EWM Picotig 200 TG Operating Instructions Manual Download

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Operating instructions

Welding machine

Picotig 200 TG

099-002058-EW501

26.11.2015

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Summary of Contents for Picotig 200 TG

Page 1: ...Operating instructions EN Welding machine Picotig 200 TG 099 002058 EW501 26 11 2015 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group com ...

Page 2: ... accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are observed during installation operation usage and maintenance of the equipment An incorrectly performed installation can result in material damage and injure persons as a result For this re...

Page 3: ...5 3 Workpiece lead general 20 5 4 Transport and installation 20 5 4 1 Adjusting the length of the carrying strap 20 5 5 Mains connection 21 5 5 1 Mains configuration 21 5 5 2 Welding data display 22 5 6 TIG welding 23 5 6 1 Welding torch and workpiece line connection 23 5 6 2 Shielding gas supply shielding gas cylinder for welding machine 24 5 6 2 1 Connecting the shielding gas supply 24 5 6 2 2 S...

Page 4: ...st 46 6 2 2 Monthly maintenance tasks 46 6 2 2 1 Visual inspection 46 6 2 2 2 Functional test 46 6 2 3 Annual test inspection and testing during operation 47 6 3 Disposing of equipment 47 6 3 1 Manufacturer s declaration to the end user 47 6 4 Meeting the requirements of RoHS 47 7 Rectifying faults 48 7 1 Checklist for rectifying faults 48 7 2 Machine faults error messages 49 7 3 Resetting welding...

Page 5: ...he 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 warning symbol The risk is explained using a symbol on the edge of the page CAUTION Working and operating procedures which must be followed p...

Page 6: ...users must observe Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu 4 s 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 7: ...shocks 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 Switching off alone is not sufficient Place welding torch and stick electrode holder on an insulated surface The unit should only be opened by specialist staff after the mains plug has been unplugged Onl...

Page 8: ...nts 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 Inform persons in the working area that they must comply with the regulations Danger when coupling multiple power sources Coupling multiple power sources in para...

Page 9: ...g 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 securely connected and check regularly Always ensure a proper and secure electrical connection to the workpiece Set up attach or suspend all conductive power source components like casing transport vehi...

Page 10: ...dard 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 neighbouring persons e...

Page 11: ...uitable 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 during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to IEC 60974 1 Set up and transport the machine on level solid ground Secure add on parts using suitable equipme...

Page 12: ...ities 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 ambient conditions 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 distan...

Page 13: ...nly be used in line with proper usage and by trained or expert staff Do not modify or convert the equipment improperly 3 1 Applications 3 1 1 TIG welding TIG welding with direct current Non contact HF ignition or contact ignition with Liftarc 3 1 2 MMA welding Manual arc welding or for short MMA welding It is characterised by the fact that the arc burns between a melting electrode and the molten p...

Page 14: ...y is enclosed 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 hazard 3 2 4 Service documents spare parts and circuit diagrams DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repa...

Page 15: ...ol Operating elements chapter 3 Connection socket welding current TIG Connection for workpiece lead MMA Electrode holder or workpiece lead connection 4 Cooling air outlet 5 Machine feet 6 Connection socket 5 pole Standard TIG torch control lead 7 Connection socket welding current TIG Welding current lead connection for TIG welding torch MMA Electrode holder or workpiece lead connection 8 G connect...

Page 16: ... Rear view Figure 4 2 Item Symbol Description 0 1 Main switch machine on off 2 Cooling air inlet 3 Mains connection cable See 5 5 Mains connection chapter 4 G connecting nipple Shielding gas connection on the pressure regulator 5 Connection socket 19 pole Remote control connection ...

Page 17: ...t any further measures 4 AMP Main current signal light Imin to Imax 1 A increments 5 Welding parameter setting rotary dial Setting currents times and parameters 6 AMP Secondary current TIG Setting range 1 to 200 1 increments Percentage of the main current 7 Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used...

Page 18: ...re power saving mode push button MMA welding TIG welding non latched operating mode TIG welding latched operating mode Signal light green HF start contactless switched on ex works Signal light red Liftarc contact ignition switched on STBY Press for 2 s to put the machine into power saving mode To reactivate activate one of the operating elements ...

Page 19: ...se direction if necessary Risk from electrical current If welding is 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 The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks...

Page 20: ...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 The machine may not be lifted by crane or suspended 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 T...

Page 21: ...ng the generator always 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 The machine may only be connected to a one phase system with two conductors and an earthed neutral conductor Figure 5 2 Legend Item Designation Colour code L Outer conductor brown N Neutral cond...

