Related Manuals for EWM TIG 200 GRIP GD CW
Summary of Contents for EWM TIG 200 GRIP GD CW
- Page 1 Operating instructions welding torch TIG 200 GRIP GD CW TIG-SR 18 GRIP WD CW, -HW TIG 260 GRIP WD CW, -HW TIG 450 GRIP WD CW, -HW 099-500091-EW501 Observe additional system documents! 23.02.2023...
- Page 2 +49 2680 181-0. 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.
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Page 3: Table Of Contents
Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use .......................... - Page 4 Contents Notes on using these operating instructions 8 Technical data ..........................55 TIG 200 GD .......................... 55 TIG 18, -260, -450, -CW / HW....................56 9 Accessories ..........................57 Welding torch cooling system ....................57 9.1.1 Coolant - type blueCool ..................57 9.1.2 Coolant - type KF ....................
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Page 5: For Your Safety
For your safety Notes on using these operating instructions For your safety 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. •... -
Page 6: Explanation Of Icons
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn... -
Page 7: Safety Instructions
For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 8 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
- Page 9 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases may lead to shortness of breath and poisoning! The ultraviolet radia- tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso- nous phosgene. • Ensure sufficient fresh air! •...
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Page 10: Transport And Installation
For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines. - Page 11 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.
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Page 12: Intended Use
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 This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 13: Part Of The Complete Documentation
Intended use Documents which also apply 3.3.4 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. -
Page 14: Machine Description - Quick Overview
Machine description – quick overview Overview of device types Machine description – quick overview Overview of device types Version Functions Torch type Cold wire TIG 200, TIG 260, TIG 450, TIG-SR 18 Cold wire welding. GRIP Grip TIG 200, TIG 260, TIG 450, TIG-SR 18 Ergonomic grip for secure handling. - Page 15 Machine description – quick overview TIG 450 GRIP WD HW Item Symbol Description Support plate Welding current connector plug (hot wire) - HW version Minus potential Rapid-action closure nipple, red - version Coolant return Rapid-action closure nipple, blue - WD version Coolant supply Connecting nipple, shielding gas Rapid-action closure...
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Page 16: Ways Of Combination
Machine description – quick overview Ways of combination Ways of combination Figure 4-2 Item Symbol Description Filler wire guide Fix 30°/39°/42° Flexible filler wire guide (15°–41°) Gas nozzle for jumbo version > see 5.5.1.2 chapter Bottle neck gas nozzle version > see 5.5.1.3 chapter Filler wire guide - WO version 099-500091-EW501 23.02.2023... -
Page 17: Design And Function
Design and function General Design and function General WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •... -
Page 18: Transport And Installation
Design and function Transport and installation Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! •... -
Page 19: Maximal Hose Package Length
All information relates to the total hose package length of the complete welding system and presents exemplary configurations (of components of the EWM product portfolio with standard lengths). A straight kink-free installation is to be ensured, taking into account the max. delivery height. -
Page 20: Welding Torch Connection
Design and function Transport and installation 5.3.3 Welding torch connection Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coo- lant circuit is interrupted and equipment damage can occur. •... -
Page 21: Control Cable Pin Configuration
Design and function Transport and installation • Extend and lay out the torch hose package. • Insert the wire feed plug of the welding torch into the wire electrode connector and lock by turning to the right. • Push the cable plug for the welding current (TIG) onto the connection socket (TIG) and lock by turning to the right. -
Page 22: Equipment Recommendations
Design and function Equipment recommendations Equipment recommendations 1.5 x 4.0 Liner EWM Cu- Dinse Low-alloy 1.5 x 4.0 V-groove CrZr connector 2.0 x 4.0 1.5 x 4.0 Torch EWM Cu- Combined PA li- Medium-alloy 1.5 x 4.0 V-groove CrZr neck 2.0 x 4.0... - Page 23 Design and function Equipment recommendations Figure 5-3 Item Symbol Description V-groove U-groove Knurled V-groove Steel liner Wire feed nipple Equipment side – Dinse connector Equipment side – torch neck Connecting sleeve Combined liner Equipment side for steel liner or liner > see 5.4 chapter. 099-500091-EW501 23.02.2023...
