EWM RTF1 User manual

Operating instructions
EN
Remote control
RTF1
RT1
RTG1
RT PWS1
RTP1
RTP2
RTP3
RTAC1
099-008097-EW501 Observe additional system documents! 22.03.2018

General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the location where the machine is operated.
• Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
• Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers.
Liability relating to the operation of this equipment is restricted solely to the function of the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of
liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Strasse 8
56271 Mündersbach Germany
Tel.: [phone], Fax: -244
Email: [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 the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2Safety instructions.................................................................................................................................5
2.1 Notes on the use of these operating instructions ..........................................................................5
2.2 Explanation of icons.......................................................................................................................6
2.3 General ..........................................................................................................................................6
3Intended use...........................................................................................................................................9
3.1 Applications....................................................................................................................................9
3.2 Use and operation solely with the following machines..................................................................9
3.3 Documents which also apply .......................................................................................................10
3.3.1 Warranty.......................................................................................................................10
3.3.2 Declaration of Conformity.............................................................................................10
3.3.3 Service documents (spare parts and circuit diagrams)................................................10
3.3.4 Calibration/Validation....................................................................................................10
4Machine description – quick overview ..............................................................................................11
4.1 RTF1 19POL................................................................................................................................11
4.2 RT1 19POL..................................................................................................................................11
4.3 RTG1 19POL...............................................................................................................................12
4.4 RT PWS1 19POL.........................................................................................................................12
4.5 RTP1 19POL................................................................................................................................13
4.6 RTP2 19POL................................................................................................................................15
4.7 RTP3 spotArc 19POL ..................................................................................................................17
4.8 RTAC1 19POL.............................................................................................................................19
5Design and function.............................................................................................................................20
5.1 Transport......................................................................................................................................20
5.2 Scope of delivery .........................................................................................................................20
5.2.1 Ambient conditions .......................................................................................................20
5.2.1.1 In operation ...................................................................................................20
5.2.1.2 Transport and storage...................................................................................20
5.3 Establishing the connections.......................................................................................................21
5.4 Functional characteristics ............................................................................................................21
5.4.1 RTF1 -, RT1 -, RTG1 19POL .......................................................................................22
5.4.2 RT PWS1 19POL .........................................................................................................22
5.4.3 RTP1 19POL ................................................................................................................22
5.4.4 RTP2 19POL ................................................................................................................22
5.4.4.1 Calculation examples for pulse and pulse pause currents ...........................23
5.4.5 RTP3 spotArc 19POL...................................................................................................24
5.4.5.1 Calculation examples for pulse and pulse pause currents ...........................25
5.4.5.2 spotArc..........................................................................................................26
5.4.5.3 Diagram of TIG spotArc spot welding with pulsed welding current ..............26
5.4.5.4 Setting instructions........................................................................................26
5.4.5.5 Standard operation........................................................................................27
5.4.6 RTAC1 19POL..............................................................................................................27
5.4.6.1 Standard operation........................................................................................27
6Maintenance, care and disposal.........................................................................................................28
6.1 General ........................................................................................................................................28
6.1.1 Cleaning .......................................................................................................................28
6.1.2 Dirt filter ........................................................................................................................28
6.2 Maintenance work, intervals ........................................................................................................29
6.2.1 Daily maintenance tasks...............................................................................................29
6.2.2 Monthly maintenance tasks..........................................................................................29
6.2.3 Annual test (inspection and testing during operation)..................................................29
6.3 Disposing of equipment ...............................................................................................................30
7Technical data ......................................................................................................................................31
8Accessories..........................................................................................................................................32
8.1 Connection and extension cables................................................................................................32
9Appendix A ...........................................................................................................................................33
9.1 Searching for a dealer..................................................................................................................33

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

Safety instructions
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release / Tap / Tip
Switch off machine Release
Switch on machine
Press and hold
Switch
Incorrect / Invalid Turn
Correct / Valid
Numerical value – adjustable
Input
Signal light lights up in green
Navigation Signal light flashes green
Output Signal light lights up in red
Time representation (e.g.: wait 4 s /
actuate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use
2.3 General
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!
• The device must not be used to defrost pipes!

