EWM Tetrix AC/DC Smart 2.0 User manual

Operating instructions
EN
Control
T4.04 - Tetrix AC/DC Smart 2.0
T4.10 - Tetrix AC/DC Smart 2.0
099-00T404-EW501
Observe additional system documents!
02.07.2020

General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read and observe the operating instructions for all system components, especially the sa-
fety instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the location where the machine is operated.
•Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and re-
pair the machine.
•Technical changes due to further development in machine technology may lead to a dif-
fering welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers.
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 ac-
cepted 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
Tel.: [phone], Fax: -244
Email: [email protected]
www.ewm-group.com
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.

Contents
Notes on using these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2For your safety.......................................................................................................................................5
2.1 Notes on using these operating instructions..................................................................................5
2.2 Explanation of icons.......................................................................................................................5
2.3 Part of the complete documentation..............................................................................................7
3Intended use...........................................................................................................................................8
3.1 Use and operation solely with the following machines..................................................................8
3.2 Documents which also apply.........................................................................................................8
3.3 Software version............................................................................................................................8
4Machine control –Operating elements................................................................................................9
4.1 Overview of control sections..........................................................................................................9
4.1.1 Control section A..........................................................................................................10
4.1.2 Control section B..........................................................................................................11
4.2 Machine display...........................................................................................................................12
4.2.1 Setting the welding current (absolute/percentage).......................................................12
4.3 Operating the machine control.....................................................................................................12
4.3.1 Main screen..................................................................................................................12
4.3.2 Welding power setting..................................................................................................12
4.3.3 Welding parameter setting in the operation sequence.................................................13
4.3.4 Setting advanced welding parameters (Expert menu).................................................13
4.3.5 Changing basic settings (machine configuration menu) ..............................................13
5Functional characteristics...................................................................................................................14
5.1 TIG welding..................................................................................................................................14
5.1.1 Setting the shielding gas volume (gas test)/rinse hose package.................................14
5.1.1.1 Automatic gas post-flow................................................................................14
5.1.2 Welding task selection..................................................................................................15
5.1.3 AC welding ...................................................................................................................16
5.1.3.1 AC balance (optimise cleaning effect and penetration characteristics)........16
5.1.3.2 AC commutation optimisation.......................................................................16
5.1.3.3 Alternating current waveforms......................................................................17
5.1.4 Arc ignition....................................................................................................................18
5.1.4.1 HF ignition.....................................................................................................18
5.1.4.2 Liftarc ............................................................................................................18
5.1.4.3 Automatic cut-out..........................................................................................18
5.1.5 Operating modes (functional sequences) ....................................................................19
5.1.5.1 Explanation of symbols.................................................................................19
5.1.5.2 Non-latched mode.........................................................................................20
5.1.5.3 Latched mode ...............................................................................................21
5.1.5.4 spotArc..........................................................................................................22
5.1.5.5 spotmatic.......................................................................................................24
5.1.5.6 Non-latched operation, version C .................................................................25
5.1.6 Average value pulse welding........................................................................................26
5.1.6.1 Pulsed welding in the upslope and downslope phases ................................27
5.1.6.2 Automated pulses .........................................................................................27
5.1.7 TIG activArc welding.....................................................................................................28
5.1.8 TIG antistick..................................................................................................................28
5.1.9 Welding torch (operating variants) ...............................................................................28
5.1.9.1 Tapping function (tap torch trigger)...............................................................28
5.1.9.2 Torch mode setting.......................................................................................29
5.1.9.3 Up/down speed.............................................................................................29
5.1.9.4 Current jump .................................................................................................29
5.1.9.5 Standard TIG torch (5-pole)..........................................................................30
5.1.9.6 TIG up/down torch (8-pole)...........................................................................32
5.1.9.7 Potentiometer torch (8-pole).........................................................................34
5.1.9.8 Configuring the TIG potentiometer torch connection....................................35
5.1.10 RTF 1 foot-operated remote control.............................................................................36
5.1.10.1 RTF start ramp..............................................................................................36
5.1.10.2 RTF response ...............................................................................................37

