EWM T 4.01 User manual

Operating instructions
EN
Control
T 4.01, 4.09, 4.12 - DC Comfort 2.0
099-00T401-EW501
Observe additional system documents!
21.06.2018

General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the location where the machine is operated.
•Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
•Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of 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 accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Strasse 8
56271 Mündersbach Germany
Tel.: [phone], Fax: -244
Email: [email protected]
www.ewm-group.com
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2For your safety.......................................................................................................................................5
2.1 Notes on the use of these operating instructions ..........................................................................5
2.2 Explanation of icons.......................................................................................................................6
2.3 Part of the complete documentation..............................................................................................7
3Intended use...........................................................................................................................................8
3.1 Use and operation solely with the following machines..................................................................8
3.2 Documents which also apply.........................................................................................................8
3.3 Software version............................................................................................................................8
4Machine control –Operating elements................................................................................................9
4.1 Overview of control sections..........................................................................................................9
4.1.1 Control section A..........................................................................................................10
4.1.2 Control section B..........................................................................................................12
4.2 Machine display...........................................................................................................................13
4.2.1 Setting the welding current (absolute/percentage).......................................................13
4.3 Operating the machine control.....................................................................................................13
4.3.1 Main screen..................................................................................................................13
4.3.2 Welding power setting..................................................................................................13
4.3.3 Welding parameter setting in the operation sequence.................................................14
4.3.4 Setting advanced welding parameters (Expert menu).................................................14
4.3.5 Changing basic settings (machine configuration menu) ..............................................14
5Functional characteristics...................................................................................................................15
5.1 TIG welding..................................................................................................................................15
5.1.1 Setting the shielding gas volume (gas test)/rinse hose package.................................15
5.1.1.1 Automatic gas post-flow................................................................................15
5.1.2 Welding task selection..................................................................................................16
5.1.2.1 Recurring welding tasks (JOB 1-100)...........................................................17
5.1.3 Arc ignition....................................................................................................................17
5.1.3.1 HF ignition.....................................................................................................17
5.1.3.2 Liftarc ............................................................................................................18
5.1.3.3 Automatic cut-out..........................................................................................18
5.1.4 Operating modes (functional sequences) ....................................................................19
5.1.4.1 Explanation of symbols.................................................................................19
5.1.4.2 Non-latched mode.........................................................................................20
5.1.4.3 Latched mode ...............................................................................................21
5.1.4.4 spotArc..........................................................................................................22
5.1.4.5 spotmatic.......................................................................................................24
5.1.4.6 Non-latched operation, version C .................................................................25
5.1.5 TIG activArc welding.....................................................................................................26
5.1.6 TIG antistick..................................................................................................................26
5.1.7 Pulse welding ...............................................................................................................27
5.1.7.1 Automated pulses .........................................................................................27
5.1.7.2 Thermal pulsing.............................................................................................27
5.1.7.3 Pulsed welding in the upslope and downslope phases................................28
5.1.7.4 Metallurgical pulsing (kHz pulsing) ...............................................................29
5.1.8 Average value pulse welding........................................................................................30
5.1.9 Welding torch (operating variants) ...............................................................................30
5.1.9.1 Tapping function (tap torch trigger)...............................................................30
5.1.9.2 Torch mode setting.......................................................................................31
5.1.9.3 Up/down speed.............................................................................................31
5.1.9.4 Current jump .................................................................................................31
5.1.9.5 Standard TIG torch (5-pole)..........................................................................32
5.1.9.6 TIG up/down torch (8-pole)...........................................................................34
5.1.9.7 Potentiometer torch (8-pole).........................................................................36
5.1.9.8 Configuring the TIG potentiometer torch connection....................................36
5.1.9.9 RETOX TIG torch (12-pole)..........................................................................38
5.1.10 RTF 1 foot-operated remote control.............................................................................39
5.1.10.1 RTF start ramp..............................................................................................39

