EWM T 4.06 - AC/DC Smart 2.0 User manual

Operating instructions
EN
Control
T 4.06 - AC/DC Smart 2.0 (Tetrix 230)
099-00T406-EW501
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13.07.2017
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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 sa-
fety instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the location where the machine is operated.
•Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and re-
pair the machine.
•Technical changes due to further development in machine technology may lead to a dif-
fering welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com.
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
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..........................................................................................................10
3.2 Machine display...........................................................................................................................11
3.2.1 Setting the welding current (absolute/percentage).......................................................11
3.3 Operating the machine control.....................................................................................................11
3.3.1 Main screen..................................................................................................................11
3.3.2 Welding power setting..................................................................................................12
3.3.3 Welding parameter setting in the operation sequence.................................................12
3.3.4 Setting advanced welding parameters (Expert menu).................................................12
3.3.5 Changing basic settings (machine configuration menu) ..............................................12
4Functional characteristics...................................................................................................................13
4.1 TIG welding..................................................................................................................................13
4.1.1 Gas test –setting the shielding gas volume.................................................................13
4.1.2 Welding task selection..................................................................................................14
4.1.3 AC welding ...................................................................................................................15
4.1.3.1 AC balance (optimise cleaning effect and penetration characteristics)........15
4.1.3.2 Alternating current waveforms......................................................................16
4.1.4 Arc ignition....................................................................................................................17
4.1.4.1 HF ignition.....................................................................................................17
4.1.4.2 Liftarc ............................................................................................................17
4.1.4.3 Automatic cut-out..........................................................................................17
4.1.5 Operating modes (functional sequences) ....................................................................18
4.1.5.1 Explanation of symbols.................................................................................18
4.1.5.2 Non-latched mode.........................................................................................19
4.1.5.3 Latched mode ...............................................................................................20
4.1.5.4 spotArc..........................................................................................................21
4.1.5.5 spotmatic.......................................................................................................23
4.1.6 Average value pulse welding........................................................................................25
4.1.6.1 Pulsed welding in the upslope and downslope phases ................................26
4.1.6.2 Automated pulses .........................................................................................26
4.1.7 TIG activArc welding.....................................................................................................27
4.1.8 TIG antistick..................................................................................................................27
4.1.9 Welding torch (operating variants) ...............................................................................27
4.1.9.1 Tapping function (tap torch trigger)...............................................................27
4.1.9.2 Torch mode setting.......................................................................................28
4.1.9.3 Up/down speed.............................................................................................28
4.1.9.4 Current jump .................................................................................................28
4.1.9.5 Standard TIG torch (5-pole)..........................................................................28
4.1.9.6 TIG up/down torch (8-pole)...........................................................................31
4.1.9.7 Potentiometer torch (8-pole).........................................................................32
4.1.9.8 Configuring the TIG potentiometer torch connection....................................34
4.1.10 Expert menu (TIG)........................................................................................................35
4.2 MMA welding ...............................................................................................................................36
4.2.1 Welding task selection..................................................................................................36
4.2.1.1 Hotstart..........................................................................................................36
4.2.1.2 Antistick.........................................................................................................37
4.2.2 Average value pulse welding........................................................................................37
4.2.3 Expert menu (MMA) .....................................................................................................39
4.3 Power-saving mode (Standby) ....................................................................................................39
4.4 Access control..............................................................................................................................40

Contents
Notes on the use of these operating instructions
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4.5 Voltage reducing device...............................................................................................................40
4.6 Machine configuration menu........................................................................................................41
4.6.1 Selecting, changing and saving parameters.................................................................41
5Rectifying faults....................................................................................................................................44
5.1 Error messages (power source)...................................................................................................44
5.2 Dynamic power adjustment..........................................................................................................45
5.3 Resetting welding parameters to the factory settings..................................................................45
5.4 Display machine control software version....................................................................................45
6Appendix A............................................................................................................................................46
6.1 Parameter overview –setting ranges ..........................................................................................46
6.1.1 TIG welding...................................................................................................................46
6.1.2 MMA welding................................................................................................................47
7Appendix B............................................................................................................................................48
7.1 Overview of EWM branches.........................................................................................................48

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 sym-
bol.
•The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
•The safety information includes the "CAUTION" keyword in its heading with a general warn-
ing 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 combina-
tion 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 two sections (A, B) to en-
sure maximum clarity. The setting ranges for the parameter values are summarised in the para-
meter 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

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
Pulsed welding push-button
TIG-------pulsed welding > see 4.1.6 chapter
MMA-----pulsed welding > see 4.2.2 chapter
5
Welding current polarity push-button
--------DC welding with negative polarity at the torch (or electrode holder) with
respect to the workpiece.
---Alternating current welding/alternating current forms > see 4.1.3.2 chapter
6
Welding procedure push-button
---------TIG welding
---------MMA welding
7
Display switching push-button
kW -------Welding power display
V----------Welding voltage display
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 4.1.10 chapter.

