EWM Picotig 200 puls TG Operating Instructions Manual Download

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Rectifying faults

Checklist for rectifying faults

099-002058-EW501

26.11.2020

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.

7.1 Checklist for rectifying faults

The correct machine equipment for the material and process gas in use is a fundamental

requirement for perfect operation!

Legend

Symbol

Description



Fault/Cause



Remedy

Mains fuse triggers



Mains fuse triggers - unsuitable mains fuse



Set up recommended mains fuse

> see 8 chapter

Functional errors



Several parameters cannot be set (machines with access block)



Entry level is blocked, disable access lock



All machine control signal lights are illuminated after switching on



No machine control signal light is illuminated after switching on



No welding power



Phase failure > check mains connection (fuses)



Connection problems



Make control lead connections and check that they are fitted correctly.



Loose welding current connections



Tighten power connections on the torch and/or on the workpiece



Tighten contact tip correctly

No arc ignition



Incorrect ignition type setting.



Ignition type: Select “HF start”. Depending on the machine, the setting is defined by the change-

over switch for ignition types or the

parameter in one of the machine menus (see the “Con-

trol operating instructions”, if applicable).

Bad arc ignition



Material inclusions in the tungsten electrode due to contact with filler material or workpiece



Regrind or replace the tungsten electrode



Bad current transfer on ignition



Check the setting on the "Tungsten electrode diameter/Ignition optimisation" rotary dial and in-

crease if necessary (higher ignition energy).

Welding torch overheated



Loose welding current connections



Tighten power connections on the torch and/or on the workpiece



Tighten contact tip correctly



Overload



Check and correct welding current setting



Use a more powerful welding torch

Summary of Contents for Picotig 200 puls TG

Page 1: ...Operating instructions EN Welding machine Picotig 200 puls TG 099 002058 EW501 Observe additional system documents 26 11 2020 ...

Page 2: ... 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 This exclusion of liability shall be deemed ac cepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or...

Page 3: ... 1 In operation 19 5 1 3 2 Transport and storage 19 5 1 4 Transport belt 19 5 1 4 1 Adjusting the length of the carrying strap 19 5 1 5 Notes on the installation of welding current leads 20 5 1 6 Stray welding currents 21 5 1 7 Mains connection 22 5 1 7 1 Mains configuration 22 5 2 TIG welding 23 5 2 1 Welding torch and workpiece line connection 23 5 2 1 1 Control lead connection 23 5 2 2 Shieldin...

Page 4: ...42 6 2 1 Daily maintenance tasks 42 6 2 2 Monthly maintenance tasks 42 6 2 3 Annual test inspection and testing during operation 42 6 3 Disposing of equipment 43 7 Rectifying faults 44 7 1 Checklist for rectifying faults 44 7 2 Error messages power source 45 7 3 Resetting welding parameters to the factory settings 47 7 4 Display machine control software version 47 7 5 Dynamic power adjustment 47 8...

Page 5: ...us and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning sym bol The hazard is also highlighted using a symbol 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 with a general warn ing symbol The risk i...

Page 6: ...itch off machine Release Switch on machine Press and hold Switch Incorrect Invalid Turn Correct Valid Numerical value adjustable Input Signal light lights up in green Navigation Signal light flashes green Output Signal light lights up in red Time representation e g wait 4 s ac tuate Signal light flashes red Interruption in the menu display other setting options possible Tool not required do not us...

Page 7: ...t Prevention Regulation BVG D1 formerly VBG 15 or country specific regulations Before commencing arc welding a test must verify that the equipment cannot exceed the maximum permitted open circuit voltage Only qualified personnel may connect the machine When taking individual power sources out of operation all mains and welding current leads must be safely disconnected from the welding system as a ...

Page 8: ...osion 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 Be watchful of pote...

Page 9: ...s specified in the standard The 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 see also EN 60974 10 Appendix A Mains control signal and telecommunication lines Radios and televisions Computers and other control systems Safety equipment The health of...

Page 10: ...eplacement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the ma chine is switched off Requirements for connection to the public mains network High performance machines can influence the mains quality by taking current from the mains network For some types of machines connection restrictions or requirements relating to the ma...

Page 11: ...ion or connection points can heat up significantly during operation water cooled version When opening the coolant circuit escaping coolant may cause scalding Open the coolant circuit only when the power source or cooling unit is switched off Wear proper protective equipment protective gloves Seal open connections of the hose leads with suitable plugs The units are designed for operation in an upri...

