EWM Tetrix 300 Comfort 2.0 puls TM User manual

Operating instructions
EN
Power source
Tetrix 300 Comfort 2.0 puls TM
Tetrix 300 AC/DC Comfort 2.0 puls TM
Tetrix 300 AC/DC Comfort 2.0 puls TM (AUS)
099-000235-EW501
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12.07.2016
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the site of operation.
•Safety and warning labels at the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to the state of the art and any regulations and
standards applicable. It may be operated, serviced and repaired by trained personnel only.
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
Notes on the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2Safety instructions.................................................................................................................................5
2.1 Notes on the use of these operating instructions ..........................................................................5
2.1.1 Complete documentation ...............................................................................................6
2.1.2 Explanation of icons .......................................................................................................7
2.2 General ..........................................................................................................................................8
2.3 Personal protective equipment ......................................................................................................8
2.4 Electrical hazards...........................................................................................................................8
2.5 Radiation and heat.........................................................................................................................9
2.6 Fire and risk of explosion...............................................................................................................9
2.7 Smoke and gases ..........................................................................................................................9
2.8 Noise............................................................................................................................................10
2.9 EMC classification........................................................................................................................10
2.10 Other hazards ..............................................................................................................................11
2.11 Transport and installation ............................................................................................................12
3Intended use.........................................................................................................................................13
3.1 Documents which also apply .......................................................................................................13
3.1.1 Warranty.......................................................................................................................13
3.1.2 Declaration of Conformity.............................................................................................13
3.1.3 Welding in environments with increased electrical hazards.........................................13
3.1.4 Service documents (spare parts and circuit diagrams)................................................13
3.1.5 Calibration/Validation....................................................................................................13
4Machine description –quick overview ..............................................................................................14
4.1 Front view ....................................................................................................................................14
4.2 Rear view.....................................................................................................................................15
5Design and function.............................................................................................................................16
5.1 Transport and installation ............................................................................................................16
5.1.1 Ambient conditions .......................................................................................................16
5.1.1.1 In operation ...................................................................................................16
5.1.1.2 Transport and storage...................................................................................16
5.1.2 Machine cooling............................................................................................................16
5.1.3 Workpiece lead, general...............................................................................................16
5.1.4 Adjusting the length of the carrying strap.....................................................................17
5.1.5 Welding torch cooling system.......................................................................................17
5.1.6 Notes on the installation of welding current leads........................................................18
5.1.7 Mains connection..........................................................................................................20
5.1.7.1 Mains configuration.......................................................................................20
5.2 TIG welding..................................................................................................................................21
5.2.1 Welding torch and workpiece line connection..............................................................21
5.2.1.1 Torch connection options and pin assignments............................................22
5.2.2 Shielding gas supply (shielding gas cylinder for welding machine) .............................23
5.2.2.1 Connecting the shielding gas supply ............................................................24
5.2.3 Arc ignition....................................................................................................................25
5.2.3.1 HF ignition.....................................................................................................25
5.2.3.2 Liftarc ............................................................................................................25
5.2.3.3 Automatic cut-out ..........................................................................................25
5.3 MMA welding ...............................................................................................................................26
5.3.1 Connecting the electrode holder and workpiece lead ..................................................26
5.4 Remote control.............................................................................................................................27
5.4.1 RT1 19POL...................................................................................................................27
5.4.2 RTG1 19POL................................................................................................................27
5.4.3 RTP1 19POL ................................................................................................................27
5.4.4 RTP 2............................................................................................................................27
5.4.5 RTP3 spotArc 19POL...................................................................................................27
5.4.6 RT AC 1 19POL............................................................................................................27
5.4.7 RT50 7POL...................................................................................................................28

Contents
Notes on the use of these operating instructions
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5.4.8 RT PWS 1 19POL.........................................................................................................28
5.4.9 RTF1 19POL.................................................................................................................28
5.5 Voltage reducing device...............................................................................................................29
5.6 PC interface .................................................................................................................................29
5.7 Interfaces for automation .............................................................................................................30
5.7.1 Remote control connection socket, 19-pole .................................................................30
6Maintenance, care and disposal .........................................................................................................31
6.1 General.........................................................................................................................................31
6.2 Cleaning.......................................................................................................................................31
6.3 Maintenance work, intervals.........................................................................................................32
6.3.1 Daily maintenance tasks...............................................................................................32
6.3.1.1 Visual inspection ...........................................................................................32
6.3.1.2 Functional test...............................................................................................32
6.3.2 Monthly maintenance tasks..........................................................................................32
6.3.2.1 Visual inspection ...........................................................................................32
6.3.2.2 Functional test...............................................................................................32
6.3.3 Annual test (inspection and testing during operation) ..................................................33
6.4 Disposing of equipment................................................................................................................33
6.4.1 Manufacturer's declaration to the end user ..................................................................33
6.5 Meeting the requirements of RoHS..............................................................................................33
7Rectifying faults....................................................................................................................................34
7.1 Checklist for rectifying faults ........................................................................................................34
7.2 Vent coolant circuit.......................................................................................................................36
8Technical data.......................................................................................................................................37
8.1 Tetrix 300 .....................................................................................................................................37
8.2 Tetrix 300 AC/DC.........................................................................................................................38
9Accessories ..........................................................................................................................................39
9.1 Remote controls and accessories................................................................................................39
9.1.1 7-pole connection .........................................................................................................39
9.1.2 19-pole connection .......................................................................................................39
9.2 Welding torch cooling system ......................................................................................................39
9.3 Transport systems........................................................................................................................39
9.4 General accessories ....................................................................................................................40
9.5 Options.........................................................................................................................................40
9.6 Computer communication............................................................................................................40
10 Appendix A............................................................................................................................................41
10.1 Overview of EWM branches.........................................................................................................41