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Page 24: Equipping The Welding Torch
Design and function Equipping the welding torch Equipping the welding torch Figure 5-4 Item Symbol Description Torch body Torch body Insulation Gas lens Area of application: high-alloy steels and aluminium materials Collet Electrode Gas nozzle Back cap 099-500091-EW501 23.02.2023... -
Page 25: Convert Welding Torch
Design and function Equipping the welding torch 5.5.1 Convert welding torch 5.5.1.1 Standard version delivery state Figure 5-5 099-500091-EW501 23.02.2023... - Page 26 Design and function Equipping the welding torch Item Symbol Description Back cap Allen screw Filler wire guide Hexagon nut Support plate - TIG 200 / 450 version Stud bolts, M4 x 10 SW7 L26 MM, - L36 MM, - L41 MM Gas nozzle Tungsten electrode Gas diffuser...
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Page 27: Converting To Jumbo Version
Design and function Equipping the welding torch 5.5.1.2 Converting to jumbo version Figure 5-6 099-500091-EW501 23.02.2023... - Page 28 Design and function Equipping the welding torch Item Symbol Description Back cap Allen screw Filler wire guide Hexagon nut Stud bolt, M4X15 L56MM SW7 Gas nozzle for jumbo version > see 5.5.1.2 chapter Tungsten electrode Gas diffuser for jumbo version Support plate - TIG 260 version Gas diffuser Support plate - TIG 200 / 450 version...
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Page 29: Converting To Bottle Neck
Design and function Equipping the welding torch 5.5.1.3 Converting to bottle neck Figure 5-7 099-500091-EW501 23.02.2023... -
Page 30: Assemble The Wire Guide
Design and function Equipping the welding torch Item Symbol Description Back cap Allen screw Filler wire guide Hexagon nut Support plate - TIG 200 / 450 version Stud bolt, M4X10 L44MM SW7 Gas nozzle Tungsten electrode Gas diffuser Support plate - TIG 260 version Plastic insulation O-ring Grip plate... -
Page 31: Replace Steel Liner
Design and function Equipping the welding torch 5.5.2.1 Replace steel liner Figure 5-8 Item Symbol Description Crown nut Connecting sleeve Welding wire Collet chuck Insulation piece Steel liner Wire feed tube New steel liner Wire feed nipple • Cut off the welding wire tip. •... - Page 32 Design and function Equipping the welding torch Figure 5-9 • Remove the crown nut, collet chuck and insulating tube from the steel liner. Figure 5-10 • Disconnect the torch connector from the wire feeding. • Unscrew the crown nut from the inlet tube. •...
- Page 33 Design and function Equipping the welding torch Figure 5-11 • Chamfer the steel liner on one side at 30°. • Screw a suitable inlet guide tightly to the new steel liner on the side that is not chamfered, if neces- sary.
- Page 34 Design and function Equipping the welding torch Figure 5-13 • Chamfer the welding wire at 30° before inserting into the new steel liner. • Connect the torch connector to the wire feeding > see 5.3.3 chapter. • Using the wire feeding, insert the welding wire into the new steel liner until it protrudes 40 mm at the end of the steel liner.
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Page 35: Plastic Liner
Design and function Equipping the welding torch Figure 5-15 • Insert the new steel liner into the jointing sleeve as far as it goes. • Tighten the crown nut by hand. 5.5.2.2 Plastic liner Figure 5-16 Item Symbol Description Crown nut Connecting sleeve Welding wire Collet chuck... - Page 36 Design and function Equipping the welding torch Item Symbol Description Wire feed tube New combined liner Wire feed nipple • Loosen the crown nut of the jointing sleeve. • Cut off the welding wire tip. • Remove the combined liner from the jointing sleeve. •...
