes not possible. 8 Connection socket, 9-pole Remote control connection 9 G¼ connecting nipple, welding current "-" (with DC- polarity) Shielding gas connection (with yellow insulating cap) for TIG welding torch 0 Connection socket, welding current - (with DC- polarity) connection TIG welding torch Connection socket, welding current - (with DC- polarity) connection for Electrode holder Connection socket, welding current + (with DC- polarity) Connection for workpiece lead Rubber feet Item No.: EWM0

24 Machine description TETRIX 500 AC/DC COMFORT activarc.. Rear view Figure - Item No.: EWM0

25 Machine description TETRIX 500 AC/DC COMFORT activarc Item Symbol Description 0 digital digital PC INT 7-pole connection socket (option) Wire feed unit connection (cold wire); RINT; Q-DOC, etc. 7-pole connection socket (option) Wire feed unit connection (cold wire); RINT; Q-DOC, etc. 9-pole D-SUB connection socket, serial PC interface Interface set SECINTX0 DSUB required (observe installation instructions) 8-pole connection socket Cooling unit control lead 5 analog 9-pole connection socket (option) Analogue interface for mechanised welding G¼ connecting nipple Shielding gas connection on the pressure reducer 7 "Automatic circuit-breaker" key button; fuse protection: Ignition unit V/A Gas valve Peripheral devices on the 7-pole, digital interfaces (rear of the machine) Reset triggered automatic cutout by pressing 8 Strain relief with mains connection cable 9 -pole connection socket Cooling unit voltage supply 0 HF HF Ignition type changeover switch HF= HF ignition HF = Liftarc (contact ignition) Cooling air outlet Item No.: EWM0 5

26 Functional characteristics Machine control Operating elements 5 Functional characteristics 5. Machine control Operating elements Machine control provides the user with up to 8 welding tasks (JOBs). JOB "0" represents manual operating mode. This is where you can change/optimise all parameters directly in machine control (see chapter "Operating concepts"). Figure 5- Item Symbol Description 0 "Welding process" button MMA welding, lights up in green / arcforce setting, lights up in red TIG welding "Operating mode" button spotarc (spot time setting range 0.0 sec. to 0.0 sec.) Non-latched Latched "TIG pulse welding" TIG automated pulses (frequency and balance) TIG pulses with times, green light / Fast TIG DC pulses with frequency and balance, red light TIG AC special Item No.: EWM0

27 Functional characteristics Machine control Operating elements Item Symbol Description 0 Welding current polarity button Direct current welding with positive polarity on the electrode holder in relation to the workpiece (pole reversal switch, MMA only). DC welding with negative polarity on the torch (or stick electrode holder) in relation to the workpiece. Alternating current welding with rectangular current output wave form. Maximum power loading and safe welding. Alternating current welding with trapezoidal current output wave form. The all-rounder for most applications. Alternating current welding with sinusoidal current output wave form. Low noise level. 5 "Display changeover" button Welding current display Welding voltage display JOB number display "Alternating current frequency (TIG AC)" rotary dial 50 Hz to 00 Hz ( Hz increments) 7 "Alternating current balance (TIG AC)" rotary dial Max. setting range: - 0% to + 0% (% increments). The setting range may also be lower depending on the factory setting. 8 Tungsten electrode diameter / Ignition optimisation rotary dial Infinitely adjustable from mm to mm or greater 9 Welding parameter setting rotary dial Setting all parameters such as ignition, welding, end current, gas pre-flow and gas post-flow times, pulse edges, etc. 0 Three-figure LED display Welding parameter display (see also chap. Welding data display ). Error/status indicators Collective interference signal light (see Operating problems chapter) Water deficiency signal light (welding torch cooling) S Excess temperature signal light S safety sign signal light see "Function specification" chapter Item No.: EWM0 7

28 Functional characteristics Machine control Operating elements 5... Function sequence Figure 5- Item Symbol Description 0 Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. Gas pre-flow time (TIG), absolute setting range 0.0 sec to 0.0 sec (0.s increments). sec Ignition current (TIG) AMP% Percentage of the main current. Setting range % to 00 % ( % increments). There are no pulses during the ignition current phase. sec Up-slope time (TIG) Setting ranges: 0.00 sec to 0.0 sec (0. sec increments). The up-slope time can be set separately for non-latched and latched. 5 sec AMP Pulse time / slope time from AMP% to AMP / Spot time Pulse time setting range: 0.0 sec to 0.0 sec (0.0s increments < 0.5 sec; 0. sec increments > 0.5 sec) Slope time (ts) setting range: 0.0 sec to 0.0 sec (see chapter "Advanced settings") Spot time setting range: 0.0 sec to 0.0 sec TIG pulses The pulse time applies to the main current phase (AMP) for pulses. Main current (TIG) / pulse current I min to I max ( A increments) Hotstart current (MMA) Percentage of the main current. Setting range % to 00 % ( % increments). Hotstart time (MMA) Setting ranges: 0.00 sec to 0.0 sec (0. sec increments). TIG AC Special The pulse time applies to the AC phase for AC special. Main current (MMA) I min to I max ( A increments) 8 Item No.: EWM0

