Tetrix 300 Acdc Manual

EWM HIGHTEC WELDING GmbH

Dr. Günter - Henle - Straße 8 • D-56271 Mündersbach Phone: +49 2680 181 0 • Fax: +49 2680 181 244

www.ewm.de • [email protected]

GB Operating instructions

Welding machines for TIG and MMA welding

TETRIX 270, 300, 350, 500 AC/DC COMFORT activArc

N. B. These operating instructions must be read before commissioning. Failure to do so may be dangerous. Machines may only be operated by personnel who are familiar with the appropriate safety regulations.

The machines bear the conformity mark and thus comply with the • EC Low Voltage Directive (2006/95/ EG) • EC EMC Directive (2004/108/ EG)

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

© 2008 Subject to alteration. Item No.: 099-004877-EWM01 Revised: 21.01.2008

http://www.ewm.de/

mailto:[email protected]

Dear customer,

Congratulations! You have chosen a quality product from EWM HIGHTEC WELDING GmbH.

EWM machines provide results of the highest perfection thanks to their PREMIUM quality. Therefore we are happy to provide you with a full 3-year warranty according to our operating instructions.

We develop and produce quality! From individual components to the final product, we retain sole responsibility for our machines.

In all their high-tech components, our welding machines embody future-oriented advanced technology at the utmost level of quality. Each of our products is carefully checked; we guarantee that the material and processing of our products is faultless.

These operating instructions contain everything about commissioning the machine, notes regarding safety, maintenance and care, technical data as well as information regarding the warranty. Please heed all these notes to ensure many years of safe operation of the machine.

Thank you for the trust that you have placed in us. We look forward to a long-term partnership with you in the spirit of “ONCE EWM – ALWAYS EWM”.

Yours sincerely,

EWM HIGHTEC WELDING GmbH

Bernd Szczesny

Executive management

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Please enter the EWM machine data and your company’s data in the appropriate fields.

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EWM HIGHTEC WELDING GMBHD-56271 MÜNDERSBACH

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3

Contents For your safety

4 Item No.: 099-004877-EWM01

1 Contents 1 Contents ..................................................................................................................................................4 2 Safety instructions .................................................................................................................................7

2.1 For your safety ...............................................................................................................................7 2.2 Transport and installation...............................................................................................................9

2.2.1 Ambient conditions .........................................................................................................9 2.3 Notes on the use of these operating instructions.........................................................................10

3 Technical data.......................................................................................................................................11 3.1 TETRIX 270; 300 AC/DC COMFORT activArc............................................................................11 3.2 TETRIX 350 AC/DC COMFORT activArc ....................................................................................12 3.3 TETRIX 500 AC/DC COMFORT activArc ....................................................................................13

4 Machine description.............................................................................................................................14 4.1 TETRIX 270; 300 AC/DC COMFORT activArc............................................................................14

4.1.1 Front view .....................................................................................................................14 4.1.2 Rear view......................................................................................................................16

4.2 TETRIX 350 AC/DC COMFORT activArc ....................................................................................18 4.2.1 Front view .....................................................................................................................18 4.2.2 Rear view......................................................................................................................20

4.3 TETRIX 500 AC/DC COMFORT activArc ....................................................................................22 4.3.1 Front view .....................................................................................................................22 4.3.2 Rear view......................................................................................................................24

5 Functional characteristics...................................................................................................................26 5.1 Machine control – Operating elements ........................................................................................26

5.1.1.1 Function sequence........................................................................................28 5.2 Operating concepts ......................................................................................................................29

5.2.1 Manual, standard operation (JOB 0) ............................................................................30 5.2.2 JOB operation (JOB 1 to 7) ..........................................................................................31

5.2.2.1 Displaying and changing the JOB number....................................................31 5.2.3 Welding data display.....................................................................................................32

5.2.3.1 Welding parameter setting ............................................................................32 5.2.3.2 Machine configuration menu .........................................................................32

5.3 TIG welding ..................................................................................................................................33 5.3.1 Arc ignition ....................................................................................................................33

5.3.1.1 HF ignition .....................................................................................................33 5.3.1.2 Liftarc.............................................................................................................33

5.3.2 Optimising the ignition characteristics for pure tungsten electrodes ............................34 5.3.2.1 Manual, standard operation (JOB 0) .............................................................34 5.3.2.2 JOB operation (JOB 1 to 7)...........................................................................34

5.3.3 TIG automatic cut-out ...................................................................................................34 5.3.4 Tapping operating mode...............................................................................................34 5.3.5 Optimal and fast spherical cup formation .....................................................................35 5.3.6 TIG function sequences / operating modes..................................................................36

5.3.6.1 Explanation of symbols .................................................................................36 5.3.6.2 TIG non-latched operation ............................................................................37 5.3.6.3 TIG latched operation....................................................................................38 5.3.6.4 TIG spotArc ...................................................................................................39 5.3.6.5 TIG non-latched operation, C version ...........................................................42

5.3.7 TIG pulses, function sequences ...................................................................................43 5.3.7.1 TIG pulses – non-latched operation ..............................................................43 5.3.7.2 TIG pulses - latched operation ......................................................................43

5.3.8 TIG pulse variants.........................................................................................................44 5.3.8.1 Pulses (thermal pulses).................................................................................44 5.3.8.2 KHz pulses (metallurgic pulses)....................................................................45 5.3.8.3 Automated pulses..........................................................................................45 5.3.8.4 AC special .....................................................................................................46

ContentsFor your safety

Item No.: 099-004877-EWM01 5

5.3.9 TIG activArc welding.....................................................................................................47 5.3.10 TIG shielding gas setting..............................................................................................48

5.3.10.1 Gas test.......................................................................................................48 5.3.11 TIG welding torch (operating variants) .........................................................................48 5.3.12 Torch mode and up/down speed setting ......................................................................49

5.3.12.1 Standard TIG torch (5-pole) ........................................................................50 5.3.12.2 TIG up/down torch (8-pole) .........................................................................52 5.3.12.3 Potentiometer torch (8-pole) .......................................................................54 5.3.12.4 RETOX TIG torch (12-pole) ........................................................................55

5.3.13 Setting the first increment.............................................................................................56 5.4 MMA welding ...............................................................................................................................57

5.4.1 Selection and adjustment .............................................................................................57 5.4.2 Hotstart .........................................................................................................................57

5.4.2.1 Hotstart current .............................................................................................57 5.4.2.2 Hotstart time..................................................................................................58

5.4.3 Arcforcing .....................................................................................................................58 5.4.4 Antistick ........................................................................................................................58

5.5 Key switch....................................................................................................................................58 5.6 Advanced settings........................................................................................................................59

5.6.1 Setting slope times for secondary current AMP% or pulse edges ...............................59 5.6.2 TIG non-latched operating mode, C version ................................................................60 5.6.3 Configuring the TIG potentiometer torch connection ...................................................61 5.6.4 Switching between percentage and absolute welding currents ...................................61

5.6.4.1 Selection and adjustment..............................................................................62 5.7 Remote control.............................................................................................................................63

5.7.1 Foot-operated remote control RTF 1............................................................................63 5.7.2 Manual remote control RT 1.........................................................................................63 5.7.3 Manual remote control RT AC 1...................................................................................63 5.7.4 Manual remote control RTP 1 ......................................................................................63 5.7.5 Manual remote control RTP 2 ......................................................................................64 5.7.6 RTP 3 manual remote control ......................................................................................64 5.7.7 Manual remote control RT PWS 1................................................................................64

5.8 Interfaces for automation .............................................................................................................65 5.8.1 TIG interface for mechanised welding..........................................................................65 5.8.2 Remote control connection socket, 19-pole .................................................................66

6 Commissioning ....................................................................................................................................67 6.1 General ........................................................................................................................................67 6.2 Area of application – proper usage..............................................................................................67 6.3 Installation....................................................................................................................................67 6.4 Mains connection.........................................................................................................................67 6.5 Machine cooling ...........................................................................................................................67 6.6 Workpiece lead, general ..............................................................................................................67 6.7 TIG welding..................................................................................................................................68

6.7.1 Welding torch connection .............................................................................................68 6.7.2 Torch connection options and pin assignments ...........................................................69 6.7.3 Connection for workpiece lead .....................................................................................69 6.7.4 Shielding gas supply (shielding gas cylinder for welding machine) .............................70

6.7.4.1 Connecting the shielding gas supply ............................................................70 6.7.4.2 Setting the shielding gas quantity .................................................................70

6.8 MMA welding ...............................................................................................................................71 6.8.1 Electrode holder connection.........................................................................................71 6.8.2 Connection for workpiece lead .....................................................................................72

6.9 Cooling unit function specification ...............................................................................................72 6.9.1 Coolant error.................................................................................................................72

6.10 Simultaneous welding on both sides, synchronisation types ......................................................72 6.10.1 Synchronisation via mains voltage...............................................................................72

6.10.1.1 Selection and adjustment............................................................................73 6.11 PC interface .................................................................................................................................73

Contents For your safety

6 Item No.: 099-004877-EWM01

7 Maintenance and testing .....................................................................................................................74 7.1 General.........................................................................................................................................74 7.2 Cleaning .......................................................................................................................................74 7.3 Test ..............................................................................................................................................74

7.3.1 Test equipment .............................................................................................................74 7.3.2 Scope of the test...........................................................................................................75 7.3.3 Visual inspection...........................................................................................................75 7.3.4 Measuring the open circuit voltage...............................................................................75 7.3.5 Measurement of insulation resistance ..........................................................................75 7.3.6 Measuring the leakage current (protective conductor and contact current) .................76 7.3.7 Measurement of protective conductor resistance.........................................................76 7.3.8 Functional test of the welding machine ........................................................................76 7.3.9 Documentation of the test.............................................................................................76

7.4 Repair Work .................................................................................................................................77 7.5 Disposing of equipment................................................................................................................78

7.5.1 Manufacturer's declaration to the end user ..................................................................78 7.6 Meeting the requirements of RoHS..............................................................................................78

8 Warranty ................................................................................................................................................79 8.1 General Validity............................................................................................................................79 8.2 Warranty Declaration ...................................................................................................................80

9 Operating problems, causes and remedies.......................................................................................81 9.1 Error messages (power source)...................................................................................................81

10 Accessories, options ...........................................................................................................................82 10.1 General accessories ....................................................................................................................82 10.2 Remote control / connection cable...............................................................................................82 10.3 Options.........................................................................................................................................82 10.4 TIG welding torch .........................................................................................................................82 10.5 Transport vehicle..........................................................................................................................83 10.6 Cooling units ................................................................................................................................83 10.7 Synchronisation............................................................................................................................83

11 Circuit diagrams ...................................................................................................................................84 11.1 TETRIX 270 AC/DC COMFORT activArc ....................................................................................84 11.2 TETRIX 300 AC/DC COMFORT activArc ....................................................................................86 11.3 TETRIX 350 AC/DC COMFORT activArc ....................................................................................88 11.4 TETRIX 500 AC/DC COMFORT activArc ....................................................................................90

12 Appendix A............................................................................................................................................92 12.1 Declaration of Conformity.............................................................................................................92

Safety instructions

For your safety

Item No.: 099-004877-EWM01 7

2 Safety instructions 2.1 For your safety

Observe accident prevention regulations! Ignoring the following safety procedures can be fatal!

Proper usage This machine has been manufactured according to the latest developments in technology and current regulations and standards. It is to be operated only for the use for which it was designed (see chapter Commissioning/Area of application). Improper usage However, this machine may be a hazard to persons, animals and property if it is • not used as directed • used by unskilled persons who have not been trained • modified or converted improperly

Our operating instructions will provide you with an introduction into the safe use of the machine. Therefore please read them carefully and only start work when you are familiar with them. Any person involved in the operation, maintenance and repair of this machine must read and follow these operating instructions, especially the safety precautions. Where appropriate, this should be confirmed by signature. Furthermore, the • relevant accident prevention regulations, • generally accepted safety regulations, • local regulations, etc. must be observed.

Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves. • Protect eyes and face with protective visor.

Electric shocks can be fatal! • Do not touch any live parts in or on the machine! • The machine may only be connected to correctly earthed sockets. • Only operate with intact connection lead including protective conductor and safety plug. • An improperly repaired plug or damaged mains cable insulation can cause electric shocks. • The machine may only be opened by qualified and authorised specialist staff. • Disconnect from the mains before opening. Switching off is not sufficient. Wait for 2 minutes until the

capacitors have discharged. • Always put down welding torch, stick electrode holder in an insulated condition. • The machine must not be used to defrost pipes!

Even touching low voltages can cause you to get a shock and lead to accidents, so: • Protect yourself from falling before working on platforms or scaffolding. • During welding ensure that you operate earth tongs, torch and workpiece correctly, and not in ways for

which they are not intended. Do not touch live parts with bare skin. • Only replace electrodes when wearing dry gloves. • Never use torches or earth cables with damaged insulation.

Smoke and gases can lead to breathing difficulties and poisoning. • Do not breathe in smoke and gases. • Ensure that there is sufficient fresh air. • Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can be

converted into poisonous phosgene by ultraviolet radiation.

Safety instructions For your safety

8 Item No.: 099-004877-EWM01

Workpiece, flying sparks and droplets are hot! • Keep children and animals well away from the working area. Their behaviour is unpredictable. • Move containers with inflammable or explosive liquids away from the working area. There is a danger

of fire and explosion. • Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of

explosions when apparently harmless substances develop high pressures in enclosed containers by heating.

Take care to avoid fire hazards • Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when parts

are glowing or hot slag is present. • A constant check must be kept on whether fire hazards have arisen in the working area. • Highly inflammable objects, such as matches and cigarette lighters for example, must not be carried in

trouser pockets. • You must ensure that fire extinguishing equipment - appropriate for the welding process - is available

close to the welding work area and that this equipment can be accessed easily. • Containers in which fuels or lubricants have been present must be thoroughly cleaned before welding

begins. It is not sufficient simply for the receptacle to be empty. • After a workpiece has been welded, it must only be touched or brought into contact with inflammable

material when it has cooled down sufficiently. • Loose welding connections can completely destroy protective conductor systems of interior

installations and cause fires. Before beginning welding work, ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source.

Noise exceeding 70 dBA can cause permanent hearing damage! • Wear suitable earmuffs or plugs. • Ensure that other people who spend time in the working area are not inconvenienced by the noise.

Interference by electrical and electromagnetic fields is possible e.g. from the welding machine or from the high-voltage pulses of the ignition unit. • As laid down in Electromagnetic Compatibility Standard EN 50199, the machines are intended for use

in industrial areas; if they are operated in residential environments, for example, problems may occur in ensuring electromagnetic compatibility.

• The functioning of heart pacemakers can be adversely affected when you are standing near the welding machine.

• It is possible that electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the welding site could malfunction.

• Other mains supply leads, control leads, signal and telecommunications leads above, under and near the welding device may be subject to interference.