Contents
Notes on using these operating instructions
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5.1.11 Expert menu (TIG)........................................................................................................38
5.1.12 Aligning the cable resistance........................................................................................39
5.2 MMA welding................................................................................................................................40
5.2.1 Welding task selection..................................................................................................40
5.2.2 Hotstart .........................................................................................................................41
5.2.3 Arcforce.........................................................................................................................41
5.2.4 Antistick.........................................................................................................................41
5.2.5 Average value pulse welding........................................................................................42
5.2.6 Expert menu (MMA)......................................................................................................43
5.3 Power-saving mode (Standby).....................................................................................................44
5.4 Access control..............................................................................................................................44
5.5 Voltage reducing device...............................................................................................................44
5.6 Machine configuration menu........................................................................................................45
5.6.1 Selecting, changing and saving parameters.................................................................45
6Rectifying faults....................................................................................................................................49
6.1 Warnings......................................................................................................................................49
6.2 Error messages............................................................................................................................50
6.3 Resetting welding parameters to the factory settings..................................................................51
6.4 Display machine control software version....................................................................................51
7Appendix...............................................................................................................................................52
7.1 Parameter overview –setting ranges ..........................................................................................52
7.1.1 TIG welding...................................................................................................................52
7.1.2 MMA welding................................................................................................................53
7.2 Searching for a dealer..................................................................................................................54

For your safety
Notes on using these operating instructions
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2 For your safety
2.1 Notes on using these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
•The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
•Safety notes include the "WARNING" keyword in the heading with a general warning sym-
bol.
•The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
•The safety information includes the "CAUTION" keyword in its heading with a general warn-
ing symbol.
•The risk is explained using a symbol on the edge of the page.
Technical aspects which the user must observe to avoid material or equipment damage.
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.
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 hold
Switch
Incorrect / Invalid
Turn
Correct / Valid
Numerical value –adjustable
Input
Signal light lights up in green
Navigation
Signal light flashes green

For your safety
Part of the complete documentation
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Symbol
Description
Symbol
Description
Output
Signal light lights up in red
Time representation (e.g.: wait 4 s /
actuate)
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
This document is 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
Documentation
A.1
Options conversion instructions
A.2
Control
A.3
Power source
A.4
Cooling unit, voltage converter, tool box etc.
A.5
Transport cart
A.6
Welding torch
A.7
Remote control
A
Complete documentation

Intended use
Use and operation solely with the following machines
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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 Use and operation solely with the following machines
•Tetrix 300 AC/DC Smart 2.0 (T4.04)
•Tetrix 351-551 AC/DC Smart 2.0 (T4.10)
3.2 Documents which also apply
•Operating instructions for the connected welding machines
•Documents of the optional expansions
3.3 Software version
These instructions apply to the following software version:
07.03F0
The software version of the machine control can be displayed in the machine configuration menu
(menu Srv) > see 5.6 chapter.

Machine control –Operating elements
Overview of control sections
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4 Machine control – Operating elements
4.1 Overview of control sections
For description purposes, the machine control has been divided into two sections (A, B) to ensure
maximum clarity. The setting ranges for the parameter values are summarised in the parameter
overview section > see 7.1 chapter.
Figure 4-1
Item
Symbol
Description 0
1
Control section A
> see 4.1.1 chapter
2
Control section B
> see 4.1.2 chapter

Machine control –Operating elements
Overview of control sections
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4.1.1 Control section A
Figure 4-2
Item
Symbol
Description 0
1
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 4.2 chapter
2
Push-button gas test / rinse hose package > see 5.1.1 chapter
3
Operating mode > see 5.1.5 chapter / power-saving mode push-
button > see 5.3 chapter
--------- Latched
------- Non-latched
------- spotArc spot welding procedure –signal light turns green
------- spotmatic spot welding procedure –signal light turns red
--------- Press button for long interval to put machine into power-saving mode.
Activate one of the operating elements to reactivate.
4
Pulsed welding push-button
TIG ------ pulsed welding > see 5.1.6 chapter
MMA ---- pulsed welding > see 5.2.5 chapter
5
Welding current polarity push-button
-------- DC welding with negative polarity at the torch (or electrode holder) with
respect to the workpiece.
-- Alternating current welding/alternating current forms > see 5.1.3.3 chapter
6
Welding procedure push-button
--------- TIG welding
----- MMA welding (signal light turns green)
----- Arcforce setting (signal light turns red)
7
Display switching push-button
kW------- Welding power display
V --------- Welding voltage display
8
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 4.2 chapter
9
TIG ignition type signal light
Signal light on: Lift arc ignition active/HF start off. You can switch the ignition type in the
Expert menu (TIG) > see 5.1.11 chapter.