- Page 37 Design and function Equipping the welding torch Figure 5-19 • Sharpen the new combined liner with a liner sharpener. • Cut off the new combined liner to a length of at least 250 mm. • Push the new combined liner through the welding torch and the torch hose package as far as it goes. •...
- Page 38 Design and function Equipping the welding torch Figure 5-21 • Chamfer the welding wire at 30° before inserting into the new combined liner. • Connect the torch connector to the wire feeding > see 5.3.3 chapter. • Using the wire feeding, insert the welding wire into the new combined liner until it protrudes at the welding torch.
- Page 39 Design and function Equipping the welding torch Figure 5-23 • Insert the new combined liner into the jointing sleeve as far as it goes. • Tighten the crown nut by hand. • Cut off the welding wire tip. Figure 5-24 •...
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Page 40: Configuring The Welding Machine For Mechanical Arc Fusion Welding
Design and function Machine control – Operating elements 5.5.3 Configuring the welding machine for mechanical arc fusion welding The welding machine must be configured before commissioning for the first time for mechanical arc fu- sion welding (cold or hot wire welding). The basic settings are configured directly at the welding machine control. -
Page 41: Operating Modes (Functional Sequences)
Design and function Machine control – Operating elements 5.6.1 Operating modes (functional sequences) 5.6.1.1 Explanation of symbols Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger (quick pressing and releasing) Shielding gas flowing Welding performance Non-latched, manual Latched, manual Non-latched automatic Latched automatic Time... -
Page 42: Non-Latched Manual
Design and function Machine control – Operating elements 5.6.1.2 Non-latched Manual The welding machine (power source) must be set to operating mode “latched”. Figure 5-26 First cycle (current) • Press torch trigger 1 (BRT 1), the gas pre-flow time elapses. •... -
Page 43: Latched Manual
Design and function Machine control – Operating elements 5.6.1.3 Latched manual Figure 5-27 This operating mode differs from non-latched operation in the following ways: • Wire feeding is started by pressing and releasing (tapping) BRT 2. • By tapping you can switch to the reduced wire feeding. •... -
Page 44: Non-Latched Automatic
Design and function Machine control – Operating elements 5.6.1.4 Non-latched automatic The welding current has to be set to a non-latched operating mode at the welding machine. Figure 5-28 First cycle (current) • Press torch trigger 1 (BRT 1) and keep pressed. •... -
Page 45: Latched Automatic
Design and function Machine control – Operating elements 5.6.1.5 Latched automatic The welding machine (power source) must be set to operating mode “latched”. Figure 5-29 1. cycle (current) • Press torch trigger 1 (BRT 1), the gas pre-flow time elapses. •... -
Page 46: Tack Welding
Design and function Machine control – Operating elements 5.6.1.6 Tack welding The welding current has to be set to a non-latched operating mode at the welding machine. Figure 5-30 Sequence: • Press torch trigger 1 (BRT 1) and keep pressed. •... -
Page 47: Superpuls
Machine control – Operating elements 5.6.1.7 superPuls The two functions superPulse and the superimposed forward/backward movement of the wire cannot be used simultaneously. The EWM superPuls function enables automatic switching between two operating points in a process. Figure 5-31 Display Setting/selection Switch on... -
Page 48: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed. -
Page 49: Maintenance And Care Before Each Use
Maintenance, care and disposal General Torch connection • The thread of the crown nut is dirty or damaged. • For water-cooled welding torches, check the coolant connections for damage. Grip • Cracks, penetration Hose package • Cracks, penetration Figure 6-1 To prevent damage and malfunction of the welding torch: •... -
Page 50: Regular Maintenance
Maintenance, care and disposal General 6.1.3 Regular maintenance The regular maintenance of a welding torch depends heavily on the duration of use and the stress and must be specified by the operator / owner. As a rule of thumb, every time the wire spool or wire basket is replaced or, if necessary, at a change of shift. -
Page 51: Disposing Of Equipment
Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html. -
Page 52: 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 dea- ler. - Page 53 Rectifying faults Checklist for rectifying faults Wire feed problems Unsuitable or worn welding torch equipment Adjust contact tip (cold wire/hot wire) to wire diameter, blow through and replace if necessary Adjust wire guide to material in use, blow through and replace if necessary ...