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.
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
Notes on the use of these operating instructions
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2.1.1 Complete documentation
This document is part of the complete documentation and valid only in combination with the
"Control" operating instructions for the product being used!
Read and observe the operating instructions for all system components, especially the safety
instructions!
Figure 2-1
The illustration shows a general example of a welding system.
Item
Documentation
A.1
Conversion instructions
A.2
Power source
A.3
Cooling unit, voltage converter, tool box etc.
A.4
Trolley
A.5
Welding torch
A.6
Remote control
A.7
Control
A
Complete documentation

Safety instructions
Notes on the use of these operating instructions
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2.1.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/tip
Switch off machine
Release/do not activate
Switch on machine
Press and hold
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

Safety instructions
General
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2.2 General
WARNING
Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
•Carefully read the safety instructions in this manual!
•Observe the accident prevention regulations and any regional regulations!
•Inform persons in the working area that they must comply with the regulations!
2.3 Personal protective equipment
WARNING
Risk of injury due to improper clothing!
During arc welding, radiation, heat and voltage are sources of risk that cannot be
avoided. The user has to be equipped with the complete personal protective equipment
at all times. The protective equipment has to include:
•Respiratory protection against hazardous substances and mixtures (fumes and vapours);
otherwise implement suitable measures such as extraction facilities.
•Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and
heat.
•Dry welding clothing (shoes, gloves and body protection) to protect against warm
environments with conditions comparable to ambient temperatures of 100 °C or higher and
arcing and work on live components.
•Hearing protection against harming noise.
2.4 Electrical hazards
WARNING
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low
voltages can cause a shock and lead to accidents.
•Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
•Always place torches and electrode holders on an insulated surface!
•Wear the full personal protective equipment (depending on the application)!
•The machine may only be opened by qualified personnel!
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.

Safety instructions
Radiation and heat
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2.5 Radiation and heat
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!
2.6 Fire and risk of explosion
WARNING
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!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during
welding, there is a risk of flames.
•Be watchful of potential sources of fire in the working area!
•Do not carry any easily inflammable objects, e.g. matches or lighters.
•Ensure suitable fire extinguishers are available in the working area!
•Thoroughly remove any residue of flammable materials from the workpiece prior to starting
to weld.
•Only further process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!
2.7 Smoke and gases
CAUTION
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!
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 6.3 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).

Safety instructions
Noise
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2.8 Noise
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!
2.9 EMC classification
CAUTION
According to IEC 60974-10, welding machines are divided into two classes of
electromagnetic compatibility (the EMC class can be found in the Technical
data) > see 8 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 system
•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
Other hazards
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2.10 Other hazards
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.
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.
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!
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
Transport and installation
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2.11 Transport and installation
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause
serious injuries!
•Observe the instructions from the gas manufacturer and any relevant regulations
concerning the use of compressed air!
•Do not attach any element to the shielding gas cylinder valve!
•Prevent the shielding gas cylinder from heating up.
CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
•Disconnect all supply lines before transport!
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.
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!
Accessory components and the power source itself can be damaged by incorrect connection!
•Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
•Comprehensive descriptions can be found in the operating instructions for the relevant
accessory components.
•Accessory components are detected automatically after the power source is switched on.
Protective dust caps protect the connection sockets and therefore the machine against dirt and
damage.
•The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
•The cap must be replaced if faulty or if lost!