Safety instructions
General
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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!
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!
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!
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 6.2 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).
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!
Trained personnel!
Commissioning is reserved for persons who have the relevant expertise of working with arc
welding machines.
These supplementary sheets must be used in conjunction with the appropriate standard
opera
ting instructions for the described product! These supplementary sheets expand or replace
one or more chapters of the same name(s) in the standard description.
Read and observe the operating instructions for all system components, especially the safety
instructions!

Safety instructions
General
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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.

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
Remote controls are used for the remote operation of various machine functions (see operating
instructions for remote control). Depending on the machine design, the remote control connection can be
7- or 19-pole (for connection, see > see 4 chapter).
3.2 Use and operation solely with the following machines
These remote controls are specifically designed for use with Pico, Picotig and Tetrix welding machines
and give various options depending on the model.
RTF1
RT1
RTG1
• Pico 180 puls
• Pico 220 cel puls
• Pico 300 cel
• Pico 350 cel puls
• Picotig 200 puls
• Picotig 200 AC/DC puls
• Tetrix 150 Plasma
• Tetrix 200 puls
• Tetrix 230 DC 2.0 puls
• Tetrix 230 AC/DC 2.0 puls
• Tetrix 300 DC 2.0 puls
• Tetrix 300 AC/DC 2.0 puls
• Tetrix 300 TM
• Tetrix 351 DC
• Tetrix 351 AC/DC
• Tetrix 451 DC
• Tetrix 451 AC/DC
• Tetrix 551 DC
• Tetrix 551 AC/DC
• Pico 180 puls
• Pico 220 cel puls
• Pico 300 cel
• Pico 350 cel puls
• Picotig 200 puls
• Picotig 200 AC/DC puls
• Tetrix 150 Plasma
• Tetrix 200 puls
• Tetrix 230 DC 2.0 puls
• Tetrix 230 AC/DC 2.0 puls
• Tetrix 300 DC 2.0 puls
• Tetrix 300 AC/DC 2.0 puls
• Tetrix 300 TM
• Tetrix 351 DC
• Tetrix 351 AC/DC
• Tetrix 451 DC
• Tetrix 451 AC/DC
• Tetrix 551 DC
• Tetrix 551 AC/DC
• Taurus 400 Basic TDG
• Pico 220 cel puls
• Pico 350 cel puls
• Picotig 200 puls
• Picotig 200 AC/DC puls
• Tetrix 200 puls
• Tetrix 230 DC 2.0 puls
• Tetrix 230 AC/DC 2.0 puls
• Tetrix 300 DC 2.0 puls
• Tetrix 300 AC/DC 2.0 puls
• Tetrix 300 TM
• Tetrix 351 DC
• Tetrix 351 AC/DC
• Tetrix 451 DC
• Tetrix 451 AC/DC
• Tetrix 551 DC
• Tetrix 551 AC/DC

Intended use
Documents which also apply
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RT PWS 1
RTP1, RTP2, RTP3
RTAC1
• Pico 300 cel
• Pico 350 cel
• Tetrix 351 AC/DC
• Tetrix 451 AC/DC
• Tetrix 551 AC/DC
• Picotig 200 AC/DC puls
• Tetrix 150 Plasma
• Tetrix 200 puls
• Tetrix 230 DC 2.0 puls
• Tetrix 230 AC/DC 2.0 puls
• Tetrix 300 DC 2.0 puls
• Tetrix 300 AC/DC 2.0 puls
• Tetrix 300 TM
• Tetrix 351 DC
• Tetrix 351 AC/DC
• Tetrix 451 DC
• Tetrix 451 AC/DC
• Tetrix 551 DC
• Tetrix 551 AC/DC
• Tetrix 300 AC/DC 2.0 puls
• Tetrix 351 AC/DC
• Tetrix 451 AC/DC
• Tetrix 551 AC/DC
3.3 Documents which also apply
3.3.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.3.2 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 au
thorised by the manufacturer, this declaration shall be voided. An original
document of the specific declaration of conformity is included with every product.
3.3.3 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.
3.3.4 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
RTF1 19POL
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4 Machine description – quick overview
4.1 RTF1 19POL
Figure 4-1
Item
Symbol
Description 0
1
Foot-operated switch
2
Connection cable, 19-pole
4.2 RT1 19POL
Figure 4-2
Item
Symbol
Description 0
1
Holder for suspending the remote control
2
Welding current rotary dial
Infinitely adjustable welding current, 0% to 100% of the main current preset on the
power source.
3
19-pole connection socket (analogue)
For connecting the control lead.