Electromagnetic interference must be reduced to a level that no longer constitutes interference. Possible reduction measures: • Welding machines must be serviced regularly. (see Chap. Maintenance and care) • Welding leads should be as short as possible and run closely together on or near to the ground. • Selective shielding of other leads and equipment in the environment can reduce radiation.

Repair and modifications may only carried out by authorised, trained, specialist staff. The warranty becomes null and void in the event of unauthorised interference.

Safety instructions

Transport and installation

Item No.: 099-004877-EWM01 9

2.2 Transport and installation

The machines may only be transported and operated in an upright position.

Before carrying away or moving, pull out mains plug and place on the machine.

When setting up the machine, resistance to tilting is only guaranteed up to an angle of 10° (as specified in EN 60974-1).

Secure the gas cylinder! • Place shielding gas cylinders in the holders provided for them and secure with safety chains. • Take care when handling cylinders; do not throw or heat, guard against them toppling over. • When moving by crane, take off the gas cylinder from the welding machine.

2.2.1 Ambient conditions This machine must not be operated in any area where any risk of explosion exists. The following conditions must be observed during operation:

Temperature range of the ambient air • During welding: -10°C to +40°C *), • For transport and storage: -25°C to +55°C *) *) Using the appropriate coolant.

Relative air humidity • up to 50% at 40°C • up to 90% at 20°C The ambient air must be free of unusual amounts of dust, acids, corrosive gases or substances, etc., assuming these are not produced by the welding process. Examples of unusual operating conditions:

• unusual corrosive smoke, • vapour, • excessive oil vapour, • unusual vibrations or jolts, • excessive quantities of dust such as grinding dust etc., • severe weather conditions, • unusual conditions near the coast or on board ship. When setting up the machine, ensure a free inlet and outlet of air. The machine is tested to protection class IP23, i.e.:

• Protection against penetration of solid foreign bodies ∅ > 12mm, • Protection against water spray up to an angle of 60° to the vertical.

Safety instructions Notes on the use of these operating instructions

10 Item No.: 099-004877-EWM01

2.3 Notes on the use of these operating instructions

These operating instructions are arranged into chapters.

To help you find your way around more quickly, in the margins you will occasionally see symbols along with the sub-headings. These symbols refer to particularly important passages of text which are graded as follows depending on their importance:

Please note: Technical features which users must observe.

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

Caution: Working and operating procedures which must be followed precisely to avoid risk to persons and includes the "Warning" symbol. Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet points, e.g.:

• Insert the welding current lead socket into the relevant socket and lock.

Symbol Description

Press

Do not press

Turn

Switch

Technical data

TETRIX 270; 300 AC/DC COMFORT activArc

Item No.: 099-004877-EWM01 11

3 Technical data 3.1 TETRIX 270; 300 AC/DC COMFORT activArc

TETRIX 270 AC/DC 300 AC/DC

Setting range: Welding current / welding voltage TIG (DC) TIG (AC) MMA

5A - 300 A / 10,2 V – 22,0 V 5A - 270 A / 10,2 V – 20,8 V 5A - 270 A / 20,2 V – 30,8 V

Max. welding current at TIG MMA TIG MMA

20ºC ambient temperature: 45%DC 65%DC 100%DC

300 A (DC)

270 A 220 A

-

260 A 210 A

300 A 270 A 220 A

-

260 A 210 A


300 A (DC)

270 A 220 A

-

260 A 200 A

300 A 270 A 220 A

-

260 A 200 A

Load alternation 10min (60% DC ∧ 6 min. welding, 4min. break)

Open circuit voltage (with AC and DC)

93 V (DC)

Mains voltage (tolerances) 3 x 400 V -25 %; +20 % 3 x 415 V -25 %; +15 %

Frequency 50/60 Hz

Mains fuse (safety fuse, slow-blow) 3 x 16 A

Mains connection lead H07RN-F4G1,5

Max. connected power 12,4 kVA

Recommended generator rating 18,7 kVA

cosϕ / efficiency 0,99 / 85 %

Insulation class / protection classification

F / IP 23

Ambient temperature -10°C bis +40°C

Machine cooling / torch cooling Fan / gas or water

Workpiece lead 35 mm2

Dimensions L x W x H [mm] 560 x 240 x 550 mm

Weight 36,5 kg

Constructed to standards IEC 60974 / EN 60974 / VDE 0544 EN 50199 / VDE 0544 Teil 206

/

Technical data TETRIX 350 AC/DC COMFORT activArc

12 Item No.: 099-004877-EWM01

3.2 TETRIX 350 AC/DC COMFORT activArc TETRIX 350 AC/DC

Setting range: Welding current / welding voltage TIG MMA

5 A - 350 A / 10.2 V – 24.0 V 5 A - 350 A / 20.2 V – 34.0 V

Max. welding current at TIG MMA


-

350 A 260 A

350 A 310 A 250 A

40ºC ambient temperature: 35%DC 40%DC 60%DC 100%DC

-

350 A 325 A 260 A

350 A

- 290 A 230 A

Load alternation 10min (60 % DC ∧ 6 min welding, 4min break)

Open circuit voltage (with AC and DC) 95 V

Mains voltage (tolerances) 3 x 400 V (-25 %; +20 %) 3 x 415 V (-25 %; +15 %)

Frequency 50/60 Hz


Mains connection lead H07RN-F4G2.5

Max. connected power 17,7 kVA

Recommended generator rating 23,9 kVA


Insulation class / protection classification F / IP 23

Ambient temperature -10 °C to +40°C



Dimensions L x W x H [mm] 605 x 335 x 520

Weight 53 kg

Constructed to standards EN 60974 / IEC 60974 / VDE 0544 EN 50199 / VDE 0544 Part 206

/

Technical data

TETRIX 500 AC/DC COMFORT activArc

Item No.: 099-004877-EWM01 13

3.3 TETRIX 500 AC/DC COMFORT activArc TETRIX 500 AC/DC

Setting range: Welding current / welding voltage TIG MMA

5A - 500 A / 10,2 V – 30,0 V 5A - 500 A / 20,2 V – 40,0 V

Max. welding current at TIG MMA


500 A 475 A 390 A

500 A 450 A 340 A


500 A 475 A 390 A

500 A 460 A 350 A

Load alternation 10min (60% DC ∧ 6 min. welding, 4min. break)

Open circuit voltage (with AC and DC) 79 V at 400 V 91 V at 460 V

Mains voltage (tolerances) 3 x 400 V -25 %; +20 % 3 x 415 V -25 %; +15 % 3 x 460 V -25 %; +10 %

Frequency 50/60 Hz


Mains connection lead H07RN-F4G4

Max. connected power 29 kVA

Recommended generator rating 39.2 kVA


Insulation class / protection classification F / IP 23

Ambient temperature -10 °C to +40°C



Dimensions L x W x H [mm] 660 x 350 x 850 mm

Weight 104.5 kg

Constructed to standards EN 60974 / IEC 60974 / VDE 0544 EN 50199 / VDE 0544 Part 206

/

Machine description TETRIX 270; 300 AC/DC COMFORT activArc

14 Item No.: 099-004877-EWM01

4 Machine description 4.1 TETRIX 270; 300 AC/DC COMFORT activArc 4.1.1 Front view

Figure 4-1

Machine description


Item No.: 099-004877-EWM01 15

Item Symbol Description 0

1 Carrying handle

2 Control / Operating elements (see chapter Function specification)

3

Connection socket, 19-pole Remote control connection

4 Cooling air inlet

5

Connection socket, welding current “-” (with DC- polarity) connection for Electrode holder

6

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

Connection for workpiece lead

7 0

1

Key switch for locking the control (option)

Position “1” > changes possible, Position “0” > changes not possible.

8 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)

9

Connection socket, 5-pole Standard TIG torch control lead

10

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

11

G¼“ connecting nipple, welding current "-" (with DC- polarity) Shielding gas connection (with yellow insulating cap) for TIG welding torch

12 Rubber feet

Machine description TETRIX 270; 300 AC/DC COMFORT activArc

16 Item No.: 099-004877-EWM01

4.1.2 Rear view

Figure 4-2

Machine description


Item No.: 099-004877-EWM01 17


1

analog

19-pole connection socket (option) Analogue interface for mechanised welding

2

digital

7-pole connection socket (option) Wire feed unit connection (cold wire); RINT; Q-DOC, etc.

3

G¼” connecting nipple Shielding gas connection on the pressure reducer

4

Main switch, machine on/off

5 Strain relief with mains connection cable

6

4-pole connection socket Cooling unit voltage supply

7

8-pole connection socket Cooling unit control lead

8

42V/4A

"Automatic circuit-breaker" key button; fuse protection: • Ignition unit • Gas valve • Peripheral devices on the 7-pole, digital interfaces (rear of the machine)

Reset triggered automatic cutout by pressing 9

PC INT

9-pole D-SUB connection socket, serial PC interface Interface set SECINTX10 DSUB required (observe installation instructions)

10

digital


11

HF

HF

Ignition type changeover switch HF= HF ignition HF = Liftarc (contact ignition)

12 Cooling air outlet

Machine description TETRIX 350 AC/DC COMFORT activArc

18 Item No.: 099-004877-EWM01

4.2 TETRIX 350 AC/DC COMFORT activArc 4.2.1 Front view

Figure 4-3

Machine description


Item No.: 099-004877-EWM01 19


1 Carrying handle



4


5 Cooling air inlet

6 Rubber feet

7 0

1



8


9


10


11


12




20 Item No.: 099-004877-EWM01

4.2.2 Rear view

Figure 4-4

Machine description


Item No.: 099-004877-EWM01 21


1

analog


2

digital


3

digital


4

PC INT


5


6


7


8

HF

HF


9 Strain relief with mains connection cable

10


11

42V/4A


Reset triggered automatic cutout by pressing 12 Cooling air outlet


22 Item No.: 099-004877-EWM01

4.3 TETRIX 500 AC/DC COMFORT activArc 4.3.1 Front view

Figure 4-5

Machine description


Item No.: 099-004877-EWM01 23


1 Carrying handle

2



4


5 Cooling air inlet


7 0

1



8


9


10


11


12



13 Rubber feet


24 Item No.: 099-004877-EWM01

4.3.2 Rear view

Figure 4-6

Machine description


Item No.: 099-004877-EWM01 25


1

digital


2

digital


3

PC INT


4


5

analog


6


7

42V/4A


Reset triggered automatic cutout by pressing 8 Strain relief with mains connection cable

9


10

HF

HF


11 Cooling air outlet

Functional characteristics Machine control – Operating elements

26 Item No.: 099-004877-EWM01

5 Functional characteristics 5.1 Machine control – Operating elements

Machine control provides the user with up to 8 welding tasks (JOBs). JOB "0" represents manual operating mode. This is where you can change/optimise all parameters directly in machine control (see chapter "Operating concepts").

Figure 5-1


1

"Welding process" button

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

TIG welding

2

"Operating mode" button

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

Non-latched

Latched

3

"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

Functional characteristics

Machine control – Operating elements

Item No.: 099-004877-EWM01 27


“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.

4

Alternating current welding with sinusoidal current output wave form. Low noise level.

5

"Display changeover" button

Welding current display

Welding voltage display

JOB number display

6

"Alternating current frequency (TIG AC)" rotary dial 50 Hz to 200 Hz (1 Hz increments)

7

"Alternating current balance (TIG AC)" rotary dial Max. setting range: - 30% to + 30% (1% increments). The setting range may also be lower depending on the factory setting.

8

“Tungsten electrode diameter”/“Ignition optimisation” rotary dial

Infinitely adjustable from 1 mm to 4 mm or greater

9

“Welding parameter setting” rotary dial Setting all parameters such as ignition, welding, end current, gas pre-flow and gas post-flow times, pulse edges, etc.

10

Three-figure LED display Welding parameter display (see also chap. “Welding data display”).

11

S

Error/status indicators

“Collective interference” signal light (see Operating problems chapter)

“Water deficiency” signal light (welding torch cooling)

“Excess temperature” signal light

S “ safety sign” signal light

12 see "Function specification" chapter

Functional characteristics Machine control – Operating elements

28 Item No.: 099-004877-EWM01

5.1.1.1 Function sequence

Figure 5-2


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%

Ignition current (TIG) Percentage of the main current. Setting range 1 % to 200 % (1 % increments). There are no pulses during the ignition current phase.

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

4 sec Up-slope time (TIG) Setting ranges: 0.00 sec to 20.0 sec (0.1 sec increments). The up-slope time can be set separately for non-latched and latched.

Hotstart time (MMA) Setting ranges: 0.00 sec to 20.0 sec (0.1 sec increments).

Pulse time / slope time from AMP% to AMP / Spot time • Pulse time setting range: 0.01 sec to 20.0 sec

(0.01s increments < 0.5 sec; 0.1 sec increments > 0.5 sec) • Slope time (tS2) setting range: 0.0 sec to 20.0 sec

(see chapter "Advanced settings") • Spot time setting range: 0.01 sec to 20.0 sec

5 sec

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.

6 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)


Operating concepts

Item No.: 099-004877-EWM01 29


Pulse break time/slope time from AMP to AMP% • Pulse break setting range: 0.01 sec to 20.0 sec

(0.01 sec increments < 0.5 sec; 0.1 sec increments > 0.5 sec) • Slope time (tS1) setting range: 0.0 sec to 20.0 sec

(see chapter "Advanced settings").

7 sec

TIG pulses The pulse break time applies to the secondary current phase (AMP%)

TIG AC Special The pulse break time applies to the DC phase with AC special.

8 AMP%

Secondary current (TIG) / pulse pause current Setting range 1% to 100% (1% increments). Percentage of the main current.

9 sec Down-slope time (TIG)

0.00 sec to 20.0 sec (0.1 sec increments). The down-slope time can be set separately for non-latched and latched.

10 AMP%

End-crater current (TIG) Setting range 1 % to 200 % (1 % increments). Percentage of the main current.

11 sec Gas post-flow time (TIG)

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

12 “Tungsten electrode diameter”/“Ignition optimisation” LED

Infinitely adjustable from 1 mm to 4 mm or greater

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.

13

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: At a higher frequency, the cleaning effect is increased. Particularly thin panels (welding with a low current), anodised sheet aluminium or highly contaminated articles for welding can be welded and cleaned perfectly at a higher frequency.

14

Frequency fast TIG DC pulses Setting range: 50 Hz to 2.5 kHz (0.01 kHz increments)

15

"activArc" LED

Display activArc activated (on/off) function and correction of the activArc characteristic.Setting range: 0..100

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

• Manual, standard operation (JOB "0") • JOB operation, saved welding tasks (JOB 1 to 7)

Functional characteristics Operating concepts

30 Item No.: 099-004877-EWM01

5.2.1 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.

