EWM Tetrix 351 User manual

Operating instructions
EN
Welding machines and accessories
Tetrix 351 AC/DC AW FW
Tetrix 451 AC/DC AW FW
Tetrix 551 AC/DC AW FW
099-000115-EW501
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17.06.2015
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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.................................................................................................................................8
2.1 Notes on the use of these operating instructions ..........................................................................8
2.2 Explanation of icons.......................................................................................................................9
2.3 General........................................................................................................................................10
2.4 Transport and installation ............................................................................................................14
2.4.1 Lifting by crane.............................................................................................................15
2.4.2 Ambient conditions.......................................................................................................16
2.4.2.1 In operation...................................................................................................16
2.4.2.2 Transport and storage...................................................................................16
3Intended use.........................................................................................................................................17
3.1 Applications..................................................................................................................................17
3.1.1 TIG welding ..................................................................................................................17
3.1.1.1 TIG hot wire welding .....................................................................................17
3.1.1.2 TIG cold wire welding....................................................................................17
3.1.1.3 TIG activArc welding.....................................................................................17
3.1.1.4 spotArc..........................................................................................................17
3.1.1.5 Spotmatic......................................................................................................17
3.1.2 MMA welding................................................................................................................17
3.2 Use and operation solely with the following machines................................................................18
3.3 Documents which also apply.......................................................................................................18
3.3.1 Warranty.......................................................................................................................18
3.3.2 Declaration of Conformity.............................................................................................18
3.3.3 Welding in environments with increased electrical hazards.........................................18
3.3.4 Service documents (spare parts and circuit diagrams)................................................18
3.3.5 Calibration/Validation ...................................................................................................18
4Machine description –quick overview ..............................................................................................19
4.1 System overview..........................................................................................................................19
4.2 Tetrix 351 AC/DC AW..................................................................................................................20
4.3 Front view ....................................................................................................................................20
4.4 Rear view.....................................................................................................................................22
4.5 Tetrix 451, 551 AC/DC AW..........................................................................................................24
4.6 Front view ....................................................................................................................................24
4.7 Rear view.....................................................................................................................................26
4.8 Machine control –Operating elements........................................................................................28
4.8.1 Function sequence.......................................................................................................30
5Design and function.............................................................................................................................32
5.1 General........................................................................................................................................32
5.2 Machine cooling...........................................................................................................................33
5.3 Workpiece lead, general..............................................................................................................33
5.4 Notes on the installation of welding current leads.......................................................................34
5.5 Mains connection.........................................................................................................................36
5.5.1 Mains configuration ......................................................................................................36
5.6Welding torch cooling system......................................................................................................37
5.6.1 List of coolants..............................................................................................................37
5.6.2 Maximal hose package length......................................................................................37
5.6.3 Adding coolant..............................................................................................................38
5.7 Shielding gas supply (shielding gas cylinder for welding machine).............................................39
5.7.1 Connection ...................................................................................................................39
5.8 TIG welding..................................................................................................................................40
5.8.1 TIG cold or hot wire welding.........................................................................................40
5.8.2 Setting the shielding gas quantity.................................................................................40
5.8.3 Gas test........................................................................................................................40
5.8.4 “Purge hose package” function ....................................................................................40
5.9 TIG cold wire welding...................................................................................................................41
5.9.1 Connection plan............................................................................................................41

