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Summary of Contents for EWM Picotig 190 AC/DC 5P TG
- Page 1 Operating instructions Welding machine Picotig 190 AC/DC 5P TG Picotig 190 AC/DC 8P TG 099-000151-EW501 18.01.2013 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
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Page 2: General Instructions
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents..............................3 2 Safety instructions..........................6 Notes on the use of these operating instructions ................6 Explanation of icons........................7 General ............................8 Transport and installation ......................12 2.4.1 Ambient conditions ....................... - Page 4 Display machine control software version..................59 8 Technical data............................60 Picotig 190 AC/DC ........................60 9 Accessories ............................61 Remote controls and accessories....................61 9.1.1 Connection cables ......................61 9.1.2 Extension cable ......................61 Options ............................61 General accessories ........................61 10 Appendix A............................62 10.1 Overview of EWM branches......................62 099-000151-EW501 18.01.2013...
- Page 5 Contents Notes on the use of these operating instructions 099-000151-EW501 18.01.2013...
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Page 6: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions 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. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 7: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine Switch on machine ENTER (enter the menu) NAVIGATION (Navigating in the menu) EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use... -
Page 8: General
Safety instructions General General DANGER Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •... - Page 9 Safety instructions General WARNING Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
- Page 10 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
- Page 11 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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Page 12: Transport And Installation
Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •... -
Page 13: Ambient Conditions
Safety instructions Transport and installation 2.4.1 Ambient conditions CAUTION Installation site! 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 14: Intended Use
Intended use Applications Intended use This machine has been manufactured according to the latest developments in technology and current regulations and standards. It must only be operated in line with the instructions on correct usage. WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. -
Page 15: Documents Which Also Apply
Intended use Documents which also apply Documents which also apply 3.2.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.2.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view NOTE The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted (see "Accessories" chapter). Figure 4-1 Item Symbol Description Machine control... -
Page 17: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Carrying handle Carrying strap Ignition type changeover switch Liftarc (contact ignition) HF ignition Main switch, machine on/off Mains connection cable Machine feet Cooling air outlet G¼” connecting nipple Shielding gas connection on the pressure regulator. -
Page 18: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements T 2.36 VOLT AMP% Figure 4-3 Item Symbol Description Switch display button Welding current display VOLT Welding voltage display Welding process button MMA welding TIG welding Operating mode button Non-latched Latched... - Page 19 Machine description – quick overview Machine control – Operating elements Item Symbol Description Welding parameter setting rotary dial Setting currents, times and parameters. Error/status indicators Collective interference signal light Water deficiency signal light (welding torch cooling) Excess temperature signal light safety sign signal light Three-figure LED display Welding parameter display (see also chap.
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Page 20: Design And Function
Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 21: Transport And Installation
Design and function Transport and installation Transport and installation WARNING Risk of accident due to improper transport of machines that may not be lifted! Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only! •... -
Page 22: Adjusting The Length Of The Carrying Strap
Design and function Machine cooling 5.3.1 Adjusting the length of the carrying strap NOTE To demonstrate adjustment, lengthening the strap is shown in the figure. To shorten, the strap's loops must be inched in the opposite direction. Figure 5-1 Machine cooling To obtain an optimal duty cycle from the power components, the following precautions should be observed: Ensure that the working area is adequately ventilated. -
Page 23: Mains Connection
Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations! •... -
Page 24: Tig Welding
Design and function TIG welding TIG welding 5.6.1 Welding torch and workpiece line connection NOTE Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-3 Item Symbol Description Welding torch Welding torch hose package Connection socket, "-"... -
Page 25: Torch Connection Options And Pin Assignments
Design and function TIG welding 5.6.2 Torch connection options and pin assignments Figure 5-4 5.6.3 Shielding gas supply (shielding gas cylinder for welding machine) WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. •... -
Page 26: Connecting The Shielding Gas Supply
Design and function TIG welding 5.6.3.1 Connecting the shielding gas supply • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. Figure 5-5 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve NOTE... -
Page 27: Setting The Shielding Gas Quantity
Design and function TIG welding 5.6.3.2 Setting the shielding gas quantity CAUTION Electric shocks! When setting the shielding gas quantity, high voltage ignition pulses or open circuit voltage are applied at the welding torch; these can lead to electric shocks and burning on contact. -
Page 28: Select Welding Task
Design and function TIG welding 5.6.4 Select welding task The welding task is selected using the buttons on the machine control on the welding machine. Signal lights (LED) display the welding parameter selection. Set the welding task in the following order: Item Symbol Description Welding process button... -
Page 29: Arc Ignition
Design and function TIG welding 5.6.6 Arc ignition 5.6.6.1 HF ignition Figure 5-7 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. 2-3mm). b) Press the torch trigger (high voltage ignition pulses ignite the arc). -
Page 30: Function Sequences/Operating Modes
Design and function TIG welding 5.6.8 Function sequences/operating modes The parameters for the function sequence are set using the “Select welding parameters” button and the “Welding parameter setting” rotary dial. T 2.36 VOLT AMP% Figure 5-9 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: Tig Runtime Parameters
Design and function TIG welding 5.6.9 TIG runtime parameters Figure 5-10 Display Setting/selection Main current I1 (AMP) Main current setting Secondary current (AMP%) Setting range in percent: 1% to 100% (depending on main current). Setting range, absolute: Imin to Imax. Downslope time 0.00 s to 20.0 s (0.1 s increments). - Page 32 Design and function TIG welding Display Setting/selection Gas pre-flow time Setting range: 0.1 s to 5.0 s (0.1 s increments) Ignition current Setting range in percent: depending on main current Setting range, absolute: Imin to Imax. Upslope time to main current Setting: 0.0 sec.
