EWM Tetrix drive 4L User manual

Operating instructions
EN
Wire feed unit
Tetrix drive 4L
099-000094-EW501
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18.07.2017
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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
3Intended use...........................................................................................................................................8
3.1 Applications....................................................................................................................................8
3.1.1 Use and operation solely with the following machines...................................................8
3.2 Documents which also apply .........................................................................................................8
3.2.1 Warranty.........................................................................................................................8
3.2.2 Declaration of Conformity...............................................................................................8
3.2.3 Service documents (spare parts and circuit diagrams)..................................................8
3.2.4 Calibration/Validation......................................................................................................8
4Machine description –quick overview ................................................................................................9
4.1 Front view ......................................................................................................................................9
4.2 Rear view.....................................................................................................................................10
4.3 Inside view ...................................................................................................................................11
4.4 Machine control –Operating elements........................................................................................12
5Design and function.............................................................................................................................13
5.1 Ambient conditions.......................................................................................................................13
5.1.1 In operation...................................................................................................................13
5.1.2 Transport and storage..................................................................................................13
5.2 Transport and installation ............................................................................................................13
5.2.1 Connection plan............................................................................................................14
5.2.1.1 TIG hot wire welding .....................................................................................14
5.2.1.2 TIG cold wire welding....................................................................................15
5.2.1.3 Legend ..........................................................................................................15
5.2.2 Welding torch cooling system.......................................................................................16
5.2.2.1 Approved coolants overview.........................................................................16
5.2.2.2 Maximal hose package length ......................................................................17
5.2.3 Notes on the installation of welding current leads........................................................17
5.2.3.1 Stray welding currents...................................................................................18
5.2.4 Intermediate hose package connection........................................................................19
5.2.4.1 Connecting the shielding gas supply ............................................................20
5.2.5 Welding torch connection.............................................................................................20
5.2.5.1 Control cable pin configuration .....................................................................21
5.3 Wire feed......................................................................................................................................22
5.3.1 Open the protective flap of the wire feeder ..................................................................22
5.3.1.1 Inserting the wire spool.................................................................................22
5.3.1.2 Changing the wire feed rollers ......................................................................23
5.3.1.3 Inching the wire electrode.............................................................................23
5.3.1.4 Spool brake setting .......................................................................................24
5.4 Remote control.............................................................................................................................24
6Maintenance, care and disposal.........................................................................................................26
6.1 General ........................................................................................................................................26
6.2 Cleaning.......................................................................................................................................26
6.2.1 Dirt filter ........................................................................................................................26
6.3 Maintenance work, intervals ........................................................................................................27
6.3.1 Daily maintenance tasks...............................................................................................27
6.3.2 Monthly maintenance tasks..........................................................................................27
6.3.3 Annual test (inspection and testing during operation)..................................................27
6.4 Disposing of equipment ...............................................................................................................28
6.5 Meeting the requirements of RoHS .............................................................................................28
7Rectifying faults ...................................................................................................................................29
7.1 Checklist for rectifying faults........................................................................................................29

Contents
Notes on the use of these operating instructions
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8Technical data.......................................................................................................................................31
8.1 Tetrix drive 4L ..............................................................................................................................31
9Accessories ..........................................................................................................................................32
9.1 General accessories ....................................................................................................................32
9.2 Options.........................................................................................................................................32
9.3 Remote control / connection cable...............................................................................................32
10 Replaceable parts.................................................................................................................................33
10.1 Wire feed rollers...........................................................................................................................33
10.1.1 Wire feed rollers for steel wire......................................................................................33
10.1.2 Wire feed rollers for aluminium wire .............................................................................33
10.1.3 Wire feed rollers for cored wire.....................................................................................33
10.1.4 Conversion kit...............................................................................................................33
11 Appendix A............................................................................................................................................35
11.1 Overview of EWM branches.........................................................................................................35

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
Operating instructions
A.1
Wire feeder
A.2
Options xxx conversion instructions
A.3
Power source
A.4
Welding torch
A.5
Control
A.6
Remote control
A
Complete documentation

