EWM T 4.02 - AC/DC Comfort 2.0 User manual

Operating instructions
EN
Control
T 4.02 - AC/DC Comfort 2.0 (Tetrix 230)
099-00T402-EW501
Observe additional system documents!
24.04.2018

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: [email protected]
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
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
3Machine control –Operating elements................................................................................................8
3.1 Overview of control sections..........................................................................................................8
3.1.1 Control section A............................................................................................................9
3.1.2 Control section B..........................................................................................................11
3.1.3 Control section C..........................................................................................................12
3.2 Machine display...........................................................................................................................12
3.2.1 Setting the welding current (absolute/percentage).......................................................12
3.3 Operating the machine control.....................................................................................................12
3.3.1 Main screen..................................................................................................................12
3.3.2 Welding power setting..................................................................................................13
3.3.3 Welding parameter setting in the operation sequence.................................................13
3.3.4 Setting advanced welding parameters (Expert menu).................................................13
3.3.5 Changing basic settings (machine configuration menu) ..............................................13
4Functional characteristics...................................................................................................................14
4.1 TIG welding..................................................................................................................................14
4.1.1 Gas test –setting the shielding gas volume.................................................................14
4.1.2 Welding task selection..................................................................................................15
4.1.2.1 Recurring welding tasks (JOB 1–7) ..............................................................16
4.1.3 AC welding ...................................................................................................................16
4.1.3.1 AC balance (optimise cleaning effect and penetration characteristics)........16
4.1.3.2 Tungsten balling function..............................................................................17
4.1.3.3 Alternating current waveforms......................................................................18
4.1.3.4 Automatic AC frequency...............................................................................18
4.1.4 Arc ignition....................................................................................................................19
4.1.4.1 HF ignition.....................................................................................................19
4.1.4.2 Liftarc ............................................................................................................20
4.1.4.3 Automatic cut-out..........................................................................................20
4.1.5 Operating modes (functional sequences) ....................................................................21
4.1.5.1 Explanation of symbols.................................................................................21
4.1.5.2 Non-latched mode.........................................................................................22
4.1.5.3 Latched mode ...............................................................................................23
4.1.5.4 spotArc..........................................................................................................24
4.1.5.5 spotmatic.......................................................................................................26
4.1.6 TIG activArc welding.....................................................................................................27
4.1.7 TIG antistick..................................................................................................................27
4.1.8 Pulse welding ...............................................................................................................28
4.1.8.1 Automated pulses .........................................................................................28
4.1.8.2 Thermal pulsing.............................................................................................28
4.1.8.3 Pulsed welding in the upslope and downslope phases ................................29
4.1.9 Average value pulse welding........................................................................................30
4.1.9.1 Metallurgical pulsing (kHz pulsing) ...............................................................30
4.1.9.2 AC special.....................................................................................................32
4.1.10 Welding torch (operating variants) ...............................................................................33
4.1.10.1 Tapping function (tap torch trigger)...............................................................33
4.1.10.2 Torch mode setting.......................................................................................33
4.1.10.3 Up/down speed.............................................................................................33
4.1.10.4 Current jump .................................................................................................33
4.1.10.5 Standard TIG torch (5-pole)..........................................................................34
4.1.10.6 TIG up/down torch (8-pole)...........................................................................36
4.1.10.7 Potentiometer torch (8-pole).........................................................................38
4.1.10.8 Configuring the TIG potentiometer torch connection....................................39
4.1.10.9 RETOX TIG torch (12-pole)..........................................................................40
4.1.11 Expert menu (TIG)........................................................................................................41

