EWM Picotig 200 AC/DC puls 5P TG Operating Instructions Manual
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Summary of Contents for EWM Picotig 200 AC/DC puls 5P TG
- Page 1 Operating instructions Welding machine Picotig 200 AC/DC puls 5P TG Picotig 200 AC/DC puls 8P TG 099-000188-EW501 22.02.2016...
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Page 2: General Instructions
+49 2680 181-0. 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. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 General ............................7 Transport and installation ......................11 2.4.1 Ambient conditions ....................... - Page 4 9 Accessories ............................69 Remote controls and accessories ....................69 9.1.1 Connection cables ......................69 9.1.2 Extension cable ......................69 Options ............................69 General accessories ........................69 10 Appendix A ............................70 10.1 Overview of EWM branches......................70 099-000188-EW501 22.02.2016...
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Page 5: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions 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. •... -
Page 6: Explanation Of Icons
Safety instructions Explanation of icons 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 enter the menu ENTER Navigating in the menu NAVIGATION Exit the menu EXIT... -
Page 7: General
Safety instructions General General DANGER Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •... - Page 8 Safety instructions General WARNING Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
- Page 9 Safety instructions General 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.
- Page 10 Safety instructions General 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.
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Page 11: Transport And Installation
Safety instructions Transport and installation 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! •... -
Page 12: Ambient Conditions
Safety instructions Transport and installation 2.4.1 Ambient conditions CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 13: Intended Use
3.1.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.1.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 14: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Carrying handle Machine control- See 4.3 Machine control – Operating elements chapter Connection socket, 5-pole/8-pole/12-pole (depending on variant) 5-pole: Standard TIG torch control lead 8-pole: TIG Up/Down or potentiometer torch control lead 12-pole:... -
Page 15: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Carrying strap - See 5.3.1 Adjusting the length of the carrying strap chapter Carrying handle Ignition type changeover switch- See 5.8.5 Arc ignition chapter Liftarc (contact ignition) HF ignition Main switch, machine on/off Cooling air outlet... -
Page 16: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values- See 5.7 Welding data display chapter Error/status displays ---------- Collective interference signal light -------- Water deficiency signal light (welding torch cooling) --------- Excess temperature signal light... - Page 17 Machine description – quick overview Machine control – Operating elements Item Symbol Description Gas post-flow time (TIG) Setting ranges: 0.1 s to 20.0 s (0.1 s increments). Welding current potential push-button -------- DC welding with negative polarity at the torch (or electrode holder) with respect to the workpiece.
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Page 18: Design And Function
Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 19: Workpiece Lead, General
Design and function Workpiece lead, general Workpiece lead, general CAUTION Risk of burns due to incorrect connection of the workpiece lead! Paint, rust and dirt on the connection restrict the power flow and may lead to stray welding currents. Stray welding currents may cause fires and injuries! •... -
Page 20: Transport And Installation
Design and function Transport and installation Transport and installation WARNING Risk of accident due to improper transport of machines that may not be lifted! Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only! •... -
Page 21: Mains Connection
Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations! •... -
Page 22: Notes On The Installation Of Welding Current Leads
Design and function Notes on the installation of welding current leads Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc (flickering). Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel. - Page 23 Design and function Notes on the installation of welding current leads Use an individual welding lead to the workpiece for each welding machine! Figure 5-4 Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders.