Page 12: ...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 The product comes with a relevant declaration of conformity in the original The manufacturer recommends carrying out the safety inspection according to national and in ternational ...

Page 13: ...entation 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 Figure 3 1 I tem Documentation A 1 Power source A 2 Remote control A 3 Welding torch A Complete documentation ...

Page 14: ...accessories depends on the welding procedure Please observe the connection description for the corresponding welding procedure see 5 chapter 4 Cooling air outlet 5 Machine feet 6 Connection socket welding torch control cable see 5 2 1 1 chapter 7 Connection socket welding current How to connect the accessories depends on the welding procedure Please observe the connection description for the corre...

Page 15: ...20 15 4 2 Rear view Figure 4 2 Item Symbol Description 0 1 Main Switch Switching the machine on or off 2 Cooling air inlet 3 Mains connection cable see 5 1 7 chapter 4 Connection thread G Shielding gas connection inlet 5 Connection socket 19 pole Remote control connection ...

Page 16: ...hout any further measures 5 AMP Main current signal light Imin to Imax 1 A increments 6 Welding parameter setting rotary dial Setting currents times and parameters 7 Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used 8 Pulse welding average value pulses signal light see 5 2 7 chapter On Function switched on...

Page 17: ...3 s see 7 5 chapter The value shown on welding data display depends on the selected parameter current or time After ap prox 5 s the display switches back to the welding current nominal value Advanced parameters are shown by the alternate display of the welding parameter with the respective value the parameter code illuminates for approx 2 s parameter value illuminates for approx 2 s After approx 6...

Page 18: ...nd cause injuries The handles straps or brackets are suitable for transport by hand only The machine must not be suspended or lifted using a crane 5 1 1 Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Keep the cooling air inlet and outlet clear Observe the minimum distance of 0 5 m from obstacles 5 1 2 Workpiece lea...

Page 19: ...r substances can damage the machine observe maintenance intervals see 6 2 chapter Avoid large amounts of smoke steam oily fumes grinding dust and corrosive ambient air 5 1 3 1 In operation Temperature range of the ambient air 25 C to 40 C 13 F to 104 F Relative humidity up to 50 at 40 C 104 F up to 90 at 20 C 68 F 5 1 3 2 Transport and storage Storage in a closed room temperature range of the ambi...

Page 20: ...lation of welding current leads Use an individual welding lead to the workpiece for each welding machine Figure 5 2 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 Figure 5 3 ...

Page 21: ...Check that all welding current connections are firmly secured and electrical connections are in perfect condition Set up attach or suspend all conductive power source components such as casing trans port vehicles and crane frames so they are insulated Do not place any other electronic devices such as drills or angle grinders on the power source transport vehicle or crane frames unless they are ins...

Page 22: ... operate machine using a socket that has correctly fitted protective earth Mains plug socket and lead must be checked by a qualified electrician on a regular basis When operating the generator always ensure it is earthed as stipulated in the operating in structions The network created must be suitable for operating machines according to pro tection class I 5 1 7 1 Mains configuration The machine m...

Page 23: ...n socket welding torch control cable see 5 2 1 1 chapter 6 Workpiece 7 Connection socket for welding current Workpiece lead connection Insert the welding current plug on the welding torch into the welding current connection socket and lock by turning to the right Remove yellow protective cap on G connecting nipple Screw welding torch shielding gas connection tightly onto the G connection nipple Pl...

Page 24: ...ielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch being destroyed Always re fit the yellow protective cap when not using the shielding gas connection All shielding gas connections must be gas tight 5 2 2 1 Pressure regulator connection Figure 5 8 Item Symbol Description 0 1 P...

Page 25: ...applied at the welding torch these can lead to electric shocks and burning on contact Keep the welding torch electrically insulated from persons animals or equipment during the setting procedure If the shielding gas setting is too low or too high this can introduce air to the weld pool and may cause pores to form Adjust the shielding gas quantity to suit the welding task Rule of thumb for the gas ...

Page 26: ...ch gas nozzle and tungsten 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 3 mm between the electrode tip and the workpiece The arc ignites and the welding current is increased depending on the operat ing mode set to the ignition or main current set c L...

