EWM Tetrix 351 AW FW User manual

Operating instructions
EN
Welding machines and accessories
Tetrix 351 AW FW
Tetrix 451 AW FW
Tetrix 551 AW FW
099-000118-EW501
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24.11.2017
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the location where the machine is operated.
•Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
•Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of
liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Straße 8
56271 Mündersbach
Germany
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.

Contents
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1 Contents
1Contents..................................................................................................................................................3
2For your safety .......................................................................................................................................7
2.1 Notes on the use of these operating instructions ..........................................................................7
2.2 Explanation of icons.......................................................................................................................8
2.3 Part of the complete documentation..............................................................................................9
2.4 Safety instructions..........................................................................................................................9
2.5 Transport and installation ............................................................................................................13
3Intended use.........................................................................................................................................14
3.1 Applications..................................................................................................................................14
3.2 Documents which also apply .......................................................................................................14
3.2.1 Warranty.......................................................................................................................14
3.2.2 Declaration of Conformity.............................................................................................14
3.2.3 Welding in environments with increased electrical hazards.........................................14
3.2.4 Service documents (spare parts and circuit diagrams)................................................14
3.2.5 Calibration/Validation....................................................................................................14
4Machine description –quick overview ..............................................................................................15
4.1 Front view ....................................................................................................................................15
4.2 Rear view.....................................................................................................................................17
4.3 Machine control –Operating elements........................................................................................19
4.3.1 Function sequence .......................................................................................................20
5Design and function.............................................................................................................................22
5.1 Transport and installation ............................................................................................................22
5.1.1 Lifting by crane .............................................................................................................22
5.1.2 Ambient conditions .......................................................................................................23
5.1.2.1 In operation ...................................................................................................23
5.1.2.2 Transport and storage...................................................................................23
5.1.3 Machine cooling............................................................................................................23
5.1.4 Workpiece lead, general...............................................................................................23
5.1.5 Welding torch cooling system.......................................................................................24
5.1.5.1 Approved coolants overview.........................................................................24
5.1.5.2 Maximal hose package length ......................................................................24
5.1.5.3 Adding coolant ..............................................................................................25
5.1.6 Notes on the installation of welding current leads........................................................26
5.1.6.1 Stray welding currents...................................................................................27
5.1.7 Mains connection..........................................................................................................27
5.1.7.1 Mains configuration.......................................................................................28
5.2 TIG cold wire welding...................................................................................................................29
5.2.1 Connection plan............................................................................................................29
5.2.1.1 Legend ..........................................................................................................30
5.3 Installation....................................................................................................................................31
5.3.1 Intermediate hose package connection........................................................................31
5.4 TIG hot wire welding....................................................................................................................33
5.4.1 Connection plan............................................................................................................33
5.4.1.1 Legend ..........................................................................................................34
5.5 Installation....................................................................................................................................35
5.5.1 Wire feed unit ...............................................................................................................35
5.5.2 Power source for hot wire welding ...............................................................................36
5.5.3 Mains connection..........................................................................................................37
5.6 Intermediate hose package connection.......................................................................................38
5.7 Welding data display....................................................................................................................39
5.7.1 Welding parameter setting ...........................................................................................39
5.7.2 Setting the welding current (absolute/percentage).......................................................39
5.8 Configuring the welding machine for mechanical arc fusion welding..........................................40
5.8.1 Selecting a welding task by means of the JOB list.......................................................40
5.8.2 Select wire speed operating mode (KORREKTUR / MANUELL).................................40
5.8.3 Setting the welding current and wire speed .................................................................40
5.8.4 Operating modes (functional sequences).....................................................................41
5.8.4.1 Explanation of symbols.................................................................................41

