EWM TETRIX 300 AC/DC COMFORT activArc Operating Instructions Manual

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EWM TETRIX 300 AC/DC COMFORT activArc Operating Instructions Manual | Manualzz

Operating instructions

Welding machine

GB

Tetrix 300 AC/DC Comfort

099-000120-EW501 26.07.2011

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General instructions

CAUTION

Read the operating instructions!

The operating instructions provide an introduction to the safe use of the products.

• Read the operating instructions for all system components!

• Observe accident prevention regulations!

• Observe all local regulations!

• Confirm with a signature where appropriate.

NOTE

In the event of queries on installation, commissioning, operation or special conditions at the installation site, or on usage, please contact your sales partner or our customer service department on +49 2680 181-0.

A list of authorised sales partners can be found at www.ewm-group.com.

Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed accepted by the user on commissioning the equipment.

The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are observed during installation, operation, usage and maintenance of the equipment.

An incorrectly performed installation can result in material damage and injure persons as a result. For this reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation, improper operation or incorrect usage and maintenance or any actions connected to this in any way.

© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany

The copyright to this document remains the property of the manufacturer.

Reprinting, including extracts, only permitted with written approval.

Subject to technical amendments.

Contents

Notes on the use of these operating instructions

1 Contents

1 Contents.................................................................................................................................................. 3

2 Safety instructions................................................................................................................................. 6

2.1

Notes on the use of these operating instructions .......................................................................... 6

2.2

Explanation of icons....................................................................................................................... 7

2.3

General .......................................................................................................................................... 8

2.4

Transport and installation ............................................................................................................ 12

2.5

Ambient conditions....................................................................................................................... 13

2.5.1

In operation................................................................................................................... 13

2.5.2

Transport and storage .................................................................................................. 13

3 Intended use ......................................................................................................................................... 14

3.1

Applications.................................................................................................................................. 14

3.1.1

TIG welding .................................................................................................................. 14

3.1.2

MMA welding ................................................................................................................ 14

3.2

Documents which also apply ....................................................................................................... 15

3.2.1

Warranty ....................................................................................................................... 15

3.2.2

Declaration of Conformity ............................................................................................. 15

3.2.3

Welding in environments with increased electrical hazards......................................... 15

3.2.4

Service documents (spare parts and circuit diagrams) ................................................ 15

4 Machine description – quick overview .............................................................................................. 16

4.1

Front view .................................................................................................................................... 16

4.2

Rear view ..................................................................................................................................... 18

4.3

Machine control – Operating elements ........................................................................................ 20

4.3.1

Function sequence ....................................................................................................... 22

5 Design and function............................................................................................................................. 24

5.1

General ........................................................................................................................................ 24

5.2

Transport and installation ............................................................................................................ 25

5.3

Machine cooling ........................................................................................................................... 25

5.4

Workpiece lead, general .............................................................................................................. 25

5.5

Mains connection ......................................................................................................................... 26

5.5.1

Mains configuration ...................................................................................................... 26

5.6

TIG welding.................................................................................................................................. 27

5.6.1

Welding torch and workpiece line connection .............................................................. 27

5.6.2

Torch connection options and pin assignments ........................................................... 28

5.6.3

Shielding gas supply (shielding gas cylinder for welding machine) ............................. 28

5.6.3.1

Connecting the shielding gas supply ............................................................ 29

5.6.3.2

Setting the shielding gas quantity ................................................................. 30

5.6.3.3

Gas test......................................................................................................... 30

5.6.4

Select welding task....................................................................................................... 31

5.6.4.1

Manual, standard operation (JOB 0)............................................................. 31

5.6.4.2

Save welding tasks (JOBs) ........................................................................... 32

5.6.5

Welding data display .................................................................................................... 32

5.6.5.1

Welding parameter setting ............................................................................ 32

5.6.6

Arc ignition.................................................................................................................... 33

5.6.6.1

HF ignition ..................................................................................................... 33

5.6.6.2

Liftarc ignition ................................................................................................ 33

5.6.7

Automatic cut-out.......................................................................................................... 33

5.6.8

Optimising the ignition characteristics for pure tungsten electrodes............................ 34

5.6.8.1

Manual, standard operation (JOB 0)............................................................. 34

5.6.8.2

JOB operation (JOB 1 to 7)........................................................................... 34

5.6.9

Optimal and fast spherical cup formation ..................................................................... 35

5.6.10

Function sequences/operating modes ......................................................................... 36

5.6.10.1

Explanation of symbols ................................................................................. 36

5.6.10.2

SpotArc ......................................................................................................... 39

5.6.10.3

Spotmatic ...................................................................................................... 41

5.6.10.4

Non-latched operation, version C ................................................................. 42

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Contents

Notes on the use of these operating instructions

5.6.11

Pulses, function sequences ..........................................................................................43

5.6.11.1

TIG pulses – non-latched operation ..............................................................43

5.6.11.2

TIG pulses - latched operation ......................................................................43

5.6.12

Pulse variants ...............................................................................................................44

5.6.12.1

Pulses (thermal pulses).................................................................................44

5.6.12.2

KHz pulses (metallurgic pulses)....................................................................45

5.6.12.3

Automated pulses..........................................................................................45

5.6.12.4

AC pulses ......................................................................................................46

5.6.12.5

AC special .....................................................................................................46

5.6.13

TIG activArc welding.....................................................................................................47

5.6.14

Welding torch (operating variants)................................................................................48

5.6.14.1

Tap torch trigger (tapping function) ...............................................................48

5.6.15

Torch mode and up/down speed setting ......................................................................49

5.6.15.1

Standard TIG torch (5-pole) ..........................................................................50

5.6.15.2

TIG up/down torch (8-pole) ...........................................................................52

5.6.15.3

Potentiometer torch (8-pole) .........................................................................54

5.6.15.4

RETOX TIG torch (12-pole)...........................................................................55

5.6.16

Setting the first increment .............................................................................................56

5.7

MMA welding................................................................................................................................57

5.7.1

Connecting the electrode holder and workpiece lead ..................................................57

5.7.2

Select welding task .......................................................................................................58

5.7.3

Hotstart current and Hotstart time ................................................................................59

5.7.4

Switching the welding current polarity ..........................................................................60

5.7.5

Arcforce.........................................................................................................................60

5.7.6

Antistick.........................................................................................................................60

5.8

Protecting welding parameters from unauthorised access ..........................................................60

5.9

Remote control.............................................................................................................................61

5.9.1

Manual remote control RT 1 .........................................................................................61

5.9.2

RTG1 19POL manual remote control ...........................................................................61

5.9.3

Manual remote control RTP 1.......................................................................................61

5.9.4

Manual remote control RTP 2.......................................................................................61

5.9.5

RTP 3 manual remote control.......................................................................................61

5.9.6

Manual remote control RT AC 1 ...................................................................................61

5.9.7

Manual remote control RT PWS 1................................................................................62

5.9.8

Foot-operated remote control RTF 1 ............................................................................62

5.10

PC interface .................................................................................................................................63

5.11

Simultaneous welding on both sides, synchronisation types.......................................................64

5.11.1

Synchronisation via mains voltage (50Hz / 60Hz)........................................................64

5.11.1.1

Selection and adjustment ..............................................................................64

5.12

Interfaces for automation .............................................................................................................65

5.12.1

TIG interface for mechanised welding ..........................................................................65

5.12.2

Remote control connection socket, 19-pole .................................................................66

5.13

Advanced settings........................................................................................................................67

5.13.1

Setting slope times for secondary current AMP% or pulse edges ...............................67

5.13.2

TIG non-latched operating mode, C version.................................................................68

5.13.3

Configuring the TIG potentiometer torch connection....................................................69

5.13.4

Welding current display (ignition, secondary, end and hotstart currents) ....................70

5.13.5

Ramp function foot-operated remote control RTF 1.....................................................71

5.14

Menus and sub-menus on the machine control ...........................................................................72

5.14.1

Direct menus (direct access to parameters).................................................................72

5.14.2

Expert menu (TIG) ........................................................................................................72

5.14.3

Machine configuration menu ........................................................................................73

4

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Contents

Notes on the use of these operating instructions

6 Maintenance, care and disposal......................................................................................................... 76

6.1

General ........................................................................................................................................ 76

6.2

Maintenance work, intervals ........................................................................................................ 76

6.2.1

Daily maintenance tasks .............................................................................................. 76

6.2.2

Monthly maintenance tasks.......................................................................................... 76

6.2.3

Annual test (inspection and testing during operation) .................................................. 76

6.3

Maintenance work........................................................................................................................ 77

6.4

Disposing of equipment ............................................................................................................... 77

6.4.1

Manufacturer's declaration to the end user .................................................................. 77

6.5

Meeting the requirements of RoHS ............................................................................................. 77

7 Rectifying faults ................................................................................................................................... 78

7.1

Customer checklist....................................................................................................................... 78

7.2

Machine faults (error messages) ................................................................................................. 80

7.3

Resetting welding parameters to the factory settings.................................................................. 81

7.4

Display machine control software version ................................................................................... 82

7.5

General operating problems ........................................................................................................ 82

7.5.1

Interface for mechanised welding................................................................................. 82

8 Technical data ...................................................................................................................................... 83

8.1

Tetrix 300 AC/DC Comfort........................................................................................................... 83

9 Accessories .......................................................................................................................................... 84

9.1

Remote controls and accessories................................................................................................ 84

9.2

Welding torch cooling system ...................................................................................................... 84

9.3

Transportsysteme ........................................................................................................................ 84

9.4

General accessories .................................................................................................................... 84

9.5

Options......................................................................................................................................... 84

9.6

Computer communication............................................................................................................ 84

10 Appendix A ........................................................................................................................................... 85

10.1

Overview of EWM branches ........................................................................................................ 85

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Safety instructions

Notes on the use of these operating instructions

2 Safety instructions

2.1

Notes on the use of these operating instructions

DANGER

Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries.

• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.

• The hazard is also highlighted using a symbol on the edge of the page.

WARNING

Working or operating procedures which must be closely observed to prevent serious and even fatal injuries.

• Safety notes include the "WARNING" keyword in the heading with a general warning symbol.

• The hazard is also highlighted using a symbol in the page margin.

CAUTION

Working or operating procedures which must be closely observed to prevent possible minor personal injury.

• The safety information includes the "CAUTION" keyword in its heading with a general warning symbol.

• The risk is explained using a symbol on the edge of the page.

CAUTION

Working and operating procedures which must be followed precisely to avoid damaging or destroying the product.

• The safety information includes the "CAUTION" keyword in its heading without a general warning symbol.

• The hazard is explained using a symbol at the edge of the page.

NOTE

Special technical points which users must observe.

• Notes include the "NOTE" keyword in the heading without a general warning symbol.

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.

6

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Safety instructions

Explanation of icons

2.2

Explanation of icons

Symbol Description

Press

Do not press

0

1

Turn

Switch

Switch off machine

0

1

Switch on machine

ENTER (enter the menu)

NAVIGATION (Navigating in the menu)

EXIT (Exit the menu)

Time display (example: wait 4s/press)

Interruption in the menu display (other setting options possible)

Tool not required/do not use

Tool required/use

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Safety instructions

General

2.3

General

DANGER

Electromagnetic fields!

The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers.

• Observe the maintenance instructions! (see Maintenance and Testing chapter)

• Unwind welding leads completely!

• Shield devices or equipment sensitive to radiation accordingly!

• The correct functioning of pacemakers may be affected (obtain advice from a doctor if necessary).

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)!

Electric shock!

Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents.

• Do not touch any live parts in or on the machine!

• Connection cables and leads must be free of faults!

• Switching off alone is not sufficient!

• Place welding torch and stick electrode holder on an insulated surface!

• The unit should only be opened by specialist staff after the mains plug has been unplugged!

• Only wear dry protective clothing!

• Wait for 4 minutes until the capacitors have discharged!

WARNING

Risk of injury due to radiation or heat!

Arc radiation results in injury to skin and eyes.

Contact with hot workpieces and sparks results in burns.

• Use welding shield or welding helmet with the appropriate safety level (depending on the application)!

• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant regulations in the country in question!

• Protect persons not involved in the work against arc beams and the risk of glare using safety curtains!

Explosion risk!

Apparently harmless substances in closed containers may generate excessive pressure when heated.

• Move containers with inflammable or explosive liquids away from the working area!

• Never heat explosive liquids, dusts or gases by welding or cutting!

8

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Safety instructions

General

WARNING

Smoke and gases!

Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc!

• Ensure that there is sufficient fresh air!

• Keep solvent vapour away from the arc beam field!

• Wear suitable breathing apparatus if appropriate!

Fire hazard!

Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts and hot slag produced during the welding process.

Stray welding currents can also result in flames forming!

• Check for fire hazards in the working area!

• Do not carry any easily flammable objects such as matches or lighters.

• Keep appropriate fire extinguishing equipment to hand in the working area!

• Thoroughly remove any residue of flammable substances from the workpiece before starting welding.

• Only continue work on welded workpieces once they have cooled down.

Do not allow to come into contact with flammable material!

• Connect welding leads correctly!

Risk of accidents if these safety instructions are not observed!

Non-observance of these safety instructions is potentially fatal!

• Carefully read the safety information in this manual!

• Observe the accident prevention regulations in your country.

• Inform persons in the working area that they must observe the regulations!

CAUTION

Noise exposure!

Noise exceeding 70 dBA can cause permanent hearing damage!

• Wear suitable ear protection!

• Persons located within the working area must wear suitable ear protection!

CAUTION

Obligations of the operator!

The respective national directives and laws must be observed for operation of the machine!

• National implementation of the framework directive (89/391/EWG), as well as the associated individual directives.

• In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.

• The regulations regarding work safety and accident prevention for the respective country.

• Setting up and operating the machine according to IEC 60974-9.

• Check at regular intervals that users are working in a safety-conscious way.

• Regular checks of the machine according to IEC 60974-4.

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Safety instructions

General

CAUTION

Damage due to the use of non-genuine parts!

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.

Damage to the machine due to stray welding currents!

Stray welding currents can destroy protective earth conductors, damage equipment and electronic devices and cause overheating of components leading to fire.

• Make sure all welding leads are securely connected and check regularly.

• Always ensure a proper and secure electrical connection to the workpiece!

• Set up, attach or suspend all conductive power source components like casing, transport vehicle and crane frames so they are insulated!

• Do not place any other electronic devices such as drillers or angle grinders, etc., 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!

Mains connection

Requirements for connection to the public mains network

High-performance machines can influence the mains quality by taking current from the mains network. For some types of machines, connection restrictions or requirements relating to the maximum possible line impedance or the necessary minimum supply capacity at the interface with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect, attention is also drawn to the machines' technical data. In this case, it is the responsibility of the operator, where necessary in consultation with the mains network operator, to ensure that the machine can be connected.

10

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Safety instructions

General

CAUTION

EMC Machine Classification

In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data):

Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network. When ensuring the electromagnetic compatibility of class A machines, difficulties can arise in these areas due to interference not only in the supply lines but also in the form of radiated interference.

Class B machines fulfil the EMC requirements in industrial as well as residential areas, including residential areas connected to the low-voltage public mains network.

Setting up and operating

When operating arc welding systems, in some cases, electro-magnetic interference can occur although all of the welding machines comply with the emission limits specified in the standard.

The user is responsible for any interference caused by welding.

In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)

• Mains, control, signal and telecommunication lines

• Radios and televisions

• Computers and other control systems

• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing aid

• Calibration and measuring equipment

• The immunity to interference of other equipment in the surrounding area

• The time of day at which the welding work must be carried out

Recommendations for reducing interference emission

• Mains connection, e.g. additional mains filter or shielding with a metal tube

• Maintenance of the arc welding equipment

• Welding leads should be as short as possible and run closely together along the ground

• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly, it should be connected by means of suitable capacitors.

• Shielding from other equipment in the surrounding area or the entire welding system

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Safety instructions

Transport and installation

2.4

Transport and installation

WARNING

Incorrect handling of shielding gas cylinders!

Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.

• Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air!

• Place shielding gas cylinders in the holders provided for them and secure with fixing devices.

• Avoid heating the shielding gas cylinder!

Risk of accident due to improper transport of machines that may not be lifted!

Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only!

• The machine may not be lifted by crane or suspended!

CAUTION

Risk of tipping!

There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up. Tilt resistance is guaranteed up to an angle of 10°

(according to IEC 60974-1, -3, -10).

• Set up and transport the machine on level, solid ground.

• Secure add-on parts using suitable equipment.

Damage due to supply lines not being disconnected!

During transport, supply lines which have not been disconnected (mains supply leads, control leads, etc.) may cause hazards such as connected equipment tipping over and injuring persons!

CAUTION

Equipment damage when not operated in an upright position!

The units are designed for operation in an upright position!

Operation in non-permissible positions can cause equipment damage.

• Only transport and operate in an upright position!

12

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Safety instructions

Ambient conditions

2.5

Ambient conditions

CAUTION

Installation site!

The 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.

CAUTION

Equipment damage due to dirt accumulation!

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)!

Non-permissible ambient conditions!

Insufficient ventilation results in a reduction in performance and equipment damage.

• Observe the ambient conditions!

• Keep the cooling air inlet and outlet clear!

• Observe the minimum distance of 0.5 m from obstacles!

2.5.1

In operation

Temperature range of the ambient air:

• -20 °C to +40 °C

Relative air humidity:

• Up to 50% at 40 °C

• Up to 90% at 20 °C

2.5.2

Transport and storage

Storage in an enclosed space, temperature range of the ambient air:

• -25 °C to +55 °C

Relative air humidity

• Up to 90% at 20 °C

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13

Intended use

Applications

3 Intended use

This machine has been manufactured according to the latest developments in technology and current regulations and standards. It must only be operated in line with the instructions on correct usage.

WARNING

Hazards due to improper usage!

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 proper usage and by trained or expert staff!

• Do not modify or convert the equipment improperly!

3.1

Applications

3.1.1

TIG welding

TIG welding with alternating or direct current. Arc ignition optionally by means of non-contact HF ignition or contact ignition with Liftarc.

3.1.2

MMA welding

Manual arc welding or, for short, MMA welding. It is characterised by the fact that the arc burns between a melting electrode and the molten pool. There is no external protection; any protection against the atmosphere comes from the electrode.

14

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Intended use

Documents which also apply

3.2

Documents which also apply

3.2.1

Warranty

NOTE

For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"!

3.2.2

Declaration of Conformity

The designated machine conforms to EC Directives and standards in terms of its design and construction:

• EC Low Voltage Directive (2006/95/EC),

• EC EMC Directive (2004/108/EC),

This declaration shall become null and void in the event of unauthorised modifications, improperly conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted conversion work not specifically authorised by the manufacturer.

The original copy of the declaration of conformity is enclosed with the unit.

3.2.3

Welding in environments with increased electrical hazards

In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in environments with an increased electrical hazard.

3.2.4

Service documents (spare parts and circuit diagrams)

DANGER

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)!

Original copies of the circuit diagrams are enclosed with the unit.

Spare parts can be obtained from the relevant authorised dealer.

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15

Machine description – quick overview

Front view

4 Machine description – quick overview

NOTE

The maximum possible machine configuration is given in the text description.

If necessary, the optional connection may need to be retrofitted (see "Accessories" chapter).