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Page 24: Welding Data Display
Design and function Welding data display Welding data display The following welding parameters can be displayed before (nominal values), during (actual values) or after welding (hold values): Parameter Nominal values Actual values Hold values Welding current ... -
Page 25: Tig Welding
Design and function TIG welding TIG welding 5.8.1 Welding torch and workpiece line connection Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-6 Item Symbol Description Welding torch Welding torch hose package Connection socket, "-"... -
Page 26: Torch Connection Options And Pin Assignments
Design and function TIG welding 5.8.1.1 Torch connection options and pin assignments Figure 5-7 5.8.2 Shielding gas supply (shielding gas cylinder for welding machine) WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. •... -
Page 27: Connecting The Shielding Gas Supply
Design and function TIG welding 5.8.2.1 Connecting the shielding gas supply • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. Figure 5-8 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve •... -
Page 28: Setting The Shielding Gas Quantity
Design and function TIG welding 5.8.2.2 Setting the shielding gas quantity CAUTION Electric shocks! When setting the shielding gas quantity, high voltage ignition pulses or open circuit voltage are applied at the welding torch; these can lead to electric shocks and burning on contact. -
Page 29: Welding Task Selection
Design and function TIG welding 5.8.3 Welding task selection The welding task is selected using the buttons on the machine control on the welding machine. Signal lights (LED) display the welding parameter selection. Set the welding task in the following order: Item Symbol Description Welding procedure push-button... -
Page 30: Average Value Pulse Welding
Design and function TIG welding 5.8.4 Average value pulse welding Average value pulse welding means that two currents are switched periodically, a current average value (AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the parameter as a percentage of the current average value (AMP). -
Page 31: Arc Ignition
Design and function TIG welding 5.8.5 Arc ignition 5.8.5.1 HF ignition Figure 5-11 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). -
Page 32: Function Sequences/Operating Modes
Design and function TIG welding 5.8.6 Function sequences/operating modes Using the welding parameter push-button and welding parameter setting rotary knob the sequence parameters are set. Figure 5-13 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. -
Page 33: Non-Latched Mode
Design and function TIG welding 5.8.6.2 Non-latched mode Figure 5-14 1st cycle: • Press and hold torch trigger 1. • The 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 set for the ignition current I start •... -
Page 34: Latched Mode
Design and function TIG welding 5.8.6.3 Latched mode Figure 5-15 Step 1 • Press torch trigger 1, the gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece, the arc ignites. • Welding current flows and immediately assumes the ignition current value set (search arc at minimum setting). -
Page 35: Welding Torch (Operating Variants)
Design and function TIG welding 5.8.7 Welding torch (operating variants) Different torch versions can be used with this machine. Functions on the operating elements, such as torch triggers (TT), rockers or potentiometers, can be modified individually via torch modes. Explanation of symbols for operating elements: Symbol Description Press torch trigger... -
Page 36: Tap Torch Trigger (Tapping Function)
Design and function TIG welding 5.8.7.1 Tap torch trigger (tapping function) Swiftly tap the torch trigger to change the function. The torch mode set determines the operating mode of the tapping function. The user has the modes 1 to 4 and modes 11 to 14 available. Modes 11 to 14 include the same function options as 1 to 4, but without tapping function for the secondary current. -
Page 37: Torch Mode And Up/Down Speed Setting
Design and function TIG welding 5.8.8 Torch mode and up/down speed setting The user has the modes 1 to 4 and modes 11 to 14 available. Modes 11 to 14 include the same function options as 1 to 4, but without tapping function for the secondary current. The function options in the individual modes can be found in the tables for the corresponding torch types. -
Page 38: Standard Tig Torch (5-Pole)
Design and function TIG welding 5.8.8.1 Standard TIG torch (5-pole) Standard torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT1 = Torch trigger 1 (welding current on/off; secondary current via tapping function) Functions mode Operating elements Welding current On/Off (factory-set) Secondary current (Latched mode) Standard torch with two torch triggers:... - Page 39 Design and function TIG welding Standard torch with one rocker (MG rocker, two torch triggers) Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Functions mode Operating elements Welding current On/Off Secondary current (factory-set) Secondary current (tapping mode) / (latched mode)
