EWM Tetrix 352 Synergic User manual

Operating instructions
EN
Power source
Tetrix 352 Synergic
Tetrix 452 Synergic
Tetrix 552 Synergic
099-000141-EW501
Observe additional system documents!
22.03.2023

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.
Data security
The user is responsible for backing up data of all changes from the factory setting. The user is liable for
erased personal settings. The manufacturer does not assume any liability for this.

Contents
Notes on using these operating instructions
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1 Contents
1Contents .......................................................................................................................................... 3
2For your safety ............................................................................................................................... 6
2.1 Notes on using these operating instructions .......................................................................... 6
2.2 Explanation of icons ............................................................................................................... 7
2.3 Safety instructions .................................................................................................................. 8
2.4 Transport and installation .................................................................................................... 11
3Intended use ................................................................................................................................. 13
3.1 Applications .......................................................................................................................... 13
3.2 Use and operation solely with the following machines ........................................................ 13
3.3 Software version .................................................................................................................. 13
3.4 Documents which also apply ............................................................................................... 13
3.4.1 Warranty ............................................................................................................... 13
3.4.2 Declaration of Conformity ..................................................................................... 13
3.4.3 Welding in environments with increased electrical hazards ................................. 13
3.4.4 Service documents (spare parts and circuit diagrams) ........................................ 14
3.4.5 Calibration/Validation............................................................................................ 14
3.4.6 Part of the complete documentation ..................................................................... 14
4Machine description – quick overview ...................................................................................... 16
4.1 Front view ............................................................................................................................ 16
4.2 Machine control – Operating elements ................................................................................ 18
4.2.1 Machine control (Mode RC - on) .......................................................................... 18
4.2.1.1 Function sequence ................................................................................ 19
4.2.2 Machine control (Mode RC - off) .......................................................................... 20
4.2.2.1 Function sequence ................................................................................ 21
4.2.3 Welding data display ............................................................................................ 22
4.2.4 Welding parameter setting ................................................................................... 23
4.2.5 Setting the welding current (absolute/percentage) ............................................... 23
4.3 Connection plan ................................................................................................................... 24
4.3.1 Legend .................................................................................................................. 25
5Design and function ..................................................................................................................... 26
5.1 Transport and installation .................................................................................................... 26
5.1.1 Lifting by crane ..................................................................................................... 26
5.1.2 Ambient conditions ............................................................................................... 26
5.1.3 Machine cooling .................................................................................................... 27
5.1.4 Workpiece lead, general ....................................................................................... 27
5.1.5 Notes on the installation of welding current leads ................................................ 28
5.1.6 Stray welding currents .......................................................................................... 29
5.1.7 Mains connection .................................................................................................. 30
5.1.7.1 Mains configuration ............................................................................... 30
5.1.8 Shielding gas supply (shielding gas cylinder for welding machine) ..................... 31
5.1.9 Pressure regulator connection ............................................................................. 31
5.1.9.1 Shielding gas hose connection ............................................................. 32
5.1.10 Gas test – setting the shielding gas volume ......................................................... 32
5.1.10.1 Gas test ................................................................................................. 32
5.1.10.2 “Purge hose package” function ............................................................. 32
5.2 Connect the cooling unit to the power source ..................................................................... 33
5.2.1Welding torch connection ..................................................................................... 33
5.2.2 Connecting the welding torch to the media separation box ................................ 34
5.2.3 Connecting the media separation box to the power source ................................. 35
5.2.4 Connection for workpiece lead ............................................................................. 36
5.3 TIG Synergic operating principle ......................................................................................... 37
5.3.1 Synergic parameter setting in the functional sequence ....................................... 38
5.3.2 Conventional parameter setting in the functional sequence ................................ 38
5.3.2.1 Set the operating principle (conventional/synergic) .............................. 38
5.4 Welding task selection ......................................................................................................... 39
5.4.1 Select welding current .......................................................................................... 39
5.4.2 Arc ignition ............................................................................................................ 40
5.4.2.1 HF ignition ............................................................................................. 40