4.1

Front view

16

Figure 4-1

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Machine description – quick overview

Front view

9

10

3

4

5

6

7

1

8

11

12

Carrying handle

0

See Machine control – operating elements chapter

Connection socket, 19-pole

Remote control connection

Cooling air inlet

Connection socket, welding current “-” (with DC- polarity)

connection for Electrode holder

Connection socket, welding current “+” (with DC- polarity)

Connection for workpiece lead

1

Key switch for protection against unauthorised use

Position “1” > changes possible,

Position “0” > changes not possible.

Please take note of chapter “Protecting welding parameters from unauthorised access”

Connection socket, 8-pole / 12-pole

8-pole: TIG Up/Down or potentiometer torch control lead

12-pole: Control lead for TIG up/down torch with LED display (option)

Connection socket, 5-pole

Standard TIG torch control lead

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

Machine feet

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Machine description – quick overview

Rear view

4.2

Rear view

Figure 4-2

18

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Machine description – quick overview

Rear view

1

2

3

4

5

6

7

8

9

10

11 analog

19-pole mechanised welding interface (analogue)

(See chapter entitled "Design and function > interfaces".)

Connection socket, 7-pole

Connection for peripheral devices with digital interface

G¼” connecting nipple

Shielding gas connection on the pressure regulator

Main switch, machine on/off

Mains connection cable

4-pole connection socket

Cooling unit voltage supply

8-pole connection socket

Cooling unit control lead

" Automatic circuit-breaker " key button; fuse protection:

42V/4A

• Peripheral devices on the 7-pole, digital interfaces (rear of the machine)

Reset triggered automatic cutout by pressing

PC interface, serial (D-Sub connection socket, 9-pole)

COM

HF

HF

Ignition type changeover switch

HF

= HF ignition

HF

= Liftarc (contact ignition)

Cooling air outlet

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Machine description – quick overview

Machine control – Operating elements

4.3

Machine control – Operating elements

20

3

4

1

2

5

Figure 4-3

Welding process button

MMA welding, lights up in green / arcforce setting, lights up in red

Operating mode button

spotArc (spot time setting range 0.01 sec. to 20.0 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 special

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.

Switch display/JOB number button

AMP Welding current display

VOLT Welding voltage display

JOB Display and select JOB number

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Machine description – quick overview

Machine control – Operating elements

6

7

8

9

10

11

Alternating current frequency (TIG AC) rotary dial

50 Hz to 200 Hz

Alternating current balance (TIG AC) rotary dial

Max. setting range: - 30% to + 30%

Tungsten electrode diameter/Ignition optimisation rotary dial

Infinitely adjustable from 1 mm to 4 mm or greater

Welding parameter setting rotary transducer

Setting flows, times and parameters.

S

Three-figure LED display

Welding parameter display (see also chap. “Welding data display”).

Error/status indicators

Collective interference signal light

Water deficiency signal light (welding torch cooling)

S

Excess temperature signal light

safety sign signal light

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Machine description – quick overview

Machine control – Operating elements

4.3.1

Function sequence

22

Figure 4-4

1

Select welding parameters button

This button is used to select the welding parameters depending on the welding process and operating mode used.

2 sec

Gas pre-flow time (TIG)

absolute setting range 0.0 sec to 20.0 sec (0.1s increments).

3 AMP%

4

Ignition current (TIG)

Percentage of the main current.

Setting range 1 % to 200 %

(1 % increments). There are no pulses during the ignition current phase.

sec Up-slope time (TIG)

Setting ranges: 0.00 s to 20.0 s

(0.1 s increments).

The up-slope time can be set separately for non-latched and latched.

Hotstart current (MMA)

Percentage of the main current. Setting range 1 % to 200 %

(1 % increments).

Hotstart time (MMA)

Setting ranges: 0.00 s to 20.0 s

(0.1 s increments).

6

• Pulse time setting range: 0.01 s to 20.0 s

(0.01 s increments < 0.5 s; 0.1 s increments > 0.5 s)

• Slope time (tS2) setting range: 0.0 s to 20.0 s

(see chapter "Advanced settings")

TIG pulses

The pulse time applies to the main current phase (AMP) for pulses.

TIG AC Special

The pulse time applies to the AC phase for

AC special.

AMP

Main current (TIG) / pulse current

I min to I max (1 A increments)

Main current (MMA)

I min to I max (1 A increments)

• Pulse break setting range: 0.01 sec to 20.0 sec

(0.01 sec increments < 0.5 sec; 0.1 sec increments > 0.5 sec)

• Slope time (tS1) setting range: 0.0 sec to 20.0 sec

(see 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.

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Machine description – quick overview

Machine control – Operating elements

11

12

13

8

14

15

AMP%

Secondary current (TIG) / pulse pause current

Setting range 1 % to 100 % (1 % increments). Percentage of the main current.

0.00 s to 20.0 s (0.1 s increments).

The down-slope time can be set separately for non-latched and latched.

Setting range 1 % to 200 % (1 % increments). Percentage of the main current.

sec

Gas post-flow time (TIG)

Setting ranges: 0.00 sec to 40.0 sec (0.1 sec increments).

Tungsten electrode diameter / Ignition optimisation (TIG)

Infinitely adjustable from 1 mm to 4 mm or greater (0,1 mm increments)

Alternating current balance (TIG AC)

Max. setting range: -30 % to +30 % (1 % 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: 1 % to +99 % (1 % increments)

Alternating current frequency (TIG AC)

50 Hz to 200 Hz (1 Hz increments).

Constriction and stabilisation of the arc:

The cleaning effect increases with a greater frequency. 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 15 kHz

activArc TIG welding process

• Switch activArc on or off

• Correct the activArc characteristic (setting range: 0 to 100)

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Design and function

General

5 Design and function

5.1

General

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!

CAUTION

Risk of burns on the welding current connection!

If the welding current connections are not locked, connections and leads heat up and can cause burns, if touched!

• Check the welding current connections every day and lock by turning in clockwise direction, if necessary.

Risk from electrical current!

If welding is carried out alternately using different methods and if a welding torch and an electrode holder remain connected to the machine, the open-circuit/welding voltage is applied simultaneously on all cables.

• The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks.

CAUTION

Using protective dust caps!

Protective dust caps protect the connection sockets and therefore the machine against dirt and damage.

• The protective dust cap must be fitted if there is no accessory component being operated on that connection.

• The cap must be replaced if faulty or if lost!

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Design and function

Transport and installation

5.2

Transport and installation

WARNING

Risk of accident due to improper transport of machines that may not be lifted!

Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only!

• The machine may not be lifted by crane or suspended!

CAUTION

Installation site!

The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base!

• The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work.

• Safe operation of the machine must be guaranteed at all times.

5.3

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.

5.4

Workpiece lead, general

CAUTION

Risk of burns due to incorrect connection of the workpiece lead!

Paint, rust and dirt on the connection restrict the power flow and may lead to stray welding currents.

Stray welding currents may cause fires and injuries!

• Clean the connections!

• Fix the workpiece lead securely!

• Do not use structural parts of the workpiece as a return lead for the welding current!

• Take care to ensure faultless power connections!

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Design and function

Mains connection

5.5

Mains connection

DANGER

Hazard caused by improper mains connection!

An improper mains connection can cause injuries or damage property!

• Only use machine with a plug socket that has a correctly fitted protective conductor.

• If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations (any phase sequence for three-phase machines)!

• Mains plug, socket and lead must be checked regularly by an electrician!

• When operating the generator always ensure it is earthed as stated in the operating instructions. The resulting network has to be suitable for operating devices according to protection class 1.

5.5.1

Mains configuration

NOTE

The machine may be connected to:

• a three-phase system with four conductors and an earthed neutral conductor

• a three-phase system with three conductors of which any one can be earthed, e.g. the outer conductor

Figure 5-1

Legend

Item Designation

black brown grey blue

PE Protective green-yellow

CAUTION

Operating voltage - mains voltage!

The operating voltage shown on the rating plate must be consistent with the mains voltage, in order to avoid damage to the machine!

• For mains fuse protection, please refer to the “Technical data” chapter!

• Insert mains plug of the switched-off machine into the appropriate socket.

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Design and function

TIG welding

5.6

TIG welding

5.6.1

Welding torch and workpiece line connection

NOTE

Prepare welding torch according to the welding task in hand (see operating instructions for the torch).

Figure 5-2

1

2

3

Workpiece

Connection socket for "+" welding current

Workpiece lead connection

Welding torch

5

Connection socket, 8-pole / 12-pole

8-pole: TIG Up/Down or potentiometer torch control lead

12-pole: Control lead for TIG up/down torch with LED display (option)

6

7

Connection socket, 5-pole

Standard TIG torch control lead

Connection socket, "-" welding current

Welding current lead connection for TIG welding torch

8

G¼" connecting nipple

TIG welding torch shielding gas connection

• Insert the welding current plug on the welding torch into the welding current connection socket and lock by turning to the right.

• Remove yellow protective cap on G¼ connecting nipple.

• Screw welding torch shielding gas connection tightly onto the G¼" connection nipple.

• 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 12-pole with up/down torch with LED display) and tighten.

• Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by turning to the right.

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Design and function

TIG welding

If fitted:

• 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).

NOTE

Please note the relevant documentation of the accessory components.

5.6.2

Torch connection options and pin assignments

Figure 5-3

5.6.3

Shielding gas supply (shielding gas cylinder for welding machine)

WARNING

Incorrect handling of shielding gas cylinders!

Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.

• Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air!

• Place shielding gas cylinders in the holders provided for them and secure with fixing devices.

• Avoid heating the shielding gas cylinder!

CAUTION

Faults in the shielding gas supply.

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.

NOTE

Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to expel any dirt.