Page 27: ...onal sequences Using the welding parameter push button and welding parameter setting rotary knob the sequence para meters are set By pressing the select welding parameter push button for approx 2 s you can access the advanced set tings and optimise further parameters for your welding task see 5 2 8 chapter 5 2 5 1 Legend Symbol Meaning Gas pre flow Ignition current Up slope time AMP Main current A...

Page 28: ...t HF switches off The welding current ramps up to the main current AMP in the selected up slope time If torch trigger 2 is pressed together with torch trigger 1 during the main current phase the welding current decreases to the secondary current AMP If torch trigger 2 is released the welding current increases again to the main current AMP 2nd cycle Release torch trigger 1 The main current falls to...

Page 29: ... slope times can be set 3rd cycle Press torch trigger 1 The main current falls to the end crater current minimum current in the set down slope time 4th cycle Release torch trigger 1 arc is extinguished Set gas post flow time starts Ending the welding process immediately without a down slope or end crater current Briefly press the 1st torch trigger 3rd and 4th cycle The current drops to zero and th...

Page 30: ...y current The functionality of the individual modes can be found in the corresponding torch type tables The torch modes are set using the torch configuration parameters in the machine configuration menu torch mode see 5 6 chapter Only the modes listed are suitable for the corresponding torch types 5 2 6 3 Up down speed Functionality Press and hold the up push button Increase current up to the maxi...

Page 31: ...ols BRT1 torch trigger 1 BRT2 torch trigger 2 Functions Mode Operating ele ments Welding current on off 1 ex works Secondary current Secondary current tapping function 1 latched operating mode Welding current on off 3 Secondary current tapping function 1 latched operating mode Up function2 Down function2 1 see 5 2 6 1 chapter 2 see 5 2 6 3 chapter ...

Page 32: ...h trigger 2 Functions Mode Operating ele ments Welding current on off 1 ex works Secondary current Secondary current tapping function 1 latched operating mode Welding current on off 2 Secondary current tapping function1 Up function2 Down function2 Welding current on off 3 Secondary current tapping function 1 latched operating mode Up function2 Down function2 1 see 5 2 6 1 chapter 2 see 5 2 6 3 cha...

Page 33: ... a percentage of the current average value AMP The pulse pause current IPP requires no setting This value is calculated by the machine control so that the welding current average value AMP is maintained at all times Figure 5 15 AMP Main current e g 100 A Ipuls Pulse current x AMP e g 140 x 100 A 140 A IPP Pulse pause current Tpuls Duration of one pulse cycle 1 e g 1 1 Hz 1 s Balance Figure 5 16 Di...

Page 34: ...ing selection Switch ignition mode HF ignition Liftarc Gas pre flow time Ignition current as percentage dependent on main current Upslope time to main current End crater current Setting range in percent depending on main current Setting range absolute Imin to Imax Pulse balance Pulse current see 5 2 7 chapter ...

Page 35: ...ent Workpiece lead or electrode holder connection 3 Workpiece 4 Connection socket for welding current Electrode holder or workpiece lead connection Insert the electrode holder plug and workpiece lead into the welding current socket depending on ap plication and lock in place by turning to the right The corresponding polarity will be based on the infor mation of the electrode manufacturer on the el...

Page 36: ...ctrode from annealing Should the electrode stick despite the Arcforce feature the machine au tomatically switches to the minimum current within approx one second This prevents the electrode from annealing Check the welding current setting and correct for the welding task in hand Figure 5 21 5 3 6 Average value pulse welding Average value pulse welding means that two currents are switched periodica...

Page 37: ...play Setting selection Pulse welding average value pulses Function switched on Function switched off ex works Pulse frequency More parameters can be set in the Expert menu see 5 3 7 chapter 5 3 7 Expert menu MMA Figure 5 24 Display Setting selection Hotstart current Hotstart time ...

Page 38: ... stop welding operation TIG 5 4 2 RT1 19POL Functions Infinitely adjustable welding current 0 to 100 depending on the preselected main current on the welding machine 5 5 Power saving mode Standby You can activate the power saving mode by either pressing the push button see 4 3 chapter for a pro longed time or by setting a parameter in the machine configuration menu time controlled power saving mod...