Contents
Notes on using these operating instructions
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5.4.2.2 Liftarc ..................................................................................................... 40
5.4.2.3 Automatic cut-out .................................................................................. 40
5.4.3 Optimising the ignition characteristics for pure tungsten electrodes .................... 41
5.4.3.1 Tungsten balling function ...................................................................... 41
5.4.4 Operating modes (functional sequences) ............................................................. 42
5.4.4.1 Explanation of symbols ......................................................................... 42
5.4.4.2 Non-latched mode ................................................................................. 43
5.4.4.3 Latched mode ........................................................................................ 44
5.4.4.4 spotArc .................................................................................................. 45
5.4.4.5 spotmatic ............................................................................................... 46
5.4.4.6 Non-latched operation, version C .......................................................... 48
5.4.5 Pulse welding ........................................................................................................ 49
5.4.5.1 Automated pulses .................................................................................. 49
5.4.5.2 Thermal pulsing ..................................................................................... 49
5.4.5.3 Metallurgical pulsing (kHz pulsing) ........................................................ 51
5.4.6 TIG antistick .......................................................................................................... 53
5.4.7 activArc ................................................................................................................. 53
5.4.8 Expert menu (TIG) ................................................................................................ 54
5.5 Welding programs ................................................................................................................ 55
5.5.1 Selection and adjustment ..................................................................................... 55
5.5.2 Example "Program with synergetic setting" .......................................................... 56
5.5.3 Example "Program with conventional setting" ...................................................... 56
5.5.4 Accessories for switching over programs ............................................................. 56
5.6 Organising welding tasks (Mode "JOB Manager") ............................................................... 57
5.6.1 Explanation of symbols ......................................................................................... 57
5.6.2Creating a new JOB in the memory or copying a JOB ......................................... 58
5.6.3 Loading an existing JOB from the free memory ................................................... 59
5.6.4 Resetting an existing JOB to the factory setting (Reset JOB) .............................. 59
5.6.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs) ............................. 60
5.6.6 Exit JOB Manager without changes ..................................................................... 60
5.7 Interfaces for automation ..................................................................................................... 60
5.7.1 Connecting the robot interface / industrial bus interface ...................................... 61
5.7.1.1 RINT X12 robot interface....................................................................... 61
5.7.1.2 BUSINT X11 industrial bus interface ..................................................... 62
5.7.2 Automation interface ............................................................................................. 62
5.7.3 Connection socket automation torch .................................................................... 64
5.7.4 Sensor Voltage ..................................................................................................... 65
5.8 PC interface ......................................................................................................................... 65
5.8.1 Connecting the PC 300.net welding parameterisation software ........................... 65
5.9 Access control ...................................................................................................................... 66
5.10 Power-saving mode (Standby) ............................................................................................. 66
5.11 Machine configuration menu ................................................................................................ 67
5.11.1 Selecting, changing and saving parameters......................................................... 67
5.12 Aligning the cable resistance ............................................................................................... 72
6Maintenance, care and disposal ................................................................................................. 74
6.1 General ................................................................................................................................. 74
6.2 Cleaning ............................................................................................................................... 74
6.2.1 Dirt filter ................................................................................................................. 74
6.3 Maintenance work, intervals................................................................................................. 75
6.3.1 Daily maintenance tasks ....................................................................................... 75
6.3.2 Monthly maintenance tasks .................................................................................. 75
6.3.3 Annual test (inspection and testing during operation) .......................................... 75
6.4 Disposing of equipment ........................................................................................................ 76
7Rectifying faults ............................................................................................................................ 77
7.1 Checklist for rectifying faults ................................................................................................ 77
7.2 Warnings .............................................................................................................................. 78
7.3 Error messages .................................................................................................................... 79
7.4 Resetting welding parameters to the factory settings .......................................................... 81
7.5 Software version of the machine control .............................................................................. 81

Contents
Notes on using these operating instructions
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8Technical data .............................................................................................................................. 82
8.1 Tetrix 352 ............................................................................................................................. 82
8.2 Tetrix 452 ............................................................................................................................. 83
8.3 Tetrix 552 ............................................................................................................................. 84
9Accessories .................................................................................................................................. 85
9.1 General accessories ............................................................................................................ 85
9.2 Connection cables, connection sockets............................................................................... 85
9.3 Options ................................................................................................................................. 85
9.4 Transport system ................................................................................................................. 85
9.5 Computer communication .................................................................................................... 85
9.6 Welding torch cooling system .............................................................................................. 85
10 Service documents ...................................................................................................................... 86
10.1 Circuit diagrams ................................................................................................................... 86
11 Appendix ....................................................................................................................................... 89
11.1 JOB-List ............................................................................................................................... 89
11.2 Parameter overview – setting ranges .................................................................................. 93
11.2.1 TIG welding .......................................................................................................... 93
11.3 Searching for a dealer.......................................................................................................... 94