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”

Operating element

Action Result

Select and display welding process

TIG welding

+

TIG activArc welding

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

Select and display welding current polarity

Direct current welding with positive polarity at the electrode holder, MMA only

DC welding with negative polarity at the torch (or electrode holder) with respect to the workpiece

AC welding with rectangular current output wave form Maximum power loading and safe welding

AC welding with trapezoidal current output wave form An all-rounder, suitable for most applications

AC welding with sinusoidal current output wave form Low noise level

Select and display operating mode

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

Non-latched

Latched

Select and display pulse procedure


TIG pulses with times, lights up in green/fast TIG DC pulses with frequency and balance, lights up in red

TIG AC special

Set tungsten electrode diameter for optimisation of ignition

Set alternating current balance (TIG AC only)

Select welding parameter in the functional sequence

Set welding parameters


Operating concepts

Item No.: 099-004877-EWM01 31

5.2.2 JOB operation (JOB 1 to 7) 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).

5.2.2.1 Displaying and changing the JOB number Operating element

Action Result Display

X x Select JOB display JOB number

Change the JOB number 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

JOB number

The procedure for setting welding tasks is the same as described under "Manual, standard operation (JOB 0)". The "Alternating current balance (TIG AC)" and "Tungsten electrode diameter/Ignition optimisation" rotary dials are the exception. These welding parameters are set in JOB 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.

Functional characteristics Operating concepts

32 Item No.: 099-004877-EWM01

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

Parameter Before welding (nominal values)

During welding (actual values)

Welding current Welding voltage JOB number - Parameter times - Frequency, balance - Parameter currents -

5.2.3.1 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.

5.2.3.2 Machine configuration menu

If the machine configuration is changed, then the parameter and its value are shown alternately in the display.

Machine configuration menus Display Setting/Selection Display Setting/Selection

Exit menu (exit machine configuration)

Torch mode menu "Torch Mode"

Up/down speed "Up/Down"

Torch configuration menu

Set 1st increment "Delta I"

Synergic on/off "Synergic" on/off

Display • "Pro": Percentage welding currents are

shown in the display • "Abs": Absolute welding currents are

shown in the display

Non-latched C mode "Non-latched C" on/off

Cold wire operating mode "off/2t/3t/4t"

Configuration menu

Cold wire wire selection "Job/d06/d08/d10/d12/d16"

Service menu (this menu may only be used by authorised service personnel)


TIG welding

Item No.: 099-004877-EWM01 33

5.3 TIG welding 5.3.1 Arc ignition 5.3.1.1 HF ignition

Figure 5-3

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.

5.3.1.2 Liftarc

a) b) c)

Figure 5-4

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.

Functional characteristics TIG welding

34 Item No.: 099-004877-EWM01

5.3.2 Optimising the ignition characteristics for pure tungsten electrodes The best ignition and stabilisation of the arc (DC, AC) and optimum spherical cup formation in the tungsten electrode depend on the electrode diameter being used.

The set value should correspond to the diameter of the tungsten electrode. The value can of course be adjusted in line with different requirements.

The adjustable welding current is limited to the maximum permissible welding current of the tungsten electrode.

5.3.2.1 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

5.3.2.2 JOB operation (JOB 1 to 7) Operating element


x x

Select ignition characteristics parameter Press until signal light comes on

Set diameter of tungsten electrode

• Increase parameter value > more ignition power

• Reduce parameter value > less ignition power

Tungsten electrode diameter displayed in

mm

5.3.3 TIG automatic cut-out

If the arc does not ignite after starting or if the arc is interrupted when the torch is moved away, an automatic cut-out occurs after 3 sec. The HF, gas and open circuit voltage (power unit) are switched off.

5.3.4 Tapping operating mode The tapping mode was included particularly for the secondary current (AMP%) by the use of a trigger on the welding torch. Torch with one trigger: • by tapping (brief pressing and releasing) torch trigger 1

(Repeated tapping switches back to the main current). Torch with two triggers: There are two ways of switching to the secondary current:

• by tapping (see torch with one trigger) • by pressing down and holding torch trigger 2.


TIG welding

Item No.: 099-004877-EWM01 35

5.3.5 Optimal and fast spherical cup formation A conically ground needle (approx. 35°) is generally required to form an ideal spherical cup.

Spherical cup formation preset Operating element


Set spotArc operating mode Switch off pulse welding

-

Set spotArc time in line with the electrode diameter in use (refer to the table of guideline values for spherical cup formation depending on welding current)

Select AC type - Square current output wave form - Trapezoidal current output wave form -

Sinusoidal current output wave form -

Balance setting in JOB "0"

Turn rotary dial to the left as far as it will go (positive) Form spherical cups on the tungsten electrode Turn rotary dial back to its original position (positive)

-

Table of guideline values for spherical cup formation Tungsten electrode diameter spotArc time Balance Current for spherical cup

formation 1.0 1.3 sec + 10% max. 70 A

1.6 1.4 sec + 10% max. 120 A

2.0 1.5 sec + 10% max. 130 A

2.4 1.8 sec + 10% max. 190 A

3.2 2.0 sec + 20% max. 260 A

4.0 > 2.2 sec + 20% max. 330 A

Use a sample workpiece. • Ignite arc with HF ignition (non-contact) and form required spherical cups for the application in

question.

Re-set parameter values to their original values.


36 Item No.: 099-004877-EWM01

5.3.6 TIG function sequences / operating modes The "Select welding parameter" button and the "Welding parameter setting" rotary transducer can be used to control all the parameters for the TIG process:

Pos. Description 1 “Select welding parameters”

button 2 “Welding parameter setting”

rotary dial

Figure 5-5 5.3.6.1 Explanation of symbols

Symbol Meaning

Press torch trigger 1

Release torch trigger 1

I Current

t Time

Gas pre-flows

Istart Ignition current

tUp Up-slope time

tP Spot time

AMP Main current (minimum to maximum current)

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

t1 Pulse time

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)

tDown Down-slope time

Iend End-crater current

Gas post-flows


TIG welding

Item No.: 099-004877-EWM01 37

5.3.6.2 TIG non-latched operation

When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The up- and down-slopes are switched off.

Figure 5-6

Step 1: • 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 Istart. • HF is switched off. • The welding current increases in the adjusted up-slope time to the main current AMP. Step 2: • Release torch trigger 1. • The main current drops in the set down-slope time to the end-crater current Iend (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 Iend, the arc extinguishes. • The set gas post-flow time elapses.


38 Item No.: 099-004877-EWM01

5.3.6.3 TIG latched operation

When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The up- and down-slopes are switched off.

I

Istart

AMP

Iend

tUp tDown

t

AMP%

1. 2. 3. 4.

Figure 5-7

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 (for tapping mode, see also chapter “Description of tapping mode”) The slope times can be set (see chapter "Advanced settings", section "Setting slope times for secondary current AMP% or pulse edges".

Step 3 • Press torch trigger 1. • The main current drops with the set down-slope time to the end-crater current Iend (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.


TIG welding

Item No.: 099-004877-EWM01 39

5.3.6.4 TIG spotArc The TIG SpotArc function is activated with the pulse variant automated frequencies by default, because this combination produces the most effective results. The user can of course combine the function with other pulse variants depending on the selected welding process. Pulse time (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


Signal light comes on The spot time can be set for approx. 4 sec. using the "Welding parameter setting" rotary dial (spot time setting range 0.01 sec. to 20.0 sec.) Afterwards the display switches back to current/voltage. If the button is pressed again, the display switches back to the parameter and can be changed with the rotary dial accordingly. The spot time can also be set in the function sequence.

Set spot time "tP"

The TIG spotArc process is switched on with the pulse variant "TIG automated pulses" by default. The user can select other pulse variants:


TIG 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"

-


40 Item No.: 099-004877-EWM01

Figure 5-8

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 Istart. • HF is switched off. • The welding current increases in the adjusted up-slope time to the main current AMP.

The process ends when the set SpotArc time elapses or if the torch trigger is released prematurely.

spotArc/pulse variants table: Process Pulse variants

Automated pulses (factory setting)

(lights up in green) Pulses (thermal pulses)

(lights up in red) kHz pulse (metallurgic pulses)

TIG DC

No pulses

(lights up in green) Pulses (thermal pulses)

AC special

TIG AC

No pulses

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


TIG welding

Item No.: 099-004877-EWM01 41

Setting instructions for spotArc for CrNi panels

Sea

m s

hap

e

Pan

el t

hic

knes

s

Pu

lse

typ

e/

wel

din

g t

ype

Sp

ot

tim

e

Wel

din

g c

urr

ent

Do

wn

-slo

pe

tim

e

1mm Automated pulses 0.3s 100A 0.5s

1mm Fast pulsing (2.5kHz) 0.3s 100A 0.5s

Butt weld

2mm Fast pulsing (2.5kHz) with activArc 0.35s 180A 0.7s

1mm Automated pulses with activArc 0.5s 150A 0.1s Fillet weld


1mm Automated pulses with activArc 0.4s 200A 0.1s

1mm Fast pulsing (2.5kHz) 0.4s 200A 0.1s

Lap weld


spotArc setting instructions for C-steel panels

Sea

m s

hap

e

Pan

el t

hic

knes

s

Pu

lse

typ

e/

wel

din

g t

ype

Sp

ot

tim

e

Wel

din

g c

urr

ent

Do

wn

-slo

pe

tim

e

1mm Automated pulses 0.3s 165A 0.5s Butt weld

2mm Automated pulses 0.35s 245A 0.5s

1mm Automated pulses with activArc 0.5s 170A 0.5s Fillet weld


1mm Fast pulsing (2.5kHz) 0.3s 250A 0.5s Lap weld



42 Item No.: 099-004877-EWM01

5.3.6.5 TIG non-latched operation, C version

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

Figure 5-9

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.

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".


TIG welding

Item No.: 099-004877-EWM01 43

5.3.7 TIG pulses, function sequences The function sequences in pulses basically behave in the same way as in standard welding, but

during the main current phase there is a continual switching back and forth between the pulse and pause currents at the relevant times.

5.3.7.1 TIG pulses – non-latched operation

Figure 5-10 5.3.7.2 TIG pulses - latched operation

Figure 5-11


44 Item No.: 099-004877-EWM01

5.3.8 TIG pulse variants The machines have an integrated pulse device.

With pulses, the machine switches back and forth between the pulse current (main current) and pause current (secondary current).

5.3.8.1 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.

Figure 5-12

Operating element


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 sec

Select slope times "ts1" and "ts2"

Set slope time "ts1"

Switch between slope times "ts1" and "ts2"

Set slope time "ts2"


TIG welding

Item No.: 099-004877-EWM01 45

5.3.8.2 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 2.5 kHz and the pulse balance from 1 – 99%. In contrast to thermal pulses, the pulse edge times are not required.

Figure 5-13

Operating element


Select kHz pulses Press the "TIG pulses" button until the

signal light lights up in red

-

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

Select frequency Setting range: 50 Hz to 2.5 kHz (0.01 kHz increments)

5.3.8.3 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.

Operating element

Action Result

Select TIG automated pulses Press the "TIG pulses" button until the TIG automated pulses signal light comes on


46 Item No.: 099-004877-EWM01

5.3.8.4 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

ACspecial signal light comes on

AMP

AMP%

tpause tpuls

AMP

t

AMP = AC current phase pulse current AMP% = DC phase pulse pause current tpulse = Pulse time; AC phase time tbreak = Pulse break time; DC phase time

This function should only be used for TIG welding and must be switched off or not used for plasma welding.


TIG welding

Item No.: 099-004877-EWM01 47

5.3.9 TIG activArc welding The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power supplied is kept virtually constant in the event of changes in the distance between the welding torch and the weld pool, e.g. during manual welding. Voltage losses as a result of a shortening of the distance between the torch and molten pool are compensated by a current rise (ampere per volt - A/V), and vice versa. This helps prevents the tungsten electrode sticking in the molten pool and the tungsten inclusions are reduced. This is particularly useful in tacking and in spot welding.

TIG activArc combined with pulse variant "TIG automated pulses" or "kHz pulses (metallurgic pulses)" improves the positive properties of the process further depending on the task.

Operating element


x 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). Operating element


5 sec.

Select activArc parameter value

x x Select activArc parameter value

Press until LED flashes

Set parameter value • Increase parameter value (A/V) • Decrease parameter value (A/V)


48 Item No.: 099-004877-EWM01

5.3.10 TIG shielding gas setting 5.3.10.1 Gas test

Operating element

Action Result

x x

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

flashes.

5 sec.

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

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

5.3.11 TIG welding torch (operating variants) There is the option of connecting various operating and display elements to the welding torch. The functions of the torch triggers (TT) and the operating elements can be adjusted individually using different modes (see chapter “Setting the torch mode and up/down speed”).

Explanation of symbols Operating elements: Symbol Description

BRT 1

Press torch trigger

BRT 1

Tap torch trigger

BRT 2

Tap and press torch trigger

For more detailed torch descriptions, see chapter "Setting the torch mode and up/down speed".


TIG welding

Item No.: 099-004877-EWM01 49

5.3.12 Torch mode and up/down speed setting Only the modes listed are suitable for the corresponding torch types.

The user has the modes 1-6 and modes 11-16 available. Modes 11-16 include the same function options as 1-6, but without a tapping function (see chapter “Tapping operating mode”) for the secondary current.

The function options in the individual modes can be found in the tables on the torch types. The welding process can of course be switched on and off in all modes using torch trigger 1 (TT 1).

Operating element


01

Switch off the welding machine -

Press and hold key button -

Switch on the welding machine

Select Torch mode menu item "trd"

The parameter that can be changed and the associated value blink alternately in the display.

Press until menu item "tod" (torch mode) is displayed

Set torch mode (modes 1-6, with tapping operation, modes 11-16, no tapping operation)

1 x

Select up/down speed (not available in modes 4, 5, 14 and 15)

Set up/down speed Increase value = faster Reduce value = slower

Select Torch mode menu item "trd" (deselection)

Select Configuration menu item "Eit" (deselection)

1 x

Deselection "Eit" (Exit) Welding machine is re-initialised


50 Item No.: 099-004877-EWM01

5.3.12.1 Standard TIG torch (5-pole) Standard torch with one torch trigger: Diagram Operating

elements Explanation of symbols

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

Functions mode Operating elements

Welding current On/Off BRT 1

Secondary current

1 (factory-set) BRT 1

Further modes are not relevant for this torch type. Standard torch with two torch triggers: Diagram Operating


BRT1 = torch trigger 1

BRT2 = torch trigger 2



Secondary current BRT 2

Secondary current (tapping mode)

1 (factory-set)

BRT 1


Secondary current (tapping mode) BRT 1

Up function BRT 2

Down function

3

BRT 2

Further modes are not relevant for this torch type.


TIG welding

Item No.: 099-004877-EWM01 51

Standard torch with one rocker (MG rocker, two torch triggers) Diagram Operating


BRT 1 = torch trigger 1






1 (factory-set)

BRT 1


+BRT 2


+BRT 2

Up function BRT 1

Down function

2

BRT 2



Up function BRT 2

Down function

3

BRT 2

Further modes are not relevant for this torch type.