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5.6.3.1

Connecting the shielding gas supply

• Place the shielding gas cylinder into the relevant cylinder bracket.

• Secure the shielding gas cylinder using a securing chain.

Design and function

TIG welding

Figure 5-4

1

2

3

4

Pressure regulator

Shielding gas cylinder

Output side of the pressure regulator

Cylinder valve

• Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.

• Screw gas hose connection crown nut onto the output side of the pressure regulator.

Figure 5-5

1

Connecting nipple G¼, shielding gas connection

• Connect crown nut of the shielding gas line to the G¼“ connecting nipple.

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Design and function

TIG welding

5.6.3.2

Setting the shielding gas quantity

NOTE

Rule of thumb for the gas flow rate:

Diameter of gas nozzle in mm corresponds to gas flow in l/min.

Example: 7mm gas nozzle corresponds to 7l/min gas flow.

Incorrect shielding gas setting!

If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to form.

• Adjust the shielding gas quantity to suit the welding task!

5.6.3.3

Gas test

Operating element

Action Result x x

Press the "Select welding parameter" button until the "activArc" LED activArc flashes.

5 sec.

Press the "Select welding parameter" button and hold for approx. 5 sec.

The gas pre-flow time LED (TIG) will come on, shielding gas flows for approx. 20 sec.

• Set the required amount of shielding gas on the pressure reducer, about 4 - 15 l/min depending on the current strength and the material.

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Design and function

TIG welding

5.6.4

Select welding task

NOTE

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").

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 “1”.

The welding task (JOB) can be selected in two ways:

• Manual, standard operation (JOB "0")

• JOB operation, saved welding tasks (JOB 1 to 7)

5.6.4.1

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.

The welding task is selected using the buttons on the machine control on the welding machine.

Signal lights (LED) display the welding parameter selection.

Set the welding task in the following order:

1

2

3

4

5

6

7

Welding process button

MMA welding, lights up in green / arcforce setting, lights up in red

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.

Operating mode button

spotArc (spot time setting range 0.01 sec. to 20.0 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

Alternating current frequency (TIG AC) rotary dial

50 Hz to 200 Hz

Alternating current balance (TIG AC) rotary dial

Max. setting range: - 30% to + 30%

Tungsten electrode diameter/Ignition optimisation rotary dial

Infinitely adjustable from 1 mm to 4 mm or greater

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Design and function

TIG welding

8

9

Select welding parameters button

This button is used to select the welding parameters depending on the welding process and operating mode used.

Welding parameter setting rotary transducer

Setting flows, times and parameters.

5.6.4.2

Save welding tasks (JOBs)

You can select, change and save the required welding parameters for recurring welding tasks (JOBs) in up to 7 JOBs (JOB 1 to JOB 7).

Displaying and changing the JOB number

Operating element

Action Result

Select JOB display

n x

Change the JOB number

1 x

If the display switchover is pressed or if there is no keyboard input for 5 seconds, the new JOB will be active

NOTE

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 1 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.

5.6.5

Welding data display

The following welding parameters can be displayed before (nominal values) or during (actual values) welding.

(nominal values)

During welding

(actual values)

Welding current

Welding voltage

JOB number

Parameter times

Frequency, balance

;

…

;

;

;

;

;

…

…

…

Parameter currents

; …

5.6.5.1

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.

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Design and function

TIG welding

5.6.6

Arc ignition

5.6.6.1

HF ignition

Figure 5-6

The arc is started without contact from high-voltage ignition pulses.

a) Position the welding torch in welding position over the workpiece (distance between the electrode tip and workpiece should be approx. 2-3mm). b) Press the torch trigger (high voltage ignition pulses ignite the arc). c) Ignition current flows, and the welding process is continued depending on the operating mode selected.

End the welding process: Release or press the torch trigger depending on the operating mode selected.

5.6.6.2

Liftarc ignition

a) b) c)

Figure 5-7

The arc is ignited on contact with the workpiece:

a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger (liftarc current flowing, regardless of the main current set). b) Incline the torch over the torch gas nozzle to produce a gap of approx. 2-3 mm between the electrode tip and the workpiece. The arc ignites and the welding current is increased, depending on the operating mode set, to the ignition or main current set. c) Lift off the torch and swivel to the normal position.

Ending the welding process: Release or press the torch trigger depending on the operating mode selected.

5.6.7

Automatic cut-out

NOTE

The automatic cut-out function will be triggered by two conditions during the welding process:

During the ignition phase (ignition fault)

• If there is no welding current within 3s after starting the welding.

During the welding phase (arc interruption)

• If the arc is interrupted for longer than 3s.

In both cases, the welding machine ends the ignition or welding process immediately.

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Design and function

TIG welding

5.6.8

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.

5.6.8.1

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

5.6.8.2

JOB operation (JOB 1 to 7)

Operating element

Action Result 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

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TIG welding

5.6.9

Optimal and fast spherical cup formation

NOTE

A conically ground tungsten electrode (approx. 35°) is generally required to form an ideal spherical cup.

Spherical cup formation preset

Operating element

Action Result

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)

NOTE

• Use a sample workpiece.

• Ignite arc with HF ignition (non-contact) and form required spherical cup for the application in question.

• Set parameter values back to the original values.

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Design and function

TIG welding

5.6.10

Function sequences/operating modes

The parameters for the function sequence are set using the “Select welding parameters” button and the

“Welding parameter setting” rotary dial.

Figure 5-8

1

2

Select welding parameters button

This button is used to select the welding parameters depending on the welding process and operating mode used.

Welding parameter setting rotary transducer

Setting flows, times and parameters.

5.6.10.1

Explanation of symbols

Symbol Meaning

Press torch trigger 1

Release torch trigger 1

I Current

t Time

Gas pre-flows

I start

current

t

Up

AMP Main current (minimum to maximum current)

AMP% Secondary current (0% to 100% of AMP)

t2 Pulse pause time

ts1 TIG pulses: Slop time from main current (AMP) to secondary current (AMP%)

ts2 TIG pulses: Slop time from secondary current (AMP%) to main current (AMP)

t

Down

I end

Gas post-flows

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TIG welding

Non-latched mode

Figure 5-9

1st cycle:

• Press and hold torch trigger 1.

• The gas pre-flow time elapses.

• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.

• The welding current flows and immediately assumes the value set for the ignition current I start

.

• HF is switched off.

• The welding current increases with the adjusted up-slope time to the main current AMP.

If torch trigger 2 is pressed in addition to torch trigger 1 during the main current phase, the welding current drops at the slope time set (tS1) to the secondary current AMP%.

After torch trigger 2 is released, the welding current rises at the slope time set (tS2) back to the main current AMP.

2nd cycle:

• Release torch trigger 1.

• The main current falls in the set down-slope time to the end-crater current I end

(minimum current).

If the 1st 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.

NOTE

When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation.

The up- and down-slopes are switched off.

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Design and function

TIG welding

Latched mode

1.

I

AMP

2.

3.

4.

AMP%

I start

I end t

Up t

Down t

Figure 5-10

Step 1

• Press torch trigger 1, the gas pre-flow time elapses.

• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.

• Welding current flows and immediately assumes the ignition current value set (search arc at minimum setting). HF is switched off.

Step 2

• Release torch trigger 1.

• 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 2 or

• Tap torch trigger 1

The slope times can be set (see chapter "Advanced settings", section "Setting slope times for secondary current AMP% or pulse edges".

Step 3

• Press torch trigger 1.

• The main current drops with the set down-slope time to the end-crater current I end

(minimum current).

Step 4

• Release torch trigger 1, 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 1st torch trigger (3rd and 4th step).

The current drops to zero and the gas post-flow time begins.

NOTE

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.

The user can initiate the welding operation also by lightly tipping the torch trigger. This function is available from torch mode 11 (see chapter "Torch mode setting)."

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TIG welding

5.6.10.2

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 (t1) and pulse break time (t2) 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

Signal light comes on

The spot time can be set for approx. 4 s using the "Welding parameter setting" rotary dial (spot time setting range 0.01 s to 20.0 s)

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"

Figure 5-11

Sequence:

• Press and hold torch trigger 1.

• The gas pre-flow time elapses.

• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.

• The welding current flows and immediately assumes the value set for the ignition current I start

.

• HF is switched off.

• The welding current increases in the adjusted up-slope time to the main current AMP.

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Design and function

TIG welding

NOTE

The process ends when the set spotArc time elapses or if the torch trigger is released prematurely. spotArc/pulse variants table:

TIG DC

TIG AC

(lights up in green)

(lights up in red)

No pulses

(lights up in green)

No pulses

Automated pulses (factory setting)

Pulses (thermal pulses) kHz pulse (metallurgic pulses)

Pulses (thermal pulses)

AC special

NOTE

The up-slope and down-slope times should be set to “0” to achieve an effective result.

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TIG welding

5.6.10.3

Spotmatic

The arc is ignited fully automatically without actuating the torch trigger by simply touching the tip of the electrode with the workpiece. Hundreds of reproducible tacks can be made without tungsten inclusions.

NOTE

Selection and adjustment are made in the same way as with spotArc operating mode

(see chapter TIG spotArc).

Figure 5-12

NOTE

In order to achieve an effective result, the upslope time should be set to "0 s".

Sequence

The procedure is shown with the example of the HF ignition type. Arc ignition with Liftarc is, however, also possible (see chapter entitled "Arc ignition").

• The torch trigger must first be pressed once to activate the function. The spotArc signal light starts to flash rapidly. The user must now start the welding process within 30 s.

• Position the torch gas nozzle and tungsten electrode tip carefully on the workpiece.

• Incline the torch over the torch gas nozzle until there is a gap of approx. 2-3 mm between the electrode tip and the workpiece.