29 Functional characteristics Operating concepts Item Symbol Description 0 7 Pulse break time/slope time from AMP to AMP% sec Pulse break setting range: 0.0 sec to 0.0 sec (0.0 sec increments < 0.5 sec; 0. sec increments > 0.5 sec) Slope time (ts) setting range: 0.0 sec to 0.0 sec (see chapter "Advanced settings"). 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. 8 Secondary current (TIG) / pulse pause current AMP% Setting range % to 00% (% increments). Percentage of the main current. 9 Down-slope time (TIG) sec 0.00 sec to 0.0 sec (0. sec increments). The down-slope time can be set separately for non-latched and latched. 0 End-crater current (TIG) AMP% Setting range % to 00 % ( % increments). Percentage of the main current. Gas post-flow time (TIG) sec Setting ranges: 0.00 sec to 0.0 sec (0. sec increments). Tungsten electrode diameter / Ignition optimisation LED Infinitely adjustable from mm to mm or greater Alternating current balance (TIG AC) Max. setting range: -0% to +0% (% increments). The setting range may also be lower depending on the factory setting. Optimisation of cleaning effect and fusion penetration characteristics. Balance fast TIG DC pulses Setting range: % to +99% (% increments) Alternating current frequency (TIG AC) 50 Hz to 00 Hz ( Hz increments) Constriction and stabilisation of the arc: At a higher frequency, the cleaning effect is increased. Particularly thin panels (welding with a low current), anodised sheet aluminium or highly contaminated articles for welding can be welded and cleaned perfectly at a higher frequency. Frequency fast TIG DC pulses Setting range: 50 Hz to.5 khz (0.0 khz increments) 5 "activarc" LED Display activarc activated (on/off) function and correction of the activarc characteristic. Setting range: Operating concepts The welding task (JOB) can be selected in two ways: Manual, standard operation (JOB "0") JOB operation, saved welding tasks (JOB to 7) Item No.: EWM0 9

30 Functional characteristics Operating concepts 5.. Manual, standard operation (JOB 0) "Manual, standard operation (JOB 0)" is set by default on delivery and every time the machine control is reset. This means that the welder repeatedly makes all the required welding settings and re-adjusts them for each individual welding task. It is only possible to change the basic welding parameters if: no welding current is flowing and the key switch (option) is set to position Operating element Action Result Select and display welding process TIG welding + TIG activarc welding MMA welding, lights up in green/arcforce setting, lights up in red Select and display welding current polarity Direct current welding with positive polarity at the electrode holder, MMA only DC welding with negative polarity at the torch (or electrode holder) with respect to the workpiece AC welding with rectangular current output wave form Maximum power loading and safe welding AC welding with trapezoidal current output wave form An all-rounder, suitable for most applications AC welding with sinusoidal current output wave form Low noise level Select and display operating mode spotarc (spot time setting range 0.0 sec. to 0.0 sec.) Non-latched Latched Select and display pulse procedure TIG automated pulses (frequency and balance) TIG pulses with times, lights up in green/fast TIG DC pulses with frequency and balance, lights up in red TIG AC special Set tungsten electrode diameter for optimisation of ignition Set alternating current balance (TIG AC only) Select welding parameter in the functional sequence Set welding parameters 0 Item No.: EWM0

31 Functional characteristics Operating concepts 5.. JOB operation (JOB to 7) You can select, change and save the required welding parameters for recurring welding tasks (JOBs) in up to 7 JOBs (JOB to JOB 7) Displaying and changing the JOB number Operating Action Result Display element Select JOB display JOB number X x Change the JOB number JOB number x If the display switchover is pressed or if there is no keyboard input for 5 seconds, the new JOB will be active JOB number The procedure for setting welding tasks is the same as described under "Manual, standard operation (JOB 0)". The "Alternating current balance (TIG AC)" and "Tungsten electrode diameter/ignition optimisation" rotary dials are the exception. These welding parameters are set in JOB to 7 in the function sequence (the signal lights of the same names indicate selection). A JOB can only be switched if no welding current is flowing. The up-slope and down-slope times can be set separately for non-latched and latched. Item No.: EWM0

32 Functional characteristics Operating concepts 5.. Welding data display The following welding parameters can be displayed before (nominal values) or during (actual values) welding. Parameter Before welding (nominal values) During welding (actual values) Welding current Welding voltage JOB number - Parameter times - Frequency, balance - Parameter currents Welding parameter setting 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 Machine configuration menu If the machine configuration is changed, then the parameter and its value are shown alternately in the display. Machine configuration menus Display Setting/Selection Display Setting/Selection Exit menu (exit machine configuration) Torch configuration menu Configuration menu Service menu (this menu may only be used by authorised service personnel) Torch mode menu "Torch Mode" Up/down speed "Up/Down" Set st increment "Delta I" Synergic on/off "Synergic" on/off Display "Pro": Percentage welding currents are shown in the display "Abs": Absolute welding currents are shown in the display Non-latched C mode "Non-latched C" on/off Cold wire operating mode "off/t/t/t" Cold wire wire selection "Job/d0/d08/d0/d/d" Item No.: EWM0

33 Functional characteristics TIG welding 5. TIG welding 5.. Arc ignition 5... HF ignition Figure 5- 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. -mm). b) Press the torch trigger (high voltage ignition pulses ignite the arc). c) Ignition current flows, and the welding process is continued depending on the operating mode selected. End the welding process: Release or press the torch trigger depending on the operating mode selected Liftarc a) b) c) Figure 5- 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. - mm between the electrode tip and the workpiece. The arc ignites and the welding current is increased, depending on the operating mode set, to the ignition or main current set. c) Lift off the torch and swivel to the normal position. Ending the welding process: Release or press the torch trigger depending on the operating mode selected. Item No.: EWM0