52 Item No.: 099-004877-EWM01

5.3.12.2 TIG up/down torch (8-pole) Up/down torch with one torch trigger Diagram Operating


TT 1 = torch trigger 1

Functions Mode Operating elements

Welding current on/off BRT 1


Increase welding current, infinite adjustment (up function) Up

Reduce welding current, infinite adjustment (down function)

1 (factory-

set)

Down



2 BRT 1



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

Up

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

4

Down


TIG welding

Item No.: 099-004877-EWM01 53

Up/down torch with two torch triggers Diagram Operating


TT 1 = torch trigger 1 (left)

TT 2 = torch trigger 2 (right)





Increase welding current, infinite adjustment (up function) Up

Reduce welding current, infinite adjustment (down function)

1 (factory-

set)

Down




2

BRT 1




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

Up

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

4

Down


54 Item No.: 099-004877-EWM01

5.3.12.3 Potentiometer torch (8-pole)

The welding machine needs to be configured for operation with a potentiometer torch (see chap. "Configuring TIG potentiometer torch") Potentiometer torch with one torch trigger: Diagram Operating






Increase welding current, infinite adjustment

Reduce welding current, infinite adjustment

3

Potentiometer torch with two torch triggers: Diagram Operating








Increase welding current, infinite adjustment

Reduce welding current, infinite adjustment

3


TIG welding

Item No.: 099-004877-EWM01 55

5.3.12.4 RETOX TIG torch (12-pole)

The welding machine must be fitted with the 12-pole torch connection socket (option). Diagram Pictogram Explanation of symbols

888

TT1 = Torch trigger 1 (welding current on/off; secondary current via tapping function)

TT2 = Torch trigger 2 (secondary current)

Up/down = Increase/reduce welding current

Job = Job switching

Additional functions (modes 4-6) are generally selected by a brief tap on TT 2. If torch trigger 2 (TT 2) is pressed for approx. 3 seconds, the gas test will be carried out (shielding gas flows for approx. 20 secondsFehler! Es wurde kein Textmarkenname vergeben.). Select secondary current via TT 2: Tapping function switched on: Mode 1-6; tapping function switched off: Modes 11-16

Basic function (before and during welding)

Additional function (before welding)

Display Mode Pictogram

Up/down function (infinite adjustment of welding current)

- Welding current 1 888

BRT 1

BRT 2Up

Down Not used for this torch type 3 Up/down function (stepped adjustment of welding current)

Welding current 888

BRT 1

BRT 2Up

Down

Job selection Job number

4 888

BRT 1

BRT 2Job

Job

Job selection Job number 5 888

BRT 1

BRT 2Job

Job Up/down function (infinite adjustment of welding current)

Welding current 888

BRT 1

BRT 2Up

Down

Job selection Job number

6 888

BRT 1

BRT 2Job

Job


56 Item No.: 099-004877-EWM01

5.3.13 Setting the first increment

Figure 5-14

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

Operating element




Switch on welding machine

Select Torch mode menu item "trd"


1 x

Hold until menu item "tod" (torch mode) is displayed

Set torch mode (mode 4, with tapping mode, mode 14, no tapping mode)

1 x

Select increment

Set increment Setting range: 1 A to 20 A

Select Torch mode menu item "trd" (deselection)


1 x



MMA welding

Item No.: 099-004877-EWM01 57

5.4 MMA welding Once the MMA welding process is selected, there is open circuit voltage present on the welding

current sockets and on the G1/4” shielding gas connection on the front of the machine. Attach the yellow protective cap onto the G1/4” shielding gas connection on the front of the machine.

5.4.1 Selection and adjustment Operating element

Action Result Displays

Select MMA welding process

The signal light lights up in green

Display shows the last current value used for welding.

Set welding current Welding current is

displayed.

5.4.2 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current.

a) = Hotstart time b) = Hotstart current I = Welding current t = Time

5.4.2.1 Hotstart current

Operating element


x x

Select hotstart current welding parameter

Press until hotstart current signal light AMP% comes on

Set hotstart current The factory setting is a value as a percentage of the selected main current. To set an absolute value for the hotstart current, see chapter "Advanced settings".

Functional characteristics Key switch

58 Item No.: 099-004877-EWM01

5.4.2.2 Hotstart time

Operating element


Select hotstart time welding parameter

Press until hotstart time light sec comes on

Set hotstart time

5.4.3 Arcforcing Shortly before the electrode threatens to stick, the arcforcing device sets an increased current designed to prevent the electrode sticking.

Operating element


1 x Select arcforcing welding parameter

The signal light lights up in red

Set arcforcing -40 = low current increase > soft arc 0 = default setting +40 = high current increase > aggressive arc

5.4.4 Antistick

Anti-stick prevents the electrode from annealing. If the electrode sticks in spite of the Arcforce device, the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating. Check the welding current setting and correct according to the welding task!

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

Key position 1 = All parameters can be set

Key position 0 = 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


Advanced settings

Item No.: 099-004877-EWM01 59

5.6 Advanced settings 5.6.1 Setting slope times for secondary current AMP% or pulse edges

Figure 5-15

Operating element


2 sec.

Select slope time tS1

Set slope time tS1 from main current AMP% to secondary current AMP

1 x

Select slope time tS2

Set slope time tS2 from secondary current AMP% to main current AMP

Wait approx. 4 sec. to exit the menu

Functional characteristics Advanced settings

60 Item No.: 099-004877-EWM01

5.6.2 TIG non-latched operating mode, C version Operating element


01



Switch on the welding machine

Select Configuration menu item "cFG"


Hold until menu item "2tc" (TIG non-latched C version) is displayed

Switch TIG non-latched C version operating mode to “on” To switch off = "off"

Select Configuration menu item "cFG" (deselection)


1 x



Advanced settings

Item No.: 099-004877-EWM01 61

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

Welding torch configuration Setting

Prepared for TIG standard or up/down torch (factory setting) JP27

Prepared for potentiometer torches JP27

Observe the safety precautions given in the standard operating instructions! Observe accident prevention regulations! All conversion and retrofitting work must be completed by electrical engineers in accordance with the relevant VDE regulations. Disconnect from the mains before opening. Switching off is not sufficient. Wait for 2 minutes until the capacitors have discharged. It is absolutely essential that a repetition test conforming to VDE 0702, VBG 4 and VBG 15 is performed before using the machine again! For more detailed instructions, please see standard operating instructions for the welding machine.

5.6.4 Switching between percentage and absolute welding currents The currents can be set and displayed as a percentage (factory setting) or as an absolute value:

Pos. Symbol Description

1

Ignition current (TIG) Hotstart current (MMA)

2 AMP%

Secondary current (TIG)

3

End-crater current (TIG)

Functional characteristics Advanced settings

62 Item No.: 099-004877-EWM01

5.6.4.1 Selection and adjustment Operating element




Switch on welding machine

Select Configuration menu item "cFG"


1 x

Hold until "SEt" menu item is displayed

Select the operating mode Pro = percentage current setting (1% to 200%) Abs = absolute current setting (Imin to Imax)

Select Configuration menu item "cFG" (deselection)


1 x



Remote control

Item No.: 099-004877-EWM01 63

5.7 Remote control

Only the remote controls described in these operating instructions may be connected. Only plug the remote control into the remote control socket and lock when the machine is switched off. The remote control is detected automatically when the welding machine is switched on.

5.7.1 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 • It is connected to the 19-pole remote control connection socket

5.7.2 Manual remote control RT 1

Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected

main current on the welding machine. • The remote control is connected to the 19-pole remote control connection socket

on the welding machine via a 19-pole extension cable.

5.7.3 Manual remote control RT AC 1


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%.

Please note • The remote control is connected to the 19-pole remote control connection socket

on the welding machine via a 19-pole extension cable. 5.7.4 Manual remote control RTP 1

Functions • TIG / MMA • Infinitely adjustable welding current (0% to 100%) depending on the preselected

main current on the welding machine. • Pulse / spot / normal • Pulse, spot and break times are infinitely adjustable.


on the welding machine via a 19-pole extension cable. • TIG AC pulses special is not possible.

Functional characteristics Remote control

64 Item No.: 099-004877-EWM01

5.7.5 Manual remote control RTP 2

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%.


on the welding machine via a 19-pole extension cable. • TIG AC pulses special is not possible.

5.7.6 RTP 3 manual remote control

Functions • TIG / MMA. • Infinitely adjustable welding current (0% to 100%) depending on the preselected

main current on the welding machine. • Pulse / SpotArc spots / normal • Frequency and spot time infinitely adjustable. • Coarse adjustment of the pulse frequency. • Pulse/pause ratio (balance) adjustable from 10% to 90%.

Please note • The remote control is connected to a 19-pole remote control connection socket on

the welding machine via a 19-pole extension cable. • TIG AC pulses special is not possible.

5.7.7 Manual remote control RT PWS 1


main current on the welding machine. • Changeover switch for pole reversal, suitable for welding machines with PWS-

function. • The remote control is connected to the 19-pole remote control connection socketon

the welding machine via a 19-pole extension cable.


Interfaces for automation

Item No.: 099-004877-EWM01 65

5.8 Interfaces for automation The welding power sources feature a very high standard of safety. This safety standard is also maintained when peripheral equipment is connected for automatic welding if this peripheral equipment fulfils the same criteria, particularly with regard to isolation from the mains supply.

This is ensured by the use of transformers according to VDE 0551. The welding machines are prepared for automated operation as standard.

Use only shielded control leads.

5.8.1 TIG interface for mechanised welding Pin Signal

shape Designation Diagram

A Output PE Connection for cable screen B Output REGaus For servicing purposes only C Input SYN_E Synchronisation for master/slave operation D Output

(no c.) IGRO Current flows signal I>0 (maximum load

20mA / 15V) 0V = welding current flowing

E + R

Input Not/Aus Emergency stop for higher level shut-down of the power source. To use this function, jumper 1 must be unplugged on PCB T320/1 in the welding machine. Contact open = welding current off

F Output 0V Reference potential G - NC Not assigned H Output Uist Actual welding voltage, measured on pin F,

0-10V (0V = 0V, 10V = 100V) J Vschweiss Reserved for special purposes K Output SYN_A Synchronisation for master/slave operation L Input Str/Stp Start / stop welding current, same as torch

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

M Output +15V Voltage supply +15V, max. 75mA

N Output -15V Voltage supply -15V, max. 25mA

P - NC Not assigned S Output 0V Reference potential T Output Iist Actual welding current, measured on pin F;

0-10V (0V = 0A, 10V = 1000A) U NC V Output SYN_A 0V Synchronisation for master/slave operation

Functional characteristics Interfaces for automation

66 Item No.: 099-004877-EWM01

5.8.2 Remote control connection socket, 19-pole

If the machine is operated using control voltages, the connection should be made via isolating amplifiers!

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

Figure 5-16

Pos. Pin Signal shape Designation 1 A Output Connection for cable screen (PE)

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

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

4 C Input Control value specification for main current, 0-10V (0V = Imin, 10V = Imax)

5 D Input Control value specification for secondary current, 0-10V (0V = Imin, 10V = Imax)

6 J/U Output Reference 0V

7 K Output Power supply +15V, max. 75mA

8 V Output Power supply -15V, max. 25mA

9 R Input Start/Stop welding current

10 S Input Switching between MMA and TIG welding

11 H Input Switching between main and secondary welding currents (pulses)

12 M/N/P Input Activation of control voltage specification Set all 3 signals to reference potential 0V to activate external control voltage specification for main and secondary currents

13 G Output Measured value ISETPOINT (1V = 100A)

Commissioning

General

Item No.: 099-004877-EWM01 67

6 Commissioning 6.1 General

Warning – Risk from electrical current! Follow the safety instructions on the opening pages entitled “For your safety”. Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead, interfaces) may only be connected when the machine is switched off.

Re-fit protective caps onto sockets and cable plugs when not in use!

6.2 Area of application – proper usage These welding machines are only suitable for:

• MMA direct current welding for rutile and basic electrodes. • TIG direct current and alternating current welding with HF ignition or liftarc. • TIG DC: Unalloyed, low-alloy and high-alloy steels, copper, nickel-based alloys and special metals. • TIG AC/DC: Aluminium and aluminium alloys. Any other use is regarded as "improper" and no liability is assumed for any damage arising therefrom.

We can only guarantee smooth and trouble-free operation of the machines when used in conjunction with the welding torches and accessories from our range.

6.3 Installation

Ensure that the machine is set up in a stable position and is appropriately secured. With modular systems (power source, transport vehicle, cooling module), observe the operating instructions for the relevant machine. Set up the machine so that there is sufficient room to adjust the operating elements.

6.4 Mains connection

The operating voltage shown on the rating plate must match the mains voltage. For mains fuse protection, please refer to the “Technical Data” chapter.

The correct mains plug must be attached to the mains supply lead on the machine. The connection must be made by a qualified electrician in compliance with the relevant local laws and regulations. The phase sequence for three-phase machines is optional and has no effect on the fans direction of rotation. • Insert mains plug of the switched-off machine into the appropriate socket.

6.5 Machine cooling To obtain an optimal duty cycle from the power components, the following precautions should be observed: • Ensure that the working area is adequately ventilated, • Do not obstruct the air inlets and outlets of the machine, • Do not allow metal parts, dust or other objects to get into the machine.

6.6 Workpiece lead, general

Remove paint, rust and dirt from clamping and welding areas with a wire brush. The workpiece clamp must be mounted near the welding point and must be fixed in such a way that it cannot come loose of its own accord. Structural parts, pipes, rails etc. may not be used as return leads for the welding current unless they are part of the actual workpiece. Correct current connection must be ensured when using welding benches and appliances.

Commissioning TIG welding

68 Item No.: 099-004877-EWM01

6.7 TIG welding 6.7.1 Welding torch connection

We can only guarantee the perfect functioning of our machines when used with our range of welding torches. The welding torches being used must meet the following conditions (see also the operating instructions for the torch): • The torch trigger control lead must not be shielded. • Only torches with an insulated crown nut on the gas connection lead may be used.

There is an open circuit voltage or welding voltage on the G1/4” connecting nipple for shielding gas (front of the machine). If welding is carried out alternately using TIG and MMA welding and if a welding torch and an electrode holder are connected to the machine, the open-circuit or welding voltage is applied simultaneously to both. The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks.

Figure 6-1


1



3



4


5


Commissioning

TIG welding

Item No.: 099-004877-EWM01 69

Prepare welding torch according to the welding task in hand (see operating instructions for the torch). • Insert the welding current plug on the welding torch into the welding current connection socket and

lock by turning to the right. • Screw welding torch shielding gas connection tightly onto the G¼" connection nipple, welding current

“-”. • Insert the welding torch control lead plug into the connection socket for the welding torch control lead

(5-pole with standard torch, 8-pole with up/down or potentiometer torch and 12-pole with up/down torch with LED display) and tighten.