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5.9.2 Legend..........................................................................................................................42
5.9.3 Installation.....................................................................................................................42
5.9.4 Intermediate hose package connection........................................................................43
5.10 TIG hot wire welding ....................................................................................................................45
5.10.1 Connection plan............................................................................................................45
5.10.1.1 Legend...........................................................................................................46
5.10.2 Installation.....................................................................................................................47
5.10.2.1 Wire feed unit................................................................................................47
5.10.2.2 Power source for hot wire welding................................................................48
5.10.3 Intermediate hose package connection........................................................................50
5.11 Configuring the welding machine for mechanical arc fusion welding..........................................52
5.11.1 Selecting a welding task by means of the JOB list.......................................................53
5.11.2 Select wire speed operating mode (KORREKTUR / MANUELL).................................53
5.11.3 Setting the welding current and wire speed..................................................................53
5.11.4 Function sequences/operating modes..........................................................................54
5.11.4.1 Explanation of symbols .................................................................................54
5.11.4.2 Non-latched mode.........................................................................................55
5.11.4.3 3-cycle operation...........................................................................................56
5.11.4.4 Latched mode................................................................................................56
5.12 TIG welding..................................................................................................................................57
5.12.1 Welding torch and workpiece line connection..............................................................57
5.12.1.1 Torch connection options and pin assignments............................................58
5.13 TIG Synergic operating principle..................................................................................................59
5.13.1 Synergic parameter setting in the functional sequence................................................60
5.13.2 Conventional parameter setting in the functional sequence.........................................60
5.13.2.1 Set the operating principle (conventional/synergic)......................................61
5.13.3 Select welding task.......................................................................................................62
5.13.4 Select welding current ..................................................................................................63
5.13.5 Welding data display.....................................................................................................63
5.13.5.1 Welding current display (ignition, secondary, end and hotstart currents).....64
5.13.6 Expert menu (TIG)........................................................................................................65
5.13.6.1 Welding parameter setting............................................................................65
5.13.7 Arc ignition....................................................................................................................66
5.13.7.1 HF ignition.....................................................................................................66
5.13.7.2 Liftarc ignition................................................................................................66
5.13.7.3 Automatic cut-out ..........................................................................................66
5.13.8 Optimising the ignition characteristics for pure tungsten electrodes............................67
5.13.9 Optimal and fast spherical cup formation.....................................................................67
5.13.10 Function sequences/operating modes..........................................................................68
5.13.10.1Explanation of symbols .................................................................................68
5.13.10.2Non-latched mode.........................................................................................69
5.13.10.3Latched mode................................................................................................70
5.13.10.4spotArc ..........................................................................................................71
5.13.10.5Spotmatic ......................................................................................................73
5.13.10.6Non-latched operation, version C..................................................................74
5.13.11 Pulses, function sequences..........................................................................................75
5.13.11.1TIG pulses –non-latched operation..............................................................75
5.13.11.2TIG pulses - latched operation......................................................................75
5.13.12 Pulse variants...............................................................................................................76
5.13.12.1Pulses (thermal pulses).................................................................................76
5.13.12.2KHz pulses (metallurgic pulses)....................................................................77
5.13.12.3Automated pulses..........................................................................................77
5.13.12.4AC pulses......................................................................................................78
5.13.12.5AC special.....................................................................................................78
5.13.13 TIG activArc welding.....................................................................................................79
5.13.14 TIG antistick..................................................................................................................79
5.13.15 Welding torch (operating variants)................................................................................80
5.13.15.1Tap torch trigger (tapping function)...............................................................80
5.13.16 Torch mode and up/down speed setting ......................................................................81
5.13.16.1Standard TIG torch (5-pole) ..........................................................................82