Machine description
– quick overview
RTG1 19POL
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4.3 RTG1 19POL
Figure 4-3
Item
Symbol
Description 0
1
Holder for suspending the remote control
2
Welding current rotary dial
Infinitely adjustable welding current, 0% to 100% of the main current preset on the
power source.
3
Torch body
4
Connection cable, 19-pole
4.4 RT PWS1 19POL
Figure 4-4
Item
Symbol
Description 0
1
Welding current rotary dial
Infinitely adjustable welding current, 0% to 100% of the main current preset on the
power source.
2 19-pole connection socket (analogue)
For connecting the control lead.

Machine description –
quick overview
RTP1 19POL
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4.5 RTP1 19POL
Figure 4-5
Item
Symbol
Description 0
1 Holder for suspending the remote control
2
19-pole connection socket (analogue)
For connecting the control lead.
3
Welding procedure changeover switch
------MMA welding
-------TIG welding
4 Signal light Pulse current
Signal light is illuminated when the remote control is ready for operation and when
pulse current flows.
5 Signal light Pulse pause current
Signal light is illuminated when the pulse pause current flows.
6
Rotary knob I2 secondary current / pulse pause current (in% of I1)
(percentage depending on the pulse current setting I1 on the remote control 0-100%).
Pulsing: Setting the pause current
Standard:setting the secondary current
(accessible with the 2
nd
torch trigger)
7
Rotary knob I1 Welding, pulse, point current (% AMP)
(percentage depending on the welding current setting on the welding machine 0-
100%).
Pulsing: Setting the pulse current
Spot welding: Setting the point current
Standard:setting the secondary current
8
Rotary knob Pulse pause time
Pulsing: Setting the pause time (0.05 to 2sec).
9
Rotary knob Pulse / spot time
Pulsing: Setting the pulse time (0.05 to 2sec).
Spot welding: Setting the spot time (0.5 to 20sec).

Machine description
– quick overview
RTP1 19POL
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Item
Symbol
Description 0
10
Rotary switch
------- Pulsing
------- Standard
---
Spot welding

Machine description –
quick overview
RTP2 19POL
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4.6 RTP2 19POL
Figure 4-6
Item
Symbol
Description 0
1 Holder for suspending the remote control
2
19-pole connection socket (analogue)
For connecting the control lead.
3
Welding procedure changeover switch
------MMA welding
-------TIG welding
4 Signal light Pulse current
Signal light is illuminated when the remote control is ready for operation and when
pulse current flows.
5 Signal light Pulse pause current
Signal light is illuminated when the pulse pause current flows.
6
Rotary knob I2 secondary current / pulse pause current (in% of I1)
(percentage depending on the pulse current setting I1 on the remote control 0-100%).
Pulsing: Setting the pause current
Standard:setting the secondary current
(accessible with the 2
nd
torch trigger)
7
Rotary knob I1 Welding, pulse, point current (% AMP)
(percentage depending on the welding current setting on the welding machine 0-
100%).
Pulsing: Setting the pulse current
Spot welding: Setting the point current
Standard:setting the secondary current
8
Rotary knob Balance
Pulsing: -Setting the pulse/pause ratio (10% to 90%)
9
Rotary knob Pulse frequency
Setting the pulse and pulse pause time.
The setting range depends on the selection of rotary switch Frequency range /
operating mode!

Machine description
– quick overview
RTP2 19POL
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Item
Symbol
Description 0
10
Rotary switch Frequency range / operating mode
-------Pulsing
Setting the pulse frequency in 4 ranges:
0.25 to 2.5Hz
2.5 to 25Hz
25 to 250Hz
250 to 2500Hz
------- Standard
Standard pulses here are switched between thewelding current and the
secondary current.
--- Spot welding
Setting the spot time in 2 areas:
0.25 to 2.5sec
2.5 to 25sec.