Page 39: ...xit the menu Exit Torch configuration menu Set welding torch functions Torch mode ex works 1 see 5 2 6 2 chapter Up down speed see 5 2 6 3 chapter Increase value rapid current change Decrease value slow current change Machine configuration Settings for machine functions and parameter display Dynamic power adjustment see 7 5 chapter Time based power saving mode see 5 5 chapter Time to activation of...

Page 40: ...tion see 5 2 3 3 chapter Function switched off or time setting Arc detection for welding helmets TIG Modulated waviness for better arc detection Function enabled Function disabled Service menu Any changes to the service menu should be agreed with the authorised service person nel Software version of the machine control Version display ...

Page 41: ...ice matters always consult the dealer who supplied the machine Return deliveries of defective equipment subject to warranty may only be made through your dealer When replacing parts use only original spare parts When ordering spare parts please quote the machine type serial number and item number of the machine as well as the type designation and item number of the spare part Under the specified a...

Page 42: ... rollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks Visual inspection Casing damage front rear and side walls Wheels and their securing elements Transport elements strap lifting lugs handle Check coolant tubes and their connections for impurities Functional test Selector switches command devices emergency stop devices voltage reducing devices message and ...

Page 43: ...er on wheels indicates that the equipment must be collected separately This machine has to be disposed of or recycled in accordance with the waste separation systems in use According to German law law governing the distribution taking back and environmentally correct dis posal of electric and electronic equipment ElektroG used machines are to be placed in a collection system separate from unsorted...

Page 44: ...light is illuminated after switching on No welding power Phase failure check mains connection fuses Connection problems Make control lead connections and check that they are fitted correctly Loose welding current connections Tighten power connections on the torch and or on the workpiece Tighten contact tip correctly No arc ignition Incorrect ignition type setting Ignition type Select HF start Depe...

Page 45: ... and high alloy steels Unsuitable or worn welding torch equipment Check size of gas nozzle and replace if necessary Condensation hydrogen in the gas tube Purge hose package with gas or replace 7 2 Error messages power source Depending on the options of the machine display a fault is shown as follows Display type machine control Display Graphic display two 7 segment displays one 7 segment display T...

Page 46: ...error persists notify service department E23 Temperature error Allow the machine to cool down E32 Electronics error Switch the machine off and on again If the error persists notify service department E33 Adjustment error in voltage record ing Switch off the machine place the electrode hol der in an insulated position and switch the ma chine back on If the error persists notify service department E...

Page 47: ...aff It is available in the machine configuration menu see 5 6 chapter 7 5 Dynamic power adjustment This requires use of the appropriate mains fuse Observe mains fuse specification see 8 chapter This function enables aligning the machine to the mains connection fusing to avoid continuous tripping of the mains fuse The maximum power input of the machine is limited by an exemplary value for the exis ...

Page 48: ...ator rating 8 6 kVA Cos φ efficiency 0 99 86 Protection class Ⅰ Overvoltage category Ⅲ Contamination level 3 Insulation class protection classification H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 25 C to 40 C Machine cooling Fan AF Torch cooling gas Workpiece lead min 35 mm2 EMC class A Safety marking Standards used See declaration of confo...

Page 49: ... Remote controls and accessories Type Designation Item no RT1 19POL Remote control current 090 008097 00000 RTF1 19POL 5 M Foot operated remote control current with connec tion cable 094 006680 00000 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 19POL 20m Remote control e g connection cable 092 001470 0002...

Page 50: ...welding off off on Pulse frequency 2 8 0 2 2000 Hz HF start on off on Gas pre flow time 0 5 0 0 5 s Ignition current 20 1 200 Up slope time 1 0 0 0 20 0 s End crater current AMP 20 1 200 Pulse balance 50 1 99 Pulse current 140 1 200 10 1 2 MMA welding Welding data dis play Parameters function Setting range Standard ex works Min Max Unit Pulse welding off off on Pulse frequency 1 2 0 2 500 Hz Hot s...

Page 51: ...witched on Switched off Calibration Initialisation Machine configuration Exit menu Torch configuration Torch mode 1 1 13 Up down speed 10 1 100 Service menu Software version of the machine control Dynamic power adjustment 10 A 16 A 20 A 16 10 20 A Time based power saving mode 20 off 60 min Re ignite after arc interruption 3 0 off 5 0 s Arc detection for welding helmets TIG off off on Power saving ...

Page 52: ...Appendix Searching for a dealer 52 099 002058 EW501 26 11 2020 10 2 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide ...

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