Machine control –Operating elements
Overview of control sections
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Item
Symbol
Description 0
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
The VRD signal light is illuminated when the voltage reduction device is operating wit-
hout fault and the output voltage is reduced to a value specified in the relevant stan-
dard (see technical data) > see 4.5 chapter. The voltage reduction device is only active
on VRD machine versions.
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 con-
trol > see 4.4 chapter.
16
Without function in this machine version.
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 direc-
tion.
4
Signal light
•---------- AC balance > see 4.1.3 chapter
•---------- Pulse balance > see 4.1.6 chapter

Machine control –Operating elements
Machine display
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Item
Symbol
Description 0
5
Electrode diameter signal light
Ignition optimisation (TIG)/tungsten balling basic setting
6
Gas post-flow time
7
sec
Down-slope time signal light
8
AMP%
Secondary current (TIG)
9
AMP
Signal light
•-----------Main current
•-----------Pulse current
10
sec
Signal light
Up-slope time (TIG)
11
Signal light activArc > see 4.1.7 chapter
12
Signal light
•-----------AC frequency > see 4.1.3 chapter
•-----------Pulse frequency > see 4.1.6 chapter
3.2 Machine display
The following welding parameters can be displayed before (nominal values), during (actual values) or af-
ter 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



"right display"
Welding power



Welding voltage



When the hold values are displayed after welding and the settings are then changed (e.g. welding cur-
rent), 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 com-
pleted. 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. of inactivity.

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 para-
meter 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 experi-
enced 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 ig-
nition behaviour and minimum current limits. The ignition energy is controlled by the set electrode diame-
ter. 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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4.1.3 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 4-2

Functional characteristics
TIG welding
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4.1.3.2 Alternating current waveforms
Selection
EXIT
4s
Figure 4-3
Display
Setting/selection
Alternating current waveforms 1
Rectangular (ex works)
Trapezoidal
Sine
AC welding with rectangular current waveform (ex works)
Highest energy input
Alternating current welding with trapezoidal current waveform
An all-rounder, suitable for most applications
Alternating current welding with sinusoidal current waveform
Low noise level
1for AC welding machines only.

Functional characteristics
TIG welding
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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 4.1.10 chapter.
4.1.4.1 HF ignition
Figure 4-4
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 select-
ed.
End the welding process: Release or press the torch trigger depending on the operating mode
selected.
4.1.4.2 Liftarc
Figure 4-5
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 operat-
ing 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).

Functional characteristics
TIG welding
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4.1.5 Operating modes (functional sequences)
4.1.5.1 Explanation of symbols
Symbol
Meaning
Press torch trigger 1
Release torch trigger 1
I
Current
t
Time
Gas pre-flow
Ignition current
Up-slope time
Spot time
AMP
Main current (minimum to maximum current)
AMP%
Secondary current
Pulse current
Down-slope time
End-crater current
Gas post-flow
Balance
Frequency

Functional characteristics
TIG welding
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4.1.5.2 Non-latched mode
Selection
Figure 4-6
Figure 4-7
1st cycle:
•Press torch trigger 1 and hold down.
•Gas pre-flow time elapses.
•HF ignition pulses jump from the electrode to the workpiece. The arc ignites.
•The welding current flows and immediately assumes the value of the ignition current .
•HF switches off.
•The welding current ramps up to the main current (AMP) in the selected up-slope time .
If torch trigger 2 is pressed together with torch trigger 1 during the main current phase, the welding cur-
rent decreases to the secondary current (AMP%).
If torch trigger 2 is released, the welding current increases again to the main current AMP.
2nd cycle:
•Release torch trigger 1.
•The main current falls to the end-crater current (minimum current) in the set down-slope time .
If the 1st torch trigger is pressed during the down-slope time,
the welding current returns to the set main current AMP.
•Main current reaches the end-crater current ; the arc is extinguished.
•Set gas post-flow time elapses.
When the foot-operated remote control RTF is connected, the machine switches automatically to
non-latched operation.
The up- and down-slopes are switched off.

Functional characteristics
TIG welding
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4.1.5.3 Latched mode
Selection
Figure 4-8
Figure 4-9