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5.13.16.2TIG up/down torch (8-pole)...........................................................................84
5.13.16.3Potentiometer torch (8-pole).........................................................................86
5.13.16.4Configuring the TIG potentiometer torch connection....................................87
5.13.16.5RETOX TIG torch (12-pole)..........................................................................88
5.13.16.6Specifying max. no. of accessible JOBs.......................................................89
5.13.16.7Setting the first increment.............................................................................90
5.14 MMA welding ...............................................................................................................................91
5.14.1 Connecting the electrode holder and workpiece lead..................................................91
5.14.2 Select welding task.......................................................................................................92
5.14.3 Welding current polarity reversal (polarity reversal).....................................................92
5.14.4 Selection and adjustment.............................................................................................92
5.14.5 Frequency and balance setting....................................................................................93
5.14.6 Hotstart.........................................................................................................................93
5.14.6.1 Hotstart current .............................................................................................93
5.14.6.2 Hotstart time..................................................................................................94
5.14.7 Arcforce........................................................................................................................94
5.14.8 Antistick........................................................................................................................94
5.14.9 MMA pulse welding in the vertical up position (PF) .....................................................95
5.15 Welding programs........................................................................................................................96
5.15.1 Selection and adjustment.............................................................................................97
5.15.2 Specifying max. no. of accessible programs................................................................97
5.15.3 Example "Program with synergetic setting"..................................................................98
5.15.4 Example "Program with conventional setting"..............................................................98
5.15.5 Accessories for switching over programs.....................................................................98
5.16 Organising welding tasks (Mode "JOB Manager") ......................................................................99
5.16.1 Explanation of symbols ................................................................................................99
5.16.2 Creating a new JOB in the memory or copying a JOB...............................................100
5.16.3 Loading an existing JOB from the free memory.........................................................101
5.16.4 Resetting an existing JOB to the factory setting (Reset JOB) ...................................101
5.16.5 Resetting JOBs 1-128 to the factory setting (Reset All JOBs)...................................102
5.16.6 Exit JOB Manager without changes...........................................................................102
5.17 Remote control...........................................................................................................................103
5.17.1 Manual remote control RT1 19POL............................................................................103
5.17.2 RTG1 19POL manual remote control.........................................................................103
5.17.3 Manual remote control RTP1 19POL.........................................................................103
5.17.4 Manual remote control RTP2 19POL.........................................................................103
5.17.5 RTP3 spotArc 19POL manual remote control............................................................103
5.17.6 Manual remote control RT AC 1 19POL ....................................................................103
5.17.7 Manual remote control RT PWS 1 19POL.................................................................104
5.17.8 Foot-operated remote control RTF1 19POL 5 M / RTF2 19POL 5 M........................104
5.17.8.1 Ramp function foot-operated remote control RTF 1 / RTF 2......................105
5.18 Simultaneous welding on both sides, synchronisation types ....................................................106
5.18.1 Synchronisation via mains voltage (50Hz / 60Hz)......................................................106
5.18.2 Synchronisation via cable (frequency 50Hz to 200Hz) ..............................................107
5.19 Interfaces for automation...........................................................................................................108
5.19.1 TIG interface for mechanised welding........................................................................108
5.19.2 Remote control connection socket, 19-pole...............................................................109
5.20 Protecting welding parameters from unauthorised access........................................................110
5.21 PC interface...............................................................................................................................110
5.22 Machine configuration menu......................................................................................................110
5.22.1 Selecting, changing and saving parameters..............................................................110
5.22.2 Aligning the cable resistance......................................................................................116
5.22.3 Power-saving mode (Standby)...................................................................................117
6Maintenance, care and disposal.......................................................................................................118
6.1 Maintenance work......................................................................................................................118
6.2 General......................................................................................................................................118
6.3 Maintenance work, intervals......................................................................................................118
6.3.1 Daily maintenance tasks ............................................................................................118
6.3.1.1 Visual inspection.........................................................................................118
6.3.1.2 Functional test.............................................................................................118

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6.3.2 Monthly maintenance tasks........................................................................................119
6.3.2.1 Visual inspection .........................................................................................119
6.3.2.2 Functional test.............................................................................................119
6.3.3 Annual test (inspection and testing during operation)................................................119
6.4 Disposing of equipment..............................................................................................................120
6.4.1 Manufacturer's declaration to the end user................................................................120
6.5 Meeting the requirements of RoHS............................................................................................120
7Rectifying faults..................................................................................................................................121
7.1 Checklist for rectifying faults......................................................................................................121
7.2 Warnings (power source)...........................................................................................................123
7.3 Error messages (power source).................................................................................................124
7.4 Resetting welding parameters to the factory settings................................................................126
7.5 Display machine control software version..................................................................................127
7.6 General operating problems ......................................................................................................127
7.6.1 Interface for automated welding.................................................................................127
7.7 Vent coolant circuit.....................................................................................................................128
8Technical data.....................................................................................................................................129
8.1 Tetrix 351 AC/DC AW................................................................................................................129
8.2 Tetrix 451 AC/DC AW................................................................................................................130
8.3 Tetrix 551 AC/DC AW................................................................................................................131
9Accessories ........................................................................................................................................132
9.1 System components...................................................................................................................132
9.2 Options.......................................................................................................................................132
9.2.1 Tetrix 351 AC/DC........................................................................................................132
9.2.2 Tetrix 451, 551 AC/DC................................................................................................132
9.2.3 Tetrix 351, 451, 551 AC/DC .......................................................................................132
9.3 General accessories ..................................................................................................................133
9.4 Remote controls and accessories..............................................................................................133
9.5 Computer communication..........................................................................................................133
10 Appendix A..........................................................................................................................................134
10.1 JOB-List......................................................................................................................................134
11 Appendix B..........................................................................................................................................138
11.1 Overview of EWM branches.......................................................................................................138

Contents
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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
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!
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)!
WARNING
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!
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!