34 Functional characteristics TIG welding 5.. 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. The adjustable welding current is limited to the maximum permissible welding current of the tungsten electrode Manual, standard operation (JOB 0) Operating element Action Result Set diameter of tungsten electrode Increase parameter value > more ignition power Reduce parameter value > less ignition power 5... JOB operation (JOB to 7) Operating element Action Result Display x x Select ignition characteristics parameter Press until signal light comes on Set diameter of tungsten electrode Increase parameter value > more ignition power Reduce parameter value > less ignition power Tungsten electrode diameter displayed in mm 5.. TIG automatic cut-out If the arc does not ignite after starting or if the arc is interrupted when the torch is moved away, an automatic cut-out occurs after sec. The HF, gas and open circuit voltage (power unit) are switched off. 5.. Tapping operating mode The tapping mode was included particularly for the secondary current (AMP%) by the use of a trigger on the welding torch. Torch with one trigger: by tapping (brief pressing and releasing) torch trigger (Repeated tapping switches back to the main current). Torch with two triggers: There are two ways of switching to the secondary current: by tapping (see torch with one trigger) by pressing down and holding torch trigger. Item No.: EWM0

35 Functional characteristics TIG welding 5..5 Optimal and fast spherical cup formation A conically ground needle (approx. 5 ) is generally required to form an ideal spherical cup. Spherical cup formation preset Operating element Action Result Display Set spotarc operating mode - Switch off pulse welding Set spotarc time in line with the electrode diameter in use (refer to the table of guideline values for spherical cup formation depending on welding current) Select AC type - Square current output wave form - Trapezoidal current output wave form - Sinusoidal current output wave form - Balance setting in JOB "0" Turn rotary dial to the left as far as it will go (positive) Form spherical cups on the tungsten electrode Turn rotary dial back to its original position (positive) - Table of guideline values for spherical cup formation Tungsten electrode diameter spotarc time Balance Current for spherical cup formation.0. sec + 0% max. 70 A.. sec + 0% max. 0 A.0.5 sec + 0% max. 0 A..8 sec + 0% max. 90 A..0 sec + 0% max. 0 A.0 >. sec + 0% max. 0 A Use a sample workpiece. Ignite arc with HF ignition (non-contact) and form required spherical cups for the application in question. Re-set parameter values to their original values. Item No.: EWM0 5

36 Functional characteristics TIG welding 5.. TIG function sequences / operating modes The "Select welding parameter" button and the "Welding parameter setting" rotary transducer can be used to control all the parameters for the TIG process: Pos. Description Select welding parameters button Welding parameter setting rotary dial 5... Explanation of symbols Symbol Meaning Press torch trigger Figure 5-5 Release torch trigger I t Current Time Gas pre-flows I start t Up tp AMP AMP% t t ts ts t Down I end Ignition current Up-slope time Spot time Main current (minimum to maximum current) Secondary current (0% to 00% of AMP) Pulse time Pulse pause time TIG pulses: Slop time from main current (AMP) to secondary current (AMP%) TIG pulses: Slop time from secondary current (AMP%) to main current (AMP) Down-slope time End-crater current Gas post-flows Item No.: EWM0

37 Functional characteristics TIG welding 5... TIG non-latched operation When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The up- and down-slopes are switched off. Figure 5- Step : Press and hold torch trigger. 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 I start. HF is switched off. The welding current increases in the adjusted up-slope time to the main current AMP. Step : Release torch trigger. The main current drops in the set down-slope time to the end-crater current I end (minimum current). If the st torch trigger is pressed during the down-slope time, the welding current returns to the main current AMP set. The main current reaches the end-crater current I end, the arc extinguishes. The set gas post-flow time elapses. Item No.: EWM0 7

38 Functional characteristics TIG welding 5... TIG latched operation When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The up- and down-slopes are switched off..... I AMP AMP% I start I end t Up t Down t Figure 5-7 Step Press torch trigger, 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 ignition current value set (search arc at minimum setting). HF is switched off. Step Release torch trigger. The welding current increases with the set up-slope time to the main current AMP. Switching from main current AMP to secondary current AMP%: Press torch trigger or Tap torch trigger (for tapping mode, see also chapter Description of tapping mode ) The slope times can be set (see chapter "Advanced settings", section "Setting slope times for secondary current AMP% or pulse edges". Step Press torch trigger. The main current drops with the set down-slope time to the end-crater current I end (minimum current). Step Release torch trigger, the arc extinguishes. The set gas post-flow time begins. Immediate termination of the welding procedure without down-slope and end-crater current: Briefly press the st torch trigger (rd and th step). The current drops to zero and the gas post-flow time begins. 8 Item No.: EWM0

39 Functional characteristics TIG welding 5... TIG spotarc The TIG SpotArc function is activated with the pulse variant automated frequencies by default, because this combination produces the most effective results. The user can of course combine the function with other pulse variants depending on the selected welding process. Pulse time (t) and pulse break time (t) can be set independently, but the spot time (tp) should be much greater than the pulse time in order to achieve an appropriate result. Selecting and setting TIG spotarc Operating element Action Result Display Signal light comes on The spot time can be set for approx. sec. using the "Welding parameter setting" rotary dial (spot time setting range 0.0 sec. to 0.0 sec.) Afterwards the display switches back to current/voltage. If the button is pressed again, the display switches back to the parameter and can be changed with the rotary dial accordingly. The spot time can also be set in the function sequence. Set spot time "tp" The TIG spotarc process is switched on with the pulse variant "TIG automated pulses" by default. The user can select other pulse variants: TIG automated pulses (frequency and balance) TIG pulses with times, lights up in green/ fast TIG DC pulses with frequency and balance, lights up in red TIG AC special For combinations that can be selected refer to the "spotarc/pulse variants table" - Item No.: EWM0 9

40 Functional characteristics TIG welding Figure 5-8 Sequence: Press and hold torch trigger. 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 I start. HF is switched off. The welding current increases in the adjusted up-slope time to the main current AMP. The process ends when the set SpotArc time elapses or if the torch trigger is released prematurely. spotarc/pulse variants table: Process Pulse variants TIG DC (lights up in green) (lights up in red) No pulses TIG AC (lights up in green) No pulses Automated pulses (factory setting) Pulses (thermal pulses) khz pulse (metallurgic pulses) Pulses (thermal pulses) AC special The up-slope and down-slope times should be set to 0 to achieve an effective result. 0 Item No.: EWM0

