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Design and function

Workpiece lead, general

099-000188-EW501

22.02.2016

19

5.2

Workpiece lead, general

CAUTION

Risk of burns due to incorrect connection of the workpiece lead!
Paint, rust and dirt on the connection restrict the power flow and may lead to stray
welding currents.
Stray welding currents may cause fires and injuries!

•  Clean the connections!
•  Fix the workpiece lead securely!
•  Do not use structural parts of the workpiece as a return lead for the welding current!
•  Take care to ensure faultless power connections!

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Содержание Picotig 200 AC/DC puls 8P TG

Страница 1: ...ns EN Welding machine Picotig 200 AC DC puls 5P TG Picotig 200 AC DC puls 8P TG 099 000188 EW501 22 02 2016 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group com ...

Страница 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...

Страница 3: ...ction 21 5 5 1 Mains configuration 21 5 6 Notes on the installation of welding current leads 22 5 7 Welding data display 24 5 8 TIG welding 25 5 8 1 Welding torch and workpiece line connection 25 5 8 1 1 Torch connection options and pin assignments 26 5 8 2 Shielding gas supply shielding gas cylinder for welding machine 26 5 8 2 1 Connecting the shielding gas supply 27 5 8 2 2 Setting the shieldin...

Страница 4: ...ition phase 57 5 13 6 TIG antistick 58 5 13 7 Choosing the alternating current waveform 59 5 13 7 1 Configuring the TIG potentiometer torch connection 60 6 Maintenance care and disposal 61 6 1 General 61 6 2 Maintenance work intervals 61 6 2 1 Daily maintenance tasks 61 6 2 1 1 Visual inspection 61 6 2 1 2 Functional test 61 6 2 2 Monthly maintenance tasks 61 6 2 2 1 Visual inspection 61 6 2 2 2 F...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 13: ...This declaration shall become null and void in the event of unauthorised modifications improperly conducted repairs non observance of the deadlines for the repetition test and or non permitted conversion work not specifically authorised by the manufacturer The original copy of the declaration of conformity is enclosed with the unit 3 1 3 Welding in environments with increased electrical hazards In...

Страница 14: ... pole TIG Up Down or potentiometer torch control lead 12 pole Control lead for TIG up down torch with display 4 Connection socket welding current TIG Connection for workpiece lead MMA Electrode holder or workpiece lead connection 5 Cooling air inlet 6 Connection socket welding current TIG TIG welding torch connection MMA Electrode holder or workpiece lead connection 7 G connecting nipple welding c...

Страница 15: ...ying strap chapter 2 Carrying handle 3 Ignition type changeover switch See 5 8 5 Arc ignition chapter Liftarc contact ignition HF ignition 4 Main switch machine on off 5 Cooling air outlet 6 Machine feet 7 Mains connection cable See 5 5 Mains connection chapter 8 G connecting nipple Shielding gas connection on the pressure regulator 9 Connection socket 19 pole Remote control connection ...

Страница 16: ...cooling Excess temperature signal light sign signal light VRD voltage reduction device VRD 3 AMP Main current signal light Imin to Imax 1 A increments 4 AMP Secondary current TIG Setting range 1 to 100 1 increments Percentage of the main current 5 Welding parameter setting rotary dial Setting currents times and parameters 6 Select welding parameters button This button is used to select the welding...

Страница 17: ... respect to the workpiece AC welding alternating current waveform can be set 10 Pulse welding push button average value pulses 11 Operating mode power saving mode push button Non latched Latched Press for 2 s to put the machine into power saving mode To reactivate activate one of the operating elements 12 Welding procedure push button MMA welding TIG welding 13 Display switching push button AMP We...

Страница 18: ...the welding current connection If the welding current connections are not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by turning in clockwise 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...