Shielding gas flows in the set gas pre-flow time.

The arc ignites and the previously set welding current flows.

The main current phase ends when the set spotArc time expires.

The welding current drops in the set downslope time to the end current.

The gas post-flow time expires and the welding process ends.

If the welding torch with the electrode tip is placed again on the workpiece, the next welding process is started.

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Design and function

TIG welding

5.6.10.4

Non-latched operation, version C

Figure 5-13

1st cycle

• Press torch trigger 1, the gas pre-flow time elapses.

• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.

• Welding current flows and immediately adopts the ignition current value set (search arc at minimum setting). HF is switched off.

2nd cycle

• Release torch trigger 1.

• The welding current increases in the set up-slope time to the main current AMP.

NOTE

Pressing torch trigger 1 starts the slope (tS1) from main current AMP to secondary current AMP%. Releasing the torch trigger starts the slope (tS2) 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".

This operating mode needs to be activated (see chapter "Advanced settings" in the "TIG non-latched operating mode, C version") section.

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TIG welding

5.6.11

Pulses, function sequences

NOTE

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.

The pulse function can also be deactivated if necessary during the upslope and downslope phases (see chapter "Advanced settings").

5.6.11.1

TIG pulses – non-latched operation

1.

2.

I

AMP

I start

5.6.11.2

TIG pulses - latched operation t

Up

AMP%

Figure 5-14

t

Down

I end t

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Figure 5-15

43

Design and function

TIG welding

5.6.12

Pulse variants

NOTE

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).

5.6.12.1

Pulses (thermal pulses)

With thermal pulses, the pulse and pause times (frequency up to 200 Hz) and the pulse edges (ts1 and ts2) are entered in seconds on the control.

44

Operating element

Action Result

Figure 5-16

Select TIG pulses function

Signal light lights up in green

Select pulse time "t1"

LED "Pulse time" comes on (see chapter "Function sequence")

Set pulse time "t1"

Select break time "t2"

LED "Pulse break time" comes on (see chapter "Function sequence")

Set break time "t2"

2 s

Select slope times "ts1" and "ts2"

Set slope time "ts1"

Switch between slope times "ts1" and "ts2"

Set slope time "ts2"

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5.6.12.2

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 15 kHz and the pulse balance from 1-99 %.

In contrast to thermal pulses, the pulse edge times are not required.

NOTE

The pulse process continues during the up-slope and down-slope phases!

Operating element

Action Result

Figure 5-17

Select kHz pulses

Press the "TIG pulses" button until the

signal light lights up in red

Display

-

Select balance

Setting range: 1% to 99% (1% increments)

Operating element

Select frequency

Setting range: 50 Hz to 15 kHz (0.01 kHz increments)

5.6.12.3

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.

Action Result

Select TIG automated pulses

Press the "TIG pulses" button until the

TIG automated pulses signal light comes on

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5.6.12.4

AC pulses

(AC pulse, max. 50Hz)

Setting:

AMP

+

AMP

AMP% t

AMP = pulse current

AMP% = pulse pause current / basic current tpuls = pulse time tpause = pulse pause time

t pause t puls

Figure 5-18

5.6.12.5

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 signal light comes on

AMP

AMP

AMP% t

AMP = AC current phase pulse current

AMP% = DC phase pulse pause current t pulse t break

=

=

Pulse time; AC phase time

Pulse break time; DC phase time

t pause t puls

Figure 5-19

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5.6.13

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 n x

Select activArc parameter

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).

Display Operating element Action Result

Select activArc parameter value

4 s n x

Select activArc parameter value

Press until LED flashes

Set parameter value

• Increase parameter value (A/V)

• Decrease parameter value (A/V)

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Design and function

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5.6.14

Welding torch (operating variants)

Different torch versions can be used with this machine.

Functions on the operating elements, such as torch triggers (TT), rockers or potentiometers, can be modified individually via torch modes.

Explanation of symbols for operating elements:

Symbol Description

BRT 1 Press torch trigger

BRT 1

Tap torch trigger *

BRT 2

Tap * and press torch trigger

5.6.14.1

Tap torch trigger (tapping function)

NOTE

Pressing the torch trigger briefly to change a function, e.g. changing over from main to secondary current.

The function is used in torch modes 1-6 (factory setting). The function is deactivated in torch modes 11-16 (for more in-depth information, see Torch mode setting chapter).

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5.6.15

Torch mode and up/down speed setting

The user has the modes 1 to 6 and modes 11 to 16 available. Modes 11 to 16 include the same function options as 1 to 6, but without tapping function for the secondary current.

The function options in the individual modes can be found in the tables for the corresponding torch types.

The welding process can of course be switched on and off in all modes using torch trigger 1 (TT 1).

0

1

0

1

Figure 5-20

Display Setting/selection

Exit the menu

Exit

Torch configuration menu

Set welding torch functions

Torch mode

• Modes 1-6: with tapping function (factory setting 1)

• Modes 11-16: without tapping function

Up-/Down speed (not available in modes 4 and 14)

Increase value = rapid current change (factory setting 10)

Reduce value = slow current change

NOTE

Only the modes listed are suitable for the corresponding torch types.

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5.6.15.1

Standard TIG torch (5-pole)

Standard torch with one torch trigger: elements

BRT1 = Torch trigger 1 (welding current on/off; secondary current via tapping function)

Welding current On/Off

1

(factory-set)

elements

BRT 1

BRT 1

Secondary current (Latched mode)

Standard torch with two torch triggers: elements

Welding current On/Off

Secondary current

Secondary current (tapping mode) / (Latched mode)

Welding current On/Off

Secondary current (tapping mode) / (Latched mode)

Up function

Down function

1

(factory-set)

3 elements

BRT 1

BRT 2

BRT 1

BRT 1

BRT 1

BRT 2

BRT 2

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Standard torch with one rocker (MG rocker, two torch triggers) elements

BRT 1 = torch trigger 1

BRT 2 = torch trigger 2

Welding current On/Off

Secondary current

Secondary current (tapping mode) / (Latched mode)

Welding current On/Off

Secondary current (tapping mode)

Up function

Down function

Welding current On/Off

Secondary current (tapping mode) / (Latched mode)

Up function

Down function

1

(factory-set)

2 elements

BRT 1

BRT 2

BRT 1

BRT 1

BRT 2

BRT 1

BRT 1

+

BRT 2

BRT 1

+

BRT 2

BRT 1

3

BRT 2

BRT 2

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5.6.15.2

TIG up/down torch (8-pole)

Up/down torch with one torch trigger

Diagram

Operating

elements

Explanation of symbols

TT 1 = torch trigger 1

Functions

Welding current on/off

Secondary current (tapping mode) / (Latched mode)

Increase welding current, infinite adjustment (up function)

Reduce welding current, infinite adjustment (down function)

Welding current on/off

Secondary current (tapping mode)

Welding current on/off

Secondary current (tapping mode) / (Latched mode)

Increase welding current by an increment (see chapter "Setting the first increment in modes 4 and 14")

Reduce welding current by an increment (see chapter "Setting the first increment in modes 4 and 14")

Mode

1

(factory-

set)

Operating

elements

BRT 1

BRT 1

Up

2

4

Down

BRT 1

BRT 1

BRT 1

BRT 1

Up

Down

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Up/down torch with two torch triggers

Diagram

Operating

elements

Explanation of symbols

TT 1 = torch trigger 1 (left)

TT 2 = torch trigger 2 (right)

Functions Mode

Welding current on/off

Secondary current

Secondary current (tapping mode) / (Latched mode)

Increase welding current, infinite adjustment (up function)

1

(factory-

set)

Operating

elements

BRT 1

BRT 2

BRT 1

Up

Reduce welding current, infinite adjustment (down function)

Welding current on/off

Secondary current

Secondary current (tapping mode)

Welding current on/off

Secondary current

Secondary current (tapping mode)

Increase welding current by an increment (see chapter "Setting the first increment in modes 4 and 14")

Reduce welding current by an increment (see chapter "Setting the first increment in modes 4 and 14")

2

4

BRT 1

Down

BRT 2

BRT 1

BRT 1

BRT 2

BRT 1

Up

Gas test

4

Down

BRT 2

> 3 s

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5.6.15.3

Potentiometer torch (8-pole)

NOTE

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: elements

BRT 1 = torch trigger 1

Welding current On/Off

Secondary current (tapping mode)

elements

BRT 1

BRT 1

3

Increase welding current, infinite adjustment

Reduce welding current, infinite adjustment

Potentiometer torch with two torch triggers: elements

BRT 1 = torch trigger 1

BRT 2 = torch trigger 2

Welding current On/Off

Secondary current

Secondary current (tapping mode)

3

elements

BRT 1

BRT 1

BRT 2

Increase welding current, infinite adjustment

Reduce welding current, infinite adjustment

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5.6.15.4

RETOX TIG torch (12-pole)

NOTE

For operation with this welding torch, the welding machine must be equipped with the retrofit option "ON 12POL RETOX TIG" (12-pole torch connection socket)!

Diagram Operating elements Explanation of symbols

TT= torch trigger

8 8 8

BRT 1

BRT 3

BRT 2

BRT 4

Welding current on/off

Secondary current

Secondary current (tapping function)

Increase welding current (up function)

Reduce welding current (down function)

1

(ex works) elements

TT 1

TT 2

TT 1 (tapping)

TT 3

TT 4

Modes 2 and 3 are not used with this type of torch or, respectively, are not appropriate.