41 Functional characteristics TIG welding Setting instructions for spotarc for CrNi panels Seam shape Panel thickness Pulse type/ welding type Spot time Welding current Down-slope time Butt weld Fillet weld Lap weld mm Automated pulses 0.s 00A 0.5s mm Fast pulsing (.5kHz) 0.s 00A 0.5s mm Fast pulsing (.5kHz) with activarc 0.5s 80A 0.7s mm Automated pulses with activarc 0.5s 50A 0.s mm Fast pulsing (.5kHz) with activarc 0.5s 50A 0.s mm Automated pulses with activarc 0.s 00A 0.s mm Fast pulsing (.5kHz) 0.s 00A 0.s mm Fast pulsing (.5kHz) with activarc 0.5s 70A 0.5s spotarc setting instructions for C-steel panels Seam shape Panel thickness Pulse type/ welding type Spot time Welding current Down-slope time Butt weld Fillet weld Lap weld mm Automated pulses 0.s 5A 0.5s mm Automated pulses 0.5s 5A 0.5s mm Automated pulses with activarc 0.5s 70A 0.5s mm Fast pulsing (.5kHz) with activarc 0.5s 70A 0.5s mm Fast pulsing (.5kHz) 0.s 50A 0.5s mm Fast pulsing (.5kHz) with activarc 0.5s 70A 0.5s Item No.: EWM0

42 Functional characteristics TIG welding TIG non-latched operation, C version This operating mode needs to be activated (see chapter "Advanced settings" in the "TIG nonlatched operating mode, C version") section. Figure 5-9 st cycle Press torch trigger, the gas pre-flow time elapses. HF ignition pulses jump from the electrode to the workpiece, the arc ignites. Welding current flows and immediately adopts the ignition current value set (search arc at minimum setting). HF is switched off. nd cycle Release torch trigger. The welding current increases in the set up-slope time to the main current AMP. Pressing torch trigger starts the slope (ts) from main current AMP to secondary current AMP%. Releasing the torch trigger starts the slope (ts) from the secondary current AMP% back to the main current AMP. This process can be repeated as often as required. The welding process is ended by the arc interruption in the secondary current (removing the torch from the workpiece until the arc is extinguished). The slope times can be set (see chapter "Advanced settings", section "Setting slope times for secondary current AMP% or pulse edges". Item No.: EWM0

43 Functional characteristics TIG welding 5..7 TIG pulses, function sequences The function sequences in pulses basically behave in the same way as in standard welding, but during the main current phase there is a continual switching back and forth between the pulse and pause currents at the relevant times TIG pulses non-latched operation TIG pulses - latched operation Figure 5-0 Figure 5- Item No.: EWM0

44 Functional characteristics TIG welding 5..8 TIG pulse variants The machines have an integrated pulse device. With pulses, the machine switches back and forth between the pulse current (main current) and pause current (secondary current) Pulses (thermal pulses) With thermal pulses, the pulse and pause times (frequency up to 00 Hz) and the pulse edges (ts and ts) are entered in seconds on the control. Figure 5- Operating element Action Result Display Select TIG pulses function - Signal light lights up in green Select pulse time "t" LED "Pulse time" comes on (see chapter "Function sequence") Set pulse time "t" Select break time "t" LED "Pulse break time" comes on (see chapter "Function sequence") Set break time "t" sec Select slope times "ts" and "ts" Set slope time "ts" Switch between slope times "ts" and "ts" Set slope time "ts" Item No.: EWM0

45 Functional characteristics TIG welding KHz pulses (metallurgic pulses) The khz pulses (metallurgic pulses) use the plasma pressure produced at high currents (arc pressure) which is used to achieve a constricted arc with concentrated heat feeding. The frequency can be infinitely adjusted from 50 Hz to.5 khz and the pulse balance from 99%. In contrast to thermal pulses, the pulse edge times are not required. Figure 5- Operating element Action Result Display Select khz pulses Press the "TIG pulses" button until the signal light lights up in red - Select balance Setting range: % to 99% (% increments) Select frequency Setting range: 50 Hz to.5 khz (0.0 khz increments) 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. Operating element Action Result Select TIG automated pulses Press the "TIG pulses" button until the TIG automated pulses signal light comes on Item No.: EWM0 5

46 Functional characteristics TIG welding AC special Application: e.g. for welding thick metal sheets onto thin metal sheets. Operating element Action Result Select TIG AC special Press the "TIG pulses" button until the AC special signal light comes on AMP AMP AMP = AC current phase pulse current AMP% = DC phase pulse pause current t pulse = Pulse time; AC phase time t break = Pulse break time; DC phase time AMP% t t pause t puls This function should only be used for TIG welding and must be switched off or not used for plasma welding. Item No.: EWM0

47 Functional characteristics TIG welding 5..9 TIG activarc welding The EWM activarc process, thanks to the highly dynamic controller system, ensures that the power supplied is kept virtually constant in the event of changes in the distance between the welding torch and the weld pool, e.g. during manual welding. Voltage losses as a result of a shortening of the distance between the torch and molten pool are compensated by a current rise (ampere per volt - A/V), and vice versa. This helps prevents the tungsten electrode sticking in the molten pool and the tungsten inclusions are reduced. This is particularly useful in tacking and in spot welding. TIG activarc combined with pulse variant "TIG automated pulses" or "khz pulses (metallurgic pulses)" improves the positive properties of the process further depending on the task. Operating element Action Result Display Select activarc parameter x x Press until LED flashes Switch parameter on Switch parameter off Parameter setting The activarc parameter (control) can be adjusted specifically for the welding task (panel thickness). These parameters have been modified for the welding current level at the factory. The "activarc" process must be selected first (activarc signal light is on permanently). Operating Action Result Display element 5 sec. Select activarc parameter value x x Select activarc parameter value Press until LED flashes Set parameter value Increase parameter value (A/V) Decrease parameter value (A/V) Item No.: EWM0 7

