EWM Tetrix 150 Synergic Plasma User manual

Operating instructions
EN
Welding machine
Tetrix 150 Synergic Plasma
099-007021-EW501
29.07.2015
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General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read the operating instructions for all system components!
•Observe accident prevention regulations!
•Observe all local regulations!
•Confirm with a signature where appropriate.
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-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, 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
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1 Contents
1Contents..................................................................................................................................................3
2Safety instructions.................................................................................................................................6
2.1 Notes on the use of these operating instructions ..........................................................................6
2.2 Explanation of icons.......................................................................................................................7
2.3 General..........................................................................................................................................8
2.4 Transport and installation ............................................................................................................12
2.4.1 Ambient conditions.......................................................................................................13
2.4.1.1 In operation...................................................................................................13
2.4.1.2 Transport and storage...................................................................................13
3Intended use.........................................................................................................................................14
3.1 Applications..................................................................................................................................14
3.1.1 Plasma welding ............................................................................................................14
3.1.2 TIG welding ..................................................................................................................14
3.1.2.1 TIG activArc welding.....................................................................................14
3.1.2.2 spotArc..........................................................................................................14
3.1.2.3 Spotmatic......................................................................................................14
3.1.3 MMA welding................................................................................................................14
3.2 Documents which also apply.......................................................................................................15
3.2.1 Warranty.......................................................................................................................15
3.2.2 Declaration of Conformity.............................................................................................15
3.2.3 Welding in environments with increased electrical hazards.........................................15
3.2.4 Service documents (spare parts and circuit diagrams)................................................15
3.2.5 Calibration/Validation ...................................................................................................15
4Machine description ............................................................................................................................16
4.1 Front view ....................................................................................................................................16
4.2 Rear view.....................................................................................................................................18
4.3 Machine control –Operating elements........................................................................................20
4.3.1 Function sequence.......................................................................................................22
5Design and function.............................................................................................................................24
5.1 General........................................................................................................................................24
5.2 Machine cooling...........................................................................................................................25
5.3 Workpiece lead, general..............................................................................................................25
5.4 Transport and installation ............................................................................................................25
5.5 Notes on the installation of welding current leads.......................................................................26
5.6 Welding torch cooling system......................................................................................................28
5.6.1 Cooling module connection..........................................................................................28
5.7 Mains connection.........................................................................................................................29
5.7.1 Mains configuration ......................................................................................................29
5.8 Welding data display....................................................................................................................30
5.8.1 Welding parameter setting ...........................................................................................30
5.8.2 Welding current display (ignition, secondary, end and hotstart currents)....................31
5.9 Plasma welding............................................................................................................................31
5.9.1 Welding torch connection (with gas metering unit GMU).............................................31
5.9.2 Welding torch connection (no gas metering unit GMU) ...............................................34
5.9.3 Connection for workpiece lead.....................................................................................35
5.9.4 Shielding and plasma gas supply.................................................................................35
5.9.5 Select welding task.......................................................................................................36
5.9.6 Select welding current..................................................................................................37
5.9.7 Arc ignition....................................................................................................................37
5.10 TIG welding..................................................................................................................................38
5.10.1 Welding torch and workpiece line connection..............................................................38
5.10.1.1 Torch connection options and pin assignments............................................39
5.10.2 Shielding gas supply (shielding gas cylinder for welding machine).............................40
5.10.2.1 Connecting the shielding gas supply ............................................................40
5.10.2.2 Setting the shielding gas quantity.................................................................41
5.10.2.3 Gas test.........................................................................................................41