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Page 33: Non-Latched Mode
Design and function TIG welding 5.6.9.1 Non-latched mode AMP% start Down Figure 5-11 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. •... -
Page 34: Latched Mode
Design and function TIG welding 5.6.9.2 Latched mode AMP% start Down Figure 5-12 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 35: Welding Torch (Operating Variants)
Design and function TIG welding 5.6.10 Welding torch (operating variants) Different torch versions can be used with this machine. Functions on the operating elements, such as torch triggers (TT), rockers or potentiometers, can be modified individually via torch modes. Explanation of symbols for operating elements: Symbol Description Press torch trigger... -
Page 36: 5.6.10.2 Torch Mode And Up/Down Speed Setting
Design and function TIG welding 5.6.10.2 Torch mode and up/down speed setting The user has the modes 1 to 4 and modes 11 to 14 available. Modes 11 to 14 include the same function options as 1 to 4, but without tapping function for the secondary current. The function options in the individual modes can be found in the tables for the corresponding torch types. -
Page 37: Standard Tig Torch (5-Pole)
Design and function TIG welding 5.6.10.3 Standard TIG torch (5-pole) Standard torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT1 = Torch trigger 1 (welding current on/off; secondary current via tapping function) Functions mode Operating elements BRT 1 Welding current On/Off (factory-set) BRT 1... - Page 38 Design and function TIG welding Standard torch with one rocker (MG rocker, two torch triggers) Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Functions mode Operating elements BRT 1 Welding current On/Off Secondary current BRT 2 (factory-set)
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Page 39: Tig Up/Down Torch (8-Pole)
Design and function TIG welding 5.6.10.4 TIG up/down torch (8-pole) Up/down torch with one torch trigger Diagram Operating Explanation of symbols elements TT 1 = torch trigger 1 Functions Mode Operating elements BRT 1 Welding current on/off BRT 1 Secondary current (tapping mode) / (latched mode) (factory- set) Increase welding current, infinite adjustment (up function) - Page 40 Design and function TIG welding Up/down torch with two torch triggers Diagram Operating Explanation of symbols elements TT 1 = torch trigger 1 (left) TT 2 = torch trigger 2 (right) Functions Mode Operating elements BRT 1 Welding current on/off BRT 2 Secondary current BRT 1...