48 Functional characteristics TIG welding 5..0 TIG shielding gas setting Gas test Operating Action Result element x x Press the "Select welding parameter" button until the "activarc" LED flashes. 5 sec. Press the "Select welding parameter" button and hold for approx. 5 sec. The gas pre-flow time LED (TIG) sec will come on, shielding gas flows for approx. 0 sec. 5.. TIG welding torch (operating variants) There is the option of connecting various operating and display elements to the welding torch. The functions of the torch triggers (TT) and the operating elements can be adjusted individually using different modes (see chapter Setting the torch mode and up/down speed ). Explanation of symbols Operating elements: Symbol Description BRT Press torch trigger BRT Tap torch trigger BRT Tap and press torch trigger For more detailed torch descriptions, see chapter "Setting the torch mode and up/down speed". 8 Item No.: EWM0

49 Functional characteristics TIG welding 5.. Torch mode and up/down speed setting Only the modes listed are suitable for the corresponding torch types. The user has the modes - and modes - available. Modes - include the same function options as -, but without a tapping function (see chapter Tapping operating mode ) for the secondary current. The function options in the individual modes can be found in the tables on the torch types. The welding process can of course be switched on and off in all modes using torch trigger (TT ). Operating element 0 Action Result Display Switch off the welding machine - Press and hold key button - Switch on the welding machine Select Torch mode menu item "trd" The parameter that can be changed and the associated value blink alternately in the display. Press until menu item "tod" (torch mode) is displayed Set torch mode (modes -, with tapping operation, modes -, no tapping operation) x Select up/down speed (not available in modes, 5, and 5) Set up/down speed Increase value = faster Reduce value = slower Select Torch mode menu item "trd" (deselection) Select Configuration menu item "Eit" (deselection) x Deselection "Eit" (Exit) Welding machine is re-initialised Item No.: EWM0 9

50 Functional characteristics TIG welding 5... Standard TIG torch (5-pole) Standard torch with one torch trigger: Diagram Operating elements Explanation of symbols BRT = Torch trigger (welding current on/off; secondary current via tapping function) Functions mode Operating elements Welding current On/Off Secondary current BRT (factory-set) BRT Further modes are not relevant for this torch type. Standard torch with two torch triggers: Diagram Operating elements Explanation of symbols BRT = torch trigger BRT = torch trigger Functions mode Operating elements Welding current On/Off BRT Secondary current Secondary current (tapping mode) (factory-set) BRT BRT Welding current On/Off BRT Secondary current (tapping mode) Up function BRT BRT Down function BRT Further modes are not relevant for this torch type. 50 Item No.: EWM0

51 Functional characteristics TIG welding Standard torch with one rocker (MG rocker, two torch triggers) Diagram Operating elements Explanation of symbols BRT = torch trigger BRT = torch trigger Functions mode Operating elements Welding current On/Off BRT Secondary current BRT (factory-set) Secondary current (tapping mode) BRT Welding current On/Off Secondary current (tapping mode) Up function BRT + BRT BRT + BRT BRT Down function BRT Welding current On/Off BRT Secondary current (tapping mode) Up function BRT BRT Down function BRT Further modes are not relevant for this torch type. Item No.: EWM0 5

52 Functional characteristics TIG welding 5... TIG up/down torch (8-pole) Up/down torch with one torch trigger Diagram Operating elements Explanation of symbols TT = torch trigger Functions Mode Operating elements Welding current on/off BRT Secondary current (tapping mode) Increase welding current, infinite adjustment (up function) (factoryset) BRT Up Reduce welding current, infinite adjustment (down function) Welding current on/off Secondary current (tapping mode) Down BRT BRT Welding current on/off BRT Secondary current (tapping mode) Increase welding current by an increment (see chapter "Setting the first increment in modes and ") Reduce welding current by an increment (see chapter "Setting the first increment in modes and ") BRT Up Down 5 Item No.: EWM0

53 Functional characteristics TIG welding Up/down torch with two torch triggers Diagram Operating elements Explanation of symbols TT = torch trigger (left) TT = torch trigger (right) Functions Mode Operating elements Welding current on/off BRT Secondary current Secondary current (tapping mode) Increase welding current, infinite adjustment (up function) (factoryset) BRT BRT Up Reduce welding current, infinite adjustment (down function) Welding current on/off BRT Down Secondary current BRT Secondary current (tapping mode) BRT Welding current on/off BRT Secondary current BRT Secondary current (tapping mode) BRT Increase welding current by an increment (see chapter "Setting the first increment in modes and ") Reduce welding current by an increment (see chapter "Setting the first increment in modes and ") Up Down Item No.: EWM0 5

54 Functional characteristics TIG welding 5... Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch (see chap. "Configuring TIG potentiometer torch") Potentiometer torch with one torch trigger: Diagram Operating elements Explanation of symbols BRT = torch trigger Functions Mode Operating elements Welding current On/Off Secondary current (tapping mode) Increase welding current, infinite adjustment BRT BRT Reduce welding current, infinite adjustment Potentiometer torch with two torch triggers: Diagram Operating elements Explanation of symbols BRT = torch trigger BRT = torch trigger Functions Mode Operating elements Welding current On/Off Secondary current Secondary current (tapping mode) BRT BRT BRT Increase welding current, infinite adjustment Reduce welding current, infinite adjustment 5 Item No.: EWM0