Welding current on/off

Secondary current

Secondary current (tapping function)

Raise welding current in stages (setting the first increment)

Decrease welding current in stages (setting the first decrement)

Switchover between Up-Down and JOB changeover

4

TT 1

TT 2

TT 1 (tapping)

TT 3

TT 4

TT 2 (tapping)

Increase JOB number

Decrease JOB number

Gas test

Welding current on/off

Secondary current

Secondary current (tapping function)

Increase welding current, infinite adjustment (up function)

Reduce welding current, infinite adjustment (down function)

Switchover between Up-Down and JOB changeover

Increase JOB number

Decrease JOB number

Gas test

6

TT 3

TT 4

TT 2 (3 s)

TT 1

TT 2

TT 1 (tapping)

TT 3

TT 4

TT 2 (tapping)

TT 3

TT 4

TT 2 (3 s)

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5.6.16

Setting the first increment

0

1

0

1

Figure 5-21

Figure 5-22

Display Setting/selection

Exit the menu

Exit

Torch configuration menu

Set welding torch functions

Setting the first increment

Setting: 1 to 20 (factory setting 1)

NOTE

This function is only available when using up/down torches in modes 4 and 14!

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MMA welding

5.7

MMA welding

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.

Shielding gas connection!

During MMA welding open circuit voltage is applied at the shielding gas connection

(G¼" connecting nipple).

• Place yellow insulating cap on the G¼" connection nipple (protects against electrical voltage and dirt).

5.7.1

Connecting the electrode holder and workpiece lead

NOTE

Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

1

2

3

4

Figure 5-23

Electrode holder

Connection socket, “-” welding current

Workpiece lead or electrode holder connection

Workpiece

Connection socket for "+" welding current

Electrode holder or workpiece lead connection

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MMA welding

• Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right.

• Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and lock by turning to the right.

NOTE

The welding current polarity can be reversed on the machine control

(see chapter "Reversing the welding current polarity").

5.7.2

Select welding task

NOTE

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 “1”.

The welding task is selected using the buttons on the machine control on the welding machine.

Signal lights (LED) display the welding parameter selection.

Set the welding task in the following order:

1

Welding process button

MMA welding, lights up in green / arcforce setting, lights up in red

2

3

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.

Select welding parameters button

This button is used to select the welding parameters depending on the welding process and operating mode used.

4 AMP%

Ignition current (TIG)

Percentage of the main current.

Setting range 1 % to 200 %

(1 % increments). There are no pulses during the ignition current phase.

5 sec Up-slope time (TIG)

Setting ranges: 0.00 s to 20.0 s

(0.1 s increments).

The up-slope time can be set separately for non-latched and latched.

Hotstart current (MMA)

Percentage of the main current. Setting range 1 % to 200 %

(1 % increments).

Hotstart time (MMA)

Setting ranges: 0.00 s to 20.0 s

(0.1 s increments).

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6

Alternating current frequency (TIG AC)

50 Hz to 200 Hz (1 Hz increments).

Constriction and stabilisation of the arc:

The cleaning effect increases with a greater frequency. 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 15 kHz

5.7.3

Hotstart current and Hotstart time

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

Operating element

Action Result

4 sec.

Select expert menu

Hotstart current parameter (Iht)

Set hotstart current parameter value

Select hotstart time parameter (tht) x x

Set hotstart time parameter value

Display

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Protecting welding parameters from unauthorised access

5.7.4

Switching the welding current polarity

This function can be used to reverse the welding current polarity electronically.

For example, when welding with different electrode types for which different polarities are stipulated by the manufacturer, the welding current polarity can be switched easily on the control.

Operating

element

Action Result n x

Select welding current polarity welding parameter:

Position :

"-" polarity on connection socket, welding current "-"

"+" polarity on connection socket, welding current "+"

Position :

"+" polarity on connection socket, welding current "-"

"-" polarity on connection socket, welding current "+"

5.7.5

Arcforce

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

1 x

Select arcforcing welding parameter

The signal light lights up in red

5.7.6

Antistick

Set arcforcing

-40 = low current increase > soft arc

0

+40

= default setting

= 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 1 second to prevent the electrode from overheating. Check the welding current setting and correct according to the welding task!

Figure 5-24

5.8

Protecting welding parameters from unauthorised access

NOTE

These accessory components can be retrofitted as an option, see Accessories chapter.

To protect against unauthorised or unintentional adjustment of the welding parameters on the machine, the control input can be locked with the aid of a key switch.

Key position 1 =

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

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Remote control

5.9

Remote control

NOTE

The remote control is operated on the 19-pole remote control connection socket.

5.9.1

Manual remote control RT 1

Functions

• Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine.

5.9.2

RTG1 19POL manual remote control

Functions

• Infinite setting of the welding current (0% to 100%) depending on the main current preselected at the welding machine

5.9.3

Manual remote control RTP 1

Functions

RTP2

• TIG/MMA

• Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine.

• Pulse/spot/normal

• Pulse, spot and break times are infinitely adjustable.

5.9.4

Manual remote control RTP 2

RTP2

Functions

• TIG/MMA.

• Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine.

• Pulse/spot/normal

• Frequency and spot times infinitely adjustable.

• Coarse adjustment of the cycle frequency.

• Pulse/pause ratio (balance) adjustable from 10% to 90%.

5.9.5

RTP 3 manual remote control

Functions

RTP2

• TIG / MMA.

• Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine.

• Pulse / SpotArc spots / normal

• Frequency and spot time infinitely adjustable.

• Coarse adjustment of the pulse frequency.

• Pulse/pause ratio (balance) adjustable from 10% to 90%.

5.9.6

Manual remote control RT AC 1

Functions

• Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine.

• AC frequency of welding current infinitely adjustable.

• AC balance (positive/negative half-wave ratio) can be set from +15% to -15%.

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Design and function

Remote control

5.9.7

Manual remote control RT PWS 1

Functions

• Infinitely adjustable welding current (0% to 100%) depending on the preselected main current at the welding machine

• Pole reversing switch, suitable for machines with PWS function

5.9.8

Foot-operated remote control RTF 1

Functions

• Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine.

• Start/stop welding operation (TIG)

ActivArc welding is not possible in combination with the RTF 1 foot-operated remote control.

I

FFr > off

FFr > on

I start

I end t

Figure 5-25

Symbol Meaning

Actuate foot-operated remote control (start welding process)

Operate foot-operated remote control (set welding current according to application)

Release foot-operated remote control (end welding process)

FFr

RTF ramp function on off

Welding current runs in a ramp function at the specified main current

Welding current goes immediately to the specified main current

NOTE

The RTF ramp function can be switched on and off in the machine control sub-menu

(see "Advanced settings > ramp function RTF" chapter).

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PC interface

5.10

PC interface

CAUTION

Equipment damage or faults may occur if the PC is connected incorrectly!

Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission. The PC may be destroyed due to high frequency ignition pulses.

• Interface SECINT X10USB must be connected between the PC and the welding machine!

• The connection must only be made using the cables supplied (do not use any additional extension cables)!

NOTE

Please note the relevant documentation of the accessory components.

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Simultaneous welding on both sides, synchronisation types

5.11

Simultaneous welding on both sides, synchronisation types

This function is important, if two power sources are used to simultaneously weld on both sides, as is sometimes required for welding thick aluminium materials in the PF position. This ensures that, with alternating currents, the positive and negative pole phases are present on both power sources simultaneously, thus avoiding the arcs negatively influencing each other.

5.11.1

Synchronisation via mains voltage (50Hz / 60Hz)

NOTE

This application relates to two types of synchronisation:

• Synchronisation between a Tetrix series machine and a competitor machine.

• Synchronisation between two Tetrix series machines.

Phase sequences and rotating fields of the supply voltages must be identical for both welding machines.

If this is not the case, the energy input into the weld pool will be negatively affected.

Use the "Phase sequence changeover“ rotary switch to correct the phase difference in steps of

60° (0°, 60°, 120°, 180°, 240° and 300°).

An optimum phase correction will directly achieve better welding results.

5.11.1.1

Selection and adjustment

Operating element

Action Result

Select JOB numberSignal light JOB comes on.

Select JOB "0" (synchronisation takes place in JOB 0 only).

Select AC welding with corresponding current output wave.

Square current output wave form

Trapezoidal current output wave form

Sinusoidal current output wave form

Turn the "Alternating current frequency (TIG AC)" rotary dial to the left as far as it will go Signal light Netsync. comes on.

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Interfaces for automation

5.12

Interfaces for automation

CAUTION

Damage to the machine due to improper connection!

Unsuitable control leads or incorrect connection of input and output signals can cause damage to the machine.

• Only use shielded control leads!

• If the machine is to be operated with control voltages connection via suitable isolation amplifiers is required!

• To control the main or secondary current via control voltages, the relevant inputs must be enabled (see specification for activation of control voltage).

5.12.1

TIG interface for mechanised welding

Pin

Signal shape

Designation Diagram

A

Output PE Connection for cable screen

B

Output REGaus

C

Input SYN_E Synchronisation for master/slave operation

D

E

+

R

Input

(no c.)

Input

Output

IGRO Current flows signal I>0 (maximum load

20mA / 15V)

0V = welding current flowing

Not/Aus Emergency stop for higher level shut-down of the power source.

To use this function, jumper 1 must be unplugged on PCB T320/1 in the welding machine. Contact open

=

welding current off

F

G

- NC assigned

H

Output Uist Actual welding voltage, measured on pin F,

0-10V (0V = 0V, 10V = 100V)

J

K

Input

L

Input

SYN_A

Str/Stp

Synchronisation for master/slave operation

Start / stop welding current, same as torch trigger.