Machine control –Operating elements
Overview of control sections
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Item
Symbol
Description 0
10
Character function signal light
Indicates that it is possible to weld in an environment with major electric hazards, such
as in boilers. Service must be informed if this signal light is not on.
11
Coolant fault signal light
Signals pressure loss or low coolant level in the coolant circuit.
12
VRD
Voltage reduction device (VRD) signal light > see 5.5 chapter
13
Hold
Signal light Status display
After each completed welding task, the last values used in the welding process for the
welding current and welding voltage are shown on the displays, and the signal light will
be on
14
Excess temperature signal light
In case of excess temperature, temperature monitors de-activate the power unit, and
the excess temperature control lamp comes on. Once the machine has cooled down,
welding can continue without any further measures.
15
Access control active signal light
Signal light is on when access control is active on the machine con-
trol > see 5.4 chapter.
16
Without function in this machine version.
4.1.2 Control section B
Figure 4-3
Item
Symbol
Description 0
1
Parameter selection push-button, left
The welding sequence parameters are selected one after another in an anti-clockwise
direction. For control systems without this button settings are done exclusively via the
control button.
2
Control button
Central control button to be pressed or turned > see 4.3 chapter.
3
Parameter selection push-button, right
The welding sequence parameters are selected one after another in a clockwise direc-
tion. For control systems without this button settings are done exclusively via the con-
trol button.
4
Balance signal light
Pulse balance
5
Electrode diameter signal light
Ignition optimisation (TIG)/tungsten balling basic setting

Machine control –Operating elements
Machine display
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Item
Symbol
Description 0
6
Gas post-flow time
7
sec
Down-slope time signal light
8
AMP%
sec
Signal light, two colour
Red: Secondary or pulse pause current (% of AMP)
Green: Pulse pause time /slope time (Expert menu)
9
AMP
sec
Signal light, two colour
Red: Main or pulse current
Green: Pulse time /slope time (AMP to AMP%, Expert menu)
10
sec
Signal light
Up-slope time (TIG)
11
Signal light activArc > see 5.1.7 chapter
12
signal light
4.2 Machine display
The following welding parameters can be displayed before (nominal values), during (actual values) or af-
ter welding (hold values):
"left display"
Parameter
Before welding
(nominal values)
During welding
(actual values)
After welding
(hold values)
Welding current



Parameter times



Parameter currents



Frequency, balance



"right display"
Welding power



Welding voltage



When the hold values are displayed after welding and the settings are then changed (e.g. welding cur-
rent), the display will switch to the relevant nominal values.
possible
not possible
The parameters that can be set in the function sequence of the machine control depend on the selected
welding task. This means that if for example you have not selected a pulse variant, then you cannot set
any pulse times in the function sequence.
4.2.1 Setting the welding current (absolute/percentage)
The welding current for the ignition, secondary, end and hot start current can be set as a percentage of
the main current AMP or as an absolute value. To select, use the parameter <dg in the configuration
menu_ref_source_inline>Gerätekonfigurationsmenü</dg_ref_source_inline>.
> see 5.6 chapter
4.3 Operating the machine control
4.3.1 Main screen
The machine control switches to the main screen after it has been turned on or a setting has been com-
pleted. This means that the previously selected settings (indicated by signal lights where applicable) and
the nominal value for the current (A) are displayed in the left-hand welding data display. Depending on
the selection, the right-hand display shows the welding voltage (V) nominal value or the welding power
(kW) actual value. The control always switches back to the main screen after 4 sec..
4.3.2 Welding power setting
The welding power is set using the control button. You can also adjust the parameters in the operation
sequence or settings in the different machine menus.