55 Functional characteristics TIG welding 5... RETOX TIG torch (-pole) The welding machine must be fitted with the -pole torch connection socket (option). Diagram Pictogram Explanation of symbols TT = Torch trigger (welding current on/off; secondary current via tapping function) TT = Torch trigger (secondary current) Up/down = Increase/reduce welding current Job = Job switching Additional functions (modes -) are generally selected by a brief tap on TT. If torch trigger (TT ) is pressed for approx. seconds, the gas test will be carried out (shielding gas flows for approx. 0 secondsfehler! Es wurde kein Textmarkenname vergeben.). Select secondary current via TT : Tapping function switched on: Mode -; tapping function switched off: Modes - Basic function (before and Additional function Display Mode Pictogram during welding) (before welding) Up/down function (infinite adjustment of welding - Welding current Up current) Down Not used for this torch type Up/down function (stepped adjustment of welding Welding current Up current) Down Job selection Job number Job BRT BRT BRT BRT BRT BRT Job selection Job number 5 Job Job BRT BRT Up/down function (infinite adjustment of welding current) Job selection Welding current Job number Job Up Down Job BRT BRT BRT BRT Job Item No.: EWM0 55

56 Functional characteristics TIG welding 5.. Setting the first increment Figure 5- This function is only available when using up/down torches in modes and. Operating element Action Result Display Switch off the welding machine - Press and hold key button - Switch on welding machine Select Torch mode menu item "trd" The parameter that can be changed and the associated value blink alternately in the display. Hold until menu item "tod" (torch mode) is displayed x Set torch mode (mode, with tapping mode, mode, no tapping mode) x Select increment Set increment Setting range: A to 0 A Select Torch mode menu item "trd" (deselection) Select Configuration menu item "Eit" (deselection) x Deselection "Eit" (Exit) Welding machine is re-initialised 5 Item No.: EWM0

57 Functional characteristics MMA welding 5. MMA welding Once the MMA welding process is selected, there is open circuit voltage present on the welding current sockets and on the G/ shielding gas connection on the front of the machine. Attach the yellow protective cap onto the G/ shielding gas connection on the front of the machine. 5.. Selection and adjustment Operating element Action Result Displays Select MMA welding process The signal light lights up in green Display shows the last current value used for welding. Set welding current Welding current is displayed. 5.. Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current I = Welding current t = Time 5... Hotstart current Operating element Action Result Displays x x Select hotstart current welding parameter Press until hotstart current signal light AMP% comes on Set hotstart current The factory setting is a value as a percentage of the selected main current. To set an absolute value for the hotstart current, see chapter "Advanced settings". Item No.: EWM0 57

58 Functional characteristics Key switch 5... Hotstart time Operating element Action Result Displays Select hotstart time welding parameter Press until hotstart time light sec comes on Set hotstart time 5.. Arcforcing Shortly before the electrode threatens to stick, the arcforcing device sets an increased current designed to prevent the electrode sticking. Operating element Action Result Displays Select arcforcing welding parameter x The signal light lights up in red 5.. Antistick Set arcforcing -0 = low current increase > soft arc 0 = default setting +0 = high current increase > aggressive arc Anti-stick prevents the electrode from annealing. If the electrode sticks in spite of the Arcforce device, the machine automatically switches over to the minimum current within about second to prevent the electrode from overheating. Check the welding current setting and correct according to the welding task! 5.5 Key switch 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. Key position = Key position 0 = All parameters can be set The following operating elements/functions cannot be changed: "Welding process" button "Welding current polarity" button Parameter values in the function sequence can be displayed but not changed 58 Item No.: EWM0

59 Functional characteristics Advanced settings 5. Advanced settings 5.. Setting slope times for secondary current AMP% or pulse edges Figure 5-5 Operating element Action Result Display Select slope time ts sec. Set slope time ts from main current AMP% to secondary current AMP Select slope time ts x Set slope time ts from secondary current AMP% to main current AMP Wait approx. sec. to exit the menu Item No.: EWM0 59

60 Functional characteristics Advanced settings 5.. TIG non-latched operating mode, C version Operating element Action Result Display 0 Switch off the welding machine - Press and hold key button - Switch on the welding machine Select Configuration menu item "cfg" The parameter that can be changed and the associated value blink alternately in the display. Hold until menu item "tc" (TIG non-latched C version) is displayed Switch TIG non-latched C version operating mode to on To switch off = "off" Select Configuration menu item "cfg" (deselection) Select Configuration menu item "Eit" (deselection) x Deselection "Eit" (Exit) Welding machine is re-initialised 0 Item No.: EWM0

61 Functional characteristics Advanced settings 5.. Configuring the TIG potentiometer torch connection When connecting a potentiometer torch, jumper JP7 on PCB T0/ inside the welding machine should be unplugged. Welding torch configuration Setting Prepared for TIG standard or up/down torch (factory setting) Prepared for potentiometer torches JP7 JP7 Observe the safety precautions given in the standard operating instructions! Observe accident prevention regulations! All conversion and retrofitting work must be completed by electrical engineers in accordance with the relevant VDE regulations. Disconnect from the mains before opening. Switching off is not sufficient. Wait for minutes until the capacitors have discharged. It is absolutely essential that a repetition test conforming to VDE 070, VBG and VBG 5 is performed before using the machine again! For more detailed instructions, please see standard operating instructions for the welding machine. 5.. Switching between percentage and absolute welding currents The currents can be set and displayed as a percentage (factory setting) or as an absolute value: Pos. Symbol Description Ignition current (TIG) Hotstart current (MMA) AMP% Secondary current (TIG) End-crater current (TIG) Item No.: EWM0