Contents
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5.8.4.2 Non-latched mode.........................................................................................42
5.8.4.3 3-cycle operation...........................................................................................43
5.8.4.4 Latched mode................................................................................................43
5.9 TIG welding..................................................................................................................................44
5.9.1 Welding torch and workpiece line connection ..............................................................44
5.9.1.1 Connection assignment, welding torch control cable....................................45
5.9.2 Shielding gas supply (shielding gas cylinder for welding machine)..............................46
5.9.2.1 Connecting the shielding gas supply.............................................................46
5.9.3 TIG Synergic operating principle ..................................................................................47
5.9.4 Synergic parameter setting in the functional sequence................................................48
5.9.5 Conventional parameter setting in the functional sequence.........................................48
5.9.5.1 Set the operating principle (conventional/synergic) ......................................48
5.9.6 Welding task selection..................................................................................................49
5.9.7 Select welding current ..................................................................................................49
5.9.8 Gas test or "rinse hose package" .................................................................................49
5.9.8.1 Gas test.........................................................................................................50
5.9.8.2 “Purge hose package” function .....................................................................50
5.9.9 Optimising the ignition characteristics for pure tungsten electrodes ............................51
5.9.10 Tungsten balling function..............................................................................................51
5.9.11 Arc ignition....................................................................................................................52
5.9.11.1 HF ignition .....................................................................................................52
5.9.11.2 Liftarc.............................................................................................................52
5.9.11.3 Automatic cut-out ..........................................................................................52
5.9.12 Operating modes (functional sequences).....................................................................53
5.9.12.1 Explanation of symbols .................................................................................53
5.9.12.2 Non-latched mode.........................................................................................53
5.9.12.3 Latched mode................................................................................................54
5.9.12.4 spotArc ..........................................................................................................56
5.9.12.5 spotmatic.......................................................................................................57
5.9.12.6 Non-latched operation, version C..................................................................59
5.9.13 Pulse welding................................................................................................................60
5.9.13.1 Automated pulses..........................................................................................60
5.9.13.2 Thermal pulsing.............................................................................................60
5.9.13.3 Metallurgical pulsing (kHz pulsing)................................................................62
5.9.14 TIG antistick..................................................................................................................64
5.9.15 activArc.........................................................................................................................64
5.9.16 Expert menu (TIG)........................................................................................................65
5.10 MMA welding................................................................................................................................67
5.10.1 Connecting the electrode holder and workpiece lead ..................................................67
5.10.2 Welding task selection..................................................................................................68
5.10.3 Hotstart .........................................................................................................................68
5.10.3.1 Hotstart current..............................................................................................69
5.10.3.2 Hotstart time..................................................................................................69
5.10.4 Arcforce.........................................................................................................................70
5.10.5 Antistick.........................................................................................................................70
5.10.6 Average value pulsing in the vertical-up position (PF) .................................................71
5.11 Organising welding tasks (Mode "JOB Manager").......................................................................73
5.11.1 Explanation of symbols.................................................................................................73
5.11.2 Creating a new JOB in the memory or copying a JOB.................................................74
5.11.3 Loading an existing JOB from the free memory...........................................................75
5.11.4 Resetting an existing JOB to the factory setting (Reset JOB)......................................75
5.11.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs).....................................76
5.11.6 Exit JOB Manager without changes .............................................................................76
5.12 Welding programs........................................................................................................................77
5.12.1 Selection and adjustment .............................................................................................77
5.12.2 Specifying max. no. of accessible programs ................................................................77
5.12.3 Example "Program with synergetic setting"..................................................................78
5.12.4 Example "Program with conventional setting"..............................................................78
5.12.5 Accessories for switching over programs.....................................................................78
5.13 Remote control.............................................................................................................................78

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5.13.1 RT1 19POL...................................................................................................................78
5.13.2 RTG1 19POL................................................................................................................79
5.13.3 RTP1 19POL ................................................................................................................79
5.13.4 RTP2 19POL ................................................................................................................79
5.13.5 RTP3 spotArc 19POL...................................................................................................79
5.13.6 RTF1 19POL ................................................................................................................79
5.13.6.1 RTF start ramp..............................................................................................80
5.13.6.2 RTF response ...............................................................................................81
5.13.7 Welding torch (operating variants) ...............................................................................81
5.13.7.1 Tapping function (tap torch trigger)...............................................................81
5.13.7.2 Torch mode setting .......................................................................................81
5.13.7.3 Up/down speed .............................................................................................82
5.13.7.4 Current jump .................................................................................................82
5.13.7.5 Standard TIG torch (5-pole)..........................................................................82
5.13.7.6 TIG up/down torch (8-pole)...........................................................................85
5.13.7.7 Potentiometer torch (8-pole).........................................................................87
5.13.7.8 Configuring the TIG potentiometer torch connection....................................88
5.13.7.9 RETOX TIG torch (12-pole) ..........................................................................89
5.13.7.10Specifying max. no. of accessible JOBs.......................................................90
5.14 Interfaces for automation.............................................................................................................90
5.14.1 Automation interface.....................................................................................................91
5.14.2 Remote control connection socket, 19-pole.................................................................92
5.14.3 RINT X12 robot interface..............................................................................................92
5.14.4 BUSINT X11 Industrial bus interface............................................................................92
5.15 PC interface .................................................................................................................................93
5.16 Power-saving mode (Standby) ....................................................................................................93
5.17 Access control..............................................................................................................................94
5.18 Machine configuration menu........................................................................................................95
5.18.1 Selecting, changing and saving parameters ................................................................95
5.19 Aligning the cable resistance.....................................................................................................100
6Maintenance, care and disposal.......................................................................................................102
6.1 General ......................................................................................................................................102
6.2 Cleaning.....................................................................................................................................102
6.2.1 Dirt filter ......................................................................................................................102
6.3 Maintenance work, intervals ......................................................................................................103
6.3.1 Daily maintenance tasks.............................................................................................103
6.3.2 Monthly maintenance tasks........................................................................................103
6.3.3 Annual test (inspection and testing during operation)................................................103
6.4 Disposing of equipment .............................................................................................................104
7Rectifying faults .................................................................................................................................105
7.1 Checklist for rectifying faults......................................................................................................105
7.2 Warnings....................................................................................................................................106
7.3 Error messages..........................................................................................................................107
7.4 Resetting welding parameters to the factory settings................................................................108
7.5 Display machine control software version .................................................................................108
7.6 Vent coolant circuit.....................................................................................................................109
8Technical data ....................................................................................................................................110
8.1 Tetrix 351 AW ............................................................................................................................110
8.2 Tetrix 451 AW ............................................................................................................................111
8.3 Tetrix 551 AW ............................................................................................................................112
9Accessories........................................................................................................................................113
9.1 Remote controls and accessories..............................................................................................113
9.2 Welding torch cooling system....................................................................................................113
9.3 Options.......................................................................................................................................113
9.4 General accessories..................................................................................................................113
9.5 Computer communication..........................................................................................................114
9.6 System components ..................................................................................................................114
10 Appendix A .........................................................................................................................................115
10.1 JOB-List .....................................................................................................................................115