• Lock connecting nipples of the cooling water tubes into the corresponding rapid-action closure couplings: Return line red to rapid-action coupling red (coolant return line) and supply line blue to rapid-action coupling blue (coolant supply line).

Please note the relevant documentation of the accessory components.

With the TETRIX 500 AC/DC welding machine, the coolant hoses supplied should be used as the extension between the welding torch and cooling module.

6.7.2 Torch connection options and pin assignments

5

4

3

2

1

BT

I1

I2

A

C

E

D

G

H

F

B

Poti UD/einPoti UD/ein

IH-Down

Uref 10VUref 10V

Up

0V

BT1

BT2

UpDown

+ -

BT2

+

BT1

-

5-pole control lead 8-pole control lead 12-pole control lead

Figure 6-2

6.7.3 Connection for workpiece lead • Insert cable plug of the workpiece lead into the "+" or "-" welding current socket and lock by turning to

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

packaging.

Commissioning TIG welding

70 Item No.: 099-004877-EWM01

6.7.4 Shielding gas supply (shielding gas cylinder for welding machine) 6.7.4.1 Connecting the shielding gas supply

No dirt must be allowed to enter the shielding gas supply, as this would cause blockages in the shielding gas supply. All shielding gas connections must be gastight.

Figure 6-3


1


• Place shielding gas cylinder in the retainer provided for it and secure with chains. • Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to blow out

any dirt. • Mount the pressure reducer onto the gas cylinder valve. • Screw the gas hose connection nipple onto the output side of the pressure reducer. • Screw the gas hose connection nipple onto the G1/4" connection nipple.

6.7.4.2 Setting the shielding gas quantity

Rule of thumb for gas flow rate: Diameter of gas nozzle in mm corresponds to gas flow in l/min. Example: 7 mm gas nozzle corresponds to 7 l/min gas flow

Commissioning

MMA welding

Item No.: 099-004877-EWM01 71

6.8 MMA welding 6.8.1 Electrode holder connection

There is an open circuit voltage or welding voltage on the G1/4” connecting nipple for shielding gas (front of the machine). If welding is carried out alternately using TIG and MMA welding and if a welding torch and an electrode holder are connected to the machine, the open-circuit or welding voltage is applied simultaneously to both. The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks.

Fit yellow insulating cap onto G1/4" connection nipple (shielding gas connection).

Caution: Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and • Always put the electrode holder down on an insulated surface.

Figure 6-4


1


2


3



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

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

Commissioning Cooling unit function specification

72 Item No.: 099-004877-EWM01

6.8.2 Connection for workpiece lead • Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and

lock by turning to the right.

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

The welding current polarity can be reversed on the machine control (see chapter "Function specification – reversing the welding current polarity").

6.9 Cooling unit function specification A functional test is performed on the cooling module after the welding machine has been switched on.

The coolant pump and the fan are switched on. When the coolant level is sufficient and enough hydrostatic pressure has built up, the cooling module is then switched off after 25 seconds.

If the level is too low, the coolant pump continues to run for a maximum of 30 seconds. An error message is displayed, see also chapter “Operating Problems, Causes and Remedies”.

The cooling unit is switched on at the start of the welding process. Once the welding process has been completed, the water pump and fan continue to run for 5 minutes.

If the coolant pressure drops during the welding process, e.g. due to insufficient coolant, pump failure or a defective tube, the welding process is terminated (coolant pump and the welding machine power unit are shut down), see also chapter “Operating Problems, Causes and Remedies”.

6.9.1 Coolant error If the coolant pressure drops during the welding process, e.g. due to insufficient coolant, pump failure or defective hose, the welding process is terminated deliberately (coolant pump and the welding machine power unit are shut down, please as well see chapter “Operating faults, causes and cures”).

When the welding process is re-started, the coolant error is reset and the cooling module is switched on. If there is still no build-up of coolant pressure, the cooling unit is shut down and the welding process is terminated.

6.10 Simultaneous welding on both sides, synchronisation types This function is important for carrying out welding on both sides simultaneously by two welders. This is sometimes the case with thick aluminium materials in the V-up position, for example. This ensures that when using alternating current the plus and minus pole phases occur simultaneously on both power sources ensuring that the arcs do not have a negative effect on one another.

6.10.1 Synchronisation via mains voltage This application relates to two types of synchronisation:

• Synchronisation between a machine in the TETRIX series and a competitor’s machine • Synchronisation between two machines in the TETRIX series

Phase sequences and rotating fields of the supply voltages must be identical for both welding machines. It is possible to retrofit the "TSyn1" option (accessories) into a machine (rotary dial on the rear of the machine). The phase sequence can be variably adjusted with this rotary dial and optimised for the welding task. All welding machines (except frequency, 50 Hz fixed) are set separately.

Commissioning

PC interface

Item No.: 099-004877-EWM01 73

6.10.1.1 Selection and adjustment Operating element

Action Result

Select JOB numberSignal light 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 Netsyn. comes on

6.11 PC interface

The welding machine/PC connection may only ever be made using interface SECINT X10 The SECINT X10 interface should be connected as closely as possible to the PC. (If this is not observed, the PC may be damaged by high frequency ignition pulses) Observe the "TETRIX PCT 300" operating instructions.

Maintenance and testing General

74 Item No.: 099-004877-EWM01

7 Maintenance and testing

The maintenance, cleaning and testing work described below must be conducted correctly and on an annual basis in order to be entitled to claim under the EWM warranty.

7.1 General Under the indicated environmental conditions and normal operating conditions, this machine is largely maintenance-free and requires minimum care. However, a number of points 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 level of contamination in the environment and the usage time of the welding machine.

Cleaning, testing and repairing of the welding machines may only be carried out by competent, capable personnel. A capable person is one who, due to training, knowledge and experience, is able to recognise the dangers that can occur during testing of welding power sources as well as possible subsequent damage and who is able to implement the required safety procedures. In the event of failure to comply with any one of the following tests, the machine must not be operated again until it has been repaired and a new test has been carried out.

7.2 Cleaning

Before cleaning, carefully disconnect the machine from the mains. DISCONNECT THE MAINS PLUG! (Switching off or removing the fuse does not provide adequate insulation protection.) Wait 2 minutes until the capacitors are discharged. Remove the casing cover. The individual components should be handled as follows:

Power source: Depending on the amount of dust, blow out using oil- and moisture-free compressed air. Electronics: Do not blast electronic components or circuit boards with compressed air but instead use

suction from a vacuum cleaner for cleaning purposes.

Coolant: Check for impurities and replace if necessary.

Caution! Mixing with other liquids or the use of other coolants voids our manufacturer's guarantee.

7.3 Test The test should be conducted in accordance with IEC/DIN EN 60974-4 "Arc welding equipment – Inspection and testing during operation" in accordance with the German Ordinance of Operational Safety. This standard is firstly, international, and secondly, specific to arc welding equipment.

The former term of repetition test has been replaced due to a change in the corresponding standard with "Inspection and testing during operation". In addition to the regulations on the test given here, the relevant local laws and regulations must also be observed.

7.3.1 Test equipment Due to the special conditions of inverter arc welding equipment, not all test equipment is suitable

for testing in accordance with VDE 0702 to the full extent! EWM as a manufacturer offers all appropriately trained and authorised EWM sales partners the appropriate test equipment and measuring devices conforming to VDE 0404-2, which evaluate the frequency response conforming to DIN EN 61010-1 Appendix A – Measuring Circuit A1.

You as the user are tasked with ensuring that your EWM machines conform to the standard IEC/DIN EN 60974-4 and are tested with the relevant test equipment and measuring devices given above.

The following description of the test is only a brief overview of the products to be tested. For details on the test points or in the event of any queries, please refer to IEC/DIN EN 60974-4.

Maintenance and testing

Test

Item No.: 099-004877-EWM01 75

7.3.2 Scope of the test a) Visual inspection b) Electrical test: measurement of

• open circuit voltage • insulation resistance, or alternatively • leakage currents • protective conductor resistance

c) Functional test d) Documentation

7.3.3 Visual inspection The key areas in the test are:

1. Torch/stick electrode holder, welding current return lead clamp 2. Power supply: leads including plugs and strain relief 3. Welding current circuit: leads, plugs and couplings, strain relief 4. Casing 5. Operating, message, safety and adjustment devices 6. Other, general condition

7.3.4 Measuring the open circuit voltage

6u8F10nF

0...5k

0k2

1k0 1N 4007

Measuring circuit according to DIN EN 60974-1

Connect the measuring circuit to the welding current sockets. The voltmeter must display mean values and have an internal resistance ≥ 1 MΩ. In the case of step switch controlled devices, set the maximum output voltage (step switch). Adjust the potentiometer from 0 kΩ to 5 kΩ during the measurement. The measured voltage should not deviate from that specified on the rating plate by more than +/- 5% and may be no greater than 113 V (for devices with VRD: 35 V).

7.3.5 Measurement of insulation resistance The mains switch must be on so that the insulation in the interior of the machine can also be checked through to the transformer. If a mains contactor is fitted, this should be bridged or the measurement must be carried out on both sides.

The insulation resistance must not be less than:

Mains current circuit against Welding current circuit and electronics 5 MΩ Welding current circuit and electronics

against Protective conductor circuit (PE) 2.5 MΩ

Mains current circuit against Protective conductor circuit (PE) 2.5 MΩ

Maintenance and testing Test

76 Item No.: 099-004877-EWM01

7.3.6 Measuring the leakage current (protective conductor and contact current) Note: Even if the leakage current measurement according to the standard is only an alternative to the insulation resistance measurement, EWM recommends always performing both measurements, especially following repair work. The leakage current is based for the greater part on a physical effect other than the insulation resistance. For this reason, it may not be possible to uncover a dangerous leakage current using the insulation resistance measurement.

These measurements cannot be performed with a normal multimeter. Even test devices for VDE 0702 (especially older devices) are generally only intended for 50/60Hz. With inverter welding machines, however, significantly higher frequencies occur, which can interfere with some measuring devices, and result in others measuring the frequency incorrectly.

A test device must meet the requirements of VDE 0404-2. For the frequency response measurement, please refer to DIN EN 61010-1 Appendix A – Measuring circuit A1.

For these measurements the welding machine must be switched on and supplying open circuit voltage. 1. Protective conductor current: < 5mA 2. Leakage current from the welding sockets separately to PE: < 10mA

7.3.7 Measurement of protective conductor resistance Measure between the plug earthed contact and accessible live parts, e.g. casing screws. During the measurement, the connection lead must be moved across the entire length, especially near the casing and plug inlet points. This should uncover any interruptions in the protective conductor. All conductive parts of the casing accessible from outside should also be tested to ensure a correct PE connection for safety class I.

The resistance must not exceed a mains connection lead 0.3Ω up to 5m in length. For longer leads, the permissible value increases by 0.1Ω per 7.5m of lead. The maximum permissible value is 1Ω.

7.3.8 Functional test of the welding machine Safety devices, selector switches and command units (if fitted) and the entire machine or the entire system for arc welding, must be functioning perfectly.

1. Main switch 2. Emergency stop devices 3. Voltage reducing device 4. Gas solenoid valve 5. Message and control lamps

7.3.9 Documentation of the test The test report must contain: • the designation of the tested welding equipment, • the date of the test, • the test results, • the signature, name of technician and the relevant institution, • the name of the test equipment. A label with the date of the test must be affixed to the welding machine to show that the test has been passed.

Maintenance and testing

Repair Work

Item No.: 099-004877-EWM01 77

7.4 Repair Work Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under the warranty is void. In all service matters, please contact your EMW sales partner. Returns of defective equipment subject to warranty may only be made through your EWM sales partner. In the event of problems or queries, please contact the EWM Service Department directly (+49 (0) 2680 181 0). Use only genuine spare parts and replacement parts when replacing. When placing an order, please quote the type designation and item number, as well as the type, serial number and item number of the relevant equipment.

We hereby confirm that the servicing and maintenance instructions given above and the test described above have been completed correctly.

Date/Stamp/Signature of EWM sales partner Date/Stamp/Signature of EWM sales partner

Date of next maintenance work and test Date of next maintenance work and test





Maintenance and testing Disposing of equipment

78 Item No.: 099-004877-EWM01

7.5 Disposing of equipment

This machine does not belong in household waste, in accordance with the German Law on Electrical Equipment Waste. In Germany, waste equipment from private households can be disposed of free of charge at local community collection points. Your administrative office will be pleased to inform you of the options. 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, within Europe the machine can also be returned to your EWM sales partner.

7.5.1 Manufacturer's declaration to the end user • In accordance with European guidelines (Directive 2002/96/EC from the European Parliament and the

Council of 27.01.03), it is no longer permissible to dispose of used electrical and electronic equipment in unsorted household waste collections. It must be kept separate from other waste. The symbol on the wheeled bins indicates the requirement to separate this waste. Help to protect the environment and ensure that this equipment, when you no longer want to use it, is disposed of in the relevant system of separated waste disposal.

• In Germany, (German Law on the Distribution, Return and Environmentally-Friendly Disposal of Electrical and Electronic Equipment (ElektroG) of 16.03.05) you are required to take old equipment to a waste collection point separated from household waste. The public waste disposal contractor (local authorities) have set up collection points for this purpose where old equipment from private households in your area can be collected for you free of charge. It is also possible that the legally responsible waste disposal company will collect old equipment from private households.

• Please obtain the relevant information from your local waste calendar or from your town council or local authority on the options available in your area for returning or collecting old equipment.

7.6 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).

WarrantyGeneral Validity

Item No.: 099-004877-EWM01 79

8 Warranty 8.1 General Validity

3-year warranty on all new EWM machines*: • Power sources • Wire feeds • Cooling units • Trolleys

* If these are operated with genuine EWM accessories (such as intermediate tube package, remote control, remote control extension cable, coolant, etc.).

1-year warranty on:

• Used EWM machines • Automation and mechanisation components • Remote control • Inverters • Intermediate tube packages

6-month warranty on: • Spare parts supplied separately (such as circuit boards, ignition units) Manufacturer/supplier warranty on: • All additional parts used by EWM, but manufactured by other companies (e.g. motors, pumps, fans,

torches, etc.) Non-reproducible software errors and parts subject to mechanical ageing are excluded from the warranty (e.g. wire feed unit, wire feed rollers, replacement and spare wire feed parts, wheels, solenoid valves, workpiece leads, electrode holders, connection tubes, replacement torches and spare torch parts, mains and control leads, etc.).

These terms shall apply without affecting the customer’s legal rights to a warranty and subject to our General Terms and Conditions of Business and our terms on the warranty declaration. Agreements to the contrary must be confirmed by EWM in writing.

Our General Terms and Conditions of Business are available for access anytime online at www.ewm.de.

http://www.ewm.de/

Warranty Warranty Declaration

80 Item No.: 099-004877-EWM01

8.2 Warranty Declaration Your 3-year warranty Regardless of statutory warranty rights and based on our General Terms and Conditions, EWM HIGHTEC WELDING GmbH provides a 3-year warranty for its welding products starting on the date of purchase. Different warranty periods apply to accessories and spare parts; please see the “General Validity” section for these periods. Parts subject to wear are naturally exempt from the warranty.