Страница 19: ...e workpiece lead Paint rust and dirt on the connection restrict the power flow and may lead to stray welding currents Stray welding currents may cause fires and injuries Clean the connections Fix the workpiece lead securely Do not use structural parts of the workpiece as a return lead for the welding current Take care to ensure faultless power connections ...

Страница 20: ...table 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 Safe operation of the machine must be guaranteed at all times 5 3 1 Adjusting the length of the carrying strap To demonstrate adjustment lengthening the strap is shown in the figure To shorten the strap s loops must be inched in the opposite direction Fig...

Страница 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...

Страница 22: ... power sources without HF igniter MIG MAG for as long and as close as possible in parallel Lay the workpiece lead and hose package of power sources with HF igniter TIG for as long as possible in parallel with a distance of 20 cm to avoid HF sparkover Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences Always keep leads as short as possible For optimum we...

Страница 23: ...1 22 02 2016 23 Use an individual welding lead to the workpiece for each welding machine Figure 5 4 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 5 ...

Страница 24: ...before nominal values during actual values or after welding hold values Parameter Nominal values Actual values Hold values Welding current Welding voltage Welding power When the hold values are displayed after welding and the settings are then changed e g welding current the display will switch to the relevant nominal values not possible possible ...

Страница 25: ...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 Insert the welding torch control lead plug into the connection socket for the weldin...

Страница 26: ...ir Place 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 gas supply from the shielding 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...

Страница 27: ... cylinder 3 Output side of the pressure regulator 4 Cylinder valve Before connecting the pressure regulator to the gas cylinder open the cylinder valve briefly to blow out any dirt Tighten the pressure regulator screw connection on the gas bottle valve to be gas tight Screw gas hose connection crown nut onto the output side of the pressure regulator Figure 5 9 Item Symbol Description 0 1 Connectin...

Страница 28: ...ally 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 Rule of thumb for the gas flow rate Diameter of gas nozzle in mm corresponds to gas flow in l min Example 7mm gas nozzle corresponds to 7l min gas flow Incorrect shielding gas setting If the shielding gas setting is t...

Страница 29: ... button DC welding with negative polarity at the torch or electrode holder with respect to the workpiece AC welding alternating current waveform can be set 3 Operating mode power saving mode push button Non latched Latched Press for 2 s to put the machine into power saving mode To reactivate activate one of the operating elements 4 Select welding parameters button This button is used to select the...

Страница 30: ...he pulse current Ipuls is defined by the parameter as 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 10 AMP Main current e g 100 A IPL Pulse current IP1 x AMP e g 170 x 100 A 170 A IPP Pulse pause current Tpuls Duration of ...

Страница 31: ...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 3 mm between the electrode tip and the workpiece The arc ignites and the welding current is increased depending on the operating mode set to the ignition or main current set c Lift off the torch and s...

Страница 32: ...ocess and operating mode used 2 Welding parameter setting rotary dial Setting currents times and parameters 5 8 6 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 I Current t Time Gas pre flows Istart Ignition current tUp Up slope time tP Spot time AMP Main current minimum to maximum current AMP Secondary current 0 to 100 of AMP ts1 TIG pulses Slop time from ma...

Страница 33: ...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 set down slope time to the end crater current Iend minimum current If the 1st torch trigger is pressed during the down slope time the welding current returns to the main current AMP set The main current reaches the en...

Страница 34: ...rigger 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 trigger 1 the arc extinguishes The set gas post flow time begins Immediate termination of the welding process in the downslope by releasing torch trigger 1 When the foot operated remote control RTF is connected the mach...

Страница 35: ...nt 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 Tap torch trigger Tap and press torch trigger ...

Страница 36: ...tion for the secondary current The function options in the 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 ENTER EXIT l 0 Figure 5 16 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Torch configuration menu Set welding torch func...

Страница 37: ...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 NAVIGATION ENTER EXIT l 0 Figure 5 17 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Torch configuration menu Set welding torch functions Torch mode setting factory setting 1 Up Down speed not available in modes 4 and 14 Inc...

