EWM Picotig 190 AC/DC 5P TG Operating Instructions Manual Download Page 38

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Design and function

TIG welding

099-000151-EW501

18.01.2013

Standard torch with one rocker (MG rocker, two torch triggers)

Diagram Operating

elements

Explanation of symbols

BRT 1 = torch trigger 1

BRT 2 = torch trigger 2

Functions mode

Operating
elements

Welding current On/Off

BRT 1

Secondary current

BRT 2

Secondary current (tapping mode) / (latched mode)

(factory-set)

BRT 1

Welding current On/Off

BRT 1

BRT 2

Secondary current (tapping mode)

BRT 1

BRT 2

Up function

BRT 1

Down function

BRT 2

Welding current On/Off

BRT 1

Secondary current (tapping mode) / (latched mode)

BRT 1

Up function

BRT 2

Down function

BRT 2

Summary of Contents for Picotig 190 AC/DC 5P TG

Page 1: ...Welding machine GB 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 Details for ewm warra...

Page 2: ...ther form of liability regardless of type shall be accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whethe...

Page 3: ...5 3 Transport and installation 21 5 3 1 Adjusting the length of the carrying strap 22 5 4 Machine cooling 22 5 5 Mains connection 23 5 5 1 Mains configuration 23 5 6 TIG welding 24 5 6 1 Welding torch...

Page 4: ...ignition phase 50 5 9 5 Choosing the alternating current waveform 51 5 9 6 Configuring the TIG potentiometer torch connection 52 6 Maintenance care and disposal 53 6 1 General 53 6 2 Maintenance work...

Page 5: ...Contents Notes on the use of these operating instructions 099 000151 EW501 18 01 2013 5...

Page 6: ...l in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading...

Page 7: ...scription Press Do not press Turn Switch l 0 Switch off machine l 0 Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display example wait 4s press Inter...

Page 8: ...s and burns on contact Even low voltages can cause you to get a shock and lead to accidents Do not touch any live parts in or on the machine Connection cables and leads must be free of faults Switchin...

Page 9: ...to come into contact with flammable material Connect welding leads correctly Risk of accidents if these safety instructions are not observed Non observance of these safety instructions is potentially...

Page 10: ...currents Stray welding currents can destroy protective earth conductors damage equipment and electronic devices and cause overheating of components leading to fire Make sure all welding leads are sec...

Page 11: ...he user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the user must consider the following...

Page 12: ...ble for transport by hand only The machine may not be lifted by crane or suspended CAUTION Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself duri...

Page 13: ...ties of dust acid corrosive gases or substances may damage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambie...

Page 14: ...ccepted for any damages arising from improper usage The equipment must only be used in line with proper usage and by trained or expert staff Do not modify or convert the equipment improperly 3 1 Appli...

Page 15: ...d with the unit 3 2 3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be used in environments with an increased electrical hazar...

Page 16: ...g elements chapter 2 Connection socket welding current TIG Connection for workpiece lead MMA Electrode holder or workpiece lead connection 3 Connection socket 5 pole 8 pole 12 pole 5 pole Standard TIG...

Page 17: ...rrying handle 2 Carrying strap 3 HF HF Ignition type changeover switch HF Liftarc contact ignition HF HF ignition 4 Main switch machine on off 5 Mains connection cable 6 Machine feet 7 Cooling air out...

Page 18: ...welding with negative polarity at the torch or electrode holder with respect to the workpiece Alternating current welding alternating current waveform can be set 5 AMP Main current signal light Imin t...

Page 19: ...g parameter setting rotary dial Setting currents times and parameters 11 S Error status indicators Collective interference signal light Water deficiency signal light welding torch cooling Excess tempe...

Page 20: ...carried out alternately using different methods and if a welding torch and an electrode holder remain connected to the machine the open circuit welding voltage is applied simultaneously on all cables...

Page 21: ...llation 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 an...

Page 22: ...re To shorten the strap s loops must be inched in the opposite direction Figure 5 1 5 4 Machine cooling To obtain an optimal duty cycle from the power components the following precautions should be ob...

Page 23: ...ensure it is earthed as stated in the operating instructions The resulting network has to be suitable for operating devices according to protection class 1 5 5 1 Mains configuration NOTE The machine...

Page 24: ...tiometer torch control lead 12 pole Control lead for TIG up down torch with display 6 Workpiece 7 Connection socket for welding current Workpiece lead connection Insert the welding current plug on the...

Page 25: ...lace shielding gas cylinders in the holders provided for them and secure with fixing devices Avoid heating the shielding gas cylinder CAUTION Faults in the shielding gas supply An unhindered shielding...

Page 26: ...as cylinder 3 Output side of the pressure regulator 4 Cylinder valve NOTE Before connecting the pressure regulator to the gas cylinder open the cylinder valve briefly to expel any dirt Tighten the pre...

Page 27: ...y insulated from persons animals or equipment during the setting procedure Press the torch trigger and set the shielding gas quantity with the flow gauge of the pressure regulator NOTE Rule of thumb f...

Page 28: ...ith respect to the workpiece Alternating current welding alternating current waveform can be set 3 Operating mode button Non latched Latched 4 Select welding parameters button This button is used to s...

Page 29: ...sten electrode tip onto the workpiece and press the torch trigger liftarc current flowing regardless of the main current set b Incline the torch over the torch gas nozzle to produce a gap of approx 2...

Page 30: ...g parameters depending on the welding process and operating mode used 2 Welding parameter setting rotary dial Setting currents times and parameters 5 6 8 1 Explanation of symbols Symbol Meaning Press...