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
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
Incorrect / Invalid
Switch
Correct / Valid
Turn
Input
Numerical value – adjustable
Navigation
Signal light lights up in green
Output
Signal light flashes green
Time representation (e.g.: wait 4 s / ac-
tuate)
Signal light lights up in red
Interruption in the menu display (other
setting options possible)
Signal light flashes red
Tool not required/do not use
Signal light lights up in blue
Tool required/use
Signal light flashes blue

For your safety
Safety instructions
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2.3 Safety instructions
WARNING
Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
• Carefully read the safety instructions in this manual!
• Observe the accident prevention regulations and any regional regulations!
• Inform persons in the working area that they must comply with the regulations!
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low vol-
tages can cause a shock and lead to accidents.
• Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
• Always place torches and electrode holders on an insulated surface!
• Wear the full personal protective equipment (depending on the application)!
• The machine may only be opened by qualified personnel!
• The device must not be used to defrost pipes!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a techni-
cal specialist may interconnect the sources as per standard IEC 60974-9:2010: Installa-
tion and use and German Accident Prevention Regulation BVG D1 (formerly VBG 15) or
country-specific regulations.
Before commencing arc welding, a test must verify that the equipment cannot exceed
the maximum permitted open circuit voltage.
• Only qualified personnel may connect the machine.
• When taking individual power sources out of operation, all mains and welding current leads
must be safely disconnected from the welding system as a whole. (Hazard due to reverse
polarity voltage!)
• Do not interconnect welding machines with pole reversing switch (PWS series) or machines
for AC welding since a minor error in operation can cause the welding voltages to be com-
bined, which is not permitted.
Risk of injury due to radiation or heat!
Arc radiation can lead to skin and eye injuries.
Contact with hot workpieces and sparks can lead to burns.
• Use hand shield or welding helmet with the appropriate safety level (depends on the appli-
cation).
• Wear dry protective clothing (e.g. hand shield, gloves, etc.) in accordance with
the applicable regulations of your country.
• Persons who are not directly involved should be protected with a welding curtain or suitable
safety screen against radiation and the risk of blinding!

For your safety
Safety instructions
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WARNING
Risk of injury due to improper clothing!
During arc welding, radiation, heat and voltage are sources of risk that cannot be
avoided. The user has to be equipped with the complete personal protective equipment
at all times. The protective equipment has to include:
• Respiratory protection against hazardous substances and mixtures (fumes and vapours);
otherwise implement suitable measures such as extraction facilities.
• Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and
heat.
• Dry welding clothing (shoes, gloves and body protection) to protect against warm environ-
ments with conditions comparable to ambient temperatures of 100 °C or higher and arcing
and work on live components.
• Hearing protection against harming noise.
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during
welding, there is a risk of flames.
• Be watchful of potential sources of fire in the working area!
• Do not carry any easily inflammable objects, e.g. matches or lighters.
• Ensure suitable fire extinguishers are available in the working area!
• Thoroughly remove any residue of flammable materials from the workpiece prior to starting
to weld.
• Only further process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!

For your safety
Safety instructions
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CAUTION
Smoke and gases!
Smoke and gases may lead to shortness of breath and poisoning! The ultraviolet radia-
tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso-
nous phosgene.
• Ensure sufficient fresh air!
• Keep solvent vapours away from the arc beam field!
• Wear suitable respiratory protection if necessary!
• To prevent the formation of phosgene, residues of chlorinated solvents on workpieces must
first be neutralised using appropriate measures.
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
According to IEC 60974-10, welding machines are divided into two classes of electroma-
gnetic compatibility (the EMC class can be found in the Technical data) > see 8 chapter:
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas, in-
cluding residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the
surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding system
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
Electromagnetic fields!
The power source can create electrical or electromagnetic fields that may impair the
function of electronic systems such as EDP and CNC devices, telecommunication,
power and signal lines as well as pacemakers and defibrillators.
• Follow the maintenance instructions > see 6 chapter!
• Unwind the welding leads completely!
• Shield radiation-sensitive equipment or facilities appropriately!
• The function of pacemakers may be impaired (seek medical advice if necessary).