Contents
Notes on the use of these operating instructions
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4.2 MMA welding................................................................................................................................42
4.2.1 Welding task selection..................................................................................................42
4.2.2 Hotstart .........................................................................................................................42
4.2.2.1 Hotstart current..............................................................................................42
4.2.2.2 Hotstart time..................................................................................................43
4.2.3 Antistick.........................................................................................................................43
4.2.4 Welding current polarity reversal (polarity reversal).....................................................43
4.2.5 Average value pulse welding........................................................................................44
4.3 Power-saving mode (Standby).....................................................................................................44
4.4 Access control..............................................................................................................................45
4.5 Voltage reducing device...............................................................................................................45
4.6 Machine configuration menu........................................................................................................46
4.6.1 Selecting, changing and saving parameters.................................................................46
5Rectifying faults....................................................................................................................................49
5.1 Error messages (power source)...................................................................................................49
5.2 Dynamic power adjustment..........................................................................................................49
5.3 Resetting welding parameters to the factory settings..................................................................50
5.4 Display machine control software version....................................................................................50
6Appendix A............................................................................................................................................51
6.1 Parameter overview –setting ranges ..........................................................................................51
6.1.1 TIG welding...................................................................................................................51
6.1.2 MMA welding................................................................................................................52
7Appendix B............................................................................................................................................53
7.1 Searching for a dealer..................................................................................................................53

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.
Technical aspects which the user must observe to avoid material or equipment damage.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
•Insert the welding current lead socket into the relevant socket and lock.

For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release / Tap / Tip
Switch off machine
Release
Switch on machine
Press and hold
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

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
Options conversion instructions
A.2
Power source
A.3
Cooling unit, voltage converter, tool box etc.
A.4
Transport cart
A.5
Welding torch
A.6
Remote control
A.7
Control
A
Complete documentation

Machine control –Operating elements
Overview of control sections
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3 Machine control – Operating elements
3.1 Overview of control sections
For description purposes, the machine control has been divided into three sections (A, B, C) to
ensure maximum clarity. The setting range for the parameter values are summarised in the
parameter overview section > see 6.1 chapter.
Figure 3-1
Item
Symbol
Description 0
1
Control section A
> see 3.1.1 chapter
2
Control section B
> see 3.1.2 chapter
3
Control section C
> see 3.1.3 chapter

Machine control –Operating elements
Overview of control sections
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3.1.1 Control section A
Figure 3-2
Item
Symbol
Description 0
1
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 3.2 chapter
2
Gas test push-button > see 4.1.1 chapter
3
Operating mode > see 4.1.5 chapter / power-saving mode push-
button > see 4.3 chapter
---------Latched
-------Non-latched
------spotArc spot welding procedure –signal light turns green
------spotmatic spot welding procedure –signal light turns red
--------Press button for long interval to put machine into power-saving mode.
Activate one of the operating elements to reactivate.
4
Pulsing push-button > see 4.1.8 chapter
------Automated pulsing (frequency and balance)
--------Signal light turns green: Thermal pulsed TIG welding/MMA pulse
welding/average value pulsing
--------Signal light turns red: Metallurgical pulsed TIG welding (kHz pulsing)
---Special TIG AC
5
Welding current polarity/tungsten balling push-button
----Signal light turns green: DC welding with negative polarity on the electrode
holder or welding torch.
----Signal light turns red: MMA DC welding with positive polarity on the electrode
holder > see 4.2.4 chapter.
----Alternating current welding/alternating current forms > see 4.1.3.3 chapter
-Tungsten balling current > see 4.1.3.2 chapter
6
Welding procedure push-button
---------TIG welding
---------MMA welding

Machine control –Operating elements
Overview of control sections
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Item
Symbol
Description 0
7
Display switching push-button
kW------- Welding power display
V --------- Welding voltage display
JOB ----- Display and setting of the JOB number with the control button
8
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 3.2 chapter
9
TIG ignition type signal light
Signal light on: Lift arc ignition active/HF start off. You can switch the ignition type in the
Expert menu (TIG) > see 4.1.11 chapter.
10
Character function signal light
Indicates that it is possible to weld in an environment with major electric hazards, such
as in boilers. Service must be informed if this signal light is not on.
11
Coolant fault signal light
Signals pressure loss or low coolant level in the coolant circuit.
12
VRD
Voltage reduction device (VRD) signal light > see 4.5 chapter
13
Hold
Signal light Status display
After each completed welding task, the last values used in the welding process for the
welding current and welding voltage are shown on the displays, and the signal light will
be on
14
Excess temperature signal light
In case of excess temperature, temperature monitors de-activate the power unit, and
the excess temperature control lamp comes on. Once the machine has cooled down,
welding can continue without any further measures.
15
Access control active signal light
Signal light is on when access control is active on the machine
control > see 4.4 chapter.
16
Automatic AC frequency > see 4.1.3.4 chapter

