EWM Picotig 220 puls DC 5P Operating Instructions Manual
  1. Manuals
  2. Brands
  3. EWM Manuals
  4. Welding System
  5. Picotig 220 puls DC 5P
  6. Operating instructions manual
EWM Picotig 220 puls DC 5P Operating Instructions Manual

EWM Picotig 220 puls DC 5P Operating Instructions Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operating instructions
Welding machine
Picotig 220 puls DC 5P
EN
099-002068-EW501
Observe additional system documents!
15.03.2024

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Picotig 220 puls DC 5P and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for EWM Picotig 220 puls DC 5P

Summary of Contents for EWM Picotig 220 puls DC 5P

  • Page 1 Operating instructions Welding machine Picotig 220 puls DC 5P 099-002068-EW501 Observe additional system documents! 15.03.2024...
  • 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.

  • Page 3: Table Of Contents

    Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................7 Notes on using these operating instructions ................7 Explanation of icons ....................... 8 Safety instructions ........................9 Transport and installation ....................12 3 Intended use ..........................
  • Page 4 Voltage reducing device ....................... 64 Dynamic power adjustment ....................64 Resetting welding parameters to the factory settings ............64 8 Technical data..........................65 Picotig 220 puls DC 5P ......................65 8.1.1 Mains voltage 230 V ..................... 65 8.1.2 Mains voltage 120 V ..................... 66 099-002068-EW501 15.03.2024...
  • Page 5 Contents Notes on using these operating instructions 9 Accessories ..........................67 Shielding gas supply (shielding gas cylinder for welding machine) ........67 Transport system ......................... 67 19-pole remote control ......................67 9.3.1 Connection cables ....................67 Option for retrofitting ......................67 General accessories ......................
  • Page 6 Contents Notes on using these operating instructions 099-002068-EW501 15.03.2024...

  • Page 7: 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 8: 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 9: 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 10 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 11 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! •...

  • Page 12: 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 13 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.

  • Page 14: 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 15: 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 16: Machine Description - Quick Overview

    Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-002068-EW501 15.03.2024...
  • Page 17 Machine description – quick overview Front view / rear view Item Symbol Description Transport handle with additional integrated functions • Wear part compartment > see 5.1.9 chapter • Transport belt > see 5.1.1 chapter Machine control > see 4.2 chapter Connection socket (welding torch control cable) >...

  • Page 18: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements 4.2.1 Overview of control sections For description purposes, the machine control has been divided into two sections (A, B) to ensure maximum clarity. The setting ranges for the parameter values are summarised in the parameter overview section >...

  • Page 19: Control Section A

    Machine description – quick overview Machine control – Operating elements 4.2.1.1 Control section A Figure 4-3 Item Symbol Description TIG ignition type signal light Signal light on: Lift arc ignition active/HF start off. You can switch the ignition type in the Expert menu (TIG) >...

  • Page 20: Control Section B

    Machine description – quick overview Machine control – Operating elements 4.2.1.2 Control section B Figure 4-4 Item Symbol Description Signal light for main current Signal light for up-slope time Signal light for start current Signal light for Arcforce (welding characteristics) > see 5.3.4 chapter Signal light, pulse welding >...

  • Page 21: Operating The Machine Control

    Machine description – quick overview Operating the machine control Operating the machine control 4.3.1 Main screen After switching on the machine or finishing a setting, the machine control changes to the main screen. This means that the previously selected settings are accepted (if necessary, indicated by signal lights) and the nominal value of the current (A) is shown in the welding data display on the left.

  • Page 22: 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 23: Ambient Conditions

    Design and function Transport and installation 5.1.2 Ambient conditions 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 24: 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 • Use an individual welding lead to the workpiece for each welding machine! Figure 5-3 • Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! •...

  • Page 25: Mains Configuration

    Design and function Transport and installation 5.1.7.1 Mains configuration The machine may only be connected to a one-phase system with two conductors and an earthed neutral conductor. Figure 5-5 Legend Item Designation Colour code Outer conductor brown Neutral conductor blue Protective conductor green-yellow •...

