EWM T4.04, Operating Instructions Manual

Page 1: ...Operating instructions EN Control T4 04 Tetrix AC DC Smart 2 0 T4 10 Tetrix AC DC Smart 2 0 099 00T404 EW501 Observe additional system documents 02 07 2020 ...

Page 2: ... authorised sales partners can be found at www ewm group com en specialist dealers Liability relating to the operation of this equipment is restricted solely to the function of the equipment No other form of liability regardless of type shall be accepted This exclusion of liability shall be deemed ac cepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or...

Page 3: ...4 5 1 1 1 Automatic gas post flow 14 5 1 2 Welding task selection 15 5 1 3 AC welding 16 5 1 3 1 AC balance optimise cleaning effect and penetration characteristics 16 5 1 3 2 AC commutation optimisation 16 5 1 3 3 Alternating current waveforms 17 5 1 4 Arc ignition 18 5 1 4 1 HF ignition 18 5 1 4 2 Liftarc 18 5 1 4 3 Automatic cut out 18 5 1 5 Operating modes functional sequences 19 5 1 5 1 Expla...

Page 4: ...2 5 2 6 Expert menu MMA 43 5 3 Power saving mode Standby 44 5 4 Access control 44 5 5 Voltage reducing device 44 5 6 Machine configuration menu 45 5 6 1 Selecting changing and saving parameters 45 6 Rectifying faults 49 6 1 Warnings 49 6 2 Error messages 50 6 3 Resetting welding parameters to the factory settings 51 6 4 Display machine control software version 51 7 Appendix 52 7 1 Parameter overvi...

Page 5: ... CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading with a general warn ing symbol The risk is explained using a symbol on the edge of the page Technical aspects which the user must observe to avoid material or equipment damage Instructions and lists detailing step by st...

Page 6: ...W501 02 07 2020 Symbol Description Symbol Description Output Signal light lights up in red Time representation e g wait 4 s actuate Signal light flashes red Interruption in the menu display other setting options possible Tool not required do not use Tool required use ...

Page 7: ... parts of these instructions Read and observe the operating instructions for all system components especially the safety instructions The illustration shows a general example of a welding system Figure 2 1 Item Documentation A 1 Options conversion instructions A 2 Control A 3 Power source A 4 Cooling unit voltage converter tool box etc A 5 Transport cart A 6 Welding torch A 7 Remote control A Comp...

Page 8: ... is accepted for any damages arising from improper usage The equipment must only be used in line with its designated purpose and by trained or expert personnel Do not improperly modify or convert the equipment 3 1 Use and operation solely with the following machines Tetrix 300 AC DC Smart 2 0 T4 04 Tetrix 351 551 AC DC Smart 2 0 T4 10 3 2 Documents which also apply Operating instructions for the c...

Page 9: ...control sections For description purposes the machine control has been divided into two sections A B to ensure maximum clarity The setting ranges for the parameter values are summarised in the parameter overview section see 7 1 chapter Figure 4 1 Item Symbol Description 0 1 Control section A see 4 1 1 chapter 2 Control section B see 4 1 2 chapter ...

Page 10: ...the operating elements to reactivate 4 Pulsed welding push button TIG pulsed welding see 5 1 6 chapter MMA pulsed welding see 5 2 5 chapter 5 Welding current polarity push button DC welding with negative polarity at the torch or electrode holder with respect to the workpiece Alternating current welding alternating current forms see 5 1 3 3 chapter 6 Welding procedure push button TIG welding MMA we...

Page 11: ... excess temperature control lamp comes on Once the machine has cooled down welding can continue without any further measures 15 Access control active signal light Signal light is on when access control is active on the machine con trol see 5 4 chapter 16 Without function in this machine version 4 1 2 Control section B Figure 4 3 Item Symbol Description 0 1 Parameter selection push button left The ...

Page 12: ...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 4 2 1 Setting the welding current absolute percentage The welding current for the ignition secondary end and hot start current can be set as a percentage of the main current AMP or as an...

Page 13: ...n to the factory settings Factory setting example value 20 Parameter is set to optimum value Decrease the parameter value To return to the factory settings 4 3 4 Setting advanced welding parameters Expert menu The Expert menu contains functions and parameters which cannot be set directly in the machine control or which do not need to be et on a regular basis The number and display of these paramet...

Page 14: ...form Adjust the shielding gas quantity to suit the welding task Setting instructions Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11 5 l min MIG brazing Wire diameter x 11 5 l min MIG welding aluminium Wire diameter x 13 5 l min 100 argon TIG Gas nozzle diameter in mm corresponds to l min gas throughput Helium rich gas mixtures require a higher gas volume The tabl...

