EWM PICOTIG 180 AC/DC Operating Instructions Manual
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EWM PICOTIG 180 AC/DC Operating Instructions Manual

EWM PICOTIG 180 AC/DC Operating Instructions Manual

Tig and mma welding
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Operating instructions

Welding machines for
TIG and MMA welding
These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machine may only be operated by personnel familiar with the appropriate safety
regulations.
The machines bear the conformity mark and thus comply with the
• EC Low Voltage Guideline (73/23/EEC)
• EC EMV Directive (89/336/EEC)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
© 2008
Subject to alteration!
EWM HIGHTEC WELDING GmbH
Dr. Günter - Henle - Straße 8; D-56271 Mündersbach
Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244
www.ewm.de
Internet:
; E-mail:
Art. Nr.: 099-002004-EWM01
info@ewm.de
GB
Stand: 15.02.2008

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  • Page 1: Operating Instructions

    EWM HIGHTEC WELDING GmbH Dr. Günter - Henle - Straße 8; D-56271 Mündersbach Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244 www.ewm.de info@ewm.de Internet: ; E-mail: Operating instructions Welding machines for TIG and MMA welding These operating instructions must be read before commissioning.
  • Page 2 / or unauthorized modifications, which changements autorisés, Veränderungen, unsachgemäßen have not been expressly allowed by EWM, réparations inadéquates Reparaturen und / oder unerlaubten this declaration will lose its validity. modifications prohibeés, qui n´ont pas été Umbauten, die nicht ausdrücklich von autorisés expressément par EWM, cette...
  • Page 3 Congratulations! You have chosen a quality product from EWM HIGHTEC WELDING GmbH. EWM machines provide results of the highest perfection thanks to their PREMIUM quality. Therefore we are happy to provide you with a full 3-year warranty according to our operating instructions.
  • Page 4 Machine and Company Data Please enter the EWM machine data and your company’s data in the appropriate fields. EWM HIGHTEC WELDING GMBH D-56271 MÜNDERSBACH TYP: SNR: ART: PROJ: GEPRÜFT/CONTROL: Name of Customer / company Name of Customer / company Adress...

  • Page 5: Table Of Contents

    Table of contents Page Safety instructions ..........................S/1 For your safety ........................... S/1 Transport and set-up........................S/4 Notes on the use of these operating instructions............... S/4 Technical data ...........................1/1 Description of the machine ......................2/1 Function specification ......................3/1 Machine control units T2.10 and T2.15 ................3/1 Remote control........................3/4 Other setting options......................3/5 3.3.1...

  • Page 6: Safety Instructions

    Safety instructions For your safety Observe accident prevention regulations! Ignoring the following safety procedures can be fatal! Proper usage This machine has been manufactured according to the latest developments in technology and current regulations and standards. It is to be operated only for the use for which it was designed (see chapter Commissioning/Area of application).
  • Page 7 Safety instructions Workpiece, flying sparks and droplets are hot! • Keep children and animals well away from the working area. Their behaviour is unpredictable. • Move containers with inflammable or explosive liquids away from the working area. There is a danger of fire and explosion.

  • Page 8: Transport And Installation

    Safety instructions Transport and installation The machines may only be transported and operated in an upright position. Before carrying away or moving, pull out mains plug and place on the machine. When setting up the machine, resistance to tilting is only guaranteed up to an angle of 15° (as specified in EN 60974).

  • Page 9: Notes On The Use Of These Operating Instructions

    Safety instructions Notes on the use of these operating instructions These operating instructions are arranged into chapters. To help you find your way around more quickly, in the margins you will occasionally see symbols along with the sub-headings. These symbols refer to particularly important passages of text which are graded as follows depending on their importance: Please note: Technical features which users must observe.

  • Page 10: Technical Data

    Technical data PICOTIG 180 AC/DC PICOTIG 220 DC PICOTIG 220 AC/DC Setting range: Welding current / welding voltage 5A - 180A 3A (5A AC) -220A / 10,1V - 17,2V 10,1V -18,8V 5A - 140A 5A - 180A / 20,2V - 25,6V 20,2V - 27,2V Max.

  • Page 11: Description Of The Machine

    Description of the machine Front view Fig.2 / 1 PICOTIG 180; 220AC/DC Rear view Item Symbol Description Carrying handle with carrying strap Control (see chap. 3.1) G¼ connecting nipple Shielding gas to the welding torch Welding current potential "-" 5-pole connection socket Standard TIG torch control lead 8-pole connection socket TIG Up/Down or potentiometer torch control lead (option) Welding current socket "+"...