  • Page 26: Protective Flap, Welding Machine Control

    Design and function Transport and installation 5.1.8 Protective flap, welding machine control Figure 5-6 • Open the protective cap. • Apply slight pressure to the left and/or right connecting bridge (illustration) until the protective cap can be removed. 5.1.9 Wear part compartment The transport handle of this machine series holds a wear parts compartment for storing typical small wear parts.

  • Page 27: 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 Workpiece Connection socket for "+" welding current Workpiece lead connection Welding torch “-”...

  • Page 28: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function TIG welding 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 seri- ous injuries! •...

  • Page 29: Shielding Gas Hose Connection

    Design and function TIG welding 5.2.3.1 Shielding gas hose connection Figure 5-11 Item Symbol Description Shielding gas cylinder Connection thread - G¼" Shielding gas connection (inlet) • Screw the gas hose connection nipple onto the G¼" connection nipple. 5.2.4 Setting the shielding gas volume (gas test)/rinse hose package •...

  • Page 30: Setting Welding Procedure

    Design and function TIG welding 5.2.5 Setting welding procedure Figure 5-12 5.2.5.1 Basic setting (tungsten electrode diameter) Setting the tungsten electrode diameter presets the ignition energy and minimum current limit opti- mally. Smaller electrode diameters require less ignition energy than larger electrode diameters. With the selection of the electrode diameter, a minimum current limit is set that in turn affects the start, main and secondary currents.

  • Page 31: Arc Ignition

    Design and function TIG welding 5.2.6 Arc ignition 5.2.6.1 HF ignition Figure 5-14 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. 2-3 mm). b) Press the torch trigger (high-voltage ignition pulses start the arc).

  • Page 32: Operating Modes (Functional Sequences)

    Design and function TIG welding 5.2.7 Operating modes (functional sequences) 5.2.7.1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 Current Time Gas pre-flow Start current Start time Up-slope time Spot time Main current (minimum to maximum current) Secondary current Pulse current (average value pulsing) Balance (average value pulsing)

  • Page 33: Non-Latched Mode

    Design and function TIG welding 5.2.7.2 Non-latched mode Sequence Figure 5-16 1st cycle: • Press and hold torch trigger 1. • The gas pre-flow time expires (shielding gas flows). • The arc is ignited (HF ignition). • The start current flows for the start time •...

  • Page 34: Latched Mode

    Design and function TIG welding 5.2.7.3 Latched mode Sequence Figure 5-17 1st cycle • Press the torch trigger 1 • The gas pre-flow time expires (shielding gas flows). • The arc is ignited (HF ignition). • The start current flows as long as the torch trigger is held, but at least for the start time 2nd cycle •...

  • Page 35: Spotarc

    Design and function TIG welding 5.2.7.4 spotArc This process is suitable for tack welding or joint welding of metal sheets made from steel and CrNi alloys up to a thickness of approximately 2.5 mm. Metal sheets of different thicknesses can also be welded on top of one another.

  • Page 36: Spotmatic

    Design and function TIG welding 5.2.7.5 spotmatic In contrast to the spotArc operating mode, the arc is not started by pressing the torch trigger as in the conventional method, but by briefly placing the tungsten electrode on the workpiece. The torch trigger is used to enable the welding process.
  • Page 37 Design and function TIG welding Example display with factory settings of the parameters: Figure 5-21  Tap the torch trigger to activate the welding process.  Place the torch gas nozzle and tungsten electrode tip carefully on the workpiece.  Incline the welding torch over the torch gas nozzle until there is a gap of approx. 2-3 mm between the electrode tip and the workpiece.

  • Page 38: Pulse Welding

    Design and function TIG welding 5.2.8 Pulse welding 5.2.8.1 Average value pulse welding A special feature with average value pulses is that the power source will always maintain the preset average value. This makes this method especially suitable for welding according to welding procedure specifications.

