EWM Tetrix 451 AC/DC Smart 2.0 FW User manual

Operating instructions
EN
Power source
Tetrix 451 AC/DC Smart 2.0 FW
Tetrix 551 AC/DC Smart 2.0 FW
Tetrix 451 AC/DC Comfort 2.0 FW
Tetrix 551 AC/DC Comfort 2.0 FW
099-000251-EW501
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27.10.2017
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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.
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
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
2.4 Safety instructions..........................................................................................................................7
2.5 Transport and installation ............................................................................................................11
3Intended use.........................................................................................................................................12
3.1 Applications..................................................................................................................................12
3.2 Documents which also apply .......................................................................................................12
3.2.1 Warranty.......................................................................................................................12
3.2.2 Declaration of Conformity.............................................................................................12
3.2.3 Welding in environments with increased electrical hazards.........................................12
3.2.4 Service documents (spare parts and circuit diagrams)................................................12
3.2.5 Calibration/Validation....................................................................................................12
4Machine description –quick overview ..............................................................................................13
4.1 Front view ....................................................................................................................................13
4.2 Rear view.....................................................................................................................................15
5Design and function.............................................................................................................................17
5.1 Transport and installation ............................................................................................................17
5.1.1 Lifting by crane .............................................................................................................17
5.1.2 Ambient conditions .......................................................................................................18
5.1.2.1 In operation ...................................................................................................18
5.1.2.2 Transport and storage...................................................................................18
5.1.3 Machine cooling............................................................................................................18
5.1.4 Workpiece lead, general...............................................................................................18
5.1.5 Welding torch cooling system.......................................................................................19
5.1.5.1 Approved coolants overview.........................................................................19
5.1.5.2 Maximal hose package length ......................................................................19
5.1.5.3 Adding coolant ..............................................................................................20
5.1.6 Notes on the installation of welding current leads........................................................21
5.1.6.1 Stray welding currents...................................................................................22
5.1.7 Mains connection..........................................................................................................22
5.1.7.1 Mains configuration.......................................................................................23
5.2 TIG welding..................................................................................................................................24
5.2.1 Welding torch and workpiece line connection..............................................................24
5.2.1.1 Connection assignment, welding torch control cable....................................26
5.2.2 Shielding gas supply (shielding gas cylinder for welding machine) .............................26
5.2.2.1 Connecting the shielding gas supply ............................................................27
5.3 MMA welding ...............................................................................................................................27
5.3.1 Connecting the electrode holder and workpiece lead ..................................................27
5.4 Remote control.............................................................................................................................29
5.4.1 RT1 19POL...................................................................................................................29
5.4.2 RTG1 19POL................................................................................................................29
5.4.3 RTP1 19POL ................................................................................................................29
5.4.4 RTP2 19POL ................................................................................................................29
5.4.5 RTP3 spotArc 19POL...................................................................................................29
5.4.6 RT50 7POL...................................................................................................................29
5.4.7 RTF1 19POL ................................................................................................................29
5.4.8 RT AC 1 19POL............................................................................................................30
5.4.9 RT PWS 1 19POL ........................................................................................................30
5.5 Interfaces for automation.............................................................................................................31
5.5.1 Automation interface.....................................................................................................32
5.5.2 Remote control connection socket, 19-pole.................................................................33
5.5.3 RINT X12 robot interface..............................................................................................33
5.5.4 BUSINT X11 Industrial bus interface............................................................................33
5.6 PC interface .................................................................................................................................34

Contents
Notes on the use of these operating instructions
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6Maintenance, care and disposal .........................................................................................................35
6.1 General.........................................................................................................................................35
6.2 Cleaning.......................................................................................................................................35
6.2.1 Dirt filter.........................................................................................................................35
6.3 Maintenance work, intervals.........................................................................................................36
6.3.1 Daily maintenance tasks...............................................................................................36
6.3.2 Monthly maintenance tasks..........................................................................................36
6.3.3 Annual test (inspection and testing during operation) ..................................................36
6.4 Disposing of equipment................................................................................................................37
7Rectifying faults....................................................................................................................................38
7.1 Checklist for rectifying faults ........................................................................................................38
7.2 Vent coolant circuit.......................................................................................................................39
8Technical data.......................................................................................................................................40
8.1 Tetrix 451 AC/DC.........................................................................................................................40
8.2 Tetrix 551 AC/DC.........................................................................................................................41
9Accessories ..........................................................................................................................................42
9.1 Remote controls and accessories................................................................................................42
9.2 Welding torch cooling system ......................................................................................................42
9.3 Options.........................................................................................................................................42
9.4 General accessories ....................................................................................................................43
9.5 Simultaneous welding on both sides, synchronisation types.......................................................43
9.5.1 Synchronisation via cable (frequency 50Hz to 200Hz).................................................43
9.5.2 Synchronisation via mains voltage (50Hz / 60Hz)........................................................43
9.6 Computer communication............................................................................................................43
10 Appendix A............................................................................................................................................44
10.1 Overview of EWM branches.........................................................................................................44

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.
Special technical points which users must observe.
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 keep pressed
Switch
Wrong
Turn
Correct
Numerical value –adjustable
Menu entry
Signal light lights up in green
Navigating the menu
Signal light flashes green
Exit menu
Signal light lights up in red
Time representation (e.g.: wait
4 s/activate)
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
Remote control
A.2
Control
A.3
Power source
A.4
Welding torch
A
Complete documentation
2.4 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!