EWM guarantees the error-free condition of the products in terms of materials and processing. If the product proves to be defective in terms of materials or processing within the warranty period, you are entitled to free repair or to replacement with an appropriate product, at our discretion. On receipt by EWM the returned product becomes the property of EWM.

Condition The prerequisite for receiving the full 3-year warranty is simply to operate the products in accordance with the EWM operating instructions observing the relevant legal recommendations and guidelines and having annual maintenance work and testing conducted by an EWM sales partner (see “Maintenance and testing” chapter). This is because only machines that are maintained regularly function correctly in the long term.

Making a claim When making a claim under the warranty, please contact your EWM authorised sales partner only.

Warranty exclusions No warranty claims can be accepted if the EWM products in question are not operated using genuine EWM accessories (such as intermediate tube package, remote control, remote control extension cable, coolant, etc.). The warranty does not apply to products that are damaged due to accidents, misuse, improper operation, incorrect installation, use of force, disregard of the specifications and operating instructions, inadequate maintenance (see chapter “Maintenance and testing”), exterior influences, acts of God or personal misfortunes. Furthermore, it is not valid in the case of improper changes, repairs or modifications. In addition, a claim for warranty does not exist in the case of partially or completely dismantled products and interventions by persons who are not authorised by EWM, as well as in the case of normal wear.

Limitation All claims regarding fulfilment or non-fulfilment on the part of EWM from this declaration in connection with this product are limited as follows to the replacement of the actual damages. EWM’s liability stemming from this declaration in connection with this product is fundamentally limited to the amount that the purchaser originally paid for the original purchase. This limitation does not apply to personal injuries or damage to property caused by negligent behaviour on the part of EWM. In no way will EWM be responsible for lost profits, indirect or subsequent damage. EWM is not liable for damages based on the claims of third parties.

Place of jurisdiction If the person making the claim is a business person, the sole place of jurisdiction for all disputes resulting directly or indirectly from the contractual relationship shall be the headquarters or the branch office of the supplier, at the discretion of the supplier. The purchaser gains ownership of the products supplied as replacements within the framework of the warranty adjustment at the time of the exchange.

Operating problems, causes and remedies

Error messages (power source)

Item No.: 099-004877-EWM01 81

9 Operating problems, causes and remedies All machines are subject to rigorous production checks and final checks. If despite this, anything fails to work at any time, please check the machine using the following chart. If none of the fault rectification procedures described leads to the correct functioning of the machine, please inform your authorised dealer.

9.1 Error messages (power source)

A welding machine error is indicated by the collective fault signal light (1) coming on and an error code (see table) being displayed in the display of the machine controller (2). In the event of a machine error, the power unit is shut down. • If multiple errors occur, these are displayed in succession. • Document machine errors and inform service staff as necessary.

Pos. Description

1 Collective interference signal light

2 Three-figure LED display

Figure 9-1

Error message Possible cause Remedy Err 3 Speedometer error Check wire guide / tube package

Err 4 Temperature error Allow machine to cool down

Err 5 Excess voltage

Err 6 Undervoltage Switch off the machine and check mains voltages

Err 7 Coolant error (only if cooling module connected)

Check coolant level and refill if necessary

Err 8 Gas error Check gas supply

Err 9 Secondary excess voltage

Err 10 PE error

Err 11 FastStop

Switch the machine off and on again. If the error persists, inform the service dept.

Err 32 Electronics error (I>0 error)

Err 33 Electronics error (Uactual error)

Err 34 Electronics error (A/D channel error)

Err 35 Electronics error (edge error)

Err 36 Electronics error (S sign)


Err 37 Electronics error (temperature error) Allow machine to cool down.

Err 38 ---

Err 39 Electronics error (secondary overvoltage)


Accessories, options General accessories

82 Item No.: 099-004877-EWM01

10 Accessories, options 10.1 General accessories

Type Designation Item number KF 23E-10 Coolant (-10 °C), 10 litres 094-000530-00000

KF 23E-10 Coolant (-10 °C), 10 litres 094-000530-00000

KF 37E-10 Coolant (-20 °C), 10 litres 094-006256-00000

DM1 32L/MIN Manometer pressure reducer 094-000009-00000

G1 G1/4 R 2M Gas hose 094-000010-00000

10.2 Remote control / connection cable Type Description / Name Item number RT1 Remote control for current 090-008097-00000

RTP1 Remote control for spots/pulses 090-008098-00000

RTP2 Remote control for spots/pulses 090-008099-00000

RTP3 SpotArc remote control for spots/pulses 090-008211-00000

RTAC1 Remote control for current/balance/frequency 090-008197-00000

RA5 19POLE 5M Connection cable, e.g. for remote control 092-001470-00005



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

094-006680-00000

RV5M19 19POLE 5M Extension cable 092-000857-00000

10.3 Options Type Description / Name Item number ON 7POL Optional 7-pole retrofit connection socket

Accessory components and digital interfaces 092-001826-00000

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

ON 19POL Optional 19-pole retrofit connection socket Accessory components and analogue A interface

092-001827-00000

ON 19POL 500 Optional 19-pole retrofit connection socket Accessory components and analogue A interface

092-001951-00000

ON KEY SWITCH Optional retrofit kit for key switch 092-001828-00000

ON NETSYNCHRON Optional retrofit set for phase sequence switching for synchronous welding

090-008212-00000

10.4 TIG welding torch Type Description / Name Item number TIG 20 U/D WD 1T 8POL 4M TIG welding torch, water, decentralised, up/down, 1

trigger 094-007535-00000

RETOX TIG 12POL 4M TIG welding torch, water, up/down, LED 094-008928-00000

Accessories, options

Transport vehicle

Item No.: 099-004877-EWM01 83

10.5 Transport vehicle Type Description / Name Item number TROLLY 75 B1 Transport vehicle disassembled, boxed, for power

source + 1 module + 1 gas cylinder 090-008176-00000

10.6 Cooling units Type Description Item number COOL35 U30 Air cooling unit (TETRIX 270) 090-008196-00102

COOL71 U42 Air cooling unit, enhanced version 090-008201-00102

COOL71 U43 Air cooling unit with centrifugal pump and reinforced cooling

090-008220-00102

10.7 Synchronisation Type Designation Item number ON NETSYNCHRON Optional retrofit set for phase sequence switching

for synchronous welding 090-008212-00000

SYNINT X10 19POL Synchronisation set incl. interface and connection cable

090-008189-00000



RA20 19POL 20M Connection cable, e.g. for remote control 092-001470-00020

ON 19POL Optional 19-pole retrofit connection socket Accessory components and analogue A interface

092-001827-00000

Circuit diagrams TETRIX 270 AC/DC COMFORT activArc

84 Item No.: 099-004877-EWM01

11 Circuit diagrams Original format circuit diagrams are located inside the machine.

11.1 TETRIX 270 AC/DC COMFORT activArc

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Item No.: 099-004877-EWM01 85

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tplatte

X1

X2/2

X2/1X2

Sch

lüsselsch

alter12Sch

lüsse

lscha

lter

S2

-

11

1

? T

2

? T

C 91

D 91

A 61

B 61

E 81

Op

tion

al:

PE

PE

PE

Da

tum:

Na

me

:

ge

zeich

ne

t:

ge

prüft:

Fre

iga

be

:

23.05.2006N

IEDEN

THAL

Bla

tt: / 2This draw



or comm



ission!

2

TETRIX 270 AC

/DC

4153-00

Ze

ichn

un

gsn

um

me

r:

WIG

-GER

AET, 3X400V CO

MFO

RT

Änderung-

Änderung-

Änderung-

Änderung-

Figure 11-2


86 Item No.: 099-004877-EWM01


X7

/10

X7

/11

X7

/12

X7

/13

X7

/14

X7

/15

X7

/16

X7

/17

X7

/18

X7

/1

X7

/2

X7

/3

X7

/4

X7

/5

X7

/6

X7

/7

X7

/8

X7

/9

L1

L2

L3

TR

I

A1

-

D C

2 6

0

X3

/1

X3

/2

A3-1

SP

W6

GL

-Dro

ssel

PE L1L2L3

Q1

-

L1L2L3

T1

T2

T3

A1

-L

1

A1

-L

2

A1

-L

3

X5/1

X5/2

X4/1

D-S

ub.

15

polig

T1

T2

T4

T3X

4X

6

T R

F 6

A2

-

X5

X1

-

PEPE

123

Rü

ckseite

12

?T

18

?T

3

40

0V

AC

6

23

0V

AC

9

0V

AC

T1

-

0V

42V

20V0V

20V0V

0V 400V

230V

0V 20V

17

/1

8

17

/18

14

/1

5

14

/15

10

/1

1

10

/11

A

B

B

A

8/

9

3/46

/7

1/27

7

6

6

9

9

8

8

1

0V

AC

2

20

VA

C

X3

/1

X3

/2

X3

/3

X3

/4

X3

X1

/1

X1

/2

X1

X3

/5

X3

/6

X2

/1

X2

/2

X2

X2

/3

X2

/4

A1

0-

LD

C1

1

20

VA

C

2

0V

AC

1

42

VA

C

2

0V

AC

1

42

VA

C

2

0V

AC

5

0V

AC

6

42

VA

C

8

PE

120VAC

20VAC

X2

/1

X2

/2

X2

/3

X2

/4

X2

X1

/1

X1

/2

X1

X4

/1

X4

/2

X4

/3

X4

/4

X3

/1

X3

/2

X4

X3

HF

-DC

1/T

A7

-

1

+1

5V

3

HF

1

Co

il

2

Co

il

2

42

VA

C

4

0V

AC

WIG

ELW

AE

HF

-Dro

ssel

L2-

22

nF

PE

2x2

n2F

PE

1

PE

1-

T?

PE

2-

1

PE

4-

3A

2

3B

2

3C

2

3D

2

X8/2

X8/1

15poligD-Sub.

15poligD-Sub.

15poligD-Sub.

15poligD-Sub.

X3

/1

X3

/2

X3

/3

X3

/4

X1

/1

X1

/2

X1

/3

X1

/4

X1

/5

X1

/6

X1

/7

X1

/8

T2

4A

TF

1

T1

12

V

W K

- 6A

6-

X9

/1

X9

/2

X2

/1

X2

/2

X2

/3

X2

/4

X7

X6

X5

X4

E5

2

1

?T

2

?T

1

Absicherung

2

Absicherung

12

4A

F1

-

Option

al:

1

PE

3-

PE

A3

-

42

V

RS

GN

D

RX

D

TX

D

RS

+1

2V

0V

Sch

irmX

1/7

X1

/6

X1

/5

X1

/4

X1

/3

X1

/2

X1

/1

42

V

RX

D

RS

GN

D

TX

D

RS

+1

2V

0V

Sch

irmX

2/7

X2

/6

X2

/5

X2

/4

X2

/3

X2

/2

X2

/1

2x2

n2

F

Stecker X3

D-SUB15polig

A3

-V

P5

/2D

Da

tum:

Na

me

:

ge

zeich

ne

t:

ge

prüft:

Fre

iga

be

:

26.09.2006N

IEDEN

THAL

Bla

tt: / 2This draw



or comm



ission!

1

TETRIX 300 AC

/DC

4420-00

Ze

ichn

un

gsn

um

me

r:

WIG

-GER

AET, 3X400V CLASSIC

Änderung-

Änderung-

Änderung-

Änderung-

Figure 11-3

Circuit diagrams


Item No.: 099-004877-EWM01 87

X1

/1

X1

/2

X1

/3

X1

/4

X1

/5

X1

/6

X1

/7

X1

/8

X1

/9

X1

/10

BR

T1

BR

T2

Ure

f+1

0V

IH-D

ow

n

UP

Po

ti UD

/ein

NC

NC0V

0V

4M

7

7x2

n2

F

X2

/2

X2

/1

X3

/4

X3

/3

X3

/2

X3

/1

X2

/6

X2

/5

X2

/4

X2

/3

X2

/2

X2

/1

X2

/7

X2

/8

2345678910

11

12

1

A9

-

BT

F1

X2

-23456789 1N

CPC

-RX

D

PC

-GN

D

NC

NC

PC

-TX

D

PC

-DT

R

PC

-RT

S

NC

123456

ABCDEFGH

Pu

mp

e

Lü

fter

+1

5V

Wa

sserm

an

ge

l

Wa

sserkü

hle

r

0V

NC

NC

X3

-

Ringkern

1W

dg

. du

rchg

ezo

ge

n

Ga

s

Y1

-

12

PE

ABCDEFGHJKLMNPRSTUV

PE

IGR

0

Po

ti IH

Po

ti IL

Po

lwe

nd

. PW

S

Ure

f.10

V

Isoll

Pu

ls Fre

qu

en

z

0V

+1

5V

IGR

0

FR

-Typ

1

FR

-Typ

2

FR

-Typ

3

FR

ST

R/S

TP

FR

WIG

/EL

EK

.

FR

MIG

ein

/au

s

0V

-15

V

X4

-

1

2

3

4

5

6

7

8

9

1 0

1 1

1 2

1 3

1 4

1 5

1 6

1 7

1 8

Rin

gke

rn

1236710

11

12

13

14

15

16

12 4

ABCDEFGHJKLMNPRSTUV

PE

RE

Ga

us

SY

N_

E

IGR

0

No

t/Au

s

0V

NC

Uist

VS

chw

eiss

SY

N_

A

Str./S

tp.

+1

5V

-15

V

NC

No

t/Au

s

0V

Iist

NC

SY

N_

A 0

V

X6

-

Rin

gke

rn

12

HF

ein

/au

s

S1

-

1

1

2

5

6

7

9

1 1

1 2

2

1

PE

4-

+15V

HF

42VAC

0VAC

0V

Gasrelais

Gasrelais

HF-Liftarc

Op

tion

al:

Iist

RE

Ga

us

SY

N_

E

IGR

0

0V

+1

5V

Uist

VS

chw

eiss

SY

N_

A

Str./S

tp.

SY

N_

A 0

V

0V

-15

V

No

t/Au

s

No

t/Au

s

Relais IGRO

Polwendung PWS

-15V

0V

FR MIG ein/aus

FR WIG/ELEK

FR STR./STP.

FR-Typ1

FR-Typ2

FR-Typ3

+15V

IGR0

0V

Puls Frequenz

Isoll

Uref.10V

Poti-IL

Poti-IH

12345678123

BT

1

X5

-12B

T2

30

V

4T

?

5U

ref.1

0V

6IH

-Do

wn

7U

p

8P

oti U

D/e

in

B1 1 2 3 4 5

Do

pp

elta

ster

WIG

-Bre

nn

er m

it

2-B

T

1-BT

12345678 X5

b-

BT

1

BT

2

0V

T?

