EWM T4.02 User manual

Operating instructions
EN
Control
T4.02 - Tetrix AC/DC Comfort 2.0 (Tetrix 230)
099-00T402-EW501
Observe additional system documents!
02.07.2020

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 sa-
fety 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 re-
pair the machine.
• Technical changes due to further development in machine technology may lead to a dif-
fering 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 ac-
cepted 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: [e-mail]
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 using these operating instructions
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1 Contents
1Contents .................................................................................................................................................. 3
2For your safety ....................................................................................................................................... 5
2.1 Notes on using these operating instructions .................................................................................. 5
2.2 Explanation of icons ....................................................................................................................... 5
2.3 Part of the complete documentation .............................................................................................. 6
3Intended use ........................................................................................................................................... 7
3.1 Use and operation solely with the following machines .................................................................. 7
3.2 Documents which also apply ......................................................................................................... 7
3.3 Software version ............................................................................................................................ 7
4Machine control – Operating elements ................................................................................................ 8
4.1 Overview of control sections .......................................................................................................... 8
4.1.1 Control section A ............................................................................................................ 9
4.1.2 Control section B .......................................................................................................... 10
4.1.3 Control section C .......................................................................................................... 11
4.2 Machine display ........................................................................................................................... 12
4.2.1 Setting the welding current (absolute/percentage) ....................................................... 12
4.3 Operating the machine control ..................................................................................................... 12
4.3.1 Main screen .................................................................................................................. 12
4.3.2 Welding power setting .................................................................................................. 12
4.3.3 Welding parameter setting in the operation sequence ................................................. 12
4.3.4 Setting advanced welding parameters (Expert menu) ................................................. 13
4.3.5 Changing basic settings (machine configuration menu) .............................................. 13
5Functional characteristics ................................................................................................................... 14
5.1 TIG welding .................................................................................................................................. 14
5.1.1 Gas test – setting the shielding gas volume ................................................................. 14
5.1.2 Welding task selection .................................................................................................. 15
5.1.2.1 Recurring welding tasks (JOB 1–7) .............................................................. 16
5.1.3 AC welding ................................................................................................................... 16
5.1.3.1 AC balance (optimise cleaning effect and penetration characteristics) ........ 16
5.1.3.2 Tungsten balling function .............................................................................. 17
5.1.3.3 Alternating current waveforms ...................................................................... 18
5.1.3.4 Automatic AC frequency ............................................................................... 18
5.1.4 Arc ignition .................................................................................................................... 20
5.1.4.1 HF ignition ..................................................................................................... 20
5.1.4.2 Liftarc ............................................................................................................ 20
5.1.4.3 Automatic cut-out .......................................................................................... 20
5.1.5 Operating modes (functional sequences)..................................................................... 21
5.1.5.1 Explanation of symbols ................................................................................. 21
5.1.5.2 Non-latched mode ......................................................................................... 22
5.1.5.3 Latched mode ............................................................................................... 23
5.1.5.4 spotArc .......................................................................................................... 24
5.1.5.5 spotmatic ....................................................................................................... 26
5.1.6 TIG activArc welding ..................................................................................................... 27
5.1.7 TIG antistick .................................................................................................................. 27
5.1.8 Pulse welding ............................................................................................................... 28
5.1.8.1 Automated pulses ......................................................................................... 28
5.1.8.2 Thermal pulsing ............................................................................................. 28
5.1.8.3 Pulsed welding in the upslope and downslope phases ................................ 29
5.1.9 Average value pulse welding ........................................................................................ 30
5.1.9.1 Metallurgical pulsing (kHz pulsing) ............................................................... 30
5.1.9.2 AC special ..................................................................................................... 32
5.1.10 Welding torch (operating variants) ............................................................................... 33
5.1.10.1 Tapping function (tap torch trigger) ............................................................... 33
5.1.10.2 Torch mode setting ....................................................................................... 33
5.1.10.3 Up/down speed ............................................................................................. 33
5.1.10.4 Current jump ................................................................................................. 33
5.1.10.5 Standard TIG torch (5-pole) .......................................................................... 34
5.1.10.6 TIG up/down torch (8-pole) ........................................................................... 36