For your safety
Transport and installation
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CAUTION
Obligations of the operator!
The respective national directives and laws must be complied with when operating the
machine!
• Implementation of national legislation relating to framework directive 89/391/EEC on the in-
troduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
• In particular, directive 89/655/EEC concerning the minimum safety and health requirements
for the use of work equipment by workers at work.
• The regulations applicable to occupational safety and accident prevention in the country
concerned.
• Setting up and operating the machine as per IEC 60974.-9.
• Brief the user on safety-conscious work practices on a regular basis.
• Regularly inspect the machine as per IEC 60974.-4.
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode hold-
ers, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the ma-
chine is switched off.
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of the
operator, where necessary in consultation with the mains network operator, to ensure that the
machine can be connected.
2.4 Transport and installation
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause seri-
ous injuries!
• Observe the instructions from the gas manufacturer and any relevant regulations concern-
ing the use of compressed air!
• Do not attach any element to the shielding gas cylinder valve!
• Prevent the shielding gas cylinder from heating up.

For your safety
Transport and installation
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CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
• Disconnect all supply lines before transport!
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10° (ac-
cording to IEC 60974-1).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Risk of accidents due to incorrectly installed leads!
Incorrectly installed leads (mains, control and welding leads or intermediate hose
packages ) can present a tripping hazard.
• Lay the supply lines flat on the floor (avoid loops).
• Avoid laying the leads on passage ways.
Risk of injury from heated coolant and its connections!
The coolant used and its connection or connection points can heat up significantly
during operation (water-cooled version). When opening the coolant circuit, escaping
coolant may cause scalding.
• Open the coolant circuit only when the power source or cooling unit is switched off!
• Wear proper protective equipment (protective gloves)!
• Seal open connections of the hose leads with suitable plugs.
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant ac-
cessory components.
• Accessory components are detected automatically after the power source is switched on.
Protective dust caps protect the connection sockets and therefore the machine against dirt and
damage.
• The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
• The cap must be replaced if faulty or if lost!

Intended use
Applications
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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 stand-
ards applicable for use in industry and trade. It may only be used for the welding proce-
dures 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 Applications
Power source for integration into the automated arc welding system.
• Power source with machine control
• Interface for automated welding (robot or industrial bus interface)
• Connection capability for torch cooling unit
It may be possible to expand the range of functions by using accessories (see the documentation in the
relevant chapter).
3.2 Use and operation solely with the following machines
• BUSINT X11*
• RINT X12
• cool82 U44
• cool82 U45
(*)
Please note the interface capabilities!
3.3 Software version
The software version of the machine control can be displayed in the machine configuration menu
(menu Srv) > see 5.11 chapter.
3.4 Documents which also apply
3.4.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information regarding
warranty, maintenance and testing at www.ewm-group.com!
3.4.2 Declaration of Conformity
This product corresponds in its design and construction to the EU directives listed in the decla-
ration. The product comes with a relevant declaration of conformity in the original.
The manufacturer recommends carrying out the safety inspection according to national and in-
ternational standards and guidelines every 12 months (from commissioning).
3.4.3 Welding in environments with increased electrical hazards
Power sources with this marking can be used for welding in an environment with increased
electrical hazard (e.g. boilers). For this purpose, appropriate national or international regulations
must be followed. The power source must not be placed in the danger zone!

Intended use
Documents which also apply
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3.4.4 Service documents (spare parts and circuit diagrams)
WARNING
No improper repairs and modifications!
To prevent injuries and damage to the machine, only competent personnel (authorised
service personnel) are allowed to repair or modify the machine.
Unauthorised manipulations will invalidate the warranty!
• Instruct competent personnel (authorised service personnel) to repair the machine.
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.4.5 Calibration/Validation
An original certificate is enclosed with the product. The manufacturer recommends calibration / validation
at intervals of 12 months (from commissioning).
3.4.6 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 3-1

Intended use
Documents which also apply
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Item
Operating instructions
A.1
Wire feeder, media separation box
A.2
Options conversion instructions
A.3
Robot
A.4
Robot interface
A.5
Transport pallet
A.6
Cooling unit, voltage converter, media separation box etc.
A.7
Power source
A.8
Control
A.9
Remote control
A.10
Collision sensor
A.11
Hot wire power source
A.12
Welding torches
A
Complete documentation

Machine description – quick overview
Front view
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4 Machine description – quick overview
4.1 Front view
Figure 4-1