  • Page 12: Function Specification

    Function specification Machine control T 2.10 and T 2.15 T 2.10 VOLT Fig. 3/1: T 2.10 (PICOTIG 220 DC) T 2.15 VOLT Fig. 3/2: T 2.15 (PICOTIG 180; 220 AC/DC)
  • Page 13 Function specification Item Symbol Description Three-figure display (on when the machine is ready for operation) Depending on the setting on the key button (B1), displays the welding current and welding voltage. Display of error messages (see chap. 7) Display of the welding parameter values for the TIG process (F1): •...
  • Page 14 Function specification Item Symbol Description Excess temperature Thermal monitors in the power unit trigger at excess temperature and the excess temperature control lamp comes on. After cooling, welding can proceed without any further measures. Collective interference: If the collective interference signal light is on, the power unit is automatically switched off.

  • Page 15: Remote Control

    Function specification Remote control • Only the remote controls described in these operating instructions should be connected. • Only plug and lock the remote control unit into the remote control connection socket and only when the machine is switched off. •...

  • Page 16: Other Setting Options

    Function specification Other setting options In addition to the settings already described, other settings can be made using the T 2.10 or T 2.15. These settings are described in detail in the PICOTIG PRO mode operating instructions. The following values are set at the factory. 3.3.1 TIG welding parameters Parameters...

  • Page 17: Quick Start - The Fastest Way To Weld

    Quick start – the fastest way to weld Preparations Setting Fault elimination • Plug in the mains plug. • Set the welding process LED S - safety sign (PICOTIG 180; 220 AC/DC only): (Remember fuse!) If the LED is off, call the service dept. •...

  • Page 18: Commissioning

    Commissioning Area of application 5.1.1 Proper usage These welding machines are suitable exclusively for TIG and MMA welding. Any other use is regarded as "improper" and no liability is assumed for any damage arising therefrom. We can only guarantee smooth and trouble-free operation of the machines when used in conjunction with the welding torches and accessories from our range.

  • Page 19: Workpiece Lead

    Commissioning 5.5.1 Workpiece lead • Insert cable plug of the workpiece lead and lock by turning to the right. TIG welding: Welding current socket “+” (C1) MMA welding: Welding current socket “+” (C1) The polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

  • Page 20: General Setting Instructions

    Commissioning • Select latched mode with the key button (chap. 3, D1). During the adjustment, the open-circuit voltage is applied to the torch electrode (when the torch trigger has been pressed). • Press and release the torch trigger. • Slowly open the gas cylinder valve. •...

  • Page 21: Tig Welding

    Commissioning Antistick: If the stick electrode sticks in spite of the arcforcing device, the machine automatically switches over to the minimum current within about 1 sec, so that overheating of the electrode is prevented. If the antistick device has been triggered, check the welding current setting and correct if necessary. After welding, place electrode holder onto insulated base, switch off welding machine.

  • Page 22: Tig Welding With Hf Ignition

    Commissioning Finish welding: • Activate torch trigger in accordance with the operating mode selected. • After welding, place electrode holder onto insulated base, switch off welding machine. Tungsten electrode is hot! 5.8.2 TIG welding with HF ignition • Select HF ignition type using changeover switch (H1). •...

  • Page 23: Tig Welding Torch, Operating Variants

    Commissioning 5.8.4 TIG welding torch, operating variants The welding process can be controlled with various torch designs (TT=torch trigger): In addition to the operating variants described in chaps. 5.8.4.1 and 5.8.4.2, other variants can be found in the PICOTIG PRO mode operating instructions. 5.8.4.1 Standard TIG torch, 5-pole connector plug (factory setting) The welding machine is prepared for these torch types as standard.

  • Page 24: Tig Function Sequences

    Commissioning 5.8.6 TIG function sequences All the parameters for the TIG process can be controlled using the key button (F1) to select the parameters and the rotary transducer (G1) to set them: • Main current AMP, • Down-slope time, • Gas post-flow time 5.8.6.1 Explanation of symbols Symbol...

  • Page 25: Tig Non-Latched Operation

    Commissioning 5.8.6.2 TIG non-latched operation • Adjust the appropriate key buttons or changeover switches to the following settings: start Down Fig. 3/4: Function sequence of TIG non-latched operation 1st step: • Press and hold torch trigger 1. • The gas pre-flow time passes. •...

  • Page 26: Tig Latched Operation

    Commissioning 5.8.6.3 TIG latched operation • Adjust the appropriate key buttons or changeover switches to the following settings: AMP% start Down Fig. 3/5: TIG latched function sequence Step 1 • Press torch trigger 1, the gas pre-flow time passes. • HF ignition pulses jump from the electrode to the workpiece, the arc ignites. •...