Contents
Notes on using these operating instructions
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5.1.10.7 Potentiometer torch (8-pole) ......................................................................... 38
5.1.10.8 Configuring the TIG potentiometer torch connection .................................... 39
5.1.10.9 RETOX TIG torch (12-pole)........................................................................... 39
5.1.11 Expert menu (TIG) ........................................................................................................ 40
5.2 MMA welding ................................................................................................................................ 41
5.2.1 Welding task selection .................................................................................................. 41
5.2.2 Hotstart ......................................................................................................................... 41
5.2.2.1 Hotstart current .............................................................................................. 42
5.2.2.2 Hotstart time .................................................................................................. 42
5.2.3 Antistick ......................................................................................................................... 42
5.2.4 Welding current polarity reversal (polarity reversal) ..................................................... 43
5.2.5 Average value pulse welding ........................................................................................ 44
5.3 Power-saving mode (Standby) ..................................................................................................... 44
5.4 Access control .............................................................................................................................. 45
5.5 Voltage reducing device ............................................................................................................... 45
5.6 Machine configuration menu ........................................................................................................ 46
5.6.1 Selecting, changing and saving parameters................................................................. 46
6Rectifying faults .................................................................................................................................... 49
6.1 Error messages (power source) ................................................................................................... 49
6.2 Dynamic power adjustment .......................................................................................................... 50
6.3 Resetting welding parameters to the factory settings .................................................................. 50
6.4 Display machine control software version .................................................................................... 50
7Appendix ............................................................................................................................................... 51
7.1 Parameter overview – setting ranges .......................................................................................... 51
7.1.1 TIG welding ................................................................................................................... 51
7.1.2 MMA welding ................................................................................................................ 52
7.2 Searching for a dealer .................................................................................................................. 53

For your safety
Notes on using these operating instructions
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2 For your safety
2.1 Notes on using 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 sym-
bol.
• 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 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-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.
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

For your safety
Part of the complete documentation
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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
2.3 Part of the complete documentation
This document is 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
Power source
A.3
Cooling unit, voltage converter, tool box etc.
A.4
Transport cart
A.5
Welding torch
A.6
Remote control
A.7
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
• Tetrix 230 AC/DC Comfort 2.0 (T4.02)
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:
034
The software version of the machine control can be displayed in the machine configuration menu
(menu Srv)> see 5.6 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 three sections (A, B, C) to
ensure maximum clarity. The setting range 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
3
Control section C
> see 4.1.3 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
Gas test push-button > see 5.1.1 chapter
3
Operating mode > see 5.1.5 chapter / power-saving mode push-
button > see 5.3 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 5.1.8 chapter
---- Automated pulsing (frequency and balance)
--------- Signal light turns green: Thermal pulsed TIG welding/MMA pulse
welding/average value pulsing
--------- Signal light turns red: Metallurgical pulsed TIG welding (kHz pulsing)
-------- Special TIG AC
5
Welding current polarity/tungsten balling push-button
------ Signal light turns green: DC welding with negative polarity on the electrode
holder or welding torch.
------ Signal light turns red: MMA DC welding with positive polarity on the electrode
holder > see 5.2.4 chapter.
- Alternating current welding/alternating current forms > see 5.1.3.3 chapter
------ Tungsten balling current > see 5.1.3.2 chapter
6
Welding procedure push-button
---------- TIG welding
--------- MMA welding
7
Display switching push-button
kW-------- Welding power display
V ---------- Welding voltage display
JOB ------ Display and setting of the JOB number with the control button

Machine control – Operating elements
Overview of control sections
10
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Item
Symbol
Description 0
8
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 4.2 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.
10
Character function signal light
Indicates that it is possible to weld in an environment with major electric hazards, such
as in boilers. Service must be informed if this signal light is not on.
11
Coolant fault signal light
Signals pressure loss or low coolant level in the coolant circuit.
12
VRD
Voltage reduction device (VRD) signal light > see 5.5 chapter
13
Hold
Signal light Status display
After each completed welding task, the last values used in the welding process for the
welding current and welding voltage are shown on the displays, and the signal light will
be on
14
Excess temperature signal light
In case of excess temperature, temperature monitors de-activate the power unit, and
the 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
Automatic AC frequency > see 5.1.3.4 chapter
4.1.2 Control section B
Figure 4-3
Item
Symbol
Description 0
1
Parameter selection push-button, left
The welding sequence parameters are selected one after another in an anti-clockwise
direction. For control systems without this button settings are done exclusively via the
control button.
2
Control button
Central control button to be pressed or turned > see 4.3 chapter.
3
Parameter selection push-button, right
The welding sequence parameters are selected one after another in a clockwise direc-
tion. For control systems without this button settings are done exclusively via the con-
trol button.