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Page 41: Potentiometer Torch (8-Pole)
Design and function TIG welding 5.6.10.5 Potentiometer torch (8-pole) NOTE The welding machine needs to be configured for operation with a potentiometer torch (see chap. "Configuring TIG potentiometer torch") Potentiometer torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions... -
Page 42: Retox Tig Torch (12-Pole)
Design and function TIG welding 5.6.10.6 RETOX TIG torch (12-pole) NOTE For operation with this welding torch, the welding machine must be equipped with the retrofit option "ON 12POL RETOX TIG" (12-pole torch connection socket)! Diagram Operating elements Explanation of symbols TT= torch trigger BRT 1 BRT 2... -
Page 43: Mma Welding
Design and function MMA welding MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •... -
Page 44: Hotstart Current And Hotstart Time
Design and function Remote control 5.7.2 Hotstart current and Hotstart time The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current Welding current Time Figure 5-15 Display Setting/selection Main current I1 (AMP) Main current setting... -
Page 45: Rtg1 19Pol Manual Remote Control
Design and function Remote control 5.8.2 RTG1 19POL manual remote control Functions • Infinite setting of the welding current (0% to 100%) depending on the main current preselected at the welding machine 5.8.3 Foot-operated remote control RTF1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. -
Page 46: Advanced Settings
Design and function Advanced settings Advanced settings NOTE ENTER (enter the menu) • Switch off machine at the main switch • Press and hold the "welding parameters" button and switch the machine on again at the same time. NAVIGATION (navigating in the menu) •... -
Page 47: Protecting Welding Parameters From Unauthorised Access
Design and function Advanced settings 5.9.2 Protecting welding parameters from unauthorised access NOTE The machine code is set to the factory setting of 000 after each reset (see chapter "Resetting welding parameters to the factory setting". See chapter "Changing the three-digit machine code" for information on how to change this code). -
Page 48: Changing The Three-Digit Machine Code
Design and function Advanced settings 5.9.2.1 Changing the three-digit machine code In this menu you can change the 3-digit machine code. After entering and confirming the old code, you can enter a new code. The correct machine code is necessary for activating and deactivating the access lock! Figure 5-19 Display Setting/selection... -
Page 49: Setting The Welding Current (Absolute/Percentage)
Design and function Advanced settings 5.9.3 Setting the welding current (absolute/percentage) The welding currents for start current, secondary current, end current and hotstart current can be set as percentages (factory setting) or absolute values. If absolute current display is set, the "AMP" signal light for the main current is lit in addition to the respective "AMP%"... -
Page 50: Selecting The Welding Current Polarity During The Ignition Phase
Design and function Advanced settings 5.9.4 Selecting the welding current polarity during the ignition phase Selection of welding current polarity during ignition phase, until the arc stabilises. It always switches over to DC- polarity after a few milliseconds. Figure 5-21 Display Setting/selection Lock JOB menu... -
Page 51: Choosing The Alternating Current Waveform
Design and function Advanced settings 5.9.5 Choosing the alternating current waveform Figure 5-22 Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access Settings Settings for machine functions and parameter displays Alternating current welding with rectangular current waveform Maximum power loading and safe welding Alternating current welding with trapezoidal current waveform An all-rounder, suitable for most applications Alternating current welding with sinusoidal current waveform... -
Page 52: Configuring The Tig Potentiometer Torch Connection
Design and function Advanced settings 5.9.6 Configuring the TIG potentiometer torch connection DANGER Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. -
Page 53: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! •... -
Page 54: Maintenance Work
Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922. •... -
Page 55: 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 56 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 Pore formation Inadequate or missing gas shielding Check shielding gas setting and replace shielding gas cylinder if necessary Shield welding site with protective screens (draughts affect the welding result) Use gas lens for aluminium applications and high-alloy steels...
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Page 57: Machine Faults (Error Messages)
Rectifying faults Machine faults (error messages) Machine faults (error messages) NOTE 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 58: Resetting Welding Parameters To The Factory Settings
Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings NOTE 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). 099-000151-EW501 18.01.2013... -
Page 59: Display Machine Control Software Version
Rectifying faults Display machine control software version Display machine control software version NOTE The query of the software versions only serves to inform the authorised service staff! Figure 7-2 Display Setting/selection Lock JOB menu Protect welding parameters from unauthorised access Service menu Service settings Exit the menu... -
Page 60: Technical Data
Technical data Picotig 190 AC/DC Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Picotig 190 AC/DC Setting range Welding current 3 A-190 A 5 A-140 A 5 A-190 A 5 A-140 A Welding voltage 10.1 V-17.6 V 20.2 V-25.6 V... -
Page 61: Accessories
Accessories Remote controls and accessories Accessories NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Remote controls and accessories Type Designation Item no. RT1 19POL Remote control current 090-008097-00000 RTG1 19POL Remote control, current 090-008106-00000 RTF1 19POLE 5M... -
Page 62: Appendix A
· info@ewm-automation.de www.ewm-ransbach-baumbach.de · info@ewm-ransbach-baumbach.de Sales and Service International EWM HIGHTEC WELDING GmbH EWM HIGHTEC WELDING Sales s.r.o. / Prodejní a poradenské centrum Fichtenweg 1 Tyršova 2106 4810 Gmunden · Austria · Tel: +43 7612 778 02-0 · Fax: -20 256 01 Benešov u Prahy ·...
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