Machine description –
quick overview
RTP3 spotArc 19POL
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4.7 RTP3 spotArc 19POL
Figure 4-7
Item
Symbol
Description 0
1
Holder for suspending the remote control
2 19-pole connection socket (analogue)
For connecting the control lead.
3
Welding procedure changeover switch
------MMA welding
-------TIG welding
4
Signal light Pulse current
Signal light is illuminated when the remote control is ready for operation and when
pulse current flows.
5
Signal light Pulse pause current
Signal light is illuminated when the pulse pause current flows.
6
Rotary knob I2 secondary current / pulse pause current (in% of I1)
(percentage depending on the pulse current setting I1 on the remote control 0-100%).
Pulsing: Setting the pause current
Standard:setting the secondary current
(accessible with the 2
nd
torch trigger)
7
Rotary knob I1 Welding, pulse, point current (% AMP)
(percentage depending on the welding current setting on the welding machine 0-
100%).
Pulsing: Setting the pulse current
Spot welding: Setting the point current
Standard:setting the secondary current
8
Rotary knob Pulse frequency
Setting the pulse and pulse pause time.
The setting range depends on the selection of rotary switch Frequency range /
operating mode!
9
Rotary knob Balance
Pulsing: -Setting the pulse/pause ratio (10% to 90%)

Machine description
– quick overview
RTP3 spotArc 19POL
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Item
Symbol
Description 0
10
Rotary switch Frequency range / operating mode
------Pulses
Setting the pulse frequency in 4 areas:
0.25 to 2.5Hz
2.5 to 25Hz
25 to 250Hz
250 to 2500Hz
------- Standard
Standard pulses are switched here between the welding current and the
secondary current.
--- spotArc spot welding
Setting the spot time in 2 areas:
0.25 to 2.5sec
2.5 to 25sec.

Machine description –
quick overview
RTAC1 19POL
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4.8 RTAC1 19POL
Figure 4-8
Item
Symbol
Description 0
1
Holder for suspending the remote control
2 19-pole connection socket (analogue)
For connecting the control lead.
3
Welding current rotary dial
Infinitely adjustable welding current, 0% to 100% of the main current preset on the
power source.
4
Alternating current frequency (TIG AC)
50 Hz to 200 Hz (1 Hz increments).
Constriction and stabilisation of the arc:
At a higher frequency, the cleaning effect is increased. Particularly thin panels (welding
with a low current), anodised sheet aluminium or highly contaminated articles for
welding can be welded and cleaned perfectly at a higher frequency.
5
Alternating current balance (TIG AC)
Max. setting range: -15% to +15% (1% increments). The setting range may also be
lower depending on the factory setting.
Optimisation of cleaning effect and fusion penetration characteristics.
An increase in the positive half-wave means:
• greater cleaning effect
• higher temperature of the tungsten electrode
• greater ball formation on the tungsten electrode
• broader weld seam, little fusion penetration
An increase in the negative half-wave means:
• narrower weld seam, deeper fusion penetration
• reduced cleaning effect
• lower temperature of the tungsten electrode
• less ball formation on the tungsten electrode

Design and function
Transport
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5 Design and function
5.1 Transport
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!
Read and observe the documentation to all system and accessory components!
5.2 Scope of delivery
The delivery is checked and packaged carefully before dispatch, however it is not possible to exclude the
possibility of damage during transit.
Receiving inspection
• Check that the delivery is complete using the delivery note!
In the event of damage to the packaging
• Check the delivery for damage (visual inspection)!
In the event of complaints
If the delivery has been damaged during transport:
• Please contact the last haulier immediately!
• Keep the packaging (for possible checking by the haulier or for the return shipment).
Packaging for returns
If possible, please use the original packaging and the original packaging material. If you have any queries
on packaging and protection during transport, please contact your supplier.
5.2.1 Ambient conditions
Equipment damage due to contamination!
Unusually high amounts of dust, acids, corrosive gases or substances can damage the machine
(observe maintenance intervals > see 6.2 chapter).
• Avoid large amounts of smoke, steam, oily fumes, grinding dust and corrosive ambient air!
5.2.1.1 In operation
Temperature range of the ambient air:
• -25 °C to +40 °C (-13 F to 104 F)
Relative humidity:
• up to 50 % at 40 °C (104 F)
• up to 90 % at 20 °C (68 F)
5.2.1.2 Transport and storage
Storage in a closed room, temperature range of the ambient air:
• -30 °C to +70 °C (-22 F to 158 F)
Relative humidity
• up to 90 % at 20 °C (68 F)