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5.10.2.4 “Purge hose package” function .....................................................................41
5.11 TIG Synergic operating principle..................................................................................................42
5.11.1 Synergic parameter setting in the functional sequence................................................43
5.11.2 Conventional parameter setting in the functional sequence.........................................43
5.11.3 Set the operating principle (conventional/synergic)......................................................44
5.11.4 Select welding task.......................................................................................................45
5.11.5 Select welding current ..................................................................................................46
5.11.6 Optimising the ignition characteristics for pure tungsten electrodes............................46
5.11.7 Expert menu (TIG)........................................................................................................47
5.11.8 Arc ignition....................................................................................................................48
5.11.8.1 HF ignition.....................................................................................................48
5.11.8.2 Liftarc ignition................................................................................................48
5.11.8.3 Automatic cut-out ..........................................................................................48
5.11.9 Function sequences/operating modes..........................................................................49
5.11.9.1 Explanation of symbols .................................................................................49
5.11.9.2 Non-latched mode.........................................................................................50
5.11.9.3 Latched mode................................................................................................51
5.11.9.4 spotArc ..........................................................................................................52
5.11.9.5 Spotmatic ......................................................................................................54
5.11.9.6 Non-latched operation, version C..................................................................55
5.11.10 Pulses, function sequences..........................................................................................56
5.11.10.1TIG pulses –non-latched operation..............................................................56
5.11.10.2TIG pulses - latched operation......................................................................56
5.11.11 Pulse variants...............................................................................................................57
5.11.12 TIG activArc welding.....................................................................................................59
5.11.13 TIG antistick..................................................................................................................59
5.11.14 Welding torch (operating variants)................................................................................60
5.11.14.1Tap torch trigger (tapping function)...............................................................60
5.11.15 Torch mode and up/down speed setting ......................................................................61
5.11.15.1Standard TIG torch (5-pole) ..........................................................................62
5.11.15.2TIG up/down torch (8-pole) ...........................................................................64
5.11.15.3Potentiometer torch (8-pole) .........................................................................66
5.11.15.4Configuring the TIG potentiometer torch connection....................................67
5.11.15.5Setting the first increment..............................................................................68
5.12 MMA welding................................................................................................................................69
5.12.1 Connecting the electrode holder and workpiece lead ..................................................69
5.12.2 Select welding task.......................................................................................................70
5.12.3 Hotstart .........................................................................................................................70
5.12.3.1 Hotstart current..............................................................................................70
5.12.3.2 Hotstart time..................................................................................................71
5.12.4 Arcforce.........................................................................................................................71
5.12.5 Antistick.........................................................................................................................71
5.12.6 MMA pulse welding in the vertical up position (PF)......................................................72
5.13 Welding programs........................................................................................................................73
5.13.1 Selection and adjustment .............................................................................................74
5.13.2 Specifying max. no. of accessible programs................................................................74
5.13.3 Example "Program with synergetic setting"..................................................................75
5.13.4 Example "Program with conventional setting"..............................................................75
5.13.5 Accessories for switching over programs.....................................................................75
5.14 Organising welding tasks (Mode "JOB Manager").......................................................................76
5.14.1 Explanation of symbols.................................................................................................76
5.14.2 Creating a new JOB in the memory or copying a JOB.................................................77
5.14.3 Loading an existing JOB from the free memory...........................................................78
5.14.4 Resetting an existing JOB to the factory setting (Reset JOB)......................................78
5.14.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs).....................................79
5.14.6 Exit JOB Manager without changes .............................................................................79
5.15 Remote control.............................................................................................................................80
5.15.1 Manual remote control RT1 19POL..............................................................................80
5.15.2 RTG1 19POL manual remote control...........................................................................80
5.15.3 Manual remote control RTP1 19POL ...........................................................................80

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5.15.4 Manual remote control RTP2 19POL...........................................................................80
5.15.5 RTP3 spotArc 19POL manual remote control..............................................................80
5.15.6 Foot-operated remote control RTF1 19POL 5 M / RTF2 19POL 5 M..........................81
5.15.6.1 Ramp function foot-operated remote control RTF 1 / RTF 2........................82
5.16 Interfaces for automation.............................................................................................................83
5.16.1 TIG interface for mechanised welding..........................................................................83
5.16.2 Remote control connection socket, 19-pole.................................................................84
5.17 Protecting welding parameters from unauthorised access..........................................................85
5.18 PC interface.................................................................................................................................85
5.19 Machine configuration menu........................................................................................................85
5.19.1 Selecting, changing and saving parameters................................................................85
5.19.2 Power-saving mode (Standby).....................................................................................89
5.19.3 Aligning the cable resistance........................................................................................90
6Maintenance, care and disposal.........................................................................................................92
6.1 General........................................................................................................................................92
6.2 Maintenance work, intervals........................................................................................................92
6.2.1 Daily maintenance tasks ..............................................................................................92
6.2.1.1 Visual inspection...........................................................................................92
6.2.1.2 Functional test...............................................................................................92
6.2.2 Monthly maintenance tasks..........................................................................................92
6.2.2.1 Visual inspection...........................................................................................92
6.2.2.2 Functional test...............................................................................................92
6.2.3 Annual test (inspection and testing during operation)..................................................93
6.3 Disposing of equipment ...............................................................................................................93
6.3.1 Manufacturer's declaration to the end user..................................................................93
6.4 Meeting the requirements of RoHS.............................................................................................93
7Rectifying faults ...................................................................................................................................94
7.1 Checklist for rectifying faults........................................................................................................94
7.2 Warnings (power source).............................................................................................................96
7.3 Machine faults (error messages).................................................................................................97
7.4 Resetting welding parameters to the factory settings..................................................................99
7.5 Display machine control software version .................................................................................100
7.6 General operating problems......................................................................................................100
7.6.1 Interface for automated welding.................................................................................100
7.7 Vent coolant circuit.....................................................................................................................101
8Technical data ....................................................................................................................................102
8.1 Tetrix 150 Plasma......................................................................................................................102
9Accessories........................................................................................................................................103
9.1 Welding torch cooling system....................................................................................................103
9.2 Transport systems .....................................................................................................................103
9.3 General accessories..................................................................................................................103
9.4 Remote controls and accessories..............................................................................................103
9.5 Options.......................................................................................................................................104
9.6 Computer communication..........................................................................................................104
10 Appendix A .........................................................................................................................................105
10.1 JOB-List.....................................................................................................................................105
11 Appendix B .........................................................................................................................................109
11.1 Overview of EWM branches......................................................................................................109