Intended use
Documents which also apply
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
•The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
•Do not improperly modify or convert the equipment!
Arc welding machine for TIG DC and AC welding with lift arc (touch starting) or HF ignition (contactless)
and MMA welding as secondary process. It may be possible to expand the functionality by using
accessories (see the documentation in the relevant chapter).
3.1 Documents which also apply
3.1.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.1.2 Declaration of Conformity
The labelled machine complies with the following EC directives in terms of its design and
construction:
•Low Voltage Directive (LVD) 2014/35/EC
•Electromagnetic Compatibility Directive (EMC) 2014/30/EC
•Restriction of Hazardous Substance (RoHS) 2011/65/EC
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment –Inspection and Testing during Operation", and/or prohibited modifications which
have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the
specific declaration of conformity is included with every product.
3.1.3 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.
3.1.4 Service documents (spare parts and circuit diagrams)
WARNING
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
•Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.1.5 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 –quick overview
Front view
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4 Machine description – quick overview
4.1 Front view
Figure 4-1
Item
Symbol
Description 0
1
Carrying handle
2
Machine control, see the relevant control operating instructions
3
Connection socket, 5-pole/8-pole (depending on variant)
5-pole: -- Control cable TIG standard torch
8-pole: -- Control cable TIG up/down or potentiometer torch
4
Connection socket, "+" welding current
•TIG: Connection for workpiece lead
•MMA: Electrode holder or workpiece lead connection
5
Cooling air inlet
6
Connection socket, "-" welding current
•TIG: TIG welding torch connection
•MMA: Electrode holder or workpiece lead connection
7
G¼” connecting nipple, “-” welding current
Shielding gas connection (with yellow insulating cap) for TIG welding torch
8
Carrying strap > see 5.1.4 chapter

Machine description –quick overview
Rear view
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4.2 Rear view
Figure 4-2
Item
Symbol
Description 0
1
Connection socket, 19-pole
Remote control connection
2
8-pole connection socket
Cooling unit control lead
3
4-pole connection socket
Cooling unit voltage supply
4
Cooling air outlet
5
Machine feet
6
Mains connection cable > see 5.1.7 chapter
7
G¼” connecting nipple
Shielding gas connection on the pressure regulator.
8
Main switch, machine on/off
9
PC interface, serial (D-Sub connection socket, 9-pole)
10
7-pole connection socket (digital)
For connecting digital accessory components

Design and function
Transport and installation
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5 Design and function
5.1 Transport and installation
WARNING
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!
5.1.1 Ambient conditions
T he machine must not be operated in the open air and must only be set up and operated on a
suitable, stable and level base!
•The operator must ensure that the ground is non-slip and level, and provide sufficient lighting
for the place of work.
•Safe operation of the machine must be guaranteed at all times.
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
•Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
•Avoid ambient air containing salt (sea air)!
5.1.1.1 In operation
Temperature range of the ambient air:
•-25 °C to +40 °C
Relative air humidity:
•Up to 50% at 40 °C
•Up to 90% at 20 °C
5.1.1.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
•-30 °C to +70 °C
Relative air humidity
•Up to 90% at 20 °C
5.1.2 Machine cooling
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!
5.1.3 Workpiece lead, general
CAUTION
Risk of burning due to incorrect welding current connection!
If the welding current plugs (machine connections) are not locked or if the workpiece
connection is contaminated (paint, rust) these connections and leads can heat up and
cause burnings when touched.
•Check welding current connections on a daily basis and lock by turning to the right, when
required.
•Thoroughly clean workpiece connection and secure properly. Do not use construction parts
of the workpiece as welding current return lead!

Design and function
Transport and installation
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5.1.4 Adjusting the length of the carrying strap
To demonstrate adjustment, lengthening the strap is shown in the figure. To shorten, the strap's
loops must be inched in the opposite direction.
Figure 5-1
5.1.5 Welding torch cooling system
Please note the relevant documentation of the accessory components.
Figure 5-2
Item
Symbol
Description 0
1
8-pole connection socket
Cooling unit control lead
2
4-pole connection socket
Cooling unit voltage supply
3
Cooling module
Control and supply lead to the welding machine
The cooling module and welding machine are connected using two leads.
•Insert the control lead plug on the welding machine.
•Insert the power supply lead plug on the welding machine.

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

Design and function
Transport and installation
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Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid
loops!
Always keep leads as short as possible!
Lay any excess cable lengths in meanders.
Figure 5-5
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!
Figure 5-6

Design and function
Transport and installation
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5.1.7 Mains connection
DANGER
Hazard caused by improper mains connection!
An improper mains connection can cause injuries or damage property!
•Only use machine with a plug socket that has a correctly fitted protective conductor.
•If a mains plug must be fitted, this may only be carried out by an electrician in accordance
with the relevant national provisions or regulations!
•Mains plug, socket and lead must be checked regularly by an electrician!
•When operating the generator always ensure it is earthed as stated in the operating
instructions. The resulting network has to be suitable for operating devices according to
protection class 1.
5.1.7.1 Mains configuration
The machine may be connected to:
•a three-phase system with four conductors and an earthed neutral conductor
•a three-phase system with three conductors of which any one can be earthed,
e.g. the outer conductor
Figure 5-7
Legend
Item
Designation
Colour code
L1
Outer conductor 1
brown
L2
Outer conductor 2
black
L3
Outer conductor 3
grey
N
Neutral conductor
blue
PE
Protective conductor
green-yellow
The operating voltage shown on the rating plate must be consistent with the mains voltage, in
order to avoid damage to the machine > see 8 chapter!
•Insert mains plug of the switched-off machine into the appropriate socket.