Contents
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11 Appendix B..........................................................................................................................................119
11.1 Parameter overview –setting ranges ........................................................................................119
11.1.1 TIG welding.................................................................................................................119
11.1.2 MMA welding ..............................................................................................................119
12 Appendix C..........................................................................................................................................120
12.1 Overview of EWM branches.......................................................................................................120

For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
•The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
•Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
•The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
•The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
•The risk is explained using a symbol on the edge of the page.
Special technical points which users must observe.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
•Insert the welding current lead socket into the relevant socket and lock.

For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/tip
Switch off machine
Release
Switch on machine
Press and keep pressed
Switch
Wrong
Turn
Correct
Numerical value –adjustable
Menu entry
Signal light lights up in green
Navigating the menu
Signal light flashes green
Exit menu
Signal light lights up in red
Time representation (e.g.: wait
4 s/activate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use

For your safety
Part of the complete documentation
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2.3 Part of the complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with all other parts of these instructions! Read and observe the operating
instructions for all system components, especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 2-1
Item
Operating instructions
A.1
Wire feeder
A.2
Options conversion instructions
A.3
Power source
A.4
Welding torch
A.5
Control
A.6
Remote control
A
Complete documentation
2.4 Safety instructions
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!

For your safety
Safety instructions
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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!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a
technical specialist may interconnect the sources as per standard IEC 60974-9:2010:
Installation and use and German Accident Prevention Regulation BVG D1 (formerly VBG
15) or country-specific regulations.
Before commencing arc welding, a test must verify that the equipment cannot exceed
the maximum permitted open circuit voltage.
•Only qualified personnel may connect the machine.
•When taking individual power sources out of operation, all mains and welding current leads
must be safely disconnected from the welding system as a whole. (Hazard due to reverse
polarity voltage!)
•Do not interconnect welding machines with pole reversing switch (PWS series) or machines
for AC welding since a minor error in operation can cause the welding voltages to be
combined, which is not permitted.
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.
Risk of injury due to radiation or heat!
Arc radiation can lead to skin and eye injuries.
Contact with hot workpieces and sparks can lead to burns.
•Use hand shield or welding helmet with the appropriate safety level (depends on the
application).
•Wear dry protective clothing (e.g. hand shield, gloves, etc.) in accordance with
the applicable regulations of your country.
•Persons who are not directly involved should be protected with a welding curtain or suitable
safety screen against radiation and the risk of blinding!
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!

For your safety
Safety instructions
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WARNING
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!
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!
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!
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

For your safety
Safety instructions
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CAUTION
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).
Obligations of the operator!
The respective national directives and laws must be complied with when operating the machine!
•Implementation of national legislation relating to framework directive 89/391/EEC on the
introduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
•In particular, directive 89/655/EEC concerning the minimum safety and health requirements for
the use of work equipment by workers at work.
•The regulations applicable to occupational safety and accident prevention in the country
concerned.
•Setting up and operating the machine as per IEC 60974.-9.
•Brief the user on safety-conscious work practices on a regular basis.
•Regularly inspect the machine as per 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.
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.