Safety instructions
Notes on the use of these operating instructions
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2 Safety instructions
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
•The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
•Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
•The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
•The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
•The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
•The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
•The hazard is explained using a symbol at 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.

Safety instructions
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Special technical points which users must observe.
Correct
Wrong
Press
Do not press
Press and keep pressed
Turn
Switch
Switch off machine
Switch on machine
ENTERENTER
ENTER (enter the menu)
NAVIGATION
NAVIGATION (Navigating in the menu)
EXIT
EXIT (Exit the menu)
4 s
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use

Safety instructions
General
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2.3 General
DANGER
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
•Observe the maintenance instructions - See 6 Maintenance, care and disposal chapter!
•Unwind welding leads completely!
•Shield devices or equipment sensitive to radiation accordingly!
•The correct functioning of pacemakers may be affected (obtain advice from a doctor if
necessary).
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)!
Electric shock!
Welding machines use high voltages which can result in potentially fatal electric shocks
and burns on contact. Even low voltages can cause you to get a shock and lead to
accidents.
•Do not touch any live parts in or on the machine!
•Connection cables and leads must be free of faults!
•Switching off alone is not sufficient!
•Place welding torch and stick electrode holder on an insulated surface!
•The unit should only be opened by specialist staff after the mains plug has been
unplugged!
•Only wear dry protective clothing!
•Wait for 4 minutes until the capacitors have discharged!
WARNING
Risk of injury due to radiation or heat!
Arc radiation results in injury to skin and eyes.
Contact with hot workpieces and sparks results in burns.
•Use welding shield or welding helmet with the appropriate safety level (depending on the
application)!
•Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
•Protect persons not involved in the work against arc beams and the risk of glare using
safety curtains!
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
•Move containers with inflammable or explosive liquids away from the working area!
•Never heat explosive liquids, dusts or gases by welding or cutting!

Safety instructions
General
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WARNING
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent
vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to
the ultraviolet radiation of the arc!
•Ensure that there is sufficient fresh air!
•Keep solvent vapour away from the arc beam field!
•Wear suitable breathing apparatus if appropriate!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
•Check for fire hazards in the working area!
•Do not carry any easily flammable objects such as matches or lighters.
•Keep appropriate fire extinguishing equipment to hand in the working area!
•Thoroughly remove any residue of flammable substances from the workpiece before
starting welding.
•Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
•Connect welding leads correctly!
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
•Carefully read the safety information in this manual!
•Observe the accident prevention regulations in your country.
•Inform persons in the working area that they must observe the regulations!
Danger when coupling multiple power sources!
Coupling multiple power sources in parallel or in series has to be carried out by
qualified personnel and in accordance with the manufacturer's guidelines. Before
bringing the power sources into service for arc welding operations, a test has to verify
that they cannot exceed the maximum allowed open circuit voltage.
•Connection of the machine may be carried out by qualified personnel only!
•When decommissioning individual power sources, all mains and welding current leads have
to be safely disconnected from the welding system as a whole. (Danger due to inverse
voltages!)
•Do not couple welding machines with pole reversing switch (PWS series) or machines for
AC welding, as a minor error in operation can cause the welding voltages to be combined.
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
•Wear suitable ear protection!
•Persons located within the working area must wear suitable ear protection!