Page 15: ...e can also be set to meet individual requirements e g for thin panels a smaller diameter is recommended to reduce the ignition energy The electrode diameter setting determines the minimum current limit which in turn affects the ignition main and secondary current The minimum current limits have a positive effect on the ignition behaviour and ensure a very high arc stability for each electrode diam...

Page 16: ... arc to become unstable and diffuse with low penetration In the negative phase the tungsten electrode is cooled and the required penetration is realised Make sure to select the correct durations balance for positive phase cleaning effect balled end size and negative phase penetration depth by setting the AC balance The default zero setting balance setting is 65 referring to the duration of the neg...

Page 17: ...1 3 3 Alternating current waveforms Selection EXIT 4s Figure 5 3 Display Setting selection Alternating current waveforms 1 Rectangular Highest energy input ex works Trapezoidal An all rounder suitable for most applications Sine Low noise level 1 for AC welding machines only ...

Page 18: ... 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 operat ing mode set to the ignition or main current set c Lift off the torch and swivel to the ...

Page 19: ...r 1 I Current t Time Gas pre flow Ignition current Start time Up slope time Spot time AMP Main current minimum to maximum current AMP Secondary current Pulse current Pulsed TIG welding Slope time from main current AMP to secondary current AMP Pulsed TIG welding Slope time from secondary current AMP to main current AMP Down slope time End crater current End crater time Gas post flow Balance Frequen...

Page 20: ...he welding cur rent decreases to the secondary current AMP in the set slope time If torch trigger 2 is released the welding current increases again to the main current AMP in the set slope time The parameters and can be set in the Expert menu TIG see 5 1 11 chapter 2nd cycle Release torch trigger 1 The main current falls to the end crater current minimum current in the set down slope time If the 1...

Page 21: ...Functional characteristics TIG welding 099 00T404 EW501 02 07 2020 21 5 1 5 3 Latched mode Selection Figure 5 8 Sequence Figure 5 9 ...

Page 22: ... third cycle will be omitted 4th cycle Release torch trigger 1 arc is extinguished Set gas post flow time runs When the foot operated remote control is connected the machine switches automatically to non latched operation The up and down slopes are switched off Alternative welding start tapping start For the alternative welding start the durations of the first and second cycle are defined by the s...

Page 23: ...jump from the electrode to the workpiece The arc ignites The welding current flows and immediately assumes the value of the ignition current HF switches off The welding current ramps up to the main current AMP within the set up slope time The process ends when the set spotArc time elapses or by releasing the torch trigger With the spotArc function enabled the Automatic Puls pulse variant is activa...

Page 24: ...torch trigger Process activation is automatically terminated after 30 s of inactivity Permanent process activation The welding process is activated by pressing the torch trigger once The following arc ignitions are ini tiated by shortly touching the tungsten electrode against the workpiece Process activation is termina ted either by pressing the torch trigger again or automatically after 30 s of i...

Page 25: ...ess and release the torch trigger tap to reactivate the welding process only for separate process activation Touching the welding torch with the tungsten electrode tip against the workpiece again will initiate the next welding processes 5 1 5 6 Non latched operation version C Figure 5 14 1st cycle Press torch trigger 1 the gas pre flow time elapses HF ignition pulses jump from the electrode to the...

Page 26: ...ned ampere current average value is decisive the pulse current Ipuls is defined by the parameter as a percentage of the average current value AMP The pulse pause current IPP is not set the machine control calculates the value instead to ensure that the average value of the welding current AMP is maintained For average value pulsing the current is the secondary current only activated with the torch...

Page 27: ...ses parameter see 5 6 chapter Figure 5 20 5 1 6 2 Automated pulses The automated pulsing pulse variant is only activated for DC welding in combination with the spotArc ope rating mode The current dependent pulse frequency and balance create vibrations in the weld pool that have a positive effect on the gap bridging The required pulse parameters are automatically defined by the machine control If r...

Page 28: ...chapter 5 1 8 TIG antistick The function prevents uncontrolled re ignition following the sticking of the tungsten electrode in the weld pool by switching off the welding current In addition wear at the tungsten electrode is reduced After triggering the function the machine immediately switches to the gas post flow process phase The welder starts the new process again at the first cycle The user ca...

Page 29: ...ed are suitable for the corresponding torch types 5 1 9 3 Up down speed Functionality Press and hold the up push button Increase current up to the maximum value main current set in the power source Press and hold the down push button Decrease current to the minimum value Use the machine configuration menu see 5 6 chapter to set the up down speed parameter which determines the speed with which a cu...