Machine control –Operating elements
Operating the machine control
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4.3.3 Welding parameter setting in the operation sequence
Welding parameters are set by briefly pressing the control knob (selecting the function sequence) and
then turning the knob (navigation to the desired parameter). Press again to apply the selected parameter
as the setting (corresponding parameter value and signal light flash). Turn the button to set the parameter
value.
During welding parameter setting, the parameter value to be set flashes in the left hand display. A para-
meter abbreviation or a deviation in the specified parameter value upwards or downwards is shown on
the right-hand display:
Display
Meaning
Increase the parameter value
To return to the factory settings.
Factory setting (example value = 20)
Parameter is set to optimum value
Decrease the parameter value
To return to the factory settings.
4.3.4 Setting advanced welding parameters (Expert menu)
The Expert menu contains functions and parameters which cannot be set directly in the machine control
or which do not need to be et on a regular basis. The number and display of these parameters depends
on the previously selected welding procedure or the functions.
To select them hold the control button for more than 2 sec. Select the required parameter/menu item by
turning (navigate) and pressing (confirm) the control button.
You can also or alternatively use the push-buttons to the left and right of the control button to navigate.
4.3.5 Changing basic settings (machine configuration menu)
The basic welding system functions can be adjusted in the machine configuration menu. Only experi-
enced users should change the settings > see 5.6 chapter.

Functional characteristics
TIG welding
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5 Functional characteristics
5.1 TIG welding
5.1.1 Setting the shielding gas volume (gas test)/rinse hose package
•Slowly open the gas cylinder valve.
•Open the pressure regulator.
•Switch on the power source at the main switch.
•Set the relevant gas quantity for the application on the pressure regulator.
•The gas test can be activated at the machine control by pressing the "Gas test/purge " push-
button > see 4.1.1 chapter.
Setting the shielding gas quantity (gas test)
•Shielding gas flows for approx. 20 seconds or until the push-button is pressed again.
Purging long hose packages (purging)
•Press push-button for about 5 s. • Shielding gas flows for approx. 5 min. or until the push-button is
pressed again.
If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause
pores to form. Adjust the shielding gas quantity to suit the welding task!
Setting instructions
Welding process
Recommended shielding gas quantity
MAG welding
Wire diameter x 11.5 = l/min
MIG brazing
Wire diameter x 11.5 = l/min
MIG welding (aluminium)
Wire diameter x 13.5 = l/min (100 % argon)
TIG
Gas nozzle diameter in mm corresponds to l/min gas throughput
Helium-rich gas mixtures require a higher gas volume!
The table below can be used to correct the gas volume calculated where necessary:
Shielding gas
Factor
75% Ar/25% He
1.14
50% Ar/50% He
1.35
25% Ar/75% He
1.75
100% He
3.16
For connecting the shielding gas supply and handling the shielding gas cylinder refer to the
power source operating instructions.
5.1.1.1 Automatic gas post-flow
If the function is active, the gas post-flow time is defined by the machine control unit in dependence on
power output. The defined gas post-flow time can also be adjusted if required. This value is then saved
for the current welding task. The automatic gas post-flow function can be activated or deactivated in the
machine configuration menu > see 5.6 chapter.

Functional characteristics
TIG welding
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5.1.2 Welding task selection
The setting of the tungsten electrode diameter has a direct influence on the machine functionality, TIG ig-
nition behaviour and minimum current limits. The ignition energy is controlled by the set electrode diame-
ter. Smaller electrode diameters requires less ignition current and less ignition current time than greater
electrode diameters. The set value should correspond to the tungsten electrode diameter. The value can
also be set to meet individual requirements, e.g. for thin panels a smaller diameter is recommended to
reduce the ignition energy.
The electrode diameter setting determines the minimum current limit, which in turn affects the ignition,
main and secondary current. The minimum current limits have a positive effect on the ignition behaviour
and ensure a very high arc stability for each electrode diameter selected. The minimum current limit func-
tion is enabled ex works, but can be disabled with parameter in the machine configuration
menu > see 5.6 chapter.
For foot-operated remote control mode, minimum current limits are disabled by default.
The following welding task is an example of use:
EXIT
4s
mm
inch
Figure 5-1