Only available in non-latched operating mode. +15V = start, 0V

=

stop

M

Output +15V Voltage

+15V, max. 75mA

N

Output -15V Voltage

-15V, max. 25mA

P

- NC assigned

S

Output 0V Reference

T

Output Iist Actual welding current, measured on pin F;

0-10V (0V = 0A, 10V = 1000A)

U

NC

V

Output SYN_A 0V Synchronisation for master/slave operation

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Interfaces for automation

5.12.2

Remote control connection socket, 19-pole

A

1

B

2

L

2

F

10V

3

I>0

A

B M

D

C

R

P

V

N

T

E

S

U

F H

G

L

J

K

0V

+15V (max. 75mA)

-15V (max. 25mA)

C

D

E

T

J

S

H

V

R

U

K

M

N

P

6

8

9

6

7

10

4

5

0-10V

0-10V

START / STOP

11

10-100K

AMP / AMP%

(PULS)

10-100K

G

12

Figure 5-26

I

SOLL

(1V=100A)

Pos. Pin Signal

1

2

A

B/L

Output

Output

Connection for cable screen (PE)

Current flows signal I>0, galvanically isolated (max. +- 15V/100mA)

3 F Output Reference voltage for potentiometer 10V (max. 10mA)

4

5

C

D

Input

Input

Control value specification for main current, 0-10V (0V = I min

, 10V = I max

)

Control value specification for secondary current, 0-10V (0V = I min

, 10V

= I max

)

6 J/U Output Reference

7

8

K

V

9 R

10 H

Output

Output

Input

Input

Power supply +15V, max. 75mA

Power supply -15V, max. 25mA

Start/Stop welding current

Switching between main and secondary welding currents (pulses)

12 G Output

Set all 3 signals to reference potential 0V to activate external control voltage specification for main and secondary currents

I

SETPOINT

(1V = 100A)

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Advanced settings

5.13

Advanced settings

5.13.1

Setting slope times for secondary current AMP% or pulse edges

Figure 5-27

Figure 5-28

Display Setting/selection

Expert menu

Slope time tS1 (main current to secondary current)

Setting: 0.00 s to 20.0 s (factory setting 0.01 s)

Slope time tS2 (secondary current to main current)

Setting: 0.00 s to 20.0 s (factory setting 0.01 s)

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Advanced settings

5.13.2

TIG non-latched operating mode, C version

0

1

0

1

Figure 5-29

Display Setting/selection

Exit the menu

Exit

Machine configuration

Settings for machine functions and parameter display

Non-latched operation (C version)

• on = on

• off = off (factory setting)

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Advanced settings

5.13.3

Configuring the TIG potentiometer torch connection

DANGER

Risk of injury due to electrical voltage after switching off!

Working on an open machine can lead to fatal injuries!

Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to two minutes after the mains plug is removed.

1.

Switch off machine.

2.

Remove the mains plug.

3.

Wait for at last 2 minutes until the capacitors have discharged!

WARNING

Risk of accidents if these safety instructions are not observed!

Non-observance of these safety instructions is potentially fatal!

• Carefully read the safety information in this manual!

• Observe the accident prevention regulations in your country.

• Inform persons in the working area that they must observe the regulations!

CAUTION

Test!

Before re-commissioning, it is essential that an "inspection and test during operation" is carried out conforming to IEC / DIN EN 60974-4 "Arc welding devices - inspection and testing during operation"!

• For detailed instructions, please see the standard operating instructions for the welding machine.

When connecting a potentiometer torch, jumper JP27 on PCB T320/1 inside the welding machine should be unplugged.

Welding torch configuration Setting

Prepared for TIG standard or up/down torch (factory setting)

Prepared for potentiometer torches

:

JP27

†

JP27

B2-

BT1

A

BT2

0V

0V

Uref.+10V

IH-Down

Up

Poti/UD ein

B

C

D

E

F

G

H

Poti-Brenner

10k

Figure 5-30

NOTE

For this torch type the welding machine has to be set to torch mode 3, see chapter

"Setting torch mode and Up/Down speed".

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Design and function

Advanced settings

5.13.4

Welding current display (ignition, secondary, end and hotstart currents)

The welding currents for secondary current, ignition current and end current (expert menu) can be displayed as percentages (factory setting) or absolute values on the machine display.

0

1

0

1

Figure 5-31

Display Setting/selection

Exit the menu

Exit

Machine configuration

Settings for machine functions and parameter display

Welding current display (ignition, secondary, end and hotstart currents)

• Pro = welding current display as a percentage of the main current (factory setting)

• Abs = absolute welding current display

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5.13.5

Ramp function foot-operated remote control RTF 1

Design and function

Advanced settings

0

1

0

1

Figure 5-32

Display Setting/selection

Exit the menu

Exit

Machine configuration

Settings for machine functions and parameter display

Ramp function Remote control RTF 1

The ramp function can be switched on and off

Switch on

Switching on machine function

Switch off

Switching off machine function

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Design and function

Menus and sub-menus on the machine control

5.14

Menus and sub-menus on the machine control

5.14.1

Direct menus (direct access to parameters)

Functions, parameters and their values can be accessed directly, e.g. can be selected by pressing a button once.

5.14.2

Expert menu (TIG)

The expert menu includes functions and parameters which are either not set on the machine control, or which do not require regular setting.

Figure 5-33

Display Setting/selection

Expert menu

Slope time tS1 (main current to secondary current)

Setting: 0.00 s to 20.0 s (factory setting 0.01 s)

Slope time tS2 (secondary current to main current)

Setting: 0.00 s to 20.0 s (factory setting 0.01 s)

Wire return

• Increase value = more wire return

• Reduce value = less wire return

Parameter can also be set after connecting a TIG cold wire feed unit. Setting: 0 to 255

(factory setting 50).

activArc parameter

Parameter can also be set after activating TIG activArc welding.

Display shown = factory setting.

NOTE

ENTER (enter the menu)

• Keep the "welding parameters" button pressed for 4 s.

Navigating in the menu

• Parameters are selected by pressing the "welding parameters" button.

• Set or change the parameters by turning the "welding parameter setting" rotary dial.

EXIT (leave the menu)

• After 4 s, the machine will return automatically to the ready-to-operate status.

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Design and function

Menus and sub-menus on the machine control

5.14.3

Machine configuration menu

NOTE

ENTER (enter the menu)

• Switch off machine at the main switch

• Press and hold the "welding parameters" button and switch the machine on again at the same time.

NAVIGATION (navigating in the menu)

• Parameters are selected by pressing the "welding parameters" button.

• Set or change the parameters by turning the "welding parameter setting" rotary dial.

EXIT (leave the menu)

• Select the "Elt" menu item.

• Press the "welding parameters" button (settings will be applied, machine changes to the ready-to-operate status).

0

1

0

1

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Figure 5-34

73

Design and function

Menus and sub-menus on the machine control

Display Setting/selection

Exit the menu

Exit

Torch configuration menu

Set welding torch functions

Torch mode

• Modes 1-6: with tapping function (factory setting 1)

• Modes 11-16: without tapping function

Setting the first increment

Setting: 1 to 20 (factory setting 1)

Up-/Down speed (not available in modes 4 and 14)

Increase value = rapid current change (factory setting 10)

Reduce value = slow current change

Machine configuration

Settings for machine functions and parameter display

Welding current display (ignition, secondary, end and hotstart currents)

• Pro = welding current display as a percentage of the main current (factory setting)

• Abs = absolute welding current display

Non-latched operation (C version)

• on = on

• off = off (factory setting)

Power display switching (MMA)

• on = actual value display

• off = setpoint value display (factory setting)

spotMatic

Variation of operation mode spotArc, ignition with workpiece contact

• on = on

• off = off (factory setting)

Ramp function Remote control RTF 1

The ramp function can be switched on and off

Pulses in the upslope and downslope phases

The function can be switched on or off

Torch cooling mode

• AUt = automatic operation (ex works)

• on = permanently switched on

• off = permanently switched off

Expert menu

AC mean value controller

• on = on (factory setting)

• off = off

Switching option for welding current potential (dc+) with TIG DC

• off = Select option for TIG DC+ is blocked (factory setting). Serves to protect the tungsten electrode from being destroyed.

• on = Polarity can be selected freely

Reconditioning pulse (spherical cap stability)

• on = function on (factory setting)

• off = function off

activArc voltage measuring

• on = function on (factory setting)

• off = function off

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Design and function

Menus and sub-menus on the machine control

Display Setting/selection

Error output to automated welding interface, contact SYN_A

off AC synchronisation or hot wire (factory setting)

FSn

FSP

AvC

Error signal, negative logic

Error signal, positive logic

AVC (Arc voltage control) connection

Automation menu

Fast take-over of control voltage (automation)

• on = function on

• off = function off (factory setting)

Orbital welding

• off = off (ex works)

• on = on

Orbital welding

Correction value for orbital current

Service menu

Modifications to the service menu may only be carried out by authorised maintenance staff!

Reset (reset to factory settings)

• off = aus (factory setting)

• CFG = Reset the values in the machine configuration menu

• CPL = Complete reset of all values and settings

The reset is performed when leaving the menu (EXIT).

Software version query (example)

07= System ID

System bus ID and version number are separated by a dot.

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Maintenance, care and disposal

General

6 Maintenance, care and disposal

DANGER

Risk of injury from electric shock!

Cleaning machines that are not disconnected from the mains can lead to serious injuries!

• Disconnect the machine completely from the mains.

• Remove the mains plug!

• Wait for 4 minutes until the capacitors have discharged!

6.1

General

When used in the specified environmental conditions and under normal operating conditions, this machine is largely maintenance-free and requires a minimum of care.

There are some points, which should be observed, to guarantee fault-free operation of your welding machine. Among these are regular cleaning and checking as described below, depending on the pollution level of the environment and the length of time the unit is in use.