Machine control –Operating elements
Overview of control sections
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3.1.2 Control section B
Figure 3-3
Item
Symbol
Description 0
1
Parameter selection push-button, left
The welding sequence parameters are selected one after another in an anti-clockwise
direction.
2
Control button
Central control button to be pressed or turned > see 3.3 chapter.
3
Parameter selection push-button, right
The welding sequence parameters are selected one after another in a clockwise
direction.
4
Balance signal light
AC balance (JOBs 1–7), pulse balance
5
Electrode diameter signal light
Ignition optimisation (TIG)/tungsten balling basic setting (JOB 1-100)
6
Gas post-flow time
7
AMP%
End current signal light
8
sec
Down-slope time signal light
9
AMP%
sec
Signal light, two colour
Red: Secondary or pulse pause current (% of AMP)
Green: Pulse pause time
10
AMP
sec
Signal light, two colour
Red: Main current /pulse current
Green: Pulse time
11
sec
Signal light
Up-slope time (TIG)/hot start time (MMA)
12
AMP%
Signal light
Ignition current (TIG)/hot start current (MMA)
13
Gas pre-flow time signal light
14
Signal light activArc > see 4.1.6 chapter
15
signal light
AC frequency (TIG, JOBs 1–7)/pulse frequency (TIG, average value pulsing)/pulse
frequency (MMA)

Machine control –Operating elements
Machine display
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3.1.3 Control section C
Figure 3-4
Item
Symbol
Description 0
1
AC frequency rotary knob (JOB 0)
2
Balance
AC balance rotary knob (JOB 0)
3
Tungsten electrode diameter rotary knob (JOB 0)
3.2 Machine display
The following welding parameters can be displayed before (nominal values), during (actual values) or
after welding (hold values):
"left display"
Parameter
Before welding
(nominal values)
During welding
(actual values)
After welding
(hold values)
Welding current



Parameter times



Parameter currents



Frequency, balance



JOB number



"right display"
Welding power



Welding voltage



When the hold values are displayed after welding and the settings are then changed (e.g. welding
current), the display will switch to the relevant nominal values.
possible
not possible
The parameters that can be set in the function sequence of the machine control depend on the selected
welding task. This means that if for example you have not selected a pulse variant, then you cannot set
any pulse times in the function sequence.
3.2.1 Setting the welding current (absolute/percentage)
The welding current for the ignition, secondary, end and hot start current can be set as a percentage of
the main current AMP or as an absolute value. To select, use the parameter <dg in the configuration
menu_ref_source_inline>Gerätekonfigurationsmenü</dg_ref_source_inline>.
> see 4.6 chapter
3.3 Operating the machine control
3.3.1 Main screen
The machine control switches to the main screen after it has been turned on or a setting has been
completed. This means that the previously selected settings (indicated by signal lights where applicable)
and the nominal value for the current (A) are displayed in the left-hand welding data display. Depending
on the selection, the right-hand display shows the welding voltage (V) nominal value or the welding power
(kW) actual value. The control always switches back to the main screen after 4 sec..