Страница 38: ...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...

Страница 39: ...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 ...

Страница 40: ...urrent on off 1 ex works Secondary current tapping function latched operating mode Increase welding current infinite adjustment up function Decrease welding current infinite adjustment down function Welding current on off 2 Secondary current tapping function Welding current on off 4 Secondary current tapping function latched operating mode Skipping increase of welding current Skipping decrease of ...

Страница 41: ... on off 1 ex works Secondary current Secondary current tapping function latched operating mode Increase welding current infinite adjustment up function Decrease welding current infinite adjustment down function Welding current on off 2 Secondary current Secondary current tapping function Welding current on off 4 Secondary current Secondary current tapping function Skipping increase of welding curr...

Страница 42: ...ymbols BRT 1 torch trigger 1 Functions Mode Operating elements Welding current On Off 3 Secondary current tapping mode Increase welding current infinite adjustment Reduce welding current infinite adjustment Potentiometer torch with 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 Of...

Страница 43: ...r up to four minutes after the mains plug 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 test during operation is carried out conforming to IEC DIN EN 60974 4 Arc welding devices inspection and testing during operation For detailed instructions plea...

Страница 44: ...on off 1 ex works 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 TT 4 Welding current on off 2 TT 1 Secondary current TT 2 Secondary current tapping function TT 1 tapping Welding current on off 3 TT 1 Secondary current TT 2 Secondary current tapping function TT 1 tapping Welding current on o...

Страница 45: ...n current Setting 0 0 sec to 20 0 sec factory setting 1 0 sec End crater current Setting range in percent depending on main current Setting range absolute Imin to Imax Diameter of tungsten electrode ignition optimisation 1 mm to 4 mm or larger 0 1 mm increments Alternating current balance AC Max setting range 30 to 30 1 increments Optimisation of cleaning and fusion penetration AC frequency AC Set...

Страница 46: ...st electrical voltage and dirt 5 9 1 Connecting the electrode holder and workpiece lead Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging Figure 5 20 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...

Страница 47: ...wing order g 5 9 3 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 I Welding current t Time For parameter setting See 5 9 6 Expert menu MMA chapter 5 9 4 Antistick Anti stick prevents the electrode from annealing If the electrode sticks in spite of the Arcforce device the mac...

Страница 48: ...he pulse current Ipuls is defined by the parameter as 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 22 AMP Main current e g 100 A IPL Pulse current IP1 x AMP e g 170 x 100 A 170 A IPP Pulse pause current Tpuls Duration of ...

Страница 49: ...Pulse current Setting range 1 to 200 ex works 142 5 10 Voltage reducing device The voltage reducing device is a requirement in some countries and in many internal company safety guidelines for power sources The voltage reduction device is only active on VRD machine versions To increase safety particularly in hazardous environments like shipbuilding pipe construction or mining the machine is equipp...

Страница 50: ... 11 4 RTP 2 Functions TIG MMA Infinitely adjustable welding current 0 to 100 depending on the preselected main current on the welding machine Pulse spot normal Frequency and spot times infinitely adjustable Coarse adjustment of the cycle frequency Pulse pause ratio balance adjustable from 10 to 90 5 11 5 RTP3 spotArc 19POL Functions TIG MMA Infinitely adjustable welding current 0 to 100 depending ...

Страница 51: ...oltage Figure 5 24 Item Pin Signal shape Designation 1 A Output Connection for cable screen PE 2 B L Output Current flowing signal I 0 galvanically isolated max 15V 100mA 3 F Output Reference voltage for potentiometer 10V max 10mA 4 C Input Control voltage specification for main current 0 10V 0V Imin 10V Imax 5 D Input Control voltage specification for secondary current 0 10V 0V Imin 10V Imax 6 J ...

Страница 52: ...e the power saving mode 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...