Page 22: ...power adjustment chapter The value shown on welding data display depends on the selected parameter current or time After approx 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 appr...

Page 23: ...nection 5 Connection socket 5 pole Standard TIG torch control lead 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...

Page 24: ...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 Before connecting the pressure regulator to the gas cylinder open the cylinder valve briefly to expel any dirt 5 6 2 1 Conn...

Page 25: ...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 Incorrect shielding gas setting 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 g...

Page 26: ...ng current setting range Secondary current AMP selection Secondary current setting Setting range 1 to 200 percentage depending on the main current Down slope time selection Down slope time setting sec Setting range 0 0 s to 20 0 s Gas post flow time selection sec Gas post flow time setting Setting range 0 0 s to 20 0 s This completes the basic settings and you can now start welding Further welding...

Page 27: ...n contact with the workpiece a Carefully place the torch 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 opera...

Page 28: ...e advanced settings and optimise further parameters for your welding task See 5 6 9 Expert menu TIG chapter 5 6 6 1 Legend Symbol Meaning Gas pre flows factory setting 0 5 s Istart Ignition current factory setting 20 tUp Upslope time factory setting 1 0 s AMP Main current minimum to maximum current AMP Secondary current 1 to 200 of main current AMP tDown Downslope time Iend End crater current fact...

Page 29: ...rt HF is switched off The welding current increases in the set up slope time to the main current AMP 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 decrease...

Page 30: ... 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 trigger 1 the arc extinguishes The set gas post flow time begins Immediate termination of the welding procedure without down slope and end crater current Briefly press the 1st torch trigger 3rd and 4th step The current drops to zero and the gas post flow ti...

Page 31: ...rating elements can be customised in different modes Explanation of operating element symbols Symbol Description Press torch trigger Tap torch trigger Tap torch trigger and then press See 5 6 8 Torch mode and up down speed setting chapter 5 6 7 1 Tap torch trigger tapping function Swiftly tap the torch trigger to change the function The torch mode set determines the operating mode of the tapping f...

Page 32: ...current The function options in the individual modes can be found in the tables for the corresponding torch types ENTER NAVIGATION EXIT l 0 Figure 5 10 Display Setting selection Calibration The machine will be calibrated for approx 2 seconds each time it is switched on Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode factory setting 1 Up Down speed Increase value ...

Page 33: ...tion Functions mode Operating elements Welding current On Off 1 factory set Secondary current Latched mode Standard torch with two torch triggers Diagram Operating elements Explanation of symbols BRT1 torch trigger 1 BRT2 torch trigger 2 Functions mode Operating elements Welding current On Off 1 factory set Secondary current Secondary current tapping mode latched mode Welding current On Off 3 Seco...

Page 34: ...of symbols BRT 1 torch trigger 1 BRT 2 torch trigger 2 Functions mode Operating elements Welding current On Off 1 factory set Secondary current Secondary current tapping mode latched mode Welding current On Off 2 Secondary current tapping mode Up function Down function Welding current On Off 3 Secondary current tapping mode latched mode Up function Down function ...

Page 35: ...ng 099 002058 EW501 26 11 2015 35 5 6 8 2 TIG pulsed welding Figure 5 11 Display Setting selection Pulsed welding On Function switched on Off Function switched off ex works Pulsed TIG welding frequency Setting range 0 2 Hz 2 0 kHz ...

Page 36: ...ulse pause current Tpuls Duration of one pulse cycle 1 FrE e g 1 1 Hz 1 s bAL Balance bAL x Tpuls e g 30 x 1 s 0 3 s For parameter setting See 5 7 6 Expert menu MMA chapter The pulse pause current I2 requires no setting This value is calculated by the machine control so that the welding current average value always corresponds to the main current selected ...

Page 37: ... 5 13 Display Setting selection Switch ignition mode HF ignition Liftarc Gas pre flow time Setting range 0 0 s to 5 0 s 0 1 s increments Ignition current Setting 1 to 200 of main current AMP depending on main current Upslope time to main current Setting 0 0 sec to 20 0 sec factory setting 1 0 sec End crater current Setting range in percent 1 to 200 depending on main current Pulse current Setting r...

Page 38: ...der and workpiece lead Figure 5 14 Item Symbol Description 0 1 Electrode holder 2 Connection socket welding current Workpiece lead or electrode holder connection 3 Workpiece 4 Connection socket for welding current Electrode holder or workpiece lead connection Insert cable plug of the electrode holder into either the or welding current connection socket and lock by turning to the right Insert cable...