Contents
Notes on the use of these operating instructions
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5.1.10.2 RTF response................................................................................................40
5.1.11 Expert menu (TIG)........................................................................................................41
5.1.12 Aligning the cable resistance........................................................................................43
5.2 MMA welding................................................................................................................................44
5.2.1 Welding task selection..................................................................................................44
5.2.2 Hotstart .........................................................................................................................45
5.2.2.1 Hotstart current..............................................................................................45
5.2.2.2 Hotstart time..................................................................................................45
5.2.3 Arcforce.........................................................................................................................46
5.2.4 Antistick.........................................................................................................................46
5.2.5 Pulse welding................................................................................................................47
5.2.6 Average value pulse welding........................................................................................48
5.3 Filler wire welding.........................................................................................................................48
5.3.1 Configuring the welding machine for mechanical arc fusion welding...........................48
5.3.2 Selecting a welding task by means of the JOB list.......................................................48
5.3.3 Select wire speed operating mode (KORREKTUR / MANUELL).................................49
5.3.4 Setting the welding current and wire speed..................................................................49
5.3.5 Operating modes (functional sequences).....................................................................50
5.3.5.1 Explanation of symbols .................................................................................50
5.3.5.2 Non-latched mode.........................................................................................51
5.3.5.3 3-cycle operation...........................................................................................52
5.3.5.4 Latched mode................................................................................................52
5.4 Power-saving mode (Standby).....................................................................................................52
5.5 Access control..............................................................................................................................53
5.6 Voltage reducing device...............................................................................................................53
5.7 Machine configuration menu........................................................................................................54
5.7.1 Selecting, changing and saving parameters.................................................................54
6Rectifying faults....................................................................................................................................59
6.1 Warnings......................................................................................................................................59
6.2 Error messages............................................................................................................................60
6.3 Resetting welding parameters to the factory settings..................................................................61
6.4 Display machine control software version....................................................................................61
7Appendix A............................................................................................................................................62
7.1 Parameter overview –setting ranges ..........................................................................................62
7.1.1 TIG welding...................................................................................................................62
7.1.2 MMA welding................................................................................................................63
8Appendix B............................................................................................................................................64
8.1 Searching for a dealer..................................................................................................................64

For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
•The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
•Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
•The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
•The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
•The risk is explained using a symbol on the edge of the page.
Technical aspects which the user must observe to avoid material or equipment damage.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
•Insert the welding current lead socket into the relevant socket and lock.

For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release / Tap / Tip
Switch off machine
Release
Switch on machine
Press and hold
Switch
Incorrect / Invalid
Turn
Correct / Valid
Numerical value –adjustable
Input
Signal light lights up in green
Navigation
Signal light flashes green
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

For your safety
Part of the complete documentation
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2.3 Part of the complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with all other 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
Complete documentation

Intended use
Use and operation solely with the following machines
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
•The equipment must only be used in line with 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
Machine control
T 4.01
T 4.09
T 4.12
Product series
Tetrix 300
Tetrix 351-551
Tetrix 200
3.2 Documents which also apply
•Operating instructions for the connected welding machines
•Documents of the optional expansions
3.3 Software version
These instructions apply to the following software version:
07.03E0
The query of the software versions only serves to inform the authorised service staff. It is available in the
machine configuration menu > see 5.7 chapter.

Machine control –Operating elements
Overview of control sections
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4 Machine control – Operating elements
4.1 Overview of 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

Machine control –Operating elements
Overview of control sections
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4.1.1 Control section A
Figure 4-2
Item
Symbol
Description 0
1
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 4.2 chapter
2
Push-button gas test / rinse hose package > see 5.1.1 chapter
3
Operating mode > see 5.1.4 chapter / power-saving mode push-
button > see 5.4 chapter
--------- Latched
------- Non-latched
------ spotArc spot welding procedure –signal light turns green
------ spotmatic spot welding procedure –signal light turns red
-------- Press button for long interval to put machine into power-saving mode.
Activate one of the operating elements to reactivate.
4
Pulsing push-button > see 5.1.7 chapter
----- Automated pulsing (frequency and balance)
------- Signal light turns green: Thermal pulsed TIG welding/MMA pulse welding
------- Signal light turns red: Metallurgical pulsed TIG welding (kHz pulsing)
5
Welding procedure push-button
--------- TIG welding
---- MMA welding (signal light turns green)
---- Arcforce setting (signal light turns red)
6
Display switching push-button
kW------- Welding power display
V --------- Welding voltage display
JOB ----- Display and setting of the JOB number with the control button
7
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 4.2 chapter
8
Filler wire welding signal light
For machines with filler wire only (AW) > see 5.3 chapter
9
TIG ignition type signal light
Signal light on: Lift arc ignition active/HF start off. You can switch the ignition type in the
Expert menu (TIG) > see 5.1.11 chapter.