- Page 40 Design and function TIG welding Up/down torch with one torch trigger Figure Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions Mode Operating elements Welding current on/off Secondary current (tapping function)/(latched operating mode) (ex works) Increase welding current, infinite adjustment (up function) Decrease welding current, infinite adjustment (down function) Welding current on/off Secondary current (tapping function)
- Page 41 Design and function TIG welding Up/down torch with two torch triggers Figure Operating Explanation of symbols elements BRT 1 = torch trigger 1 (left) BRT 2 = torch trigger 2 (right) Functions Mode Operating elements Welding current on/off Secondary current Secondary current (tapping function)/(latched operating mode) (ex works) Increase welding current, infinite adjustment (up function)
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Page 42: Potentiometer Torch (8-Pole)
Design and function TIG welding 5.8.8.2 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch- See 5.8.8.3 Configuring the TIG potentiometer torch connection chapter. Potentiometer torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions... -
Page 43: Configuring The Tig Potentiometer Torch Connection
Design and function TIG welding 5.8.8.3 Configuring the TIG potentiometer torch connection 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. -
Page 44: Retox Tig Torch (12-Pole)
Design and function TIG welding 5.8.8.4 RETOX TIG torch (12-pole) For operation with this welding torch, the welding machine must be equipped with the retrofit option "ON 12POL RETOX TIG" (12-pole torch connection socket)! Diagram Operating elements Explanation of symbols TT= torch trigger Functions Mode... -
Page 45: Expert Menu (Tig)
Design and function TIG welding 5.8.9 Expert menu (TIG) The expert menu includes functions and parameters which are either not set on the machine control, or which do not require regular setting. ENTER EXIT Figure 5-19 Display Setting/selection Gas pre-flow time Setting range: 0.1 s to 5.0 s (0.1 s increments) Ignition current Setting range in percent: depending on main current... -
Page 46: Mma Welding
Design and function MMA welding MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •... -
Page 47: Welding Task Selection
Design and function MMA welding 5.9.2 Welding task selection It is only possible to change the basic parameters when no welding current is flowing and any possible access control is disabled. The welding task is selected using the buttons on the machine control on the welding machine. Signal lights (LED) display the welding parameter selection. -
Page 48: Average Value Pulse Welding
Design and function MMA welding 5.9.5 Average value pulse welding Average value pulse welding means that two currents are switched periodically, a current average value (AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the parameter as a percentage of the current average value (AMP). -
Page 49: Expert Menu (Mma)
Design and function Voltage reducing device 5.9.6 Expert menu (MMA) The expert menu includes functions and parameters which are either not set on the machine control, or which do not require regular setting. ENTER EXIT Figure 5-23 Display Setting/selection Hotstart current Hotstart current setting Hotstart time Hotstart time setting... -
Page 50: Remote Control
Design and function Remote control 5.11 Remote control The remote controls are operated on the 19-pole remote control connection socket (analogue). 5.11.1 RT1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. 5.11.2 RTG1 19POL Functions •... -
Page 51: Interfaces For Automation
Design and function Interfaces for automation 5.12 Interfaces for automation 5.12.1 Remote control connection socket, 19-pole CAUTION Damage to the machine due to improper connection! Unsuitable control leads or incorrect connection of input and output signals can cause damage to the machine. •... -
Page 52: Machine Configuration Menu
Design and function Machine configuration menu 5.13 Machine configuration menu ENTER (enter the menu) • Switch off machine at the main switch • Press and hold the "welding parameters" button and switch the machine on again at the same time. NAVIGATION (navigating in the menu) •... -
Page 53: Testing The Machine Fan
Design and function Machine configuration menu 5.13.2 Testing the machine fan The machine fan can be switched on at the machine controls so that you can check that it is working correctly. ENTER NAVIGATION EXIT Figure 5-26 Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access. -
Page 54: Protecting Welding Parameters From Unauthorised Access
Design and function Machine configuration menu 5.13.3 Protecting welding parameters from unauthorised access The machine code is set to 000 ex works and after each reset- See 7.3 Resetting welding parameters to the factory settings chapter. The machine code can also be user-defined- See 5.13.3.1 Changing the three-digit machine code chapter. -
