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EWM Tetrix 350 - User Manual

EWM Tetrix 350
115 pages
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Operating instructions
Welding machine
Tetrix 350 AC/DC Synergic Plasma
19.02.2014
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Table of Contents

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Summary

Understanding Safety Symbols

Understanding Safety Symbols

Explains the meaning and usage of DANGER, WARNING, CAUTION, and NOTE safety symbols.

General Safety Precautions and Hazards

General Safety Precautions and Hazards

Covers hazards from electromagnetic fields, electric shock, radiation, heat, explosions, and unauthorized repairs.

Workplace Safety and Operational Hazards

Workplace Safety and Operational Hazards

Addresses hazards from smoke, gases, fire, noise, and risks associated with coupling multiple power sources.

Operator Responsibilities and Machine Protection

Operator Responsibilities and Machine Protection

Details operator obligations, risks from non-genuine parts, stray currents, and mains connection requirements.

Transport and Installation Safety Guidelines

Transport and Installation Safety Guidelines

Covers safe handling of gas cylinders, transport risks, tipping, and disconnection of supply lines.

Installation Site and Ambient Conditions

Installation Site and Ambient Conditions

Specifies requirements for installation sites and ambient conditions for operation and storage.

Intended Use and Welding Applications

Intended Use and Welding Applications

Details the intended use and describes various welding applications including Plasma, TIG, and MMA.

Machine Control Panel Overview

Machine Control Panel Overview

Introduction to the machine's control panel and its primary operating elements.

Control Panel Functions and Displays

Welding Parameter Setting Rotary Transducer

Rotary transducer for setting welding parameters like current, thickness, and gas pre-flow.

Function Sequence Parameter Settings

TIG Main Current and Pulse Current

Setting the main current for TIG welding and pulse current.

Function Sequence Parameter Details

activArc TIG Welding Process Control

Instructions for switching the activArc function on/off and adjusting its characteristic.

General Design and Safety Considerations

General Design and Safety Considerations

General safety warnings regarding electric shock, burns, and the use of protective dust caps.

Machine Installation Safety and Procedures

Machine Installation Safety and Procedures

Details safety precautions for installation, site requirements, and avoiding damage from incorrect connections.

Machine Cooling System Requirements

Precautions for optimal duty cycle related to machine cooling and ventilation.

Workpiece Lead Connection Safety

Highlights risks of burns and fires from incorrect workpiece lead connections and stray currents.

Mains Connection Safety Hazards

Mains Connection Safety Hazards

Details hazards associated with improper mains connection and necessary safety precautions.

Welding Torch Cooling System Connections

Welding Torch Cooling System Connections

Details the connections for the welding torch cooling system and required precautions.

Plasma Welding Torch Connection (with GMU)

Plasma Welding Torch Connection (with GMU)

Diagram and notes for connecting the plasma welding torch using a gas metering unit (GMU).

Plasma Torch Connection Details (with GMU)

Lists and describes the components and steps for connecting the plasma torch with a GMU.

Plasma Torch Connection (without GMU)

Plasma Torch Connection (without GMU)

Diagram and notes for connecting the plasma welding torch without a gas metering unit (GMU).

Workpiece Lead Connection and Gas Supply Safety

Shielding and Plasma Gas Supply Safety

Safety warnings for handling gas cylinders and precautions for gas supply faults.

Connecting the Shielding Gas Supply

Connecting the Shielding Gas Supply

Diagram and steps for connecting the shielding gas supply, including pressure regulator setup.

Shielding Gas Quantity and Testing Procedures

Setting Shielding Gas Quantity

Guidance on setting the shielding gas quantity, including a rule of thumb and potential issues.

Selecting and Loading Welding Tasks (JOBs)

Selecting a Welding Task (JOB)

Explains how to select welding tasks (JOBs) and lists factory-set JOB configurations.

Loading an Existing JOB from Memory

Step-by-step guide for loading an existing JOB from the machine's memory.

Welding Data Display and Parameter Setting

Welding Parameter Setting Process

Explains how welding parameters are set and displayed, including symbols used.

Arc Ignition Procedures and Safety

Arc Ignition Procedures and Safety

Details the pilot arc activation and deactivation, including safety measures for tungsten electrodes.

TIG Welding Torch and Workpiece Connection

TIG Welding Torch and Workpiece Connection

Safety precautions and detailed steps for connecting the TIG welding torch and workpiece lead.

Shielding Gas Supply Safety and Faults

Shielding Gas Supply Safety and Faults

Safety warnings for gas cylinders and precautions regarding shielding gas supply issues.

Connecting Shielding Gas Supply Components

Connecting Shielding Gas Supply Components

Diagram and steps for connecting the shielding gas supply, including pressure regulator setup.

TIG Synergic Operating Principle Overview

TIG Synergic Operating Principle Overview

Introduces the TIG Synergic operating principle and its three basic parameters for task selection.

TIG Synergic and Conventional Parameter Settings

Synergic Parameter Setting in Functional Sequence

Explains automatic parameter adjustment in the functional sequence during synergic operation.

Setting Operating Principle (Synergic;Conventional)

Setting Operating Principle (Synergic;Conventional)

Instructions on how to set the welding machine to synergic or conventional operating principle.

Selecting Welding Tasks and Current

Selecting the Welding Task

Guide to selecting welding tasks using machine control buttons and signal lights.

Selecting Welding Current

Details two methods for setting the welding current: via sheet metal thickness or directly.

TIG Welding Data Display and Parameter Setting

TIG Arc Ignition and Automatic Cut-out

TIG HF Arc Ignition

Detailed steps for starting the arc using HF ignition without workpiece contact.

TIG Liftarc Arc Ignition

Detailed steps for starting the arc by contact ignition (Liftarc).