Page 30: ...nts Welding current on off 1 ex works Secondary current latched operation Standard torch with two torch triggers Figure Operating ele ments Explanation of symbols BRT1 torch trigger 1 BRT2 torch trigger 2 Functions Mode Operating ele ments Welding current on off 1 ex works Secondary current Secondary current tapping function 1 latched operating mode Welding current on off 3 Secondary current tappi...

Page 31: ...orch trigger 2 Functions Mode Operating ele ments Welding current on off 1 ex works Secondary current Secondary current tapping function 1 latched operating mode Welding current on off 2 Secondary current tapping function1 Up function2 Down function2 Welding current on off 3 Secondary current tapping function 1 latched operating mode Up function2 Down function2 1 see 5 1 9 1 chapter 2 see 5 1 9 3 ...

Page 32: ...Operating ele ments Welding current on off 1 ex works Secondary current tapping function 1 latched operating mode Increase welding current up function2 Decrease welding current down function2 Welding current on off 4 Secondary current tapping function 1 latched operating mode Increase welding current via current jump3 Decrease welding current via current jump3 1 see 5 1 9 1 chapter 2 see 5 1 9 3 c...

Page 33: ...econdary current Secondary current tapping function 1 latched operating mode Increase welding current up function2 Decrease welding current down function2 Modes 2 and 3 are not used with this type of torch or respectively are not appropriate Welding current on off 4 Secondary current Secondary current tapping function1 Increase welding current via current jump3 Decrease welding current via current...

Page 34: ...mbols BRT 1 torch trigger 1 Functions Mode Operating ele ments Welding current on off 3 Secondary current tapping function1 Increase welding current Decrease welding current Potentiometer torch with two torch triggers Figure Operating ele ments Explanation of symbols BRT 1 torch trigger 1 BRT 2 torch trigger 2 Functions Mode Operating ele ments Welding current on off 3 Secondary current Secondary ...

Page 35: ...y be repaired or modified by specialist skilled persons The warranty becomes null and void in the event of unauthorised interference Appoint only skilled persons for repair work trained service personnel Dangers resulting from failure to perform test after conversion Before reconnection Inspection and Testing during Operation according to IEC BS EN 60974 4 Arc welding systems Inspection and Testin...

Page 36: ...hed on The welding current increases in a linear slow ramp to approx 100 A RTF switched off The welding current immediately jumps to approx 100 A The RTF start ramp function is activated deactivated by the parameter in the machine configuration menu see 5 6 chapter Figure 5 23 Display Setting selection RTF start ramp see 5 1 10 1 chapter Welding current rises to the specified main current level in...

Page 37: ... choose between linear and logarithmic response The logarithmic setting is especially suited for welding with low currents e g for thin panels as the logarithmic response enables a better control of the welding current In the machine configuration menu the RTF response function can be toggled between linear response and logarithmic response ex works see 5 6 chapter Figure 5 24 ...

Page 38: ...on is deactivated ENTER EXIT Figure 5 25 Display Setting selection Expert menu Gas pre flow time Ignition current Setting range in percent depending on main current Setting range absolute Imin to Imax Slope time main current to secondary current Slope time main current to secondary current Slope time main current to secondary current End crater current Setting range in percent depending on main cu...

Page 39: ...ties the electric cable resistance should be aligned again whenever an accessory component such as the welding torch or the intermediate hose package AW has been chan ged The resistance value of the cables can be set directly or can be aligned by the power source In the delivery state the cable resistance is set to the optimum values To optimise the welding properties for other cable lengths an al...

Page 40: ... ly which is used to determine and display the cable resistance The value can be between 0 mΩ and 60 mΩ The new value is immediately saved without requiring further confirmation If no value is shown on the right hand display then measurement failed The measurement must be repeated 4 Restoring welding standby mode Switch off the welding machine Lock the tungsten electrode in the collet again Screw ...

Page 41: ...I Current t Time Figure 5 28 5 2 3 Arcforce During the welding process arcforce prevents the electrode sticking in the weld pool with increases in current This makes it easier to weld large drop melting electrode types at low current strengths with a short arc in particular EXIT 4s Figure 5 29 5 2 4 Antistick The Antistick feature prevents the electrode from annealing Should the electrode stick de...