Machine control –Operating elements
Operating the machine control
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3.3.2 Welding power setting
The welding power is set using the control button. You can also adjust the parameters in the operation
sequence or settings in the different machine menus.
3.3.3 Welding parameter setting in the operation sequence
A welding parameter can be set in two ways in the operation sequence.
1. Push the "left" or "right" arrow keys (flashing signal light will indicate your selection). Turn the control
button to set the parameter value.
2. Press briefly on the control button (operation sequence selection) and then turn the button (navigate to
the required parameter). Press again to apply the selected parameter as the setting (corresponding
parameter value and signal light flash). Turn the button to set the parameter value.
During welding parameter setting, the parameter value to be set flashes in the left hand display. A
parameter abbreviation or a deviation in the specified parameter value upwards or downwards is shown
on the right-hand display:
Display
Meaning
Increase the parameter value
To return to the factory settings.
Factory setting (example value = 20)
Parameter is set to optimum value
Decrease the parameter value
To return to the factory settings.
3.3.4 Setting advanced welding parameters (Expert menu)
The Expert menu contains functions and parameters which cannot be set directly in the machine control
or which do not need to be et on a regular basis. The number and display of these parameters depends
on the previously selected welding procedure or the functions.
To select them hold the control button for more than 2 sec. Select the required parameter/menu item by
turning (navigate) and pressing (confirm) the control button.
You can also or alternatively use the push-buttons to the left and right of the control button to navigate.
3.3.5 Changing basic settings (machine configuration menu)
The basic welding system functions can be adjusted in the machine configuration menu. Only
experienced users should change the settings > see 4.6 chapter.

Functional characteristics
TIG welding
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4 Functional characteristics
4.1 TIG welding
4.1.1 Gas test –setting the shielding gas volume
•Slowly open the gas cylinder valve.
•Open the pressure regulator.
•Switch on the power source at the main switch.
•Set the relevant gas quantity for the application on the pressure regulator.
•The gas test can be activated at the machine control by pressing the "Gas test" push-
button > see 3.1.1 chapter.
Setting the shielding gas quantity (gas test)
•Shielding gas flows for approx. 20 seconds or until the push-button is pressed again.
If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause
pores to form. Adjust the shielding gas quantity to suit the welding task!
Setting instructions
Welding process
Recommended shielding gas quantity
MAG welding
Wire diameter x 11.5 = l/min
MIG brazing
Wire diameter x 11.5 = l/min
MIG welding (aluminium)
Wire diameter x 13.5 = l/min (100 % argon)
TIG
Gas nozzle diameter in mm corresponds to l/min gas throughput
Helium-rich gas mixtures require a higher gas volume!
The table below can be used to correct the gas volume calculated where necessary:
Shielding gas
Factor
75% Ar/25% He
1.14
50% Ar/50% He
1.35
25% Ar/75% He
1.75
100% He
3.16
For connecting the shielding gas supply and handling the shielding gas cylinder refer to the
power source operating instructions.

Functional characteristics
TIG welding
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4.1.2 Welding task selection
The setting of the tungsten electrode diameter has a direct influence on the machine functionality, TIG
ignition behaviour and minimum current limits. The ignition energy is controlled by the set electrode
diameter. Smaller electrode diameters requires less ignition current and less ignition current time than
greater electrode diameters. The set value should correspond to the tungsten electrode diameter. The
value can also be set to meet individual requirements, e.g. for thin panels a smaller diameter is
recommended to reduce the ignition energy.
The following welding task is an example of use:
EXIT
4s
mm
inch
Figure 4-1

Functional characteristics
TIG welding
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4.1.2.1 Recurring welding tasks (JOB 1–7)
The user has 7 more memory locations at their disposal to save recurring or different welding tasks on a
permanent basis. To do so, simply select the required memory location (JOB 1–7) and the welding task is
set as described previously.
The three rotary knobs for AC frequency, AC balance and the tungsten electrode diameter are
exceptions. These settings are made in the operation sequence (signal lights with same name).
Switching a JOB is only possible if no welding current flows. Up-slope and down-slope times can be set
individually for latched and non-latched operation.
Selection
Figure 4-2
When one or more of the recurring welding tasks (JOB 1–7) has been selected the JOB signal light
comes on.
4.1.3 AC welding
4.1.3.1 AC balance (optimise cleaning effect and penetration characteristics)
To weld aluminium and aluminium alloys, AC welding is used in combination with a continuous change in
polarity of the tungsten electrode. The process encompasses two phases (half-waves): a positive and a
negative one. The positive phase cracks the aluminium oxide layer on the material surface (so called
cleaning effect).
At the same time, tungsten balling occurs at the tip of the tungsten electrode. The size of this balled end
depends on the length of the positive phase. Please note that an excessively big balled end will cause the
arc to become unstable and diffuse, with low penetration. In the negative phase, the tungsten electrode is
cooled and the required penetration is realised. Make sure to select the correct durations (balance) for
positive phase (cleaning effect, balled end size) and negative phase (penetration depth) by setting the AC
balance. The default (zero setting) balance setting is 65%, referring to the duration of the negative half-
wave.
Figure 4-3