For your safety
Transport and installation
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2.5 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.
Risk of accidents due to incorrectly installed leads!
Incorrectly installed leads (mains, control and welding leads or intermediate hose
packages ) can present a tripping hazard.
•Lay the supply lines flat on the floor (avoid loops).
•Avoid laying the leads on passage ways.
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
Applications
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
•The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
•Do not improperly modify or convert the equipment!
3.1 Applications
Arc welding machines for TIG DC 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).
•Connection capability for system components for filler wire welding
3.2 Documents which also apply
3.2.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.2.2 Declaration of Conformity
The labelled machine complies with the following EC directives in terms of its design and
construction:
•Low Voltage Directive (LVD)
•Electromagnetic Compatibility Directive (EMC)
•Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment –Inspection and Testing during Operation," and/or prohibited modifications which
have not been explicitly authorised by the manufacturer, this declaration shall be voided. An original
document of the specific declaration of conformity is included with every product.
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)
WARNING
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
•Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.2.5 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
Lifting lug
2
Main switch, machine on/off
3
Machine control > see 4.3 chapter
4
Carrying handle

Machine description –quick overview
Front view
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Item
Symbol
Description 0
5
Automatic cut-out of coolant pump key button
press to reset a triggered fuse
6
Quick connect coupling (red)
coolant return
7
Quick connect coupling (blue)
coolant supply
8
Wheels, guide castors
9
Coolant tank
10
Coolant tank cap
11
Connection socket, welding torch control cable > see 5.9.1.1 chapter
12
Cooling air inlet
13
G¼” connecting nipple, “-” welding current
Shielding gas connection (with yellow insulating cap) for TIG welding torch
14
Connection socket, “-” welding current
TIG welding torch connection
15
Connection socket, “+” welding current
Connection for workpiece lead
16
Key switch to protect against unauthorised use (retrofitting option)
Position 1: changes possible.
Position 0: no changes possible.
> see 5.17 chapter.
17
Connection socket, 19-pole
Remote control connection
18
Connection socket, “-” welding current
Electrode holder connection
19
Operating state signal lamp
Lights up when the machine is ready for use.
20
Carrier plate for system components
only hot wire version

Machine description –quick overview
Rear view
099-000118-EW501
24.11.2017
17
4.2 Rear view
Figure 4-2
Item
Symbol
Description 0
1
Intermediate hose package strain relief
2
Securing elements for shielding gas cylinder (strap/chain)
3
Mains connection cable > see 5.5.3 chapter
4
G¼” connecting nipple
Shielding gas connection on the pressure regulator.
5
Connector plug (TIG hot wire)
Welding current, minus potential
6
Connection socket for “+” welding current
Connection to TIG power source for hot wire application
7
Connection socket (TIG)
Welding current, minus potential

Machine description –quick overview
Machine control –Operating elements
18
099-000118-EW501
24.11.2017
Item
Symbol
Description 0
8
Quick connect coupling (red)
coolant return
9
Quick connect coupling (blue)
coolant supply
10
hotWire
Control lead connection, hot wire power source
4-pole connection to the hot wire power source
11
X2
Connection socket (28-pole)
Control lead
12
Key button, automatic cutout
Wire feed motor supply voltage fuse
press to reset a triggered fuse
13
Mains connection, hot wire power source
Power supply for hot wire power source
14
Ignition type changeover switch > see 5.9.11 chapter
=----- Liftarc (contact ignition)
=------ HF ignition
15
19-pole mechanised welding interface (analogue)
> see 5.14.1 chapter
16
PC interface, serial (D-Sub connection socket, 9-pole)
17
7-pole connection socket (digital)
For connecting digital accessory components (documentation interface, robot interface
or remote control, etc.).
18
Cooling air outlet
19
Bracket for shielding gas cylinder
20
Wheels, fixed castors

Machine description –quick overview
Machine control –Operating elements
099-000118-EW501
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19
4.3 Machine control –Operating elements
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
Electrode diameter push-button > see 5.9.6 chapter
Ignition optimisation (TIG) > see 5.9.9 chapter
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
5
Operating mode / Power-saving mode button
--spotArc / spotmatic (spot time setting range)
---------Non-latched
------Latched
Press for 3 s to put machine into power-saving mode. To reactivate, activate one of the
operating elements > see 5.16 chapter.

Machine description –quick overview
Machine control –Operating elements
20
099-000118-EW501
24.11.2017
Item
Symbol
Description 0
6
Pulsing push-button
- TIG automated pulsing (frequency and balance)
------- Signal light lights up in green: Pulsing (thermal pulsing)/MMA pulse welding
------- Signal light lights up in red: kHz pulsing (metallurgical pulsing)
7
Gas test/rinse hose package button
> see 5.9.2 chapter
8
Error/status indicators
------ Collective interference signal light
- Water deficiency signal light (welding torch cooling)
--------- Excess temperature signal light
-------- S safety sign signal light
9
Display switching button
------- Material thickness display
VOLT --- Welding voltage display
JOB ----- JOB number display
PROG -- Program number display
10
Welding parameter setting rotary dial
Setting currents, times and parameters.
11
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 5.7 chapter
12
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
13
Functional sequence > see 4.3.1 chapter
4.3.1 Function sequence
Figure 4-4
Item
Symbol
Description 0
1
Select welding parameters button
This button is used to select the welding parameters depending on the welding process
and operating mode used.