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Page 54: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit Figure 7-1 • Switch off the machine and fill the coolant tank to the maximum level. • Unlock the quick-connect coupling with a suitable tool (connection open). To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-2 •... -
Page 55: Technical Data
Technical data TIG 200 GD Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! TIG 200 GD Welding torch polarity Normally negative Guide type Manually operated Voltage type Direct voltage DC or Alternating voltage AC Shielding gas according to ISO 14175 Argon Duty cycle DC at 40°... -
Page 56: Tig 18, -260, -450, -Cw / Hw
Technical data TIG 18, -260, -450, -CW / HW TIG 18, -260, -450, -CW / HW TIG 18 WD TIG 260 WD TIG 450 WD Welding torch polarity Normally negative (Direct voltage) Guide type Manually operated Voltage type DC / Alternating voltage AC Voltage measurement 113 V (Peak value) max. -
Page 57: Accessories
Accessories Welding torch cooling system Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Welding torch cooling system Type Designation Item no. HOSE BRIDGE UNI Tube bridge 092-007843-00000 9.1.1 Coolant - type blueCool Type Designation Item no. -
Page 58: Replaceable Parts
Replaceable parts TIG 18 Replaceable parts The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode hold- ers, remote controls, spare parts and replacement parts, etc.) from our range of products! •... - Page 59 Replaceable parts TIG 18 Item Order number Type Designation 094-001193-00000 COLB DIF TIG-SR 17/18/26 Ø 3.2mm Collet body with gas lens 094-001325-00000 COLB DIF TIG-SR 17/18/26 Ø 1.6mm Collet body with gas lens 094-001326-00000 COLB DIF TIG-SR 17/18/26 Ø 4.0mm Collet body with gas lens 094-019544-00000 VH M6/M9X0,75 L=24,5 Connecting sleeve...
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Page 60: Tig 260
Replaceable parts TIG 260 Item Order number Type Designation 094-020277-00000 E3; 2,4 x 75 mm Tungsten electrode, purple 094-020278-00000 E3; 3,2 x 75 mm Tungsten electrode, purple 10.2 TIG 260 Figure 10-2 Item Order number Type Designation 094-012672-00000 GN TIG 150/260 S 6.5x26mm Gas nozzle 094-012405-00000 GN TIG 150/260 S 8.0x26mm... -
Page 61: Tig 200 / Tig 450
Replaceable parts TIG 200 / TIG 450 Item Order number Type Designation 094-012672-00000 GN TIG 150/260 S 6.5x26mm Gas nozzle DIF TIG 150-450/450SC, D=1,6 094-009658-00000 Gas diffuser, JUMBO DIF TIG 150-450/450SC, D=2,4 094-009659-00000 Gas diffuser, JUMBO DIF TIG 150-450/450SC, D=3,2 094-009660-00000 Gas diffuser, JUMBO 094-011758-00000... - Page 62 Replaceable parts TIG 200 / TIG 450 Item Order number Type Designation 094-013072-00000 CT CuCrZr M6 x 28mm Ø Contact tip 1.0mm CT CuCrZr M6 x 28mm Ø 094-013122-00000 Contact tip 0.9mm CT CuCrZr M6 x 28mm Ø 094-014317-00000 Contact tip 1.2mm 094-016105-00000 CTAL E-Cu M6 X 28 mm Ø...
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Page 63: Service Documents
Service documents Circuit diagram Service documents 11.1 Circuit diagram The circuit diagrams are only intended for authorised service personnel! Figure 11-1 099-500091-EW501 23.02.2023... -
Page 64: Appendix
Appendix Searching for a dealer Appendix 12.1 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-500091-EW501 23.02.2023...
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