Page 39: ...lectrode the arc ignites with hotstart current iht for the preset hotstart time tht and then reduces to the main current AMP The parameter values for hotstart current and time can be optimised for the electrode types being used For parameter setting See 5 7 6 Expert menu MMA chapter The hotstart device improves the ignition of the stick electrodes using an increased ignition current a Hotstart tim...

Page 40: ...ct according to the welding task 5 7 5 1 MMA pulsed welding Welding characteristics Especially suitable for root welding Fine flaked weld surface with a TIG look for final passes Less finishing work thanks to less spatter Highly suitable for difficult electrodes Outstanding gap bridging with no sagging of the root side Less distortion thanks to controlled heat input Figure 5 16 Display Setting sel...

Page 41: ...ulse pause current Tpuls Duration of one pulse cycle 1 FrE e g 1 1 Hz 1 s bAL Balance bAL x Tpuls e g 30 x 1 s 0 3 s The pulse pause current I2 requires no setting This value is calculated by the machine control so that the welding current average value always corresponds to the main current selected For parameter setting See 5 7 6 Expert menu MMA chapter ...

Page 42: ...start time Hotstart time setting 0 1 s to 20 0 s Arcforce correction setting 10 to 10 factory setting 0 Increase value harder arc Decrease value softer arc Pulse current Setting range 1 200 Balance Percentage of time from pulse cycle Tpuls for pulse current IP1 Setting range 1 99 5 8 Remote control The remote controls are operated on the 19 pole remote control connection socket analogue 5 8 1 Foot...

Page 43: ...e by either pressing the push button for a prolonged time or by setting a parameter in the machine configuration menu time controlled power saving mode When power saving mode is activated the machine displays show the horizontal digit in the centre of the display only Pressing any operating element e g tapping the torch trigger deactivates power saving mode and the machine is ready for welding aga...

Page 44: ...meters are selected by pressing the welding parameters button Set or change the parameters by turning the welding parameter setting rotary dial EXIT Exit the menu Select the EIt menu item Press the Welding parameters button settings will be applied machine changes to the ready to operate status ENTER EXIT l 0 NAVIGATION Figure 5 19 Display Setting selection Calibration The machine will be calibrat...

Page 45: ...display Dynamic power adjustment 20 A Setting for 20 A mains fuse protection 16 A Setting for 16 A mains fuse protection factory setting 10 A Setting for 10 A mains fuse protection Time based power saving mode 5 min 60 min Time to activation of power saving mode in case of inactivity off inactivated ex works 20 min Service menu Modifications to the service menu may only be carried out by authorise...

Page 46: ...our 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 6 1 General When used in the specified environmental conditions and under normal operating conditions this machine is largely maintenance free and requires a minimum of ca...

Page 47: ...ean Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be collected separately The symbol depicting a waste container on wheels indicates that the equipment must be collected separately This machine is to be placed for disposal or recycling in the waste separation systems provided for this purpose Accor...

Page 48: ...ng 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 increase if necessary higher ignition energy Welding torch overheated Loose welding current connections Tighten power c...

Page 49: ...ror in current recording Switch off the machine place the electrode holder in an insulated position and switch the machine back on If the error persists notify service department E15 Error in on of the electronics supply voltages Switch the machine off and on again If the error persists notify service department E23 Temperature error Allow the machine to cool down E32 Electronics error Switch the ...

Page 50: ...release button s 7 4 Display machine control software version The query of the software versions only serves to inform the authorised service staff It is available in the machine configuration menu 7 5 Dynamic power adjustment This requires use of the appropriate mains fuse Observe mains fuse specification See 8 Technical data chapter The dynamic power adjustment automatically adjusts the welding ...

Page 51: ... 40 C 25 200 A 35 150 A 60 150 A 120 A 100 120 A 100 A Load cycle 10 min 60 DC 6 min welding 4 min pause Open circuit voltage 90 V Mains voltage tolerances 1 x 230 V 40 to 15 Frequency 50 60 Hz Mains fuse safety fuse slow blow 1 x 16 A Mains connection lead H07RN F3G2 5 Max connected load 6 0 kVA 6 4 kVA Recommended generator rating 8 6 kVA cos efficiency 0 99 86 Insulation class protection classi...

Page 52: ... 00000 9 3 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 connection 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 00...

Page 53: ...Appendix A Overview of EWM branches 099 002058 EW501 26 11 2015 53 10 Appendix A 10 1 Overview of EWM branches ...

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