Safety instructions
General
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CAUTION
Obligations of the operator!
The respective national directives and laws must be observed for operation of the
machine!
•National implementation of the framework directive (89/391/EWG), as well as the
associated individual directives.
•In particular, directive (89/655/EWG), on the minimum regulations for safety and health
protection when staff members use equipment during work.
•The regulations regarding work safety and accident prevention for the respective country.
•Setting up and operating the machine according to IEC 60974-9.
•Check at regular intervals that users are working in a safety-conscious way.
•Regular checks of the machine according to IEC 60974-4.
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
•Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of
products!
•Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Damage to the machine due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage equipment and
electronic devices and cause overheating of components leading to fire.
•Make sure all welding leads are securely connected and check regularly.
•Always ensure a proper and secure electrical connection to the workpiece!
•Set up, attach or suspend all conductive power source components like casing, transport
vehicle and crane frames so they are insulated!
•Do not place any other electronic devices such as drillers or angle grinders, etc., 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!
Mains connection
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of
the operator, where necessary in consultation with the mains network operator, to ensure that
the machine can be connected.

Safety instructions
General
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CAUTION
EMC Machine Classification
In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic
compatibility classes - See 8 Technical data chapter:
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas,
including residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the
surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
•Mains, control, signal and telecommunication lines
•Radios and televisions
•Computers and other control systems
•Safety equipment
•The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
•Calibration and measuring equipment
•The immunity to interference of other equipment in the surrounding area
•The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
•Mains connection, e.g. additional mains filter or shielding with a metal tube
•Maintenance of the arc welding equipment
•Welding leads should be as short as possible and run closely together along the ground
•Potential equalization
•Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
•Shielding from other equipment in the surrounding area or the entire welding system

Safety instructions
Transport and installation
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2.4 Transport and installation
WARNING
Incorrect handling of shielding gas cylinders!
Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.
•Observe the instructions from the gas manufacturer and in any relevant regulations
concerning the use of compressed air!
•Place shielding gas cylinders in the holders provided for them and secure with fixing
devices.
•Avoid heating the shielding gas cylinder!
Risk of accident due to improper transport of machines that may not be lifted!
Do not lift or suspend the machine! The machine can fall down and cause injuries! The
handles and brackets are suitable for transport by hand only!
•The machine may not be lifted by crane or suspended!
CAUTION
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10°
(according to IEC 60974-1).
•Set up and transport the machine on level, solid ground.
•Secure add-on parts using suitable equipment.
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
•Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
•Only transport and operate in an upright position!

Safety instructions
Transport and installation
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2.4.1 Ambient conditions
CAUTION
Installation site!
The 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.
CAUTION
Equipment damage due to dirt accumulation!
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)!
Non-permissible ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
•Observe the ambient conditions!
•Keep the cooling air inlet and outlet clear!
•Observe the minimum distance of 0.5 m from obstacles!
2.4.1.1 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
*Ambient temperature depends on coolant! Observe the coolant temperature range for the
welding torch cooling!
2.4.1.2 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

Intended use
Applications
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3 Intended use
WARNING
Hazards due to improper usage!
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 proper usage and by trained or expert staff!
•Do not modify or convert the equipment improperly!
3.1 Applications
3.1.1 Plasma welding
In plasma welding a plasma jet is used as heat source. Plasma is an electrically conducting gas that has
been heated to a very high temperature by an arc. In the plasma torch the flowing plasma gas (argon) is
ionised by high-frequency pulses and the pilot arc ignites. The pilot arc then burns between the negative
tungsten electrode and the nozzle (anode), thus ionising the gas column between nozzle and positive
workpiece. In this way a non-contact ignition of the arc is possible.
3.1.2 TIG welding
TIG welding with direct current.
Non-contact HF ignition or contact ignition with Liftarc.
3.1.2.1 TIG activArc welding
The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power
supplied is kept virtually constant in the event of changes in the distance between the welding torch and
the weld pool, e.g. during manual welding. Voltage losses as a result of a shortening of the distance
between the torch and molten pool are compensated by a current rise (ampere per volt - A/V), and vice
versa. This helps prevents the tungsten electrode sticking in the molten pool and the tungsten inclusions
are reduced. This is particularly useful in tacking and in spot welding.
3.1.2.2 spotArc
This process is suitable for tack welding or joint welding of metal sheets made from steel and CrNi alloys
up to a thickness of approximately 2.5 mm. Metal sheets of different thicknesses can also be welded on
top of one another. As this is a one-sided process, it is also possible to weld metal sheets onto tubular
sections such as round or square pipes. In arc spot welding, the arc melts through the upper metal sheet
and the lower metal sheet is melted onto it. This produces flat, fine-textured welding tacks which require
little or no post weld work, even in visible areas.
3.1.2.3 Spotmatic
In contrast to the operating mode spotArc, the arc ignites not by pressing the torch trigger as is usual, but
by shortly touching the tungsten electrode against the workpiece. The torch trigger is used for process
activation.
3.1.3 MMA welding
Manual arc welding or, for short, MMA welding. It is characterised by the fact that the arc burns between
a melting electrode and the molten pool. There is no external protection; any protection against the
atmosphere comes from the electrode.