Machine description – quick overview
Front view
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Item
Symbol
Description 0
1
Lifting lug > see 5.1.1 chapter
2
Machine control > see 4.2 chapter
3
Cooling air inlet
4
Machine feet
5
Interfaces
Optional interface in the extension casing for assembly onto the power source
• RINTX11 robot interface
• BUSINTX10 industrial bus interface
6
5-pole connection socket
Cooling unit voltage supply
7
19-pole mechanised welding interface (analogue)
> see 5.7.2 chapter
8
8-pole connection socket
Cooling unit control lead
9
19-pole (analogue) connection socket
Collision protection / sensor voltage control signals
10
7-pole connection socket (digital)
For connecting digital accessory components
11
G¼" connection thread, shielding gas connection, outlet
12
Connection socket for welding current of welding torch
Minus potential
13
Connection socket, welding current +
Workpiece connection
14
Cooling air outlet
15
Intermediate hose package strain relief
16
Connection thread - G¼"
Shielding gas connection (inlet)
17
Key button, automatic cutout
Wire feed motor supply voltage fuse
press to reset a triggered fuse
18
Mains connection cable > see 5.1.7 chapter
19
Main Switch
Switching the machine on or off.
20
Key switch to protect against unauthorised use (retrofitting option)
Position 1: changes possible.
Position 0: no changes possible.
> see 5.9 chapter.
21
Connection socket (9-pole) - D-Sub
PC interface > see 5.8 chapter

Machine description – quick overview
Machine control – Operating elements
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4.2 Machine control – Operating elements
4.2.1 Machine control (Mode RC - on)
This welding machine is operated in 'RC – on, remote-controlled' mode ex works.
RC – on: The machine is controlled via an external interface in this mode. The majority of
operating elements on the machine control are deactivated and are used to check the welding
data only.
RC – off: The welding machine is controlled using the machine control.
To switch to a different operating mode > see 5.11 chapter.
Figure 4-2
Item
Symbol
Description 0
1
Electrode diameter push-button > see 5.4 chapter
Ignition optimisation (TIG) > see 5.4.3 chapter
2
Gas test/rinse hose package button
> see 5.1.8 chapter
3
Error/status indicators
------- Collective interference signal light
--------- Water deficiency signal light (welding torch cooling)
--------- Excess temperature signal light
--------- S safety sign signal light
4
Functional sequence > see 4.2.1.1 chapter
5
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
6
Welding parameter setting rotary dial
Setting currents, times and parameters.

Machine description – quick overview
Machine control – Operating elements
099-000141-EW501
22.03.2023
19
Item
Symbol
Description 0
7
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 4.2.3 chapter
8
Display switching button
------- Material thickness display
VOLT --- Welding voltage display
JOB ----- JOB number display
PROG --- Program number display
4.2.1.1 Function sequence
Figure 4-3
Item
Symbol
Description 0
1
Select welding parameters button
This button is used to select the welding parameters depending on the welding process
and operating mode used.
2
Gas pre-flow time signal light
3
AMP%
Signal light
Start current (TIG)/hot start current (MMA)
4
sec
Signal light
Up-slope time (TIG)/hot start time (MMA)
5
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)
6
sec
Pulse time / slope time from AMP% to AMP / Spot time
7
AMP%
Secondary current (TIG)
8
sec
Pulse pause time / slope time from AMP to AMP%
The pulse time applies to the secondary current phase (AMP%)
9
sec
Down-slope time (TIG)
10
AMP%
End-crater current signal light
11
Signal light, gas post-flow time
12
Balance signal light
Pulse balance
13
Frequency signal light
Pulse frequency
14
Signal light activArc > see 5.4.7 chapter

Machine description – quick overview
Machine control – Operating elements
20
099-000141-EW501
22.03.2023
4.2.2 Machine control (Mode RC - off)
As the plasma welding process is based directly on the TIG welding process, the TIG descriptions are
used for plasma welding, with just a few differences.
Figure 4-4
Item
Symbol
Description 0
1
"Welding process" button
MMA welding, lights up in green / arcforce setting, lights up in red
TIG synergic welding (synergic parameter setting)
TIG manual welding (manual parameter setting)
2
Electrode diameter push-button > see 5.4 chapter
Ignition optimisation (TIG) > see 5.4.3 chapter
3
“Select material type” button
CrNi ----- Chrome nickel alloys
FeSt ----- Iron and steel alloys
Cu -------- Copper or copper alloys (bronzes)
CuZn ---- Copper zinc alloys (brass)
Spez ----- Special (for special custom-built tasks)
4
Select seam type button
------- Fillet weld
------- Butt joint
------ Fillet weld - lap joint
-------- Vertical-down
5
Operating mode / Power-saving mode button
-- spotArc / spotmatic (spot time setting range)
--------- Non-latched
------ Latched
Press for 3 s to put machine into power-saving mode. To reactivate, activate one of the
operating elements > see 5.10 chapter.