Safety instructions
General
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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!
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!
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!
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 Lifting by crane
DANGER
Risk of injury due to lifting by crane!
The hot wire welding system version (including machine carrier plate for wire feed unit
and hot wire power source) may not be lifted by crane!
•Do not lift hot wire welding systems by crane!
WARNING
Risk of injury during lifting by crane!
When lifting the machine by crane, persons may be severely injured by falling machines
or mount-on components.
•Simultaneous lifting of system components such as power source,wire
feeder or cooling unit without suitable crane components is not
allowed. Each system component has to be lifted separately!
•Remove any supply leads and accessories before lifting by crane(e.g.
hose package,wire spool,shielding gas cylinder,toolbox, wire feeder,
remote control,etc.)!)
•Properly close and lock all casing covers and protective capsbefore
lifting by crane!
•Use the correct number of hoisting equipment of the right size in the
correct position! Observe craning principle (see figure)!
•For machines with lifting eyes: always lift all lifting eyes simultaneously!
•When using retrofitted craning frames etc.: always use at least two
lifting points positioned as far apart as possible –observe option
description.
•Avoid any jerky movements!
•Ensure that the load is distributed evenly! • Use chain hoists and
chain slings of the same length only!
•Stay outside the danger zone underneath the machine!
•Observe the regulations regarding occupational safety and accident
prevention for the respective country.
Craning principle
Risk of injury due to unsuitable lifting eye!
In case of improper use of lifting eyes or the use of unsuitable lifting eyes, persons can
be seriously damaged by falling equipment or add-on components!
•The lifting eye must be completely screwed in!
•The lifting eye must be positioned flat onto and in full contact with the supporting surfaces!
•Check that the lifting eyes are securely fastened before use and check for any damage
(corrosion, deformation)!
•Do not use or screw in damaged lifting eyes!
•Avoid lateral loading of the lifting eyes!

Safety instructions
Transport and installation
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2.4.2 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!
2.4.2.1 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
2.4.2.2 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 TIG welding
TIG welding with alternating or direct current. Arc ignition optionally by means of non-contact HF ignition
or contact ignition with Liftarc.
3.1.1.1 TIG hot wire welding
The TIG hot wire welding system technology is based on the TIG cold wire welding system technology.
A wire feed system transports the wire-like welding consumable, which is heated at the stick-out between
contact tip and weld pool contact point by means of resistance heating. A second power source is
required for this resistance heating. Its secondary power circuit is closed by the wire's permanent contact
with the weld pool. The process of pre-heating the wire can be controlled in a wide range by the selected
hot wire power.
By pre-heating the wire, the energy taken from the weld pool for melting the wire can be reduced. This
allows a significantly larger amount of welding consumables to be used at a higher welding speed, thus
reducing the energy per unit length.
3.1.1.2 TIG cold wire welding
Cold wire welding is a variant of TIG welding featuring mechanically fed filler material. With this process,
cold welding wire is melted, without power, in the arc of a tungsten electrode.
3.1.1.3 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.
3.1.1.4 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.
3.1.1.5 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.
3.1.2 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
Use and operation solely with the following machines
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3.2 Use and operation solely with the following machines
TIG hot wire
TIG cold wire
Tetrix 351-551


Tetrix drive 4L


Tetrix 270 hotwire


TIG 450W KDK


TIG 450W HW


not possible
possible
3.3 Documents which also apply
3.3.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.3.2 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.
3.3.3 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.
3.3.4 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.
3.3.5 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
System overview
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4 Machine description – quick overview
4.1 System overview
The machine described in this manual is integrated into the welding system as shown in the
diagram.
Figure 4-1
Item
Symbol
Description 0
1
Wire feed unit
2
Power source (TIG)
Observe additional system documents!
3
Power source (TIG hot wire)
Observe additional system documents!

Machine description –quick overview
Tetrix 351 AC/DC AW
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4.2 Tetrix 351 AC/DC AW
4.3 Front view
Figure 4-2