Ure

f. 10

V

IH-D

ow

n

Up

Po

ti UD

/ein

ABCDEFGH

X5

b-

T?

T?

T?

T?

T?

T?

T?

T?

BT

1B

T2

Up

Dow

n

+-

+-

Up

-Do

wn

Bre

nn

er

12345678 X5

b-

BT

1

BT

2

0V

T?

Ure

f. 10

V

IH-D

ow

n

Up

Po

ti UD

/ein

ABCDEFGH

X5

b-

T?

T?

T?

T?

T?

T?

T?

T?

Po

ti-Bre

nn

er

10

k

Alte

rna

tiv:

1

PE

5-

2n2F

PE

12

2n2F

PE

1 2

Ringkern

1W

dg

.

du

rc

hg

ez

og

en

T?

PE

6- A

4-

T 3

2 0

/ 1

X9

/1

X9

/2

X9

/3

X9

/4

X9

/5

X9

/6

X2

0/1

X2

0/2

X2

0/3

X2

0/4

X2

0/5

X2

0/6

X2

0/7

X2

0/8

X2

0/9

X2

0/1

0

X2

1

X2

1/1

X2

1/2

X2

1/3

X2

1/4

X2

1/5

X2

1/6

X2

1/7

X2

1/8

X2

1/9

X2

1/1

0

D-Sub.15polig

X12

Fernregler

X-P

E

X12/10

X12/11

X12/12

X12/13

X12/14

X12/15

X12/16

X12/17

X12/18

X12/1

X12/2

X12/3

X12/4

X12/5

X12/6

X12/7

X12/8

X12/9

X-PE/1

X-PE/2

Bren

nertaster1

X13

X13/9

X13/8

X13/7

X13/6

X13/5

X13/4

X13/3

X13/2

X13/1

X13/10B

renn

ertaster2X

22

X22/9

X22/8

X22/7

X22/6

X22/5

X22/4

X22/3

X22/2

X22/1

X22/10

X1

4P

eriph

erie

X14/12

X14/11

X14/10

X14/9

X14/8

X14/7

X14/6

X14/5

X14/4

X14/3

X14/2

X14/1

D-S

ub.

15

polig

X11/1X11/2X11/3X11/4X11/5X11/6X11/7X11/8X11/9


X8

System

bu

sX

11

Fron

tplatte

X2

Lü

fter

X2/4

X2/3

X2/2

X2/1

Prog

ramm

iersteckerX

20

Prog

ramm

ierstecker

Wasserkü

hler

X9

Com

pu

terX

7

Erd

un

gA2

Ana. A

Ana. B

Ana. C

OE

0V-Ana.

0V-Ana.

+10V Uref.

+10V Uref.

0V1

0V1

+5V1

+5V1

+15V

+15V

-15V

-15V

WR1

RD1

CS1

CS2

CLK1

CLK1

B1

A1

B2

0V

0V

CA

N_

RX

D

RE

SE

T

CA

N_

TX

D

RX

D1

EX

T_

INT

TX

D1

+5

V

+5

V

NC

NC

+5

V2

MS

O

SC

K

MO

SI

RE

SE

T

0V

2

NC

NC

BRT1

BRT2

IH-Down

Uref.10V

0V

NC

NC

IH-Up

0V

P. UD ein

WA2

CS3

RD2

CLK2

0V

NC

NC

CS4

0V

+5V

X5

/1

X5

/2

X5

/3

X5

/4

X5

/5

X5

/6

X5

/7

X5

/8

X5

/9X

5R

obo./A

uto.

X5

/10

X5

/11

X5

/12

X5

/13

X5

/14

X5

/15

X5

/16

X5

/17

X5

/18

X6

/2

X6

/1X

6N

ot/Au

s

X1

0/2

X1

0/1

X1

0F

üh

lerspan

nu

ng

T 3 2 8 / A

CA

8-

X11/1X11/2X11/3X11/4X11/5X11/6X11/7X11/8X11/9


A2

Ana. A

Ana. B

Ana. C

OE

0V-Ana.

0V-Ana.

+10V Uref.

+10V Uref.

0V1

0V1

+5V1

+5V1

+15V

+15V

-15V

-15V

WR1

RD1

CS1

CS2

CLK1

CLK1

B1

A1

B2

Fron

tplatte

X1

X2/2

X2/1X2

Sch

lüsselsch

alter12Sch

lüsse

lscha

lter

S2

-

11

1

? T

2

? T

C 91

D 91

A 61

B 61

E 81

Op

tion

al:

Da

tum:

Na

me

:

ge

zeich

ne

t:

ge

prüft:

Fre

iga

be

:

26.09.2006N

IEDEN

THAL

Bla

tt: / 2This draw



or comm



ission!

2

TETRIX 300 AC

/DC

4420-00

Ze

ichn

un

gsn

um

me

r:

WIG

-GER

AET, 3X400V CLASSIC

Änderung-

Änderung-

Änderung-

Änderung-

Figure 11-4


88 Item No.: 099-004877-EWM01


X7

/10

X7

/11

X7

/12

X7

/13

X7

/14

X7

/15

X7

/16

X7

/17

X7

/18

X7

/1

X7

/2

X7

/3

X7

/4

X7

/5

X7

/6

X7

/7

X7

/8

X7

/9

L1

L2

L3

TR

I

A1

-

D C

3 0

0

X3

/1

X3

/2

A3-1

SP

W6

GL

-Dro

ssel

PE L1L2L3

Q1

-

L1L2L3

T1

T2

T3

A1

-L

1

A1

-L

2

A1

-L

3

X5/1

X5/2

X4/1

D-S

ub.

15

polig

T1

T2

T4

T3X

4X

6

T R

F 6

A2

-

X5

12

?T

18

?T

3

40

0V

AC

6

23

0V

AC

9

0V

AC

120VAC

20VAC

WIG

ELW

22

nF

PE

T?

PE

2-

1

PE

4-

X1

-P

E

PE

123

Rü

ckseite

8/9

6/7

17/18

14/15

10/11

T1

-AB

3/4

1/2

17

/1

8

40

0V

14

/1

5

23

0V

10

/1

1

0V

6/

7

0V

8/

9

20

V

AE

HF

-Dro

ssel

L1

-

2x2

n2F

PE

X8/2

X8/1

15poligD-Sub.

15poligD-Sub.

15poligD-Sub.

15poligD-Sub.

X3

/1

X3

/2

X3

/3

X3

/4

X1

/1

X1

/2

X1

/3

X1

/4

X1

/5

X1

/6

X1

/7

X1

/8

T2

4A

TF

1

T1

12

V

W K

- 6A

6-

X9

/1

X9

/2

X2

/1

X2

/2

X2

/3

X2

/4

X7

X6

X5

X4

E5

2

8

PE

1

PE

1-

1

42VA

C

2

0VA

C

5

42VA

C

6

0VA

C

1

Absicherung

2

Absicherung

A

42

VB

0V

B3

2

A3

2

X2

/1

X2

/2

X2

/3

X2

/4

X2

X1

/1

X1

/2

X1

X4

/1

X4

/2

X4

/3

X4

/4

X3

/1

X3

/2

X4

X3

HF

-DC

1/T

A7

-

1

+15V

3

HF

3C

2

3D

2

1

Coil

2

Coil

1

?T

2

?T

HF

-DC

Co

ilA

3-

2 El

W

Co

ilC

oil

2

0VA

C

4

42VA

C

12

4A

F1

-

Option

al:

42

V

RS

GN

D

RX

D

TX

D

RS

+1

2V

0V

Sch

irmX

1/7

X1

/6

X1

/5

X1

/4

X1

/3

X1

/2

X1

/1

42

V

RX

D

RS

GN

D

TX

D

RS

+1

2V

0V

Sch

irmX

2/7

X2

/6

X2

/5

X2

/4

X2

/3

X2

/2

X2

/1

2x2

n2

F

Stecker X3

D-SUB15polig

A5

-V

P5

/2D

1A

5-

PE

/

1P

E3

-

PE

XA-1

PE

PE

Da

tum:

Na

me

:

ge

zeich

ne

t:

ge

prüft:

Fre

iga

be

:

23.05.2006N

IEDEN

THAL

Bla

tt: / 2This draw



or comm



ission!

1

TETRIX 350 AC

/DC

4155-00Z

eich

nu

ng

snu

mm

er:

WIG

-GER

AET, 3X400V CO

MFO

RT

Änderung-

Änderung-

Änderung-

Änderung-

Figure 11-5

Circuit diagrams


Item No.: 099-004877-EWM01 89

X1

/1

X1

/2

X1

/3

X1

/4

X1

/5

X1

/6

X1

/7

X1

/8

X1

/9

X1

/10

BR

T1

BR

T2

Ure

f+1

0V

IH-D

ow

n

UP

Po

ti UD

/ein

NC

NC0V

0V

4M

7

7x2

n2

F

X2

/2

X2

/1

X3

/4

X3

/3

X3

/2

X3

/1

X2

/6

X2

/5

X2

/4

X2

/3

X2

/2

X2

/1

X2

/7

X2

/8

2345678910

11

12

1

A9

-

BT

F1

X2

-23456789 1N

CPC

-RX

D

PC

-GN

D

NC

NC

PC

-TX

D

PC

-DT

R

PC

-RT

S

NC

123456

ABCDEFGH

Pu

mp

e

Lü

fter

+1

5V

Wa

sserm

an

ge

l

Wa

sserkü

hle

r

0V

NC

NC

X3

-

Ringkern

1W

dg

. du

rchg

ezo

ge

n

Ga

s

Y1

-12

PE

ABCDEFGHJKLMNPRSTUV

PE

IGR

0

Po

ti IH

Po

ti IL

Po

lwe

nd

. PW

S

Ure

f.10

V

Isoll

Pu

ls Fre

qu

en

z

0V

+1

5V

IGR

0

FR

-Typ

1

FR

-Typ

2

FR

-Typ

3

FR

ST

R/S

TP

FR

WIG

/EL

EK

.

FR

MIG

ein

/au

s

0V

-15

V

X4

-

1

2

3

4

5

6

7

8

9

1 0

1 1

1 2

1 3

1 4

1 5

1 6

1 7

1 8

Rin

gke

rn

1236710

11

12

13

14

15

16

12 4

ABCDEFGHJKLMNPRSTUV

PE

RE

Ga

us

SY

N_

E

IGR

0

No

t/Au

s

0V

NC

Uist

VS

chw

eiss

SY

N_

A

Str./S

tp.

+1

5V

-15

V

NC

No

t/Au

s

0V

Iist

NC

SY

N_

A 0

V

X6

-

Rin

gke

rn

12Sch

lüsse

lscha

lter

S1

-

12

HF

ein

/au

s

S2

-

1

1

2

5

6

7

9

1 1

1 2

2

1

PE

4-

+15V

HF

42VAC

0VAC

0V

Gasrelais

Gasrelais

HF-Liftarc

Op

tion

al:

Iist

RE

Ga

us

SY

N_

E

IGR

0

0V

+1

5V

Uist

VS

chw

eiss

SY

N_

A

Str./S

tp.

SY

N_

A 0

V

0V

-15

V

No

t/Au

s

No

t/Au

s

Relais IGRO

Polwendung PWS

-15V

0V

FR MIG ein/aus

FR WIG/ELEK

FR STR./STP.

FR-Typ1

FR-Typ2

FR-Typ3

+15V

IGR0

0V

Puls Frequenz

Isoll

Uref.10V

Poti-IL

Poti-IH

12345678123

BT

1

X5

-12B

T2

30

V

4T

?

5U

ref.1

0V

6IH

-Do

wn

7U

p

8P

oti U

D/e

in

A4

-

T 3

2 0

/ 1

X9

/1

X9

/2

X9

/3

X9

/4

X9

/5

X9

/6

X2

0/1

X2

0/2

X2

0/3

X2

0/4

X2

0/5

X2

0/6

X2

0/7

X2

0/8

X2

0/9

X2

0/1

0

X2

1

X2

1/1

X2

1/2

X2

1/3

X2

1/4

X2

1/5

X2

1/6

X2

1/7

X2

1/8

X2

1/9

X2

1/1

0

D-Sub.9polig

X12

Fernregler

X-P

E

X12/10

X12/11

X12/12

X12/13

X12/14

X12/15

X12/16

X12/17

X12/18

X12/1

X12/2

X12/3

X12/4

X12/5

X12/6

X12/7

X12/8

X12/9

X-PE/1

X-PE/2

Bren

nertaster1

X13

X13/9

X13/8

X13/7

X13/6

X13/5

X13/4

X13/3

X13/2

X13/1

X13/10B

renn

ertaster2X

22

X22/9

X22/8

X22/7

X22/6

X22/5

X22/4

X22/3

X22/2

X22/1

X22/10

X1

4P

eriph

erie

X14/12

X14/11

X14/10

X14/9

X14/8

X14/7

X14/6

X14/5

X14/4

X14/3

X14/2

X14/1

D-S

ub.

15

polig

X11/1X11/2X11/3X11/4X11/5X11/6X11/7X11/8X11/9


X8

System

bu

sX

11

Fron

tplatte

X2

Lü

fter

X2/4

X2/3

X2/2

X2/1

Prog

ramm

iersteckerX

20

Prog

ramm

ierstecker

Wasserkü

hler

X9

Com

pu

terX

7

Erd

un

gA2

Ana. A

Ana. B

Ana. C

OE

0V-Ana.

0V-Ana.

+10V Uref.

+10V Uref.

0V1

0V1

+5V1

+5V1

+15V

+15V

-15V

-15V

WR1

RD1

CS1

CS2

CLK1

CLK1

B1

A1

B2

0V

0V

CA

N_

RX

D

RE

SE

T

CA

N_

TX

D

RX

D1

EX

T_

INT

TX

D1

+5

V

+5

V

NC

NC

+5

V2

MS

O

SC

K

MO

SI

RE

SE

T

0V

2

NC

NC

BRT1

BRT2

IH-Down

Uref.10V

0V

NC

NC

IH-Up

0V

P. UD ein

WA2

CS3

RD2

CLK2

0V

NC

NC

CS4

0V

+5V

X5

/1

X5

/2

X5

/3

X5

/4

X5

/5

X5

/6

X5

/7

X5

/8

X5

/9X

5R

obo./A

uto.

X5

/10

X5

/11

X5

/12

X5

/13

X5

/14

X5

/15

X5

/16

X5

/17

X5

/18

X6

/2

X6

/1X

6N

ot/Au

s

X1

0/2

X1

0/1

X1

0F

üh

lerspan

nu

ng

B1 1 2 3 4 5

Do

pp

elta

ster

WIG

-Bre

nn

er m

it

2-B

T

1-BT

12345678 X5

b-

BT

1

BT

2

0V

T?

Ure

f. 10

V

IH-D

ow

n

Up

Po

ti UD

/ein

ABCDEFGH

X5

b-

T?

T?

T?

T?

T?

T?

T?

T?