TIG Function Sequence Controls and Symbols

TIG Parameter Setting Rotary Transducer

Rotary transducer for setting TIG welding parameters like current, thickness, and gas pre-flow.

TIG Non-latched Operating Mode

TIG Non-latched Operating Mode

Details the TIG non-latched operating mode, including its 1st and 2nd cycle processes.

TIG Latched Operating Mode

TIG Latched Operating Mode

Details the TIG latched operating mode, explaining the steps for welding and termination.

TIG spotArc Process and Settings

TIG spotArc Process and Settings

Explains the TIG spotArc process, its operating modes (long/short interval), and spot time setting.

TIG Spotmatic Welding Process

TIG Spotmatic Welding Process

Details the TIG Spotmatic process, including its unique ignition and activation methods.

TIG Non-latched Operation (Version C)

TIG Pulse Welding Function Sequences

TIG Pulse Variants and Settings

TIG kHz and Automated Pulses

TIG activArc Welding Process

TIG activArc Welding Process

Explains the activArc process for constant power and how to adjust its parameter.

Torch Mode and Up;Down Speed Settings

MMA Welding Safety and Gas Connection

MMA Welding Safety and Gas Connection

Safety precautions for MMA welding, including handling electrodes and shielding gas connection.

Connecting MMA Electrode Holder and Workpiece Lead

Details safety for connecting the electrode holder and workpiece lead for MMA welding.

MMA Process Selection and Polarity Reversal

MMA AC Settings and Hotstart Current

MMA Hotstart Time, Arcforce, and Antistick

Welding Programs Overview and Management

Welding Programs Overview

Introduction to the welding machine's 16 welding programs and how parameter changes affect them.

Welding Program Selection and Configuration

Selecting and Adjusting Welding Programs

Guide to selecting and adjusting welding programs using the machine control.

Organising Welding Tasks via JOB Manager

Organising Welding Tasks via JOB Manager

Introduces the JOB Manager mode for loading, copying, and saving welding tasks (JOBs).

Managing Welding JOBs: Copying and Creation

Copying and Creating New Welding JOBs

Details the process of copying pre-defined welding tasks (JOBs) to the free memory.

Managing Welding JOBs: Loading and Resetting

Loading Existing JOBs from Free Memory

Step-by-step guide for loading an existing JOB from the machine's free memory.

Remote Control Options (PWS and Foot-Operated)

Parameter Security and PC Interface

Protecting Welding Parameters with Key Switch

Explains how to use the key switch to protect welding parameters from unauthorized adjustment.

Simultaneous Welding and Synchronization

Simultaneous Welding and Synchronization Types

Introduces simultaneous welding on both sides and the importance of synchronization.

Synchronization via Cable

Interfaces for Automation Connectivity

TIG Interface for Mechanised Welding

Details the pins, signals, and designations for the TIG interface used in mechanised welding.

19-Pole Remote Control Connection Socket

Configuring TIG Potentiometer Torch Connection

Configuring TIG Potentiometer Torch Connection

Details configuration steps for TIG potentiometer torch connection, including safety and jumper settings.

Menu Options for Reset, Software Version, and Ignition Limit

Menu: Reset to Factory Settings

Resets settings to factory defaults: off (aus), CFG (machine config), CPL (complete).

General Maintenance and Care Schedule

Maintenance Work and Intervals

Details maintenance tasks and their recommended intervals (daily, monthly, annual).

Maintenance Safety and Disposal Guidelines

Safety During Maintenance Work

Emphasizes safety during maintenance work and prohibits unauthorized repairs or modifications.

Checklist for Rectifying Faults

Checklist for Rectifying Faults

Provides a checklist for diagnosing and rectifying common functional errors and connection problems.

Troubleshooting Specific Welding Faults

Troubleshooting: No Arc Ignition

Addresses issues causing no arc ignition and their remedies, like incorrect ignition type settings.

Troubleshooting: Bad Arc Ignition

Diagnoses causes of bad arc ignition, such as material inclusions or poor current transfer.

Troubleshooting: Unstable Arc

Identifies causes of unstable arcs, including material inclusions and incompatible parameters.

Troubleshooting: Pore Formation in Welds

Diagnoses pore formation causes like inadequate gas shielding, torch issues, or condensation.

Machine Faults and Error Message Remedies

Machine Faults and Error Messages

Lists machine error messages, possible causes, and remedies for common faults like Err 3 to Err 19.

Troubleshooting Specific Machine Errors

Troubleshooting: Coolant Errors (Err 20, Err 22)

Addresses coolant flow and temperature errors (Err 20, Err 22) and their solutions.

Troubleshooting: HF Choke Overheating (Err 23)

Diagnoses HF choke excess temperature errors (Err 23) and provides remedies.

Troubleshooting: Electronics Errors (Err 32-39)

Covers various electronics errors (Err 32-39) and their troubleshooting steps.

Troubleshooting: Ignition Errors (Err 48, Err 51)

Addresses ignition errors (Err 48) and emergency stop circuit errors (Err 51).

Troubleshooting: Arc Interruption (Err 49)

Addresses arc interruption faults (Err 49) and advises contacting service.

Resetting Welding Parameters to Factory Defaults

Resetting Welding Parameters to Factory Defaults

Step-by-step guide for resetting all customized welding parameters to factory settings.

Software Version Check and Operating Problems

Venting the Coolant Circuit

Technical Data: Tetrix 350 AC;DC Plasma

Technical Data: Tetrix 350 AC;DC Plasma

Provides detailed technical specifications for the Tetrix 350 AC/DC Plasma welding machine.

Appendix A: JOB List Overview

EWM Tetrix 350 Specifications

General IconGeneral
BrandEWM
ModelTetrix 350
CategoryWelding System
LanguageEnglish

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