6.2

Maintenance work, intervals

6.2.1

Daily maintenance tasks

• Mains supply lead and its strain relief

• Welding current cables (check that they are fitted correctly and secured)

• Gas tubes and their switching equipment (solenoid valve)

• Operating, message, safety and adjustment devices (Functional test)

• Other, general condition

6.2.2

Monthly maintenance tasks

• Casing damage (front, rear and side walls)

• Transport elements (strap, lifting lugs, handle)

• Selector switches, command devices, emergency stop devices, voltage reducing devices, message and control lamps

6.2.3

Annual test (inspection and testing during operation)

NOTE

The welding machine may only be tested by competent, capable personsl.

A capable person is one who, because of his 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.

For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"!

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.

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Maintenance, care and disposal

Maintenance work

6.3

Maintenance work

DANGER

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)!

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.

6.4

Disposing of equipment

Proper disposal!

NOTE

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!

6.4.1

Manufacturer's declaration to the end user

• According to European provisions (guideline 2002/96/EG of the European Parliament and the Council of January, 27th 2003), 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 HIGHTEC Welding GmbH Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).

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Rectifying faults

Customer checklist

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

Customer checklist

Legend

a

: Fault/Cause

#

: Remedy

NOTE

The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation!

Functional errors

a

Machine control without displaying the signal lights after switching on

#

Phase failure > check mains connection (fuses) a

No welding performance

#

Phase failure > check mains connection (fuses) a

Various parameters cannot be set

#

Entry level is blocked, disable access lock (see chapter entitled "Lock welding parameters against unauthorised access") a

Connection problems

#

Make control lead connections and check that they are fitted correctly.

No arc ignition

a

Incorrect ignition type setting.

#

Set ignition type changeover switch to the HF ignition setting.

Bad arc ignition

a

Material inclusions in the tungsten electrode due to contact with filler material or workpiece

#

Regrind or replace the tungsten electrode a

Bad current transfer on ignition

#

Check the setting on the "Tungsten electrode diameter/Ignition optimisation" rotary dial and increase if necessary (higher ignition energy).

Welding torch overheated

a

Loose welding current connections

#

Tighten power connections on the torch and/or on the workpiece

#

Tighten contact tip/collet correctly a

Overload

#

Check and correct welding current setting

#

Use a more powerful welding torch

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Rectifying faults

Customer checklist

Unstable arc

a

Material inclusions in the tungsten electrode due to contact with filler material or workpiece

#

Regrind or replace the tungsten electrode a

Incompatible parameter settings

#

Check settings and correct if necessary

Pore formation

a

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 diffuser for aluminium applications and high-alloy steels a

Unsuitable or worn welding torch equipment

#

Check size of gas nozzle and replace if necessary a

Condensation (hydrogen) in the gas tube

#

Rinse hose package with gas or replace

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Rectifying faults

Machine faults (error messages)

7.2

Machine faults (error messages)

NOTE

A welding machine error is indicated by the collective fault signal lamp (A1) lighting up and an error code (see table) being displayed in the machine control display. In the event of a machine error, the power unit shuts down.

• If multiple errors occur, these are displayed in succession.

• Document machine errors and inform service staff as necessary.

Err 32

Err 33

Err 34

Err 35

Err 36

Err 37

Err 38

Err 39

Error message

Err 3

Err 4

Err 5

Err 6

Err 7

Err 8

Err 9

Err 10

Err 11

Err 51

Possible cause

Speedometer error

Wire feed unit not connected

Temperature error

Error in emergency stop circuit

(interface for mechanised welding)

Remedy

Check wire guide/tube package

• Switch off cold wire mode in the device configuration menu (off status)

• Connect wire feed unit

Allow machine to cool down.

• Check the external shut-down equipment

• Check plug-in jumper JP 1 on

PCB T320/1

Overvoltage

Undervoltage

Coolant error (only if cooling module connected)

Switch off the machine and check mains voltages

Check coolant level and refill if necessary

Gas error

Secondary overvoltage

PE error

FastStop position

Check gas supply

Switch the machine off and on again.

If the error persists, inform the service dept.

Edge "Acknowledge error" signal (0 to 1) via robot interface (if available)

Electronics error (I>0 error)

Electronics error (Uactual error)

Electronics error (A/D channel error)

Switch the machine off and on again.

If the error persists, inform the service dept.

Electronics error (edge error)

Electronics error (S sign)

Electronics error (temperature error) Allow machine to cool down.

---

Electronics error (secondary overvoltage)

Switch the machine off and on again.

If the error persists, inform the service dept.

Error in emergency stop circuit

(interface for mechanised welding)

• Check the external shut-down equipment

• Check plug-in jumper JP 1 on PCB

T320/1

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Rectifying faults

Resetting welding parameters to the factory settings

7.3

Resetting welding parameters to the factory settings

NOTE

All customised welding parameters that are stored will be replaced by the factory settings.

0

1

0

1

Figure 7-1

Display Setting/selection

Exit the menu

Exit

Service menu

Modifications to the service menu may only be carried out by authorised maintenance staff!

Reset (reset to factory settings)

• off = aus (factory setting)

• CFG = Reset the values in the machine configuration menu

• CPL = Complete reset of all values and settings

The reset is performed when leaving the menu (EXIT).

Switch off

Switching off machine function

Reset machine configuration

Resetting the values in the machine configuration menu

Complete reset

Complete reset of all values and settings by the factory settings

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Rectifying faults

Display machine control software version

7.4

Display machine control software version

NOTE

The query of the software versions only serves to inform the authorised service staff!

0

1

0

1

Figure 7-2

Display Setting/selection

Exit the menu

Exit

Service menu

Modifications to the service menu may only be carried out by authorised maintenance staff!

Software version query (example)

07= System bus ID

System bus ID and version number are separated by a dot.

7.5

General operating problems

7.5.1

Interface for mechanised welding

WARNING

No function of the external shut-down devices (emergency stop switch)!

If the emergency stop circuit has been realised using an external shut-down device via the interface for mechanised welding, the device must be set for this setup. If this is not observed, the power source will ignore the external shut-down devices and will not shut down!

• Disconnect jumper 1 on PCB T320/1 (Tetrix) or M320/1 (Phoenix / alpha Q)!

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Technical data

Tetrix 300 AC/DC Comfort

8 Technical data

NOTE

Performance specifications and guarantee only in connection with original spare and replacement parts!

8.1

Tetrix 300 AC/DC Comfort

Welding current setting range

Welding voltage setting range

Max. welding current

40% DC

45% DC

60% DC

65% DC

100% DC

Load alternation

No-load DC voltage

Mains voltage (tolerances)

Frequency

Mains fuse (safety fuse, slow-blow)

Mains connection lead

Max. connected power

Recommended generator rating

Cos

ϕ

Insulation class/protection classification

Ambient temperature

Machine cooling/torch cooling

Workpiece lead

Dimensions L x W x H [mm]

Weight

EMC class

Constructed to standards

5 A to 300 A (DC)

5 A to 270 A (AC)

10.2V to 22.0V (DC)

10.2V to 20.8V (AC)

5 A to 270 A

20.2 V to 30.4 V

25 °C 40 °C 25 °C 40 °C

-

300 A (DC)

-

270 A

220 A

300 A (DC)

-

270 A

-

210 A

-

-

-

260 A

210 A

10 min. (60% DC

6 min. welding, 4 min. break)

-

-

260 A

-

200 A

98 V (DC)

3 x 400 V (-25% to +20%)

50/60 Hz

3 x 16 A

H07RN-F4G2,5

8.3 kVA 12.0 kVA

16.4 kVA

0.99

F/IP 23

-20

°

C to +40 °C

Fan / gas or water

50 mm

2

570 x 240 x 550 mm

38 kg

A

IEC 60974-1, -3, -10;

;

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Accessories

Remote controls and accessories

9 Accessories

NOTE

Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer.

9.1

Remote controls and accessories

Type Designation

RTF1 19POLE 5M Foot-operated remote control current with connection cable

094-006680-00000

RT1

RTG1 19POL

RTAC1

RT PWS1

RTP1

RTP2

RTP3

RA5 19POL 5M

RA10 19POL 10M

RA20 19POL 20M

RV5M19 19POLE 5M

Remote control current

Remote control, current

090-008097-00000

090-008106-00000

Remote control current/balance/frequency 090-008197-00000

Remote control vertical-down current, pole reversal 090-008199-00000

Remote control spots/pulses

Remote control spots/pulses spotArc remote control for spots/pulses

Remote control e.g. connection cable

090-008098-00000

090-008099-00000

090-008211-00000

092-001470-00005

Remote control e.g. connection cable

Remote control e.g. connection cable

Extension cable

092-001470-00010

092-001470-00020

092-000857-00000

9.2

Welding torch cooling system

Type Designation

cool35 U31 Air cooling unit

9.3

Transportsysteme

Type Designation

Trolly 35-2 Transport vehicle

Trolly 38-2 E

9.4

General accessories

Transport vehicle, long wheelbase

Type Designation

GH 2X1/4'' 2M

DM1 32L/MIN

Gas hose

Manometer pressure regulator

090-008198-00000

090-008270-00000

094-000010-00001

094-000009-00000

094-000712-00000

9.5

Options

Type Designation

ON KEY SWITCH

ON 7POL

Optional retrofit kit for key switch 092-001828-00000

Optional 7-pole retrofit connection socket

Accessory components and digital interfaces

092-001826-00000

Optional 12-pole retrofit connection socket 092-001807-00000 12POL RETOX TIG

300/351/451/551

ON 19POL Tetrix 300/351 Optional 19-pole retrofit connection socket

Accessory components and analogue A interface

092-001827-00000

9.6

Computer communication

Type Designation

PC300.NET

CD-ROM PC300.NET

PC300.Net welding parameter software set incl. cable and SECINT X10 USB interface

PC300.Net Update on CD-ROM

090-008235-00502

090-008265-00000

092-008172-00001

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10 Appendix A

10.1

Overview of EWM branches

Appendix A

Overview of EWM branches

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