Page 55: Changing The Three-Digit Machine Code
Design and function Machine configuration menu 5.13.3.1 Changing the three-digit machine code In this menu you can change the 3-digit machine code. After entering and confirming the old code, you can enter a new code. The correct machine code is necessary for activating and deactivating the access lock! ENTER NAVIGATION EXIT... -
Page 56: Setting The Welding Current (Absolute/Percentage)
Design and function Machine configuration menu 5.13.4 Setting the welding current (absolute/percentage) The welding currents for start current, secondary current, end current and hotstart current can be set as percentages (factory setting) or absolute values. If absolute current display is set, the "AMP" signal light for the main current is lit in addition to the respective "AMP%"... -
Page 57: Selecting The Welding Current Polarity During The Ignition Phase
Design and function Machine configuration menu 5.13.5 Selecting the welding current polarity during the ignition phase Selection of welding current polarity during ignition phase, until the arc stabilises. It always switches over to DC- polarity after a few milliseconds. ENTER NAVIGATION EXIT Figure 5-30... -
Page 58: Tig Antistick
Design and function Machine configuration menu 5.13.6 TIG antistick The function prevents uncontrolled re-ignition following the sticking of the tungsten electrode in the weld pool by switching off the welding current. In addition, wear at the tungsten electrode is reduced. The function takes effect in the main current phase of the latched operating mode- See 5.8.6.3 Latched mode chapter. -
Page 59: Choosing The Alternating Current Waveform
Design and function Machine configuration menu 5.13.7 Choosing the alternating current waveform ENTER EXIT Figure 5-32 Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access. Settings Settings for machine functions and parameter displays. Alternating current welding with rectangular current waveform Maximum power loading and safe welding Alternating current welding with trapezoidal current waveform An all-rounder, suitable for most applications... -
Page 60: Configuring The Tig Potentiometer Torch Connection
Design and function Machine configuration menu 5.13.7.1 Configuring the TIG potentiometer torch connection 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. -
Page 61: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Improper maintenance and testing The equipment may only be cleaned, repaired or tested by specialist, skilled persons! A skilled person is one who, due to training, knowledge and experience, is able to recognise the dangers that can occur during testing of this equipment as well as possible subsequent damage and who is able to implement the required safety procedures. -
Page 62: Annual Test (Inspection And Testing During Operation)
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU). -
Page 63: Rectifying Faults
Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer. - Page 64 Rectifying faults Checklist for rectifying faults Unstable arc Material inclusions in the tungsten electrode due to contact with filler material or workpiece Regrind or replace the tungsten electrode Incompatible parameter settings Check settings and correct if necessary Pore formation ...
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Page 65: Machine Faults (Error Messages)
Rectifying faults Machine faults (error messages) Machine faults (error messages) A welding machine error is indicated by the collective fault signal lamp (A1) lighting up and an error code (see table) being displayed in the machine control display. In the event of a machine error, the power unit shuts down. -
Page 66: Resetting Welding Parameters To The Factory Settings
Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. RESET Figure 7-1 Display Setting/selection Input confirmation User entries are applied, release button(s). 099-000188-EW501 22.02.2016... -
Page 67: Display Machine Control Software Version
Rectifying faults Display machine control software version Display machine control software version The query of the software versions only serves to inform the authorised service staff. It is available in the machine configuration menu. ENTER EXIT Figure 7-2 Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access. -
Page 68: Technical Data
Technical data Picotig 200 AC/DC Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Picotig 200 AC/DC Setting range Welding current 3 A–200 A 5 A–140 A 5 A–200 A Welding voltage 10.1 V–18.0 V 20.2 V–25.6 V Duty cycle (DC) at 25 °C 50% DC... -
Page 69: Accessories
Accessories Remote controls and accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Remote controls and accessories Type Designation Item no. RT1 19POL Remote control current 090-008097-00000 RTG1 19POL Remote control, current 090-008106-00000 RTF1 19POL 5 M... -
Page 70: Overview Of Ewm Branches
Appendix A Overview of EWM branches Appendix A 10.1 Overview of EWM branches 099-000188-EW501 22.02.2016...
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