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
Wire feeder to feed welding consumables for MMA welding.
3.1.1 Use and operation solely with the following machines
A suitable power source (system component) is required in order to operate the wire feed unit!
A cold/hot wire Tetrix power source (AW) is required for operation.
For hot wire welding, an additional hot wire power source is required for pre-warming the wire.
•Tetrix 351, 451, 551 AW FWD
•Tetrix 351, 451, 551 AC/DC AW FWD
•Tetrix 270 Hotwire
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 EWM, this declaration shall be voided. An original document of the
specific declaration of conformity is included with every product.
3.2.3 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.
3.2.4 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
Front view
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4 Machine description – quick overview
4.1 Front view
Figure 4-1
Item
Symbol
Description 0
1
Carrying handle
2
Slide latch, lock for the protective cap
3
Wire electrode connection
Welding torch wire feed
4
Quick connect coupling (red)
coolant return
5
Quick connect coupling (blue)
coolant supply
6
Connection socket, welding torch control cable > see 5.2.5.1 chapter
7
Connection socket (TIG)
Welding current, minus potential
8
Machine control > see 4.4 chapter
9
Connection socket (TIG hot wire)
Hot wire power, minus potential
10
Quick connect coupling
Shielding gas

Machine description –quick overview
Rear view
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4.2 Rear view
Figure 4-2
Item
Symbol
Description 0
1
Connection socket, 19-pole
Remote control connection
2
Connector plug (TIG hot wire)
Welding current, minus potential
3
Connecting thread (G¼")
Shielding gas
4
X2
Connection socket (28-pole)
Control lead
5
Connector plug (TIG)
Welding current, minus potential
6
Machine feet
7
Intermediate hose package strain relief
8
Quick connect coupling (red)
coolant return
9
Quick connect coupling (blue)
coolant supply

Machine description –quick overview
Inside view
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4.3 Inside view
Figure 4-3
Item
Symbol
Description 0
1
Cover of the wire spool
2
Wire spool holder
3
Protective cap
Cover for the wire feed mechanism and other operating elements.
Depending on the machine series, additional stickers with information on the
replacement parts will be located on the inside.
4
Wire feed unit
5
Operating mode changeover switch
•Position KORREKTUR
•Position MANUELL
The setting determines the wire speed operating mode at the wire speed rotary dial.
6
Changeover switch, remote control on/off
ON Set the welding performance via the remote control
OFF Set the welding performance via the machine control

Machine description –quick overview
Machine control –Operating elements
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4.4 Machine control –Operating elements
Figure 4-4
Item
Symbol
Description 0
1
Gas test button
Shielding gas setting/tube package Rinse.
(See the operating instructions for the power source, chapter “Gas test”)
2
Wire inching button
To inch the wire electrode when changing wire spools
3
Wire return button
The welding wire is retracted to the wire spool.
4
Wire speed rotary dial
Parameters can be set in two operating modes:
•Operating mode KORREKTUR (inner scale):
The wire speed is specified primarily by the welding machine control and can be
corrected on the wire feed unit by +/- 40%.
•Operating mode MANUELL (outer scale):
The wire speed is set on the wire feed unit as an absolute value in the range from
0.2 to 10 m/min.
The operating mode is set with the operating mode changeover switch (above the wire
feed unit, under the cover).

Design and function
Ambient conditions
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5 Design and function
WARNING
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
•Follow safety instructions on the opening pages of the operating instructions.
•Commissioning may only be carried out by persons who have the relevant expertise of
working with arc welding machines!
•Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
5.1 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)!
5.1.1 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 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
5.2 Transport and installation
WARNING
Risk of accident due to improper transport of machines that must not be lifted!
Do not lift or suspend the machine! The machine can drop and cause injuries! The
handles, straps or brackets are suitable for transport by hand only!
•The machine must not be suspended or lifted using a crane.

Design and function
Transport and installation
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5.2.1 Connection plan
5.2.1.1 TIG hot wire welding
Tetrix AW
3~
AC
Tetrix Hotwire
Tetrix drive 4L TIG 450W HW 12POL
AC
HW
X2
X2
hotwire
hotwire
HW
HW HW
3~
AC
TP
TP
RT AW 1
Figure 5-1

Design and function
Transport and installation
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5.2.1.2 TIG cold wire welding
Tetrix AW
3~
AC
Tetrix drive 4L TIG 450 WD CW
AC
HW
X2
X2
hotwire
HW
TP
TP
RT AW 1
Figure 5-2
5.2.1.3 Legend
Shielding gas
Welding current(minus potential)
Coolant input (marked in colour)