For your safety
Safety instructions
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WARNING
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low
voltages 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!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a
technical specialist may interconnect the sources as per standard IEC 60974-9:2010:
Installation 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
combined, which is not permitted.
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
environments with conditions comparable to ambient temperatures of 100 °C or higher and
arcing and work on live components.
•Hearing protection against harming noise.
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
application).
•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!
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!

For your safety
Safety instructions
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WARNING
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!
CAUTION
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent
vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to
the ultraviolet radiation of the arc!
•Ensure that there is sufficient fresh air!
•Keep solvent vapour away from the arc beam field!
•Wear suitable breathing apparatus if appropriate!
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
electromagnetic 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,
including 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

For your safety
Safety instructions
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CAUTION
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
•Observe the maintenance instructions > see 6.3 chapter!
•Unwind welding leads completely!
•Shield devices or equipment sensitive to radiation accordingly!
•The correct functioning of pacemakers may be affected (obtain advice from a doctor if
necessary).
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
introduction 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
holders, 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
machine 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.

For your safety
Transport and installation
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2.5 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
serious injuries!
•Observe the instructions from the gas manufacturer and any relevant regulations
concerning the use of compressed air!
•Do not attach any element to the shielding gas cylinder valve!
•Prevent the shielding gas cylinder from heating up.
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°
(according 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.
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
accessory 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
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 Applications
Arc welding machine for TIG DC and AC welding with lift arc (touch starting) or HF ignition (contactless)
and MMA welding as secondary process. It may be possible to expand the functionality by using
accessories (see the documentation in the relevant chapter).
3.2 Documents which also apply
3.2.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.2.2 Declaration of Conformity
The labelled machine complies with the following EC directives in terms of its design and
construction:
•Low Voltage Directive (LVD)
•Electromagnetic Compatibility Directive (EMC)
•Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment –Inspection and Testing during Operation," and/or prohibited modifications which
have not been explicitly authorised by the manufacturer, this declaration shall be voided. An original
document of the specific declaration of conformity is included with every product.
3.2.3 Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
3.2.4 Service documents (spare parts and circuit diagrams)
WARNING
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only 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)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.2.5 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months

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
2
Main switch, machine on/off
3
Machine control, see the relevant control operating instructions
4
Carrying handle
5
Automatic cut-out of coolant pump key button
press to reset a triggered fuse
6
Quick connect coupling (red)
coolant return
7
Quick connect coupling (blue)
coolant supply
8
Wheels, guide castors
9
Coolant tank
10
Coolant tank cap
11
Connection socket, welding torch control cable > see 5.2.1.1 chapter
12
Connection socket, 19-pole
Remote control connection
13
G¼“ connecting nipple, welding current "-" (with DC- polarity)
Shielding gas connection (with yellow insulating cap) for TIG welding torch
14
Connection socket, welding current “-” (with DC- polarity)
connection TIG welding torch
15
Connection socket, welding current “+” (with DC- polarity)
Connection for workpiece lead
16
Connection socket, welding current “-” (with DC- polarity)
connection for Electrode holder
17
Cooling air inlet
18
Operating state signal lamp
Lights up when the machine is ready for use.

Machine description –quick overview
Rear view
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4.2 Rear view
Figure 4-2

Machine description –quick overview
Rear view
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Item
Symbol
Description 0
1
Connection socket, 7-pole (digital)
To connect digital accessories
Retrofitting option > see 9 chapter
2
PC interface, serial (D-Sub connection socket, 9-pole)
3
Automation interface 19-pin (analogue)
Option for retrofitting > see 5.5 chapter
4
Securing elements for shielding gas cylinder (strap/chain)
5
Mains connection cable > see 5.1.7 chapter
6
Cooling air outlet
7
G¼” connecting nipple
Shielding gas connection on the pressure regulator.
8
Quick connect coupling (red)
coolant return
9
Quick connect coupling (blue)
coolant supply
10
Bracket for shielding gas cylinder
11
Wheels, fixed castors