62 Functional characteristics Advanced settings 5... Selection and adjustment Operating Action Result Display element Switch off the welding machine - Press and hold key button - Switch on welding machine Select Configuration menu item "cfg" The parameter that can be changed and the associated value blink alternately in the display. Hold until "SEt" menu item is displayed x Select the operating mode Pro = percentage current setting (% to 00%) Abs = absolute current setting (Imin to Imax) Select Configuration menu item "cfg" (deselection) Select Configuration menu item "Eit" (deselection) x Deselection "Eit" (Exit) Welding machine is re-initialised Item No.: EWM0

63 Functional characteristics Remote control 5.7 Remote control Only the remote controls described in these operating instructions may be connected. Only plug the remote control into the remote control socket and lock when the machine is switched off. The remote control is detected automatically when the welding machine is switched on Foot-operated remote control RTF Functions Infinitely adjustable welding current (0% to 00%) depending on the preselected main current on the welding machine. Start/stop welding operation It is connected to the 9-pole remote control connection socket 5.7. Manual remote control RT Functions Infinitely adjustable welding current (0% to 00%) depending on the preselected main current on the welding machine. The remote control is connected to the 9-pole remote control connection socket on the welding machine via a 9-pole extension cable Manual remote control RT AC Functions Infinitely adjustable welding current (0% to 00%) 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 +5% to -5%. Please note The remote control is connected to the 9-pole remote control connection socket on the welding machine via a 9-pole extension cable Manual remote control RTP Functions TIG / MMA Infinitely adjustable welding current (0% to 00%) depending on the preselected main current on the welding machine. Pulse / spot / normal Pulse, spot and break times are infinitely adjustable. Please note The remote control is connected to the 9-pole remote control connection socket on the welding machine via a 9-pole extension cable. TIG AC pulses special is not possible. Item No.: EWM0

64 Functional characteristics Remote control Manual remote control RTP Functions TIG / MMA Infinitely adjustable welding current (0% to 00%) 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 0% to 90%. Please note The remote control is connected to the 9-pole remote control connection socket on the welding machine via a 9-pole extension cable. TIG AC pulses special is not possible RTP manual remote control Functions TIG / MMA. Infinitely adjustable welding current (0% to 00%) 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 0% to 90%. Please note The remote control is connected to a 9-pole remote control connection socket on the welding machine via a 9-pole extension cable. TIG AC pulses special is not possible Manual remote control RT PWS Functions Infinitely adjustable welding current (0% to 00%) depending on the preselected main current on the welding machine. Changeover switch for pole reversal, suitable for welding machines with PWSfunction. The remote control is connected to the 9-pole remote control connection socketon the welding machine via a 9-pole extension cable. Item No.: EWM0

65 Functional characteristics Interfaces for automation 5.8 Interfaces for automation The welding power sources feature a very high standard of safety. This safety standard is also maintained when peripheral equipment is connected for automatic welding if this peripheral equipment fulfils the same criteria, particularly with regard to isolation from the mains supply. This is ensured by the use of transformers according to VDE 055. The welding machines are prepared for automated operation as standard. Use only shielded control leads TIG interface for mechanised welding Pin Signal shape Designation A Output Connection for cable screen B Output REGaus For servicing purposes only C Input SYN_E Synchronisation for master/slave operation D Output IGRO Current flows signal I>0 (maximum load (no c.) 0mA / 5V) = welding current flowing E + R Input Not/Aus Emergency stop for higher level shut-down of the power source. To use this function, jumper must be unplugged on PCB T0/ in the welding machine. Contact open = welding current off F Output Reference potential G - Not assigned H Output Uist Actual welding voltage, measured on pin F, 0- ( =, = 0) J Vschweiss Reserved for special purposes K Output 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. +5V = start, = stop M Output +5V Voltage supply +5V, max. 75mA N Output -5V Voltage supply -5V, max. 5mA P - Not assigned S Output Reference potential T Output Iist Actual welding current, measured on pin F; 0- ( = 0A, = 000A) U V Output SYN_A Synchronisation for master/slave operation Diagram Item No.: EWM0 5

66 Functional characteristics Interfaces for automation 5.8. Remote control connection socket, 9-pole If the machine is operated using control voltages, the connection should be made via isolating amplifiers! To control the main or secondary current via control voltages, the relevant inputs must be enabled (activation of control voltage specification). Figure 5- Pos. Pin Signal shape Designation A Output Connection for cable screen () B/L Output Current flows signal I>0, galvanically isolated (max. +- 5V/00mA) F Output Reference voltage for potentiometer (max. 0mA) C Input Control value specification for main current, 0- ( = I min, = I max ) 5 D Input Control value specification for secondary current, 0- ( = I min, = I max ) J/U Output Reference 7 K Output Power supply +5V, max. 75mA 8 V Output Power supply -5V, max. 5mA 9 R Input Start/Stop welding current 0 S Input Switching between MMA and TIG welding H Input Switching between main and secondary welding currents (pulses) M/N/P Input Activation of control voltage specification Set all signals to reference potential to activate external control voltage specification for main and secondary currents G Output Measured value I SETPOINT (V = 00A) Item No.: EWM0