  • Page 39: Welding Torch (Operating Variants)

    Design and function TIG welding 5.2.9 Welding torch (operating variants) 5.2.9.1 Welding torch mode The operating elements (torch triggers or rockers) and their function can be individually adjusted using different torch modes. Up to four modes are available to the user. The tables for the corresponding torch types describe the functional options.

  • Page 40: Tapping Function (Tap Torch Trigger)

    Design and function TIG welding TIG function torch, Retox XQ Figure 5-27 Function Operation Mode Welding current On / Off BRT 1 Secondary current Secondary current BRT 2 Increase welding current (up/down speed) Decrease welding current (up/down speed) DOWN Welding current On / Off BRT 1 Secondary current Secondary current...

  • Page 41: 5.2.10.1 Response

    Design and function TIG welding 5.2.10.1 Response This function controls the responsiveness of the welding current during the main current phase. The user can choose between linear and logarithmic responsiveness. The logarithmic setting is particularly suitable for welding with low current, e.g., for thin panels as the logarithmic responsiveness enables better control of the welding current.

  • Page 42: 5.2.10.3 Start/Stop Operation

    Design and function TIG welding 5.2.10.3 Start/stop operation Start/stop operation “ ” can be enabled or disabled in the machine configuration menu > see 5.8 chapter. Enabled start/stop operation The foot-operated remote control is no longer used to specify the welding current, but rather starts or ends the welding process (see torch trigger).

  • 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: Hotstart Current

    Design and function MMA welding 5.3.3.1 Hotstart current Figure 5-34 5.3.3.2 Hotstart time The hot start times can be set in the Expert menu > see 5.4.1 chapter. 5.3.4 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current.

  • Page 45: Pulse Welding

    Design and function MMA welding 5.3.6 Pulse welding 5.3.6.1 Average value pulse welding A special feature with average value pulses is that the power source will always maintain the preset average value. This makes this method especially suitable for welding according to welding procedure specifications.

  • Page 46: Arc Length Restriction (Usp)

    Design and function Arc length restriction (USP) Arc length restriction (USP) The function of arc length restriction stops the welding process when an excessive arc voltage is de- tected (an unusually large gap between electrode and workpiece). This function can be switched on or off in the Expert menu >...

  • Page 47: Rtg1 19Pol

    Design and function Power-saving mode (Standby) 5.5.4 RTG1 19POL Functions • Infinite setting of the welding current (0% to 100%) depending on the main current preselected at the welding machine 5.5.5 RTA PWS2 Functions • Welding current setting (0 % to 100 %) •...

  • Page 48: Machine Configuration Menu

    Design and function Machine configuration menu Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.8.1 Selecting, changing and saving parameters Figure 5-41 Display Setting/selection Exit the menu Exit Power source menu Ignition type (TIG) ------- HF start active (ex works) ------- Lift arc ignition active Re-ignition after arc interruption >...
  • Page 49 Design and function Machine configuration menu Display Setting/selection Access control > see 5.7 chapter ------ Function enabled ------ Function disabled (ex works) Machine display menu Setting the system of measurement ------ Length units in mm - metric system (factory setting). ------ Length units - imperial system.
  • Page 50 Design and function Machine configuration menu Display Setting/selection Service menu Any changes to the service menu should be agreed with the authorised service person- nel. Reset (resetting to factory settings) ------- Switched off (factory setting) ------- Reset all values and adjustments ------- Reset the operating time ------- Reset the arc time ------- Reset the operating time and arc time...

  • 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! 099-002068-EW501 15.03.2024...