Design and function
Transport and installation
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5 Design and function
WARNING
Risk of injury from electrical voltage!
Contact with live parts, e.g. power connections, can be fatal!
•Observe the safety information on the first pages of the operating instructions!
•Commissioning must be carried out by persons who are specifically trained in handling
power sources!
•Connect connection or power cables while the machine is switched off!
CAUTION
Risk from electrical current!
If welding is carried out alternately using different methods and if a welding torch and
an electrode holder remain connected to the machine, the open-circuit/welding voltage
is applied simultaneously on all cables.
•The torch and the electrode holder should therefore always be placed on an insulated
surface before starting work and during breaks.
Read and observe the documentation to all system and accessory components!
5.1 Transport and installation
5.1.1 Lifting by crane
WARNING
Risk of injury during lifting by crane!
When lifting the machine by crane, persons may be severely injured by falling machines
or mount-on components.
•Simultaneous lifting of system components such as power source,wire
feeder or cooling unit without suitable crane components is not
allowed. Each system component has to be lifted separately!
•Remove any supply leads and accessories before lifting by crane (e.g.
hose package,wire spool,shielding gas cylinder,toolbox, wire feeder,
remote control,etc.)!)
•Properly close and lock all casing covers and protective caps before
lifting by crane!
•Use the correct number of hoisting equipment of the right size in the
correct position! Observe craning principle (see figure)!
•For machines with lifting eyes: always lift all lifting eyes simultaneously!
•When using retrofitted craning frames etc.: always use at least two
lifting points positioned as far apart as possible –observe option
description.
•Avoid any jerky movements!
•Ensure that the load is distributed evenly! • Use chain hoists and
chain slings of the same length only!
•Stay outside the danger zone underneath the machine!
•Observe the regulations regarding occupational safety and accident
prevention for the respective country.
Craning principle

Design and function
Transport and installation
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5.1.2 Ambient conditions
T he machine must not be operated in the open air and must only be set up and operated on a
suitable, stable and level base!
•The operator must ensure that the ground is non-slip and level, and provide sufficient lighting
for the place of work.
•Safe operation of the machine must be guaranteed at all times.
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
•Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
•Avoid ambient air containing salt (sea air)!
5.1.2.1 In operation
Temperature range of the ambient air:
•-25 °C to +40 °C
Relative air humidity:
•Up to 50% at 40 °C
•Up to 90% at 20 °C
5.1.2.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
•-30 °C to +70 °C
Relative air humidity
•Up to 90% at 20 °C
5.1.3 Machine cooling
Insufficient ventilation results in a reduction in performance and equipment damage.
•Observe the ambient conditions!
•Keep the cooling air inlet and outlet clear!
•Observe the minimum distance of 0.5 m from obstacles!
5.1.4 Workpiece lead, general
CAUTION
Risk of burning due to incorrect welding current connection!
If the welding current plugs (machine connections) are not locked or if the workpiece
connection is contaminated (paint, corrosion), these connections and leads can heat up
and cause burns when touched!
•Check welding current connections on a daily basis and lock by turning to the right when
necessary.
•Clean workpiece connection thoroughly and secure properly. Do not use structural parts of
the workpiece as welding current return lead!

Design and function
Transport and installation
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5.1.5 Welding torch cooling system
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch > see 5.1.5.1 chapter.
Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the
frost protection is adequate to prevent damage to the machine or the accessory components.
•The coolant must be checked for adequate frost protection with the TYP 1 frost protection
tester .
•Replace coolant as necessary if frost protection is inadequate!
Coolant mixtures!
Mixtures with other liquids or the use of unsuitable coolants result in material damage and
renders the manufacturer's warranty void!
•Only use the coolant described in this manual (overview of coolants).
•Do not mix different coolants.
•When changing the coolant, the entire volume of liquid must be changed.
Dispose of the coolant in accordance with local regulations and the material safety data sheets
(German waste code number: 70104).
May not be disposed of in household waste.
Prevent entry into sewers.
Absorb with liquid-binding material (sand, gravel, acid-binding agents, universal binding agents,
sawdust).
5.1.5.1 Approved coolants overview
Coolant
Temperature range
KF 23E (Standard)
-10 °C to +40 °C
KF 37E
-20 °C to +10 °C
5.1.5.2 Maximal hose package length
Pump 3.5 bar
Pump 4.5 bar
Machines with or without separate wire feeder
30 m
60 m
Compact machines with additional intermediate
drive (example. miniDrive)
20 m
30 m
Machines with separate wire feeder and additional
intermediate drive (example: miniDrive)
20 m
60 m
Data as a rule refer to the entire hose package length
including welding torch. The pump output is shown on the type plate (parameter: Pmax).
Pump 3.5 bar: Pmax = 0.35 MPa (3.5 bar)
Pump 4.5 bar: Pmax = 0.45 MPa (4.5 bar)

Design and function
Transport and installation
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099-000251-EW501
27.10.2017
5.1.5.3 Adding coolant
The unit is supplied ex works with a minimum level of coolant.
Figure 5-1
Item
Symbol
Description 0
1
Coolant tank cap
2
Coolant filter sieve
3
Coolant tank
4
"Min" mark
Minimum coolant level
•Unscrew and remove the coolant tank sealing cover.
•Check filter sieve insert for dirt, clean if necessary and reinsert into position.
•Top up coolant to the filter sieve insert, close sealing cover again.
If the cooling system is empty or only insufficiently filled with coolant, the coolant pump is
automatically switched off after approx. one minute (protection against destruction). At the same
time, the welding data display signals the lack of coolant or low coolant level.
•Reset the coolant error, fill coolant and repeat the operation.
The level of coolant must never fall below the “min” mark.
If there is less coolant in the coolant tank than the minimum required you may need to vent the
coolant circuit. In this case the welding machine will automatically shut down the coolant pump
and signal an error, > see 7.2 chapter.