BT

1B

T2

Up

Dow

n

+-

+-

Up

-Do

wn

Bre

nn

er

12345678 X5

b-

BT

1

BT

2

0V

T?

Ure

f. 10

V

IH-D

ow

n

Up

Po

ti UD

/ein

ABCDEFGH

X5

b-

T?

T?

T?

T?

T?

T?

T?

T?

Po

ti-Bre

nn

er

10

k

Alte

rna

tiv:

1

PE

5-

2n2F

PE

12

2n2F

PE

1 2

Ringkern

1W

dg

.

du

rc

hg

ez

og

en

T?P

E6

-

T 3

2 3

/ A C

D C

A8

-

X11/1X11/2X11/3X11/4X11/5X11/6X11/7X11/8X11/9


A2

Ana. A

Ana. B

Ana. C

OE

0V-Ana.

0V-Ana.

+10V Uref.

+10V Uref.

0V1

0V1

+5V1

+5V1

+15V

+15V

-15V

-15V

WR1

RD1

CS1

CS2

CLK1

CLK1

B1

A1

B2

Fron

tplatte

X1

X2/2

X2/1X2

Sch

lüsselsch

alter

1

? T

2

? T

1

?T

2

?T

Op

tion

al:

C 91

D 91

A 31

B 31

E 71

PE

PE

PE

Da

tum:

Na

me

:

ge

zeich

ne

t:

ge

prüft:

Fre

iga

be

:

23.05.2006N

IEDEN

THAL

Bla

tt: / 2This draw



or comm



ission!

2

TETRIX 350 AC

/DC

4155-00Z

eich

nu

ng

snu

mm

er:

WIG

-GER

AET, 3X400V CO

MFO

RT

Änderung-

Änderung-

Änderung-

Änderung-

Figure 11-6


90 Item No.: 099-004877-EWM01


X8

/1

X8

/2

X8

/3

X8

/4

X8

/5

X8

/6

X8

/7

X8

/8

X4

/10

X4

/11

X4

/12

X4

/13

X4

/14

X4

/15

X4

/16

X4

/17

X4

/18

X4

/1

X4

/2

X4

/3

X4

/4

X4

/5

X4

/6

X4

/7

X4

/8

X4

/9

L3

/1

L2

/1

L1

/1

11

065

T1

K1

X8

X4

PE

/1

X1

/1

X1

/2

X1

/3

X1

/4

X1

/5

X1

/6

X7

/2

X7

/1

X5

/1

X5

/2

X5

/3

X5

/4

X5

/5

X5

/6

X5

/7

X5

/8

X6

/2

X6

/1

X1

/7

X1

/8

X1

/9

X1

/10

X1

/11

X1

/12

L3

´/1

L2

´/1

L1

´/1

X1

F2

6.3

A

C/1

D/1

X5

X7

X6

X3

/2

X3

/1

line voltag

eN

etzspan

nu

ng

en

X2

/2

X2

/1

44

0V

/46

0V

40

0V

/41

5V

F3

6.3

A

N E

F - 4

A3

-

PE

A1

A2

A3

V A

1A

9-

Q1

-

L1T

1

L2T

2

L3T

3

Rin

gke

rn

n=

10

Wd

g.

Tx

x-

X1

-P

E

PE

123

1369

10

12

18

44

0/4

60

V

0V

46V

42V0V

23

0V

40

0/4

15

V

T1

-

20V0V

8642

14121110

440V/460V

AC

400V/415V

AC

230VA

C

440V/460V

AC

0VA

C

400V/415V

AC

0VA

C

L1X

-

L2

L3

PE P

E

L2

L3

L1

1212

12

1614581212

400V/460V

AC

0VA

C

Lüfter

0VA

C

Lüfter

0VA

C

Lüfter

Lüfter

18VA

C

0VA

C

X5/1

X5/2

X4/1

D-S

ub.

15

polig

T1

T2

T4

T3X

4X

6

T R

F 6 / - 6 MA

15

-

X5

2 1

?T

L1

-

1

2

T?

PE

1

2x2

n2F

PE

HF

-DC

Co

ilA

5-

Co

il-1 E

LW

Co

ilC

oil

WIG

ELW

22

nF

PE

L1

L2

L3

TR

I5

A1

-

1~

X3

/1

X3

/2S

PW

6

1~ M

1-M2

Lüfter

1212128

3A

2

3B

2

15poligD-SUB

Stecker X3

Sch

irm 0V

RS

+1

2V

TX

D

RX

D

RS

GN

D

42

V

X1

/7

X1

/6

X1

/5

X1

/4

X1

/3

X1

/2

X1

/1

Sch

irm 0V

RS

+1

2V

RS

GN

D

42

V

X2

/7

X2

/6

X2

/5

X2

/4

X2

/3

X2

/2

X2

/1

RX

D

TX

D

VP

5/2

D2x2

n2

F

A1

1-

X2

/1

X2

/2

X2

/3

X2

/4

X2

X1

/1

X1

/2

X1

X4

/1

X4

/2

X4

/3

X4

/4

X3

/1

X3

/2

X4

X3

HF

-DC

1/T

A6

-

12 24

13

3E

2

3F

2

n = ? W d g .

Rin

gke

rn

T x x - 1

n = ? W d g .

Rin

gke

rn

T x x

1

PE

2-

1

PE

3-

42VA

C

0VA

C

42VA

C

0VA

C

42VA

C

0VA

C

20VAC

0VAC

42VA

C

0VA

C

42VA

C

0VA

C

Coil

Coil

AE

HF

-Dro

ssel

L2

-

148

1~

Lü

fter

M4

-

12

T1

.1

?T

1?

1 X7

-

2T

2.

1?

T2

?

3T

3.

1?

T3

?

4T

4.

1?

T4

?

5T

5.

1?

T5

?

6T

6.

1?

T6

?

7T

7.

1?

T7

?

8T

8.

1?

T8

?

1~

Lü

fter

M3

-

12

AC

Modul

AC

Modul

A1

2-

Relais1

X2

/3

X2

/2

X2

/1

X1

/2

X1

/1

A1

2-

X2

/3

A1

2-

X2

/2

A1

2-

X2

/1

T1

.1

?T

1?

1

X6

A-

2T

2.

1?

T2

?

C4

2

D4

2

X8/2

X8/1

15poligD-Sub.

15poligD-Sub.

15poligD-Sub.

15poligD-Sub.

X3

/1

X3

/2

X3

/3

X3

/4

X1

/1

X1

/2

X1

/3

X1

/4

X1

/5

X1

/6

X1

/7

X1

/8

T2

4A

TF

1

T1

12

V

W K

- 6A

4-

X9

/1

X9

/2

X2

/1

X2

/2

X2

/3

X2

/4

X7

X6

X5

X4

G5

2

Op

tion

al:

1

Absicherung

2

Absicherung

1

?T

2

?T

12

4A

F1

-

2

?T

1

?T

A1

-L

1

A1

-L

2

PE

PE

PE

Da

tum:

Na

me

:

ge

zeich

ne

t:

ge

prüft:

Fre

iga

be

:

24.05.2006N

IEDEN

THAL

Bla

tt: / 2This draw



or comm



ission!

1

TETRIX 500 AC

/DC

4162-00Z

eich

nu

ng

snu

mm

er:

WIG

-GER

AET, 3X400V CO

MFO

RT

Änderung-

Änderung-

Änderung-

Änderung-

Figure 11-7

Circuit diagrams


Item No.: 099-004877-EWM01 91

X1

/1

X1

/2

X1

/3

X1

/4

X1

/5

X1

/6

X1

/7

X1

/8

X1

/9

X1

/10

BR

T1

BR

T2

Ure

f+1

0V

IH-D

ow

n

UP

Po

ti UD

/ein

NC

NC0V

0V

4M

7

7x2

n2

F

X2

/2

X2

/1

X3

/4

X3

/3

X3

/2

X3

/1

X2

/6

X2

/5

X2

/4

X2

/3

X2

/2

X2

/1

X2

/7

X2

/8

2345678910

11

12

1

A8

-

BT

F1

X2

-23456789 1N

C

PC

-RX

D

PC

-GN

D

NC

NC

PC

-TX

D

PC

-DT

R

PC

-RT

S

NC

123456

ABCDEFGH

Pu

mp

e

Lü

fter

+1

5V

Wa

sserm

an

ge

l

Wa

sserkü

hle

r

0V

NC

NC

X3

-

Ringkern

1W

dg

. du

rchg

ezo

ge

n

Ga

s

Y1

-

12

PE

ABCDEFGHJKLMNPRSTUV

PE

IGR

0

Po

ti IH

Po

ti IL

Po

lwe

nd

. PW

S

Ure

f.10

V

Isoll

Pu

ls Fre

qu

en

z

0V

+1

5V

IGR

0

FR

-Typ

1

FR

-Typ

2

FR

-Typ

3

FR

ST

R/S

TP

FR

WIG

/EL

EK

.

FR

MIG

ein

/au

s

0V

-15

V

X4

-

1

2

3

4

5

6

7

8

9

1 0

1 1

1 2

1 3

1 4

1 5

1 6

1 7

1 8

Rin

gke

rn

12310

11

12

13

14

15

16

12

ABCDEFGHJKLMNPRSTUV

PE

RE

Ga

us

SY

N_

E

IGR

0

No

t/Au

s

0V

NC

Uist

VS

chw

eiss

SY

N_

A

Str./S

tp.

+1

5V

-15

V

NC

No

t/Au

s

0V

Iist

NC

SY

N_

A 0

V

X6

-

Rin

gke

rn

Rin

gke

rn

Rin

gke

rn

1

1

12Sch

lüsse

lscha

lter

S1

-

11

Op

tion

al:

12

HF

ein

/au

s

S2

-

1

1

2

5

6

7

9

1 1

1 2

1

3

2

1

PE

4-

+15V

HF

42VAC

0VAC

0V

Gasrelais

Gasrelais

HF-Liftarc

Lüfter

Lüfter

Op

tion

al:

Iist

RE

Ga

us

SY

N_

E

Uist

VS

chw

eiss

SY

N_

A

Str./S

tp.

SY

N_

A 0

V

0V

-15

V

No

t/Au

s

No

t/Au

s

Relais IGRO

Polwendung PWS

-15V

0V

FR MIG ein/aus

FR WIG/ELEK

FR STR./STP.

FR-Typ1

FR-Typ2

FR-Typ3

+15V

IGR0

0V

Puls Frequenz

Isoll

Uref.10V

Poti-IL

Poti-IH

12345678123

BT

1

X5

-12B

T2

30

V

4T

?

5U

ref.1

0V

6IH

-Do

wn

7U

p

8P

oti U

D/e

in

A2

-

T 3

2 0

/ 1

X9

/1

X9

/2

X9

/3

X9

/4

X9

/5

X9

/6

X2

0/1

X2

0/2

X2

0/3

X2

0/4

X2

0/5

X2

0/6

X2

0/7

X2

0/8

X2

0/9

X2

0/1

0

X2

1

X2

1/1

X2

1/2

X2

1/3

X2

1/4

X2

1/5

X2

1/6

X2

1/7

X2

1/8

X2

1/9

X2

1/1

0

D-Sub.9polig

X12

Fernregler

X-P

E

X12/10

X12/11

X12/12

X12/13

X12/14

X12/15

X12/16

X12/17

X12/18

X12/1

X12/2

X12/3

X12/4

X12/5

X12/6

X12/7

X12/8

X12/9

X-PE/1

X-PE/2

Bren

nertaster1

X13

X13/9

X13/8

X13/7

X13/6

X13/5

X13/4

X13/3

X13/2

X13/1

X13/10B

renn

ertaster2X

22

X22/9

X22/8

X22/7

X22/6

X22/5

X22/4

X22/3

X22/2

X22/1

X22/10

X1

4P

eriph

erie

X14/12

X14/11

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Figure 11-8

Appendix A Declaration of Conformity

92 Item No.: 099-004877-EWM01

12 Appendix A 12.1 Declaration of Conformity

Originaldokument

liegt jedem Gerät bei!

Original document

is enclosed with each machine!

Document original

est joint à toute machine!

EG - KonformitätserklärungEC – Declaration of ConformityDéclaration de Conformité CE

Name des Herstellers: Name of manufacturer: Nom du fabricant:

EWM HIGHTEC WELDING GmbH (nachfolgend EWM genannt) (In the following called EWM) (nommé par la suite EWM)

Anschrift des Herstellers: Address of manufacturer: Adresse du fabricant:

Dr.- Günter - Henle - Straße 8 D - 56271 Mündersbach – Germany [email protected]

Hiermit erklären wir, daß das bezeichne-te Gerät in seiner Konzeption und Bau-art sowie in der von uns in Verkehr gebrachten Ausführung den grundle-genden Sicherheits-anforderungen der unten genannten EG- Richtlinien ent-spricht. Im Falle von unbefugten Verän-derungen, unsachgemäßen Reparaturen Nichteinhaltung der Fristen zur Wieder-holungsprüfung und / oder unerlaubten Umbauten, die nicht ausdrücklich von EWM autorisiert sind, verliert diese Erklärung ihre Gültigkeit.

We hereby declare that the machine below conforms to the basic safety requirements of the EC Directives cited both in its design and construction, and in the version re-leased by us. This declaration shall be-come null and void in the event of unau-thorised modifications, improperly con-ducted repairs, non-observance of the deadlines for the repetition test and/or non-permitted conversion work not specifically authorised by EWM.

Par la présente, nous déclarons que le poste, dans sa conception et sa construc-tion, ainsi que dans le modèle mis sur le marché par nos services ci-dessous, cor-respondent aux directives fondamentales de sécurité énoncées par l´CE et mention-nées ci-dessous. En cas de changements non autorisés, de réparations inadéquates, de non-respect des délais de contrôle en exploitation et/ou de modifications prohi-bées n’ayant pas été autorisés expressé-ment par EWM, cette déclaration devient caduque.

Gerätebezeichnung:Description of the machine: Déscription de la machine:

Gerätetyp:Type of machine: Type de machine:

Artikelnummer EWM: Article number: Numéro d´article

Seriennummer:Serial number: Numéro de série:

Optionen:Options: Options:

keinenoneaucune

Zutreffende EG - Richtlinien: Applicable EU - guidelines: Directives de la CE applicables:

EG - Niederspannungsrichtlinie (2006/95/EG)EC – Low Voltage Directive (2006/95/EG)Directive CE pour basses tensions (2006/95/EG)EG- EMV- Richtlinie (2004/108/EG)EC – EMC Directive (2004/108/ EG)Directive CE EMV (2004/108/EG)

Angewandte harmonisierte Normen: Used co-ordinated norms: Normes harmonisées appliquées:

EN 60974 / IEC 60974 / VDE 0544 EN 50199 / VDE 0544 part 206 GOST-R

Hersteller - Unterschrift: Manufacturer's signature:Signature du fabricant:

Michael Szczesny , Geschäftsführer managing director gérant

01.2007

Tetrix 300 Acdc Manual

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