  • Page 27: Cooling Unit Function Specification (Optional)

    Commissioning Cooling unit function specification (optional) A functional test is performed on the cooling module after the welding machine has been switched The coolant pump and the fan are switched on. When the pump is running, there is a sufficient coolant level and enough through-put, the cooling module is switched off.

  • Page 28: Maintenance And Care

    DIN EN 61010-1 Appendix A – Measuring Circuit A1. Have this confirmed in writing if necessary. EWM as a manufacturer has specified a separate test device and provides its EWM dealers with the necessary support to conduct a repetition test to E VDE 0544-207 correctly.
  • Page 29 Maintenance and care 6.3.1 Test intervals and scope A quarterly partial test and an annual extensive test are to be carried out. The extensive test must also be carried out each time that repairs are made; in the case of heavy use, the period can be reduced (e.g.
  • Page 30 Maintenance and care 6.3.5 Measurement of insulation resistance The mains switch must be on before the insulation in the interior of the machine through to the transformer can be checked. If a mains contactor is fitted, this should be bridged or the measurement must be carried out on both sides.

  • Page 31: Repair Work

    We hereby confirm that the servicing and maintenance guidelines given above, and the repetition test described above, have been conducted correctly in accordance with E VDE 0544 207. Date / Stamp / Signature of EWM sales partner Date / Stamp / Signature of EWM sales partner...

  • Page 32: 3-Year Warranty

    Cooling units • Trolley 1 year warranty on remote controls and used EWM machines. 6 month warranty on spare parts supplied separately (e.g. circuit boards, ignition units). Replaceable parts are components that are subject to mechanical ageing (e.g. motors, gears, pumps, fans, WF rollers, wheels, solenoid valves, etc.) and are thus excluded from the warranty.

  • Page 33: Warranty Declaration

    EWM. In no way will EWM be responsible for lost profits, indirect or subsequent damage. EWM is not liable for damages based on the claims of third parties.

  • Page 34: Operating Problems, Causes And Remedies

    Operating problems, causes and remedies Error messages • In the event of a machine error, an error code (see table below) is shown on the display (chap. 3, A1). • If multiple errors occur, they should be rectified in sequence. Error message Possible cause Remedy...

  • Page 35: Spare Parts List

    Spare parts list PICOTIG 180 AC/DC: in Bearbeitung/ in preparation Abb. 8/1: Vorderseite; Fig. 8/1: front view Item Designation Description PICOTIG 180; 220 Griffstange Hand grip 094-007501-00003 Halterung für Griffstange Hand grip mount 094-007383-00003 Gehäusewinkel Casing angle 094-007900-00002 Steuerung T2.15 komplett Control T2.15 complete...
  • Page 36 Spare parts list Abb. 8/2 Rückseite / Fig. 8/2 rear view Item Designation Description PICOTIG 180; 220 Kippschalter Toggle switch 094-001898-00000 Anschlußbuchse 8-polig (Option) Connection socket, 8-pole 094-006904-00000 (optional) Netzschalter Mains switch 094-008045-00000 Anbau Gehäuse (Option) Housing extension (optional) 094-006861-00000 Abdeckkappe (Option) Cap (optional) 094-006862-00000...
  • Page 37 Spare parts list Abb. 8/3: linke Seite; Fig. 8/3: left side (PICOTIG 220 DC) Item Designation Description PICOTIG 220 DC Drossel-Hochsetzsteller Choke power factor correction 044-002685-00000 Haupttrafo Main transformer 092-001560-00001 Lüfter 094-007861-00000 Sekundärdioden Secondary diode 044-002312-00000 LEM-Wandler LF205-S/SP1 LEM-converter LF205-S/SP1 044-002691-00000 PCB Spannungsverdoppler SV2/1 PCB voltage doubler SV2/1...
  • Page 38 Spare parts list Abb 8/4: rechte Seite; Fig. 8/4: right side (PICOTIG 220 DC) Item Designation Description PICOTIG 220 DC Steuerung T200/1 PICOTIG T200/1 PICOTIG control 040-000631-00000 Steuerung T201/2 DC T201/2 DC control 042-000653-00000 PCB Zündgerät HFAC4 PCB ignition unit HFAC4 040-000622-00000 Steuerung DC 220 Control DC 220...
  • Page 39 Spare parts list Abb. 8/5: linke Seite; Fig. 8/5: left side (PICOTIG 220 AC/DC) Item Designation Description PICOTIG 220 AC/DC Drossel-Hochsetzsteller Choke power factor correction 044-002685-00000 Haupttrafo Main transformer 092-001560-00001 Lüfter 094-007861-00000 Sekundärdioden (4x) Secondary diodes (4 x) 044-002601-00000 BYT200 PIV400 BYT200 PIV400 Wechselrichter-Module (4x) Inverse rectifier modules (4 x)
  • Page 40 Spare parts list Abb. 8/6: rechte Seite; Fig. 8/6: right side (PICOTIG 220 AC/DC) Item Designation Description PICOTIG 220 AC/DC PCB Schweißelektronik T200/1 PICOTIG PCB welding electronics T200/1 040-000631-00000 PICOTIG PCB Tastatur T201/2 PCB key board T201/2 042-000653-00000 PCB Zündgerät HF AC4 PCB ignition unit HF AC4 040-000622-00000 Frontblech...