Страница 53: ...n at the machine controls so that you can check that it is working correctly ENTER EXIT NAVIGATION l 0 Figure 5 26 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Service menu Service settings Exit the menu Exit Machine fan test Machine fan is switched off Machine fan test Machine fan is switched on ...

Страница 54: ...e 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 a previously defined range Switch display Switch welding parameters JOBs 3 s ENTER EXIT NAVIGATION l 0 Figure 5 27 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access ...

Страница 55: ...vating and deactivating the access lock 3 s 3 s ENTER EXIT NAVIGATION l 0 Figure 5 28 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Machine code Confirming the old machine code entering the new machine code Machine code Querying the three digit machine code 000 to 999 user input Error Error message after entering an incorrect machine code New machine c...

Страница 56: ...r in percentage display mode only the respective AMP signal light is lit ENTER EXIT NAVIGATION l 0 Figure 5 29 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Settings Settings for machine functions and parameter displays Welding current display percentage Representation of the welding current as a percentage in relation to the main current setting AMP E...

Страница 57: ...l the arc stabilises It always switches over to DC polarity after a few milliseconds ENTER EXIT NAVIGATION l 0 Figure 5 30 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Settings Settings for machine functions and parameter displays Negative welding current polarity during the ignition phase Positive welding current polarity during the ignition phase Ex...

Страница 58: ...current phase of the latched operating mode See 5 8 6 3 Latched mode chapter The 3rd and 4th cycle are omitted and the welder starts the new process with the 1st cycle The user can switch the function on or off see the procedure below ENTER EXIT NAVIGATION l 0 Figure 5 31 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Settings Settings for machine funct...

Страница 59: ...ised 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 Low noise level Initialising Machine adopts previously ...

Страница 60: ...esent for up to four minutes after the mains plug 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 test during operation is carried out conforming to IEC DIN EN 60974 4 Arc welding devices inspection and testing during operation For detailed instructi...

Страница 61: ...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...

Страница 62: ...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...

Страница 63: ... performance Phase failure check mains connection fuses Various parameters cannot be set Entry level is blocked disable access lock See 5 13 3 Protecting welding parameters from unauthorised access chapter Connection problems Make control lead connections and check that they are fitted correctly No arc ignition Incorrect ignition type setting Set ignition type changeover switch to the HF ignition ...

Страница 64: ...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 Unsuitable or worn welding torch equipment Check size of gas nozzle and replace if necessary Conde...

Страница 65: ...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 department E7 Balancing error in current recording Switch machine off place the torch on an insulated surface and switch on again If the fault persists inform the service department E8 Error in one of the elec...

Страница 66: ...000188 EW501 22 02 2016 7 3 Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by the factory settings RESET l 0 Figure 7 1 Display Setting selection Input confirmation User entries are applied release button s ...

Страница 67: ...e versions only serves to inform the authorised service staff It is available in the machine configuration menu 2x ENTER EXIT l 0 Figure 7 2 Display Setting selection Lock JOB menu Protect welding parameters from unauthorised access Service menu Service settings Exit the menu Exit Software version of the machine control Version display example 014 version 14 ...

Страница 68: ...35 DC 200 A 50 DC 140 A 60 DC 150 A 130 A 100 DC 120 A 110 A Load cycle 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 Frequency 50 60 Hz Mains fuse 1 x 16 A safety fuse slow blow Mains connection lead H07RN F3G2 5 Max connected load 6 0 kVA Recommended generator rating 8 1 kVA cos efficiency 0 99 85 Insulation class protection class...

Страница 69: ... no 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 00020 9 1 2 Extension cable Type Designation Item no RV5M19 19POLE 5M Extension cable 092 000857 00000 RV5M19 19POL 10M Extension cable 092 000857 00010 RV5M19 19POL 15M Extension cable 092 000857 000...

Страница 70: ...Appendix A Overview of EWM branches 70 099 000188 EW501 22 02 2016 10 Appendix A 10 1 Overview of EWM branches ...

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