Functional characteristics
TIG welding
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4.1.3.2 Tungsten balling function
The tungsten balling function provides optimum tungsten balling, ensuring that the best ignition and
welding results are achieved during AC welding.
Optimum tungsten balling requires a sharpened electrode (about 15–25°) and the set electrode diameter
on the machine control. The set electrode diameter affects the current for tungsten balling and,
consequently, also the ball size.
Press the tungsten balling push-button to activate the function. If required, this current can be adjusted on
an individual basis using the parameter (+/- 30 A). The user presses the torch trigger and the function
is started by non-contact ignition (HF start). The balled end is formed and the function then ends.
Tungsten balling should be performed on a test component as surplus tungsten may be melted and this
may lead to impurities on the weld seam.
Balling
mm
inch
Figure 4-4

Functional characteristics
TIG welding
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4.1.3.3 Alternating current waveforms
Selection
EXIT
4s
Figure 4-5
Display
Setting/selection
Alternating current waveforms 1
------- Rectangular - Highest energy input (ex works)
------- Trapezoidal - An all-rounder, suitable for most applications
------- Sine - Low noise level
4.1.3.4 Automatic AC frequency
Automatic AC frequency can be selected for JOB 1-100 only. The left stop in the frequency functional
sequence is used for activation, displayed as .
The signal light comes on when the function is activated.
The machine control adjusts or sets the AC frequency in relation to the set main current. The lower the
welding current, the higher the frequency and vice versa. This ensures a concentrated, directionally
stable arc is achieved when welding currents are low. The load from the tungsten electrode is minimised
when the welding currents are high, ensuring a longer service life.
The use of a foot-operated remote control with this function reduces manual intervention by the user
during the welding process to a minimum.
Figure 4-6

Functional characteristics
TIG welding
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Selection
<
Figure 4-7
4.1.4 Arc ignition
To change the ignition type, use parameter to switch between HF start ( ) and lift arc ( ) in the
Expert menu > see 4.1.11 chapter.
4.1.4.1 HF ignition
Figure 4-8
The arc is started without contact from high-voltage ignition pulses.
a) Position the welding torch in welding position over the workpiece (distance between the electrode tip
and workpiece should be approx. 2-3mm).
b) Press the torch trigger (high voltage ignition pulses ignite the arc).
c) Ignition current flows, and the welding process is continued depending on the operating mode
selected.
End the welding process: Release or press the torch trigger depending on the operating mode
selected.

Functional characteristics
TIG welding
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4.1.4.2 Liftarc
Figure 4-9
The arc is ignited on contact with the workpiece:
a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch
trigger (liftarc current flowing, regardless of the main current set).
b) Incline the torch over the torch gas nozzle to produce a gap of approx. 2-3 mm between the electrode
tip and the workpiece. The arc ignites and the welding current is increased, depending on the
operating mode set, to the ignition or main current set.
c) Lift off the torch and swivel to the normal position.
Ending the welding process: Release or press the torch trigger depending on the operating mode
selected.
4.1.4.3 Automatic cut-out
Once the fault periods have elapsed, the automatic cut-out stops the welding process when it has been
triggered by one of two states:
•During ignition
3 s after the start of the welding process, no welding current flows (ignition error).
•During welding
The arc is interrupted for more than 3 s (arc interruption).