Page 31: ...current Setting range absolute Imin to Imax Gas post flow time Setting range 0 1 s to 20 0 s 0 1 s increments Diameter of tungsten electrode ignition optimisation 1 mm to 4 mm or larger 0 1 mm increm...

Page 32: ...y 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...

Page 33: ...ope time to the main current AMP Switching from main current AMP to secondary current AMP Press torch trigger 2 or Tap torch trigger 1 2nd cycle Release torch trigger 1 The main current falls in the s...

Page 34: ...AMP Press torch trigger 2 or Tap torch trigger 1 Step 3 Press torch trigger 1 The main current drops with the set down slope time to the end crater current Iend minimum current Step 4 Release torch tr...

Page 35: ...triggers TT rockers or potentiometers can be modified individually via torch modes Explanation of symbols for operating elements Symbol Description BRT 1 Press torch trigger BRT 1 Tap torch trigger B...

Page 36: ...e individual modes can be found in the tables for the corresponding torch types The welding process can of course be switched on and off in all modes using torch trigger 1 TT 1 l 0 Figure 5 13 Display...

Page 37: ...g elements Welding current On Off BRT 1 Secondary current Latched mode 1 factory set BRT 1 Standard torch with two torch triggers Diagram Operating elements Explanation of symbols BRT1 torch trigger 1...

Page 38: ...orch trigger 2 Functions mode Operating elements Welding current On Off BRT 1 Secondary current BRT 2 Secondary current tapping mode latched mode 1 factory set BRT 1 Welding current On Off BRT 1 BRT 2...

Page 39: ...hed mode BRT 1 Increase welding current infinite adjustment up function Up Reduce welding current infinite adjustment down function 1 factory set Down Welding current on off BRT 1 Secondary current ta...

Page 40: ...de BRT 1 Increase welding current infinite adjustment up function Up Reduce welding current infinite adjustment down function 1 factory set Down Welding current on off BRT 1 Secondary current BRT 2 Se...

Page 41: ...1 Functions Mode Operating elements Welding current On Off BRT 1 Secondary current tapping mode BRT 1 Increase welding current infinite adjustment Reduce welding current infinite adjustment 3 Potenti...

Page 42: ...Welding current on off TT 1 Secondary current TT 2 Secondary current tapping function TT 1 tapping Increase welding current up function TT 3 Reduce welding current down function 1 ex works TT 4 Weldi...

Page 43: ...nipple protects against electrical voltage and dirt 5 7 1 Connecting the electrode holder and workpiece lead NOTE Polarity depends on the instructions from the electrode manufacturer given on the ele...

Page 44: ...3 Antistick Anti stick prevents the electrode from annealing If the electrode sticks in spite of the Arcforce device the machine automatically switches over to the minimum current within about 1 secon...

Page 45: ...ion with the foot operated remote control 5 8 5 Manual remote control RTP1 19POL RTP2 Functions TIG MMA Infinitely adjustable welding current 0 to 100 depending on the preselected main current on the...

Page 46: ...ing the welding parameter setting rotary dial EXIT leave the menu Select the Elt menu item Press the welding parameters button settings will be applied machine changes to the ready to operate status 5...

Page 47: ...es to the welding parameters you can lock the machine controls with a software key 3 digit machine code If the access lock is active only the following parameters can be changed Welding current within...

Page 48: ...for activating and deactivating the access lock l 0 Figure 5 19 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Machine code Confirming the old machine cod...

Page 49: ...owever in percentage display mode only the respective AMP signal light is lit l 0 Figure 5 20 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Settings Setti...

Page 50: ...until the arc stabilises It always switches over to DC polarity after a few milliseconds l 0 Figure 5 21 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Se...

Page 51: ...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 tra...

Page 52: ...ug is removed 1 Switch off machine 2 Remove the mains plug 3 Wait for at last 4 minutes until the capacitors have discharged CAUTION Test Before re commissioning it is essential that an inspection and...

Page 53: ...ion 6 2 1 2 Functional test Welding current cables check that they are fitted correctly and secured Gas cylinder securing elements Operating message safety and adjustment devices Functional test 6 2 2...

Page 54: ...pean provisions guideline 2002 96 EG of the European Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must...

Page 55: ...erformance Phase failure check mains connection fuses a Various parameters cannot be set Entry level is blocked disable access lock see chapter entitled Lock welding parameters against unauthorised ac...

Page 56: ...ttings and correct if necessary Pore formation a Inadequate or missing gas shielding Check shielding gas setting and replace shielding gas cylinder if necessary Shield welding site with protective scr...

Page 57: ...see E3 see E3 E5 see E3 see E3 E6 Balancing error in voltage recording Switch machine off place the torch on an insulated surface and switch on again If the fault persists inform the service departme...

Page 58: ...EW501 18 01 2013 7 3 Resetting welding parameters to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings RESET DC AC l 0 Figure 7 1 Di...

Page 59: ...sion NOTE The query of the software versions only serves to inform the authorised service staff l 0 Figure 7 2 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised acce...

Page 60: ...t 40 C 40 DC 190 A 50 DC 140 A 60 DC 150 A 130 A 100 DC 120 A 110 A Load alternation 10 min 60 DC 6 min welding 4 min pause Open circuit voltage DC 43 V Mains voltage tolerances 1 x 230 V 40 to 15 Fre...

Page 61: ...pot welding pulses 090 008211 00000 9 1 1 Connection cables RA5 19POL 5M Remote control e g connection cable 092 001470 00005 RA10 19POL 10M Remote control e g connection cable 092 001470 00010 RA20 1...

Page 62: ...irikov cz Production Sales and Service Sales and Service Germany Sales and Service International Plants Branches More than 300 EWM sales partners worldwide Headquarters EWM HIGHTEC WELDING GmbH Dr G n...

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