Intended use
Documents which also apply
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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 designated machine conforms to EC Directives and standards in terms of its design
and construction:
•EC Low Voltage Directive (2006/95/EC),
•EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly
conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted
conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
3.2.3 Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
3.2.4 Service documents (spare parts and circuit diagrams)
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
•Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.2.5 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months

Machine description
Front view
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4 Machine description
4.1 Front view
Figure 4-1

Machine description
Front view
099-007021-EW501
29.07.2015
17
Item
Symbol
Description 0
1
Carrying handle
2
Fixing screws for gas metering unit
▼ Retrofitting option ▼
3
Key switch for protection against unauthorised use
Position “1” > changes possible,
Position “0” > changes not possible.
- See 5.17 Protecting welding parameters from unauthorised access chapter
▲ Retrofitting option ▲
4
Connection socket, 19-pole
Remote control connection
5
G1/4" shielding gas connecting nipple, welding machine output
Connection to the welding torch or gas metering unit (GMU)
6
Connection socket, "-" welding current
TIG/Plasma welding current connection
7
Connection socket, welding current “+” (with DC- polarity)
Connection for workpiece lead
8
Pilot arc button with signal light
Signal light off: pilot arc off
Signal light on: pilot arc lit
9
Machine feet
10
Cooling air inlet
11
Connection socket, welding current “-” (with DC- polarity)
connection for Electrode holder
12
Pilot current connection socket
Plasma welding torch nozzle potential
13
G1/4" plasma gas connecting nipple, welding machine output
Connection to the welding torch or gas metering unit (GDE)
14
5-pole connection socket, welding torch control lead
15
Connection socket, 8-pole
TIG Up/Down or potentiometer torch control lead
16
Machine control- See 4.3 Machine control –Operating elements chapter
17
Main switch, machine on/off

Machine description
Rear view
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4.2 Rear view
Figure 4-2

Machine description
Rear view
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19
Item
Symbol
Description 0
1
7-pole connection socket (digital)
For connecting digital accessory components (documentation interface, robot interface
or remote control, etc.).
2
7-pole connection socket (digital)
For connecting digital accessory components (documentation interface, robot interface
or remote control, etc.).
3
"Automatic circuit-breaker" key button; fuse protection:
•Ignition unit
•Gas valve
•Peripheral devices on the 7-pole, digital interfaces (rear of the machine)
Reset triggered automatic cutout by pressing
4
Ignition type changeover switch- See 5.9.7 Arc ignition chapter
= Liftarc (contact ignition)
= HF ignition
5
Mains connection cable
- See 5.7 Mains connection chapter
6
4-pole connection socket
Cooling unit voltage supply
7
Cooling air outlet
8
Pilot current connection socket
Plasma welding torch nozzle potential
9
G1/4" connecting nipple, shielding gas connection
Connection to the pressure reducer
10
G1/4" connecting nipple, plasma gas connection
Connection to the pressure reducer
11
PC interface, serial (D-Sub connection socket, 9-pole)
12
8-pole connection socket
Cooling unit control lead
13
19-pole connection socket
Analogue interface for mechanised welding

Machine description
Machine control –Operating elements
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4.3 Machine control –Operating elements
As the plasma welding process is based directly on the TIG welding process, the TIG
descriptions are used for plasma welding, with just a few differences.
Figure 4-3
Item
Symbol
Description 0
1
"Welding process" button
MMA welding, lights up in green / arcforce setting, lights up in red
TIG synergic welding (synergic parameter setting)
TIG manual welding (manual parameter setting)
2
“Tungsten electrode diameter”/ “Ignition optimisation” key button
1,0mm, 1,6mm, 2,0mm, 2,4mm, 3,2mm, 4,0mm or greater.
Optimum ignition and stabilisation of the arc. The adjustable welding current is limited
to the maximum permissible welding current of the tungsten electrode.
3
“Select material type” button
CrNi Chrome nickel alloys
FeSt Iron and steel alloys
Cu Copper or copper alloys (bronzes)
CuZn Copper zinc alloys (brass)
Spez Special (for special custom-built tasks)
4
Select seam type button
Fillet weld
Butt joint
Fillet weld - lap joint
Vertical-down