  • Page 41: Accessories, Options

    Accessories, options 10.1 Standard TIG torch Designation, description Item No. WIG torch 26 GD, 4m, two triggers 094-000538-00000 WIG torch 20 WD, 4m, two triggers 094-000487-00000 10.2 TIG Up/Down torch Designation, description Item No. Opt. 8-pole connection socket for potentiometer and Up/Down torch 092-001530-00000 WIG torch 26 Up-Down GD, 4m 094-007549-00000...

  • Page 42: Circuit Diagrams

    Circuit diagrams 11.1 PICOTIG 180 AC/DC X2/1 X2/2 X2/3 X2/4 X2/5 X2/6 X2/7 I10A X2/8 X2/9 X2/10 +15V X2/11 +15V X2/12 +24V X2/13 +24V X2/14 X2/15 X2/16 X2/17 X2/18 UZWK X2/19 X2/20 -15V X2/21 Temp X2/22 X2/23 X2/24 X2/25 X2/26...
  • Page 43 Circuit diagrams X11/1 X11/2 X11/3 X11/4 X7/1 X1/1 X7/2 X1/2 X7/3 X1/3 X7/4 X1/4 X7/5 X1/5 X7/6 X1/6 X7/7 X1/7 X7/8 X1/8 I10A TRST X7/9 X1/9 EMU1 X7/10 X1/10 X1/11 +15V X1/12 +15V X1/13 +24V X10/1 X1/14 +24V RXD UC X10/2 X1/15 X10/3...
  • Page 44 Circuit diagrams 11.2 PICOTIG 220 DC X2/1 X2/2 X2/3 X2/4 X2/5 X2/6 X2/7 I10A X2/8 X2/9 X2/10 +15V X2/11 +15V X2/12 +24V X2/13 +24V X2/14 X2/15 X2/16 X2/17 X2/18 UZWK X2/19 X2/20 -15V X2/21 Temp X2/22 X2/23 X2/24 X2/25 X2/26 11/3...
  • Page 45 Circuit diagrams X11/1 X11/2 X11/3 X11/4 X7/1 X1/1 X7/2 X1/2 X7/3 X1/3 X7/4 X1/4 X7/5 X1/5 X7/6 X1/6 X7/7 X1/7 X7/8 X1/8 I10A X7/9 TRST X1/9 X7/10 EMU1 X1/10 X1/11 +15V X1/12 +15V X1/13 +24V X10/1 X10/2 X1/14 +24V RXD UC X10/3 X1/15 X1/16...
  • Page 46 Circuit diagrams 11.3 PICOTIG 220 AC/DC X2/1 X2/2 X2/3 X2/4 X2/5 X2/6 X2/7 I10A X2/8 X2/9 X2/10 +15V X2/11 +15V X2/12 +24V X2/13 +24V X2/14 X2/15 X2/16 X2/17 X2/18 UZWK X2/19 X2/20 -15V X2/21 Temp X2/22 X2/23 X2/24 X2/25 X2/26 X1/1 X1/2 X1/3...
  • Page 47 Circuit diagrams X11/1 X11/2 X11/3 X11/4 X7/1 X1/1 X7/2 X1/2 X7/3 X1/3 X7/4 X1/4 X7/5 X1/5 X7/6 X1/6 X7/7 X1/7 X7/8 X1/8 I10A TRST X7/9 X1/9 EMU1 X7/10 X1/10 X1/11 +15V X1/12 +15V X1/13 +24V X10/1 X1/14 +24V RXD UC X10/2 X1/15 X10/3...

This manual is also suitable for:

Picotig 220 dcPicotig 220 ac/dc

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