Design and function
Transport and installation
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Coolant output (marked in colour)
X2
Control lead (28-pole)
TP
Hose package (TP = tube package)
HW
Welding current (minus potential, TIG hot wire)
Welding current (plus potential, workpiece)
hotwire
Control lead, hot wire (signal input, 4-pole)
3~
AC
Connection, supply voltage (3-phase)
Supply voltage, hot wire power source
hotwire
Control lead, hot wire (signal output, 4-pole)
Control lead, welding torch (12-pole)
Remote control connection
5.2.2 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 5.2.2.1 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).
5.2.2.1 Approved coolants overview
Coolant
Temperature range
KF 23E (Standard)
-10 °C to +40 °C
KF 37E
-20 °C to +10 °C

Design and function
Transport and installation
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5.2.2.2 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)
5.2.3 Notes on the installation of welding current leads
Incorrectly installed welding current leads can cause faults in the arc (flickering).
Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as
long and as close as possible in parallel.
Lay the workpiece lead and hose package of power sources with HF igniter (TIG) for as long as
possible in parallel with a distance of 20 cm to avoid HF sparkover.
Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences
Always keep leads as short as possible! For optimum welding results max. 30 m (welding lead +
intermediate hose package + torch lead).
Figure 5-3
Use an individual welding lead to the workpiece for each welding machine!
Figure 5-4
Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid
loops!

Design and function
Transport and installation
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Always keep leads as short as possible!
Lay any excess cable lengths in meanders.
Figure 5-5
5.2.3.1 Stray welding currents
WARNING
Risk of injury due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage machines and
electronic devices and cause overheating of components, leading to fire.
•Check that all welding current connections are firmly secured and electrical connections are
in perfect condition.
•Set up, attach or suspend all conductive power source components such as casing,
transport vehicles and crane frames so they are insulated.
•Do not place any other electronic devices such as drills or angle grinders on the power
source, transport vehicle or crane frames unless they are insulated.
•Always put welding torches and electrode holders on an insulated surface when they are
not in use.
Figure 5-6

Design and function
Transport and installation
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5.2.4 Intermediate hose package connection
Figure 5-7
Item
Symbol
Description 0
1
Power source
2
Intermediate hose package
3
Quick connect coupling (blue)
coolant supply
4
Connector plug (TIG hot wire)
Welding current, minus potential
5
Connecting thread (G¼")
Shielding gas
6
X2
Connection socket (28-pole)
Control lead
7
Connector plug (TIG)
Welding current, minus potential
8
Quick connect coupling (red)
coolant return
9
Intermediate hose package strain relief
•Insert the end of the hose package through the strain relief of the hose package and lock by turning to
the right.
•Push the cable socket for the welding current (TIG) onto the connector plug (TIG) and lock by turnng
to the right.
•Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings:
Return line red to quick connect coupling, red (coolant return) and
supply line blue to quick connect coupling, blue (coolant supply).
•Insert cable plug on the control lead into the connection socket (28-pole) and secure with crown nut
(the plug can only be inserted into the connection socket in one position).
•Screw the crown nut on the shielding gas lead gastight to the connecting thread (G¼").
Where applicable:
•Push the cable socket for the welding current (TIG hot wire) onto the connector plug (TIG hot wire)
and lock by turnng to the right.

Design and function
Transport and installation
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5.2.4.1 Connecting the shielding gas supply
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!
•Place shielding gas cylinder into the designated holder and secure with
fastening elements (chain/belt)!
•Attach the fastening elements within the upper half of the shielding gas
cylinder!
•The fastening elements must tightly enclose the shielding gas cylinder!
An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a
fundamental requirement for optimum welding results. In addition, a blocked shielding gas
supply may result in the welding torch being destroyed.
•Always re-fit the yellow protective cap when not using the shielding gas connection.
•All shielding gas connections must be gas tight.
5.2.5 Welding torch connection
Equipment damage due to improperly connected coolant pipes!
If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant
circuit is interrupted and equipment damage can occur.
•Connect all coolant pipes correctly!
•Completely unroll the hose package and the torch hose package!
•Observe maximal hose package length > see 5.2.2.2 chapter.
•When using a gas-cooled welding torch, use a hose bridge to establish the coolant
circuit > see 9 chapter.
Prepare welding torch according to the welding task in hand (see operating instructions for the torch).
Figure 5-8
Item
Symbol
Description 0
1
Welding torch
Observe additional system documents!