67 Commissioning General Commissioning. General Warning Risk from electrical current! Follow the safety instructions on the opening pages entitled For your safety. Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead, interfaces) may only be connected when the machine is switched off. Re-fit protective caps onto sockets and cable plugs when not in use!. Area of application proper usage These welding machines are only suitable for: MMA direct current welding for rutile and basic electrodes. TIG direct current and alternating current welding with HF ignition or liftarc. TIG DC: Unalloyed, low-alloy and high-alloy steels, copper, nickel-based alloys and special metals. TIG AC/DC: Aluminium and aluminium alloys. Any other use is regarded as "improper" and no liability is assumed for any damage arising therefrom. We can only guarantee smooth and trouble-free operation of the machines when used in conjunction with the welding torches and accessories from our range.. Installation Ensure that the machine is set up in a stable position and is appropriately secured. With modular systems (power source, transport vehicle, cooling module), observe the operating instructions for the relevant machine. Set up the machine so that there is sufficient room to adjust the operating elements.. Mains connection The operating voltage shown on the rating plate must match the mains voltage. For mains fuse protection, please refer to the Technical Data chapter. The correct mains plug must be attached to the mains supply lead on the machine. The connection must be made by a qualified electrician in compliance with the relevant local laws and regulations. The phase sequence for three-phase machines is optional and has no effect on the fans direction of rotation. Insert mains plug of the switched-off machine into the appropriate socket..5 Machine cooling To obtain an optimal duty cycle from the power components, the following precautions should be observed: Ensure that the working area is adequately ventilated, Do not obstruct the air inlets and outlets of the machine, Do not allow metal parts, dust or other objects to get into the machine.. Workpiece lead, general Remove paint, rust and dirt from clamping and welding areas with a wire brush. The workpiece clamp must be mounted near the welding point and must be fixed in such a way that it cannot come loose of its own accord. Structural parts, pipes, rails etc. may not be used as return leads for the welding current unless they are part of the actual workpiece. Correct current connection must be ensured when using welding benches and appliances. Item No.: EWM0 7

68 Commissioning TIG welding.7 TIG welding.7. Welding torch connection We can only guarantee the perfect functioning of our machines when used with our range of welding torches. The welding torches being used must meet the following conditions (see also the operating instructions for the torch): The torch trigger control lead must not be shielded. Only torches with an insulated crown nut on the gas connection lead may be used. There is an open circuit voltage or welding voltage on the G/ connecting nipple for shielding gas (front of the machine). If welding is carried out alternately using TIG and MMA welding and if a welding torch and an electrode holder are connected to the machine, the open-circuit or welding voltage is applied simultaneously to both. The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks. Figure - Item Symbol Description 0 Connection socket, 5-pole Standard TIG torch control lead Connection socket, 8-pole / -pole 8-pole: TIG Up/Down or potentiometer torch control lead -pole: Control lead for TIG up/down torch with LED display (option) Connection socket, welding current + (with DC- polarity) Connection for workpiece lead Connection socket, welding current - (with DC- polarity) connection TIG welding torch 5 G¼ connecting nipple, welding current "-" (with DC- polarity) Shielding gas connection (with yellow insulating cap) for TIG welding torch 8 Item No.: EWM0

69 Commissioning TIG welding Prepare welding torch according to the welding task in hand (see operating instructions for the torch). 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 -. Insert the welding torch control lead plug into the connection socket for the welding torch control lead (5-pole with standard torch, 8-pole with up/down or potentiometer torch and -pole with up/down torch with LED display) and tighten. Lock connecting nipples of the cooling water tubes into the corresponding rapid-action closure couplings: Return line red to rapid-action coupling red (coolant return line) and supply line blue to rapid-action coupling blue (coolant supply line). Please note the relevant documentation of the accessory components. With the TETRIX 500 AC/DC welding machine, the coolant hoses supplied should be used as the extension between the welding torch and cooling module..7. Torch connection options and pin assignments BT BT 5 BT BT A B + - C D Uref E Down Up IH-Down Up F G + - I Poti UD/ein H BT I 5-pole control lead 8-pole control lead -pole control lead Figure -.7. Connection for workpiece lead Insert cable plug of the workpiece lead into the "+" or "-" welding current socket and lock by turning to the right. Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging. Item No.: EWM0 9

70 Commissioning TIG welding.7. Shielding gas supply (shielding gas cylinder for welding machine).7.. Connecting the shielding gas supply No dirt must be allowed to enter the shielding gas supply, as this would cause blockages in the shielding gas supply. All shielding gas connections must be gastight. Figure - Item Symbol Description 0 G¼ connecting nipple Shielding gas connection on the pressure reducer Place shielding gas cylinder in the retainer provided for it and secure with chains. Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to blow out any dirt. Mount the pressure reducer onto the gas cylinder valve. Screw the gas hose connection nipple onto the output side of the pressure reducer. Screw the gas hose connection nipple onto the G/" connection nipple..7.. Setting the shielding gas quantity Rule of thumb for gas flow rate: Diameter of gas nozzle in mm corresponds to gas flow in l/min. Example: 7 mm gas nozzle corresponds to 7 l/min gas flow 70 Item No.: EWM0

71 Commissioning MMA welding.8 MMA welding.8. Electrode holder connection There is an open circuit voltage or welding voltage on the G/ connecting nipple for shielding gas (front of the machine). If welding is carried out alternately using TIG and MMA welding and if a welding torch and an electrode holder are connected to the machine, the open-circuit or welding voltage is applied simultaneously to both. The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks. Fit yellow insulating cap onto G/" connection nipple (shielding gas connection). Caution: Risk of being crushed or burnt. When replacing spent or new stick electrodes Switch off machine at the main switch Wear appropriate safety gloves Use insulated tongs to remove spent stick electrodes or to move welded workpieces and Always put the electrode holder down on an insulated surface. Figure - Item Symbol Description 0 G¼ connecting nipple, welding current "-" (with DC- polarity) Shielding gas connection (with yellow insulating cap) for TIG welding torch Connection socket, welding current - (with DC- polarity) connection for Electrode holder Connection socket, welding current + (with DC- polarity) Connection for workpiece lead Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right. Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging. Item No.: EWM0 7