  • 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 Software version of the machine control 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 Error messages (power source) Error 6: Mains undervoltage Category A  Mains voltage is too low. Check the mains voltages and compare them with the connection voltages of the power source.  Error 7: Low coolant level Category B ...
  • Page 56 Rectifying faults Error messages (power source) Error 16: Pilot arc power source - collective error Category A  The external emergency stop circuit has been interrupted. Check the emergency stop circuit and eliminate the cause of the error.   The emergency stop circuit of the power source has been activated (internally configurable). Deactivate the emergency stop circuit.
  • Page 57 Rectifying faults Error messages (power source) Error 20: Low coolant level Category B  Low flow rate. Fill with coolant.  Check coolant flow - remove kinks in the hose package.  Adjust the flow threshold  Clean the cooler. ...
  • Page 58 Rectifying faults Error messages (power source) Error 26: Excess pilot arc module temperature Category A  The power source is overheating. Allow the switched-on machine to cool.   Fan is blocked, dirty or faulty. Check the fan and clean or replace. ...
  • Page 59 Rectifying faults Error messages (power source) Error 40: Electronics error  Error I>0 Request service.  Error 47: Radio link (BT) Category B  Connection error between welding machine and peripheral unit. Note the documentation for the data interface with radio transmission. ...
  • Page 60 Rectifying faults Error messages (power source) Error 56: Mains phase failure  One phase of the mains voltage has failed. Check the mains connection, mains plug and mains fuses.  Error 57: Slave tacho error Category B  Fault in the wire feeder (slave drive). Check the connections (connectors, lines).

  • Page 61: Warnings

    Rectifying faults Warnings Warnings Depending on the display options of the machine display, a warning message is displayed as follows: Display type - machine control Display Graphic display two 7-segment displays one 7-segment display The cause of the warning is indicated by a corresponding warning number (see table). •...

  • Page 62: Checklist For Rectifying Faults

    Rectifying faults Checklist for rectifying faults Warning Potential cause / remedy 24 Coolant flow warning Check the coolant supply. Check the coolant level and top up if necessary. Check flow and switching thresholds. 25 Flow 2 reserved 26 Flow 3 reserved 27 Flow 4 reserved...
  • Page 63 Rectifying faults Checklist for rectifying faults Functional errors  Several parameters cannot be set (machines with access block) Entry level is blocked, disable access lock > see 5.7 chapter   All machine control signal lights are illuminated after switching on ...

  • Page 64: Voltage Reducing Device

    Rectifying faults Voltage reducing device Voltage reducing device The voltage reduction device (VRD) is used to increase safety, especially in dangerous environments (such as shipbuilding, pipeline construction, mining). The use of a voltage reduction device is mandatory in some countries and specified in many in-house safety regulations for welding power sources.

  • Page 65: Technical Data

    Technical data Picotig 220 puls DC 5P Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Picotig 220 puls DC 5P 8.1.1 Mains voltage 230 V Welding current (I 5 A to 220 A...

  • Page 66: Mains Voltage 120 V

    Technical data Picotig 220 puls DC 5P 8.1.2 Mains voltage 120 V The performance specifications refer to machines with several mains voltage variants (multivolt capability). Please note the information on the relevant rating plate. The increased current consumption at a lower mains voltage requires the installation of a suitable mains plug >...

  • Page 67: Accessories

    Accessories Shielding gas supply (shielding gas cylinder for welding machine) Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Shielding gas supply (shielding gas cylinder for welding machine) Type Designation Item no.

  • Page 68: Appendix

    Appendix Parameter overview – setting ranges Appendix 10.1 Parameter overview – setting ranges 10.1.1 TIG welding Parameter / function Setting range Gas pre-flow time Start current Start time Up-slope time Main current Slope time (main current to secondary current) Secondary current Slope time (secondary current to main current) Down-slope time End current...

  • Page 69: 10.1.2 Mma Welding

    Appendix Average shielding gas usage 10.1.2 MMA welding Parameter / function Setting range Hot start current Hot start time 20,0 Main current Pulse welding Pulse frequency Pulse balance Pulse current Arcforce correction 10.1.3 Basic parameters (independent of process) Parameter / function Setting range Ignition mode switching Time-based energy-saving function...

  • Page 70: 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" 099-002068-EW501 15.03.2024...

Table of Contents