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! 07.03.2019...
- 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 the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 Part of the complete documentation ....................7 Safety instructions .......................... - Page 4 Contents Notes on the use of these operating instructions 5.2.10.4 Current jump ....................34 5.2.10.5 Standard TIG torch (5-pole) ................35 5.2.10.6 TIG up/down torch (8-pole) ................37 5.2.10.7 Potentiometer torch (8-pole) ................. 39 5.2.10.8 Configuring the TIG potentiometer torch connection ........40 5.2.10.9 RETOX TIG torch (12-pole)................
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Page 5: For Your Safety
For your safety Notes on the use of these operating instructions For your safety 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. •... -
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 Switch Incorrect / Invalid Turn Numerical value –... -
Page 7: Part Of The Complete Documentation
For your safety Part of the complete documentation Part of the complete documentation These operating instructions are 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 8: 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 9 For your safety Safety instructions WARNING Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure when heated. • Move containers with inflammable or explosive liquids away from the working area! • Never heat explosive liquids, dusts or gases by welding or cutting! Fire hazard! Due to the high temperatures, sparks, glowing parts and hot slag that occur during welding, there is a risk of flames.
- Page 10 For your safety Safety instructions CAUTION According to IEC 60974-10, welding machines are divided into two classes of electromagnetic compatibility (the EMC class can be found in the Technical data) > see 8 chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
- Page 11 For your safety Transport and installation The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...
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Page 12: Transport And Installation
For your safety Transport and installation Transport and installation WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! • Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air! •... -
Page 13: Intended Use
Intended use Applications 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. -
Page 14: Documents Which Also Apply
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 The labelled product complies with the following EC directives in terms of its design and construction: •... -
Page 15: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Machine control > see 4.3 chapter Connection socket, welding torch control cable > see 5.2.1.1 chapter Connection socket, "+" welding current •... -
Page 16: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description 8-pole connection socket Cooling unit control lead Ignition type changeover switch > see 5.2.6 chapter = ----- Liftarc (contact ignition) = ------ HF ignition Main switch, machine on/off Cooling air outlet Machine feet Mains connection cable >... -
Page 17: 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 4.3.1 chapter Error/status displays ----------- Collective interference signal light --------- Water deficiency signal light (welding torch cooling) ---------- Excess temperature signal light --------- S sign signal light... -
Page 18: Welding Data Display
Machine description – quick overview Machine control – Operating elements Item Symbol Description Pulsed welding push-button TIG ------ pulsed welding > see 5.3.5 chapter MMA ---- pulsed welding > see 5.2.8 chapter Operating mode/power-saving mode push-button -------- Non-latched ----- Latched Press for 2 s to put the machine into power-saving mode. -
Page 19: 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 20: 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 21: Welding Torch Cooling System
Design and function Transport and installation 5.1.5 Welding torch cooling system 5.1.5.1 Welding torch cooling unit connection Figure 5-2 Item Symbol Description 8-pole connection socket Cooling unit control lead 5-pole connection socket Cooling unit voltage supply 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. -
Page 22: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.6 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: Stray Welding Currents
Design and function Transport and installation 5.1.7 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 24: Mains Connection
Design and function Transport and installation 5.1.8 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 national regulations! •... -
Page 25: 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 26: Connection Assignment, Welding Torch Control Cable
Design and function TIG welding 5.2.1.1 Connection assignment, welding torch control cable Figure 5-9 5.2.2 Shielding gas supply (shielding gas cylinder for welding machine) WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! •... -
Page 27: Connecting The Shielding Gas Supply
Design and function TIG welding 5.2.2.1 Connecting the shielding gas supply Figure 5-10 Item Symbol Description Pressure regulator Output side of the pressure regulator Shielding gas cylinder Cylinder valve • Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out any dirt. -
Page 28: Ac Welding
Design and function TIG welding 5.2.4 AC welding 5.2.4.1 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. -
Page 29: 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 4.2 chapter. 5.2.6.1 HF ignition Figure 5-13 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. -
Page 30: 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 parameters 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 31: 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 ignition current I start •... -
Page 32: 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 ignition current value set (search arc at minimum setting). -
Page 33: 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 34: 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 modified individually via torch modes. Explanation of symbols for operating elements: Symbol Description Press torch trigger... -
Page 35: 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 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 (ex works) Secondary current (latched operation) Standard torch with two torch triggers... - Page 36 Design and function TIG welding Standard torch with one rocker (rocker, two torch triggers) Figure 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 (ex works) Secondary current (tapping function) )/(latched operating mode)
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Page 37: 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 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 (up function Decrease welding current (down function... - Page 38 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)
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Page 39: 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 Explanation of symbols elements BRT 1 = torch trigger 1 Functions Mode Operating... -
Page 40: 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 41: Retox Tig Torch (12-Pole)
Design and function TIG welding 5.2.10.9 RETOX TIG torch (12-pole) For operation with this welding torch, the welding machine must be retrofitted with the option "ON 12pol Retox TG.0002" (12-pole connection socket for torch)! Figure Operating elements Explanation of symbols BRT = Torch trigger Functions Mode... -
Page 42: 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 parameters shown may be limited, e.g. if a function is deactivated. The setting ranges for the parameter values are summarised in the Parameter overview section >... -
Page 43: 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 44: 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 45: 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 parameter as a percentage of the current average value (AMP). -
Page 46: Expert Menu (Mma)
Design and function Voltage reducing device 5.3.6 Expert menu (MMA) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of parameters shown may be limited, e.g. if a function is deactivated. The setting ranges for the parameter values are summarised in the Parameter overview section >... -
Page 47: Remote Control
Design and function Remote control Remote control The remote controls are operated on the 19-pole remote control connection socket (analogue). 5.5.1 RT1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. 5.5.2 RTG1 19POL Functions... -
Page 48: Interfaces For Automation
Design and function Interfaces for automation Interfaces for automation 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. • Only use shielded control leads! •... -
Page 49: Access Control
Design and function Access control Access control The machine control can be locked to secure it against unauthorised or unintentional adjustment. The access block has the following effect: • The parameters and their settings in the machine configuration menu, Expert menu and operation sequence can only be viewed but not changed. -
Page 50: 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 5-30 099-000188-EW501 07.03.2019... - Page 51 Design and function Machine configuration menu Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access. 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...
- Page 52 Design and function Machine configuration menu Display Setting/selection Software version of the machine control Version display (example 034 = version 34) Access control – access code Setting: 000 to 999 (000 ex works) Error Error message after entering an incorrect machine code New machine code •...
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Page 53: 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 54: 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 07.03.2019... -
Page 55: Disposing Of Equipment
• Information about returning used equipment or about collections can be obtained from the respective municipal administration office. • In addition to this, returns are also possible throughout Europe via EWM sales partners. 099-000188-EW501 07.03.2019... -
Page 56: 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 57 Rectifying faults Error messages (power source) 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 58: 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 59: 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). Display machine control software version The query of the software versions only serves to inform the authorised service staff. -
Page 60: 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 10,1 V to 18,0 V 20,2 V to 25,6 V standard (U... -
Page 61: 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 systems Type Designation Item no. -
Page 62: Appendix
Appendix Parameter overview – setting ranges Appendix Parameter overview – setting ranges 10.1 Parameters/function Setting range TIG (TIG) Gas pre-flow time Ignition 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 63: Searching For A Dealer
Appendix Searching for a dealer 10.2 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-000188-EW501 07.03.2019...
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