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 Observe additional system documents! 10.10.2023...
- 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 5.2.10.7 Potentiometer torch (8-pole) ..............38 5.2.10.8 Configuring the TIG potentiometer torch connection ......39 5.2.10.9 RETOX TIG torch (12-pole)..............40 5.2.11 Expert menu (TIG) ....................41 MMA welding ........................42 5.3.1 Connecting the electrode holder and workpiece lead .......... 42 5.3.2 Welding task selection ..................
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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 3.3.6 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 Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-000188-EW501 10.10.2023... - Page 15 Machine description – quick overview Front view / rear view Item Symbol Description Transport elements Transport handle and transport belt > see 5.1.4 chapter Machine control > see 4.2 chapter Connection socket (welding torch control cable) > see 5.2.1.1 chapter Connection socket, “+”...
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Page 16: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-2 Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values > see 4.2.1 chapter Error/status displays ----------- Collective interference signal light --------- Water deficiency signal light (welding torch cooling) --------- Excess temperature signal light --------- S sign signal light... -
Page 17: Welding Data Display
Machine description – quick overview Machine control – Operating elements Item Symbol Description Pulsed welding push-button TIG ------- pulsed welding > see 5.2.8 chapter MMA ----- pulsed welding > see 5.3.5 chapter Operating mode/power-saving mode push-button -------- Non-latched ------ Latched Press for 2 s to put the machine into power-saving mode. -
Page 18: Design And Function
Design and function Transport and installation Design and function 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 19: Workpiece Lead, General
Design and function Transport and installation 5.1.3 Workpiece lead, general CAUTION Risk of burning due to incorrect welding current connection! If the welding current plugs (machine connections) are not locked or if the workpiece connection is contaminated (paint, corrosion), these connections and leads can heat up and cause burns when touched! •... -
Page 20: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation Item Symbol Description Cooling module • Insert and lock the 8-pole control lead plug on the cooling unit into the 8-pole connection socket on the welding machine. • Insert and lock the 5-pole supply plug on the cooling unit into the 5-pole connection socket on the welding machine. - Page 21 Design and function Transport and installation • 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 22: Stray Welding Currents
Design and function Transport and installation 5.1.6 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. •... -
Page 23: Mains Connection
Design and function Transport and installation 5.1.7 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • The connection (mains plug or cable), the repair or voltage adjustment of the device must be carried out by a qualified electrician in accordance with the respective local laws or nati- onal regulations! •... -
Page 24: Tig Welding
Design and function TIG welding TIG welding 5.2.1 Welding torch and workpiece line connection Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-8 Item Symbol Description Welding torch Welding torch hose package Connection socket, "-"... -
Page 25: Control Lead Connection
Design and function TIG welding 5.2.1.1 Control lead connection TIG welding machines are equipped ex works with a dedicated connection socket for the welding torch control cable (5- or 8-pole). As mobile machines offer more free space, they may even feature two control cable connection sockets. -
Page 26: Welding Task Selection
Design and function TIG welding Item Symbol Description Shielding gas cylinder Cylinder valve • Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out any dirt. • Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight. •... -
Page 27: Ac Welding
Design and function TIG welding 5.2.4 AC welding 5.2.4.1 AC balance (optimise cleaning effect and penetration characteristics) It is important to choose the right time relationship (balance) between the positive phase (cleaning effect, balled end size) and the negative phase (penetration depth). This may differ from the factory setting de- pending on the material and task. -
Page 28: Arc Ignition
Design and function TIG welding 5.2.6 Arc ignition The ignition type can be set at the ignition type changeover switch > see 4.1 chapter. 5.2.6.1 HF ignition Figure 5-13 The arc is started without contact using high-voltage ignition pulses: a) Position the welding torch in the welding position above the workpiece (distance between the electrode tip and the workpiece approx. -
Page 29: Operating Modes (Functional Sequences)
Design and function TIG welding 5.2.7 Operating modes (functional sequences) Using the welding parameter push-button and welding parameter setting rotary knob the sequence para- meters are set. Figure 5-15 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 30: Non-Latched Mode
Design and function TIG welding 5.2.7.2 Non-latched mode Figure 5-16 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 start current I start •... -
Page 31: Latched Mode
Design and function TIG welding 5.2.7.3 Latched mode Figure 5-17 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 start current value set (search arc at minimum setting). -
Page 32: Average Value Pulse Welding
Design and function TIG welding 5.2.8 Average value pulse welding Once the function is activated, the red signal lights for the main current AMP and secondary current AMP% light up at the same time. Average value pulse welding means that the system switches between two currents periodically, an average current value (AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been... -
Page 33: Welding Torch (Operating Variants)
Design and function TIG welding 5.2.10 Welding torch (operating variants) Different torch versions can be used with this machine. Functions on the operating elements, such as torch triggers (BRT), rockers or potentiometers, can be mo- dified individually via torch modes. Explanation of symbols for operating elements: Symbol Description... -
Page 34: Standard Tig Torch (5-Pole)
Design and function TIG welding 5.2.10.5 Standard TIG torch (5-pole) Standard torch with one torch trigger Figure Operating ele- Explanation of symbols ments BRT1 = torch trigger 1 (welding current on/off; secondary cur- rent via tapping function) Functions Mode Operating ele- ments Welding current on/off (ex works) - Page 35 Design and function TIG welding Standard torch with one rocker (rocker, two torch triggers) Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Functions Mode Operating ele- ments Welding current on/off Secondary current (ex works) Secondary current (tapping function)
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Page 36: Tig Up/Down Torch (8-Pole)
Design and function TIG welding 5.2.10.6 TIG up/down torch (8-pole) Up/down torch with one torch trigger Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 Functions Mode Operating ele- ments Welding current on/off Secondary current (tapping function) )/(latched operating mode) (ex works) Increase welding current (up function... - Page 37 Design and function TIG welding Up/down torch with two torch triggers Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 (left) BRT 2 = torch trigger 2 (right) Functions Mode Operating ele- ments Welding current on/off Secondary current Secondary current (tapping function) )/(latched operating mode)
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Page 38: Potentiometer Torch (8-Pole)
Design and function TIG welding 5.2.10.7 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch > see 5.2.10.8 chapter. Potentiometer torch with one torch trigger Figure Operating ele- Explanation of symbols ments BRT 1 = torch trigger 1 Functions Mode Operating ele-... -
Page 39: 5.2.10.8 Configuring The Tig Potentiometer Torch Connection
Design and function TIG welding 5.2.10.8 Configuring the TIG potentiometer torch connection 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 40: Retox Tig Torch (12-Pole)
Design and function TIG welding 5.2.10.9 RETOX TIG torch (12-pole) These accessory components can be retrofitted as an option > see 9 chapter. Figure Operating elements Explanation of symbols BRT = Torch trigger Functions Mode Operating elements Welding current On/Off BRT 1 Secondary current BRT 2... -
Page 41: Expert Menu (Tig)
Design and function TIG welding 5.2.11 Expert menu (TIG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa- rameters shown may be limited, e.g. if a function is deactivated. The setting ranges for the parameter values are summarised in the Parameter overview sec- tion >... -
Page 42: Mma Welding
Design and function MMA welding MMA welding 5.3.1 Connecting the electrode holder and workpiece lead CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. •... -
Page 43: Welding Task Selection
Design and function MMA welding 5.3.2 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 > see 5.7 chapter. The following welding task selection is an example of use. In general, the selection process always has the same sequence. -
Page 44: Average Value Pulse Welding
Design and function MMA welding 5.3.5 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 para- meter as a percentage of the current average value (AMP). -
Page 45: Voltage Reducing Device
Design and function Voltage reducing device Display Setting/selection Pulse balance Pulse frequency Pulse current > see 5.3.5 chapter Voltage reducing device Only machine variants with the (VRD/SVRD/AUS/RU) code are equipped with a voltage reduction device (VRD). The VRD is used for increased safety, especially in hazardous environments such as shipbuilding, pipe construction or mining. -
Page 46: Rtp3 Spotarc 19Pol
Design and function Interfaces for automation 5.5.5 RTP3 spotArc 19POL Functions • TIG / MMA. • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. • Pulse / SpotArc spots / normal •... -
Page 47: Access Control
Design and function Access control Item Signal shape Designation Output Connection for cable screen (PE) Output Current flowing signal I>0, galvanically isolated (max. +- 15V/100mA) Output Reference voltage for potentiometer 10V (max. 10mA) Input Control voltage specification for main current, 0–10V (0V = I /10V = I- Input Control voltage specification for secondary current, 0–10V (0V =... -
Page 48: Machine Configuration Menu
Design and function Machine configuration menu Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.9.1 Selecting, changing and saving parameters ENTER NAVIGATION EXIT Figure 5-30 Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access. 099-000188-EW501 10.10.2023... - Page 49 Design and function Machine configuration menu Display Setting/selection Machine code Querying the three-digit machine code (000 to 999), user input Error Error message after entering an incorrect machine code Switch on Switching on machine function Switch off Switching off machine function Torch configuration menu Set welding torch functions Torch mode setting (factory setting 1)
- Page 50 Design and function Machine configuration menu Display Setting/selection Error Error message after entering an incorrect machine code New machine code • Machine code entered correctly • Prompt for entering the new machine code Machine code Querying the three-digit machine code (000 to 999), user input Exit the menu Exit Numerical value –...
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Page 51: 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 52: Maintenance Work, Intervals
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-000188-EW501 10.10.2023... -
Page 53: 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 54: 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 55 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 ...
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Page 56: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) 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 57: 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). Software version of the machine control The query of the software versions only serves to inform the authorised service staff. -
Page 58: 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 Welding current (I 3 A to 200 A 5 A to 140 A Welding voltage according to stan- 10,1 V to 18,0 V 20,2 V to 25,6 V dard (U... -
Page 59: 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. cool40 U31 Cooling module 090-008593-00502 Transport system Type Designation Item no. -
Page 60: Option For Conversion
Accessories Option for conversion Option for conversion 9.5.1 Machine control Comfort CAUTION Risk of injury and equipment damage due to inadequate training! The conversion options listed below generally involve opening the device. An opened machine poses various dangers (e.g., electrical voltages, hot coolant, etc.). Dangerous voltages can still be present in power sources even after they have been switched off. -
Page 61: Appendix
Appendix Parameter overview – setting ranges Appendix 10.1 Parameter overview – setting ranges Parameters/function Setting range TIG (TIG) Gas pre-flow time Start current Up-slope time, non-latched operation 20,0 Up-slope time, latched operation 20,0 Secondary current AMP% Down-slope time, non-latched operation Down-slope time, latched operation End current Gas post-flow time... -
Page 62: Average Shielding Gas Usage
Appendix Average shielding gas usage 10.2 Average shielding gas usage Gas nozzle number 12.5 inch 0.26 0.31 0.37 0.43 0.63 l/min gal/min 1.58 2.11 2.64 3.17 3.96 099-000188-EW501 10.10.2023... -
Page 63: Searching For A Dealer
Appendix Searching for a dealer 10.3 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-000188-EW501 10.10.2023...
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