Functional characteristics
TIG welding
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5.1.3 AC welding
5.1.3.1 AC balance (optimise cleaning effect and penetration characteristics)
To weld aluminium and aluminium alloys, AC welding is used in combination with a continuous change in
polarity of the tungsten electrode. The process encompasses two phases (half-waves): a positive and a
negative one. The positive phase cracks the aluminium oxide layer on the material surface (so called
cleaning effect).
At the same time, tungsten balling occurs at the tip of the tungsten electrode. The size of this balled end
depends on the length of the positive phase. Please note that an excessively big balled end will cause the
arc to become unstable and diffuse, with low penetration. In the negative phase, the tungsten electrode is
cooled and the required penetration is realised. Make sure to select the correct durations (balance) for
positive phase (cleaning effect, balled end size) and negative phase (penetration depth) by setting the AC
balance. The default (zero setting) balance setting is 65%, referring to the duration of the negative half-
wave.
Figure 5-2
5.1.3.2 AC commutation optimisation
The AC commutation assistance function can help to increase process stability when welding materials
such as pure aluminium. If half-wave failures should occur during the welding process, the parameter can
be increased, counteracting half-wave failures.
The parameter must first be switched on in the machine configuration menu > see 5.6 chapter. The
parameter value can then be selected and set in the Expert menu > see 5.1.11 chapter.

Functional characteristics
TIG welding
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5.1.3.3 Alternating current waveforms
Selection
EXIT
4s
Figure 5-3
Display
Setting/selection
Alternating current waveforms 1
-------Rectangular - Highest energy input (ex works)
-------Trapezoidal - An all-rounder, suitable for most applications
-------Sine - Low noise level
1for AC welding machines only.

Functional characteristics
TIG welding
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5.1.4 Arc ignition
To change the ignition type, use parameter to switch between HF start ( ) and lift arc ( ) in the
Expert menu > see 5.1.11 chapter.
5.1.4.1 HF ignition
Figure 5-4
The arc is started without contact from high-voltage ignition pulses.
a) Position the welding torch in welding position over the workpiece (distance between the electrode tip
and workpiece should be approx. 2-3mm).
b) Press the torch trigger (high voltage ignition pulses ignite the arc).
c) Ignition current flows, and the welding process is continued depending on the operating mode select-
ed.
End the welding process: Release or press the torch trigger depending on the operating mode
selected.
5.1.4.2 Liftarc
Figure 5-5
The arc is ignited on contact with the workpiece:
a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch
trigger (liftarc current flowing, regardless of the main current set).
b) Incline the torch over the torch gas nozzle to produce a gap of approx. 2-3 mm between the electrode
tip and the workpiece. The arc ignites and the welding current is increased, depending on the operat-
ing mode set, to the ignition or main current set.
c) Lift off the torch and swivel to the normal position.
Ending the welding process: Release or press the torch trigger depending on the operating mode select-
ed.
5.1.4.3 Automatic cut-out
Once the fault periods have elapsed, the automatic cut-out stops the welding process when it has been
triggered by one of two states:
•During ignition
5 s after the start of the welding process, no welding current flows (ignition error).
•During welding
The arc is interrupted for more than 5 s (arc interruption).
> see 5.6 chapter
You can disable or set the time for re-ignition after an arc interruption in the machine configuration
menu > see 5.6 chapter (parameter ).
The setting is specified separately for each welding task (JOB).

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

Functional characteristics
TIG welding
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5.1.5.2 Non-latched mode
Selection
Figure 5-6
Sequence
Figure 5-7
1st cycle:
•Press torch trigger 1 and hold down.
•Gas pre-flow time elapses.
•HF ignition pulses jump from the electrode to the workpiece. The arc ignites.
•The welding current flows and immediately assumes the value of the ignition current .
•HF switches off.
•The welding current ramps up to the main current (AMP) in the selected up-slope time .
If torch trigger 2 is pressed together with torch trigger 1 during the main current phase, the welding cur-
rent decreases to the secondary current (AMP%) in the set slope time .
If torch trigger 2 is released, the welding current increases again to the main current AMP in the set slope
time . The parameters and can be set in the Expert menu (TIG) > see 5.1.11 chapter.
2nd cycle:
•Release torch trigger 1.
•The main current falls to the end-crater current (minimum current) in the set down-slope time .
If the 1st torch trigger is pressed during the down-slope time,
the welding current returns to the set main current AMP
•Main current reaches the end-crater current ; the arc is extinguished.
•Set gas post-flow time elapses.
When the foot-operated remote control is connected, the machine switches automatically to non-latched
operation. The up- and down-slopes are switched off.