Page 42: ... average value is decisive the pulse current Ipuls is defined by the pa rameter as a percentage of the current average value AMP The pulse pause current IPP requires no setting This value is calculated by the machine control so that the welding current average value AMP is maintained at all times Figure 5 31 AMP Main current e g 100 A Ipuls Pulse current x AMP e g 140 x 100 A 140 A IPP Pulse pause...

Page 43: ...nu MMA The Expert menu has adjustable parameters stored that don t require regular setting The number of pa rameters shown may be limited e g if a function is deactivated The setting ranges for the parameter values are summarised in the Parameter overview sec tion see 7 1 chapter ENTER EXIT Figure 5 36 Display Setting selection Expert menu ...

Page 44: ...rameters for setting the access block are configured in the machine configuration menu see 5 6 chapter Enabling access block Assign the access code for the access block Select parameter and select a number code 0 999 Enable access block Set parameter to access block enabled The access block activation is indicated by the Access block active signal light see 4 chapter Disabling access block Enter t...

Page 45: ...ine configuration menu 5 6 1 Selecting changing and saving parameters ENTER l 0 A A B A A A A EXIT NAVIGATION A B B B B B B B B B B B B B B A B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B Figure 5 37 Display Setting selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode ex works 1 see 5 1 9 2 chapter ...

Page 46: ...display Pulsed TIG welding thermic in the upslope and downslope pha ses see 5 1 6 1 chapter Function enabled ex works Function disabled TIG antistick see 5 1 8 chapter function active factory setting function inactive Show warnings see 6 1 chapter Function disabled ex works Function enabled Setting the system of units Units of length in mm m min metric system Unit of length in inches ipm imperial ...

Page 47: ...ning pulse tungsten ball stability 1 Cleaning effect of the tungsten ball at the end of welding Function enabled ex works Function disabled Automatic gas post flow function see 5 1 1 1 chapter Function on Function off factory setting activArc voltage measuring Function enabled ex works Function disabled Error output to interface for automated welding contact SYN_A AC synchronisation or hot wire ex...

Page 48: ...be agreed with the authorised service person nel Reset to factory setting Disabled ex works Reset the values in the machine configuration menu Complete reset of all values and settings Resetting is performed when exiting the menu Automated Manual rC on off operating mode 3 Select machine function control with external control voltages signals with machine control Software version query example 07 ...

Page 49: ...ne warning and inform service personnel if required Warning code Possible cause Remedy 1 Machine excess temperature Allow the machine to cool down 2 Half wave failures Check process parameters 3 Welding torch cooling warning Check coolant level and refill if necessary 4 Gas warning Check gas supply 5 See warning number 3 6 Welding consumable wire electrode fault Check wire feeding with machines wi...

Page 50: ...ecessary 8 Gas error Check the gas supply 9 Secondary overvoltage Switch the machine off and on If the error persists notify the service department 10 PE error 11 FastStop position Slope Acknowledge error signal 0 to 1 using the robot interface if present 12 VRD error Switch the machine off and on If the error persists notify the service department 16 Pilot arc current Check welding torch 17 Fille...

Page 51: ...error Check the welding process 49 Arc interruption Inform service 51 Error in the emergency stop circuit interface for automated welding Check the external shutdown devices Check jumper JP 1 on PCB T320 1 57 Auxiliary drive error tacho error Check the auxiliary drive tacho no signal M3 51 defective notify Service 59 Incompatible component Replace component 6 3 Resetting welding parameters to the ...

Page 52: ... 00 s 0 00 20 0 Down slope time 1 0 s 0 0 20 0 End current percentage of AMP 20 1 200 End current absolute depending on power source A End current time 0 01 s 0 01 20 0 Gas post flow time 8 s 0 0 40 0 Electrode diameter metric 2 4 mm 1 0 4 0 Electrode diameter imperial 92 mil 40 160 spotArc time 2 s 0 01 20 0 spotmatic time 200 ms 5 999 spotmatic time 2 s 0 01 20 0 AC commutation optimisation 1 2 ...

Page 53: ...n current AMP depending on power source A Hot start current percentage of AMP 120 1 200 Hot start current percentage of AMP 1 150 1 150 Hot start current absolute depending on power source A Hot start time 0 5 s 0 0 10 0 Hot start time 1 0 1 s 0 0 5 0 Arcforce 2 0 40 40 AC frequency 2 3 100 Hz 30 300 AC balance 2 3 60 40 90 Pulse current 142 1 200 Pulse frequency 1 2 Hz 0 2 50 Pulse frequency DC 1...

Page 54: ...Appendix Searching for a dealer 54 099 00T404 EW501 02 07 2020 7 2 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide ...