EWM PICOTIG 220 DC Operating Instructions Manual

Category
Welding System
Type
Operating Instructions Manual

This manual is also suitable for

EWM HIGHTEC WELDING GmbH
Dr. Günter - Henle - Straße 8; D-56271 Mündersbach
Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244
Internet:
www.ewm.de ; E-mail: info@ewm.de
Operating instructions
GB
Welding machines for
TIG and MMA welding
These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machine may only be operated by personnel familiar with the appropriate safety
regulations.
The machines bear the conformity mark and thus comply with the
EC Low Voltage Guideline (73/23/EEC)
EC EMV Directive (89/336/EEC)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
© 2008 Subject to alteration! Art. Nr.: 099-002004-EWM01 Stand: 15.02.2008
Originaldokument
liegt jedem Gerät bei!
Original document
is enclosed with each machine!
Document original
est joint à toute machine!
EG - Konformitätserklärung
EU - conformity declaration
Déclaration de Conformité de U.E.
Name des Herstellers:
Name of manufacturer:
Nom du fabricant:
EWM HIGHTEC WELDING GmbH
(nachfolgend EWM genannt)
(In the following called EWM)
(nommé par la suite EWM)
Anschrift des Herstellers:
Address of manufacturer:
Adresse du fabricant:
Dr.- Günter - Henle - Straße 8
D - 56271 Mündersbach Germany
info@ewm.de
Hiermit erklären wir, daß das
nachstehend bezeichnete Gerät in
seiner Konzeption und Bauart sowie in
der von uns in Verkehr gebrachten
Ausführung den grundlegenden
Sicherheits-anforderungen der unten
genannten EG- Richtlinien entspricht.
Im Falle von unbefugten
Veränderungen, unsachgemäßen
Reparaturen und / oder unerlaubten
Umbauten, die nicht ausdrücklich von
EWM autorisiert sind, verliert diese
Erklärung ihre Gültigkeit.
We herewith declare that the machine
described below meets the standard safety
regulations of the EU- guidelines
mentionned below in its conception and
construction, as well as in the design put
into circulation by us. In case of
unauthorized changes, improper repairs
and / or unauthorized modifications, which
have not been expressly allowed by EWM,
this declaration will lose its validity.
Par la présente, nous déclarons que la
conception et la construction ainsi que le
modèle, mis sur le marché par nous, de
l´appareil décrit ci - dessous
correspondent aux directives
fondamentales de sécurité de la U.E.
mentionnées ci- dessous. En cas de
changements non autorisés, de
réparations inadéquates et / ou de
modifications prohibeés, qui n´ont pas été
autorisés expressément par EWM, cette
déclaration devient caduque.
Gerätebezeichnung:
Description of the machine:
Déscription de la machine:
Gerätetyp:
Type of machine:
Type de machine:
Artikelnummer EWM:
Article number:
Numéro d´article
Seriennummer:
Serial number:
Numéro de série:
Optionen:
Options:
Options:
keine
none
aucune
Zutreffende EG - Richtlinien:
Applicable EU - guidelines:
Directives de la U.E. applicables:
EG - Niederspannungsrichtlinie (73/23/EWG)
EU - low voltage guideline
Directive de la U.E. pour basses tensions
EG- EMV- Richtlinie (89/336/EWG)
EU- EMC guideline
U.E.- EMC directive
Angewandte harmonisierte Normen:
Used co-ordinated norms:
Normes harmonisées appliquées:
EN 60974 / IEC 60974 / VDE 0544
EN 50199 / VDE 0544 Teil 206
Hersteller - Unterschrift:
Signature of manufacturer:
Signature du fabricant:
Michael Szczesny , Geschäftsführer
managing director
gérant
05.2000
Dear customer,
Congratulations! You have chosen a quality product from EWM HIGHTEC WELDING
GmbH.
EWM machines provide results of the highest perfection thanks to their PREMIUM
quality. Therefore we are happy to provide you with a full 3-year warranty according to
our operating instructions.
We develop and produce quality! From individual components to the final product, we
retain sole responsibility for our machines.
In all their high-tech components, our welding machines embody future-oriented
advanced technology at the utmost level of quality. Each of our products is carefully
checked; we guarantee that the material and processing of our products is faultless.
These operating instructions contain everything about commissioning the machine,
notes regarding safety, maintenance and care, technical data as well as information
regarding the warranty. Please heed all these notes to ensure many years of safe
operation of the machine.
Thank you for the trust that you have placed in us. We look forward to a long-term
partnership with you in the spirit of “ONCE EWM – ALWAYS EWM”.
Yours sincerely,
EWM HIGHTEC WELDING GmbH
Bernd Szczesny
Executive management
Machine and Company Data
Please enter the EWM machine data and your company’s data in the appropriate fields.
CE
EWM HIGHTEC WELDING GMBH
D-56271 MÜNDERSBACH
TYP:
ART:
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GEPRÜFT/CONTROL:
Name of Customer / company
Adress
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Country
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Date of purchase
Name of Customer / company
Adress
Post code / Place
Country
Stamp / Signature of EWM-distibutor
Date of purchase
Table of contents Page
Contents/1
Safety instructions............................................................................................................................. S/1
For your safety ...........................................................................................................................S/1
Transport and set-up..................................................................................................................S/4
Notes on the use of these operating instructions.......................................................................S/4
1 Technical data ...........................................................................................................................1/1
2 Description of the machine......................................................................................................2/1
3 Function specification..............................................................................................................3/1
3.1 Machine control units T2.10 and T2.15 ...........................................................................3/1
3.2 Remote control..................................................................................................................3/4
3.3 Other setting options.........................................................................................................3/5
3.3.1 TIG welding parameters.......................................................................................3/5
3.3.2 MMA welding parameters....................................................................................3/5
4 Quick start – the fastest way to weld......................................................................................4/1
5 Commissioning .........................................................................................................................5/1
5.1 Area of application............................................................................................................5/1
5.1.1 Proper usage........................................................................................................5/1
5.2 Setting up the welding machine........................................................................................5/1
5.3 Mains connection..............................................................................................................5/1
5.4 Welding machine cooling system .....................................................................................5/1
5.5 Connections......................................................................................................................5/1
5.5.1 Workpiece lead ....................................................................................................5/2
5.5.2 Electrode holder...................................................................................................5/2
5.5.3 TIG welding torch ................................................................................................5/2
5.5.4 Shielding gas supply............................................................................................5/2
5.6 General setting instructions..............................................................................................5/3
5.7 MMA welding ....................................................................................................................5/3
5.8 TIG welding.......................................................................................................................5/4
5.8.1 TIG welding with liftarc ignition ............................................................................5/4
5.8.2 TIG welding with HF ignition................................................................................5/5
5.8.3 Automatic cut-out.................................................................................................5/5
5.8.4 TIG welding torch, operating variants..................................................................5/6
5.8.4.1 Standard TIG torch, 5-pole connector plug (factory setting)..............5/6
5.8.4.2 TIG Up/Down torch, 8-pole connector plug (optional) .......................5/6
5.8.5 Tapping operating mode......................................................................................5/6
5.8.6 TIG function sequences.......................................................................................5/7
5.8.6.1 Explanation of symbols......................................................................5/7
5.8.6.2 TIG non-latched operation.................................................................5/8
5.8.6.3 TIG latched operation.........................................................................5/9
5.9 Cooling unit function specification (optional)..................................................................5/10
5.9.1 Coolant error......................................................................................................5/10
6 Maintenance and care...............................................................................................................6/1
7 3-Year Warranty.........................................................................................................................7/1
8 Operating problems, causes and remedies ...........................................................................8/1
9 Spare parts list ..........................................................................................................................9/1
10 Accessories, options..............................................................................................................10/1
10.1 Standard TIG torch .........................................................................................................10/1
10.2 TIG Up/Down torch.........................................................................................................10/1
10.3 Electrode holder / workpiece lead...................................................................................10/1
10.4 General accessories.......................................................................................................10/1
10.5 Remote control / connection cable .................................................................................10/1
11 Circuit diagrams......................................................................................................................11/1
Safety instructions
S/1
For your safety
Observe accident prevention regulations!
Ignoring the following safety procedures can be fatal!
Proper usage
This machine has been manufactured according to the latest developments in technology and
current regulations and standards. It is to be operated only for the use for which it was designed
(see chapter Commissioning/Area of application).
Improper usage
However, this machine may be a hazard to persons, animals and property if it is
not used as directed
used by unskilled persons who have not been trained
modified or converted improperly
Our operating instructions will provide you with an introduction into the safe use of the machine.
Therefore please read them carefully and only start work when you are familiar with them.
Any person involved in the operation, maintenance and repair of this machine must read and
follow these operating instructions, especially the safety precautions. Where appropriate, this
should be confirmed by signature.
Furthermore, the
relevant accident prevention regulations,
generally accepted safety regulations,
local regulations, etc. must be observed.
Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves.
Protect eyes and face with protective visor.
Electric shocks can be fatal!
Do not touch any live parts in or on the machine!
The machine may only be connected to correctly earthed sockets.
Only operate with intact connection lead including protective conductor and safety plug.
An improperly repaired plug or damaged mains cable insulation can cause electric shocks.
The machine may only be opened by qualified and authorised specialist staff.
Disconnect from the mains before opening. Switching off is not sufficient. Wait for 2 minutes until the
capacitors have discharged.
Always put down welding torch, stick electrode holder in an insulated condition.
The machine must not be used to defrost pipes!
Even touching low voltages can cause you to get a shock and lead to accidents, so:
Protect yourself from falling before working on platforms or scaffolding.
During welding ensure that you operate earth tongs, torch and workpiece correctly, and not in ways for
which they are not intended. Do not touch live parts with bare skin.
Only replace electrodes when wearing dry gloves.
Never use torches or earth cables with damaged insulation.
Smoke and gases can lead to breathing difficulties and poisoning.
Do not breathe in smoke and gases.
Ensure that there is sufficient fresh air.
Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can be
converted into poisonous phosgene by ultraviolet radiation.
Safety instructions
S/2
Workpiece, flying sparks and droplets are hot!
Keep children and animals well away from the working area. Their behaviour is unpredictable.
Move containers with inflammable or explosive liquids away from the working area. There is a danger
of fire and explosion.
Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of
explosions when apparently harmless substances develop high pressures in enclosed containers by
heating.
Take care to avoid fire hazards
Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when parts
are glowing or hot slag is present.
A constant check must be kept on whether fire hazards have arisen in the working area.
Highly inflammable objects, such as matches and cigarette lighters for example, must not be carried in
trouser pockets.
You must ensure that fire extinguishing equipment - appropriate for the welding process - is available
close to the welding work area and that this equipment can be accessed easily.
Containers in which fuels or lubricants have been present must be thoroughly cleaned before welding
begins. It is not sufficient simply for the receptacle to be empty.
After a workpiece has been welded, it must only be touched or brought into contact with inflammable
material when it has cooled down sufficiently.
Loose welding connections can completely destroy protective conductor systems of interior
installations and cause fires. Before beginning welding work, ensure that the earth tongs are properly
fixed to the workpiece or welding bench and that there is a direct electrical connection from the
workpiece to the power source.
Noise exceeding 70 dBA can cause permanent hearing damage!
Wear suitable earmuffs or plugs.
Ensure that other people who spend time in the working area are not inconvenienced by the noise.
Interference by electrical and electromagnetic fields is possible e.g. from the welding machine or
from the high-voltage pulses of the ignition unit.
As laid down in Electromagnetic Compatibility Standard EN 50199, the machines are intended for use
in industrial areas; if they are operated in residential environments, for example, problems may occur
in ensuring electromagnetic compatibility.
The functioning of heart pacemakers can be adversely affected when you are standing near the
welding machine.
It is possible that electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the welding site
could malfunction.
Other mains supply leads, control leads, signal and telecommunications leads above, under and near
the welding device may be subject to interference.
Electromagnetic interference must be reduced to a level that no longer constitutes interference.
Possible reduction measures:
Welding machines must be serviced regularly. (see Chap. Maintenance and care)
Welding leads should be as short as possible and run closely together on or near to the ground.
Selective shielding of other leads and equipment in the environment can reduce radiation.
Repair and modifications may only carried out by authorised, trained, specialist staff.
The warranty becomes null and void in the event of unauthorised interference.
Safety instructions
S/3
Transport and installation
The machines may only be transported and operated in an upright position.
Before carrying away or moving, pull out mains plug and place on the machine.
When setting up the machine, resistance to tilting is only guaranteed up to an angle of 15°
(as specified in EN 60974).
Secure the gas cylinder!
Place shielding gas cylinders in the holders provided for them and secure with safety chains.
Take care when handling cylinders; do not throw or heat, guard against them toppling over.
When moving by crane, take off the gas cylinder from the welding machine.
Ambient conditions
The welding machine must not be used in a location with risk of explosion
For usage, the following conditions must be kept:
Temperature range of the ambient air
During welding: -10°C to +40°C
During transport and storage -25°C to +55°C.
Relative air humidity
up to 50% at 40°C;
up to 90% at 20°C.
The ambient air must be free of unusual amounts of dust, acids, corrosive gases or substances,
etc., assuming these are not produced by the welding process.
Examples of unusual operating conditions:
• unusual corrosive smoke,
• vapour,
• excessive oil vapour,
unusual vibrations or jolts,
excessive quantities of dust such as grinding dust etc.,
severe weather conditions,
unusual conditions near the coast or on board ship.
When setting up the machine, ensure a free inlet and outlet of air.
The machine is tested to protection class IP23, i.e.:
Protection against penetration of solid foreign bodies > 12mm,
Protection against water spray up to an angle of 60° to the vertical.
Safety instructions
S/4
Notes on the use of these operating instructions
These operating instructions are arranged into chapters.
To help you find your way around more quickly, in the margins you will occasionally see symbols
along with the sub-headings. These symbols refer to particularly important passages of text which
are graded as follows depending on their importance:
Please note:
Technical features which users must observe.
Warning:
Working and operating procedures which must be followed precisely to avoid damaging or
destroying the machine.
Caution:
Working and operating procedures which must be followed precisely to avoid risk to persons and
includes the "Warning" symbol.
Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet
points, e.g.:
Insert the welding current lead socket into the relevant socket and lock.
Symbol Description
Press
Do not press
Turn
Switch
1 Technical data
1/1
PICOTIG 180 AC/DC PICOTIG 220 DC PICOTIG 220
AC/DC
Setting range:
Welding current / welding voltage
TIG
MMA
5A - 180A
10,1V - 17,2V
5A - 140A
20,2V - 25,6V
3A (5A AC) -220A /
10,1V -18,8V
5A - 180A /
20,2V - 27,2V
Max. welding current for TIG MMA TIG MMA TIG MMA
20ºC ambient temperature: 40%DC
45%DC
50%DC
60%DC
100%DC
40°C ambient temperature: 35%DC
40%DC
50%DC
60%DC
100%DC
------
------
------
180A
150A
------
180A
------
150A
120A
------
------
140A
130A
110A
------
------
140A
130A
110A
220A
------
------
180A
150A
220A
------
------
160A
130A
------
180A
------
160A
140A
180A
------
------
140A
110A
220A
------
------
180A
150A
220A
------
------
160A
130A
------
180A
------
160A
140A
180A
------
------
140A
110A
Load alternation
10 min (60% DC
6 min welding, 4 min break)
Open circuit voltage 43V 90V 45V
Mains voltage (tolerances) 1 x 230V -40%; +15%
1x240V -40%; +10%
Frequency 50/60 Hz
Mains fuse (slow-blow safety fuse) 1 x 16A
Mains connection lead 3 x 2.5mm
2
H07RN-F
Max. connected power 6,0kVA 5.8kVA 5.9kVA
Recommended generator rating 8,1kVA 7.8kVA 8.0kVA
cosϕ / efficiency
0,99 / 88% 1.0 / 89%
Insulation class / protection classification F / IP 23
Ambient temperature
-10°C to +40°C
Machine cooling / torch cooling Fan / gas or water
Workpiece lead 35mm
2
Dimensions L x W x H [mm] 480 x 185 x 390
Weight approx. 16.5kg approx. 15.5kg approx. 17.5kg
Constructed to standards IEC 60974 / EN 60974 / VDE 0544
EN 50199 / VDE 0544 Teil 206
/
2 Description of the machine
2/1
Front view Fig.2 / 1 PICOTIG 180; 220AC/DC Rear view
Item Symbol Description
A1
Carrying handle with carrying strap
B1
Control (see chap. 3.1)
C1
G¼ connecting nipple Shielding gas to the welding torch
Welding current potential "-"
D1
5-pole connection socket Standard TIG torch control lead
or
8-pole connection socket TIG Up/Down or potentiometer torch control lead
(option)
E1
+
Welding current socket "+" TIG welding workpiece connection,
MMA welding workpiece connection
F1
-
Welding current socket "-" TIG welding torch connection,
MMA welding electrode holder connection
G1
Cooling air inlets
H1
Cooling air outlets
I1
Mains cable with connector plug
J1
G¼ connecting nipple Shielding gas connection from pressure reducer
K1
5-pole connection socket Cooling unit voltage supply (option)
L1
Main switch Machine On/Off
M1
8-pole connection socket Cooling unit control lead (option)
N1
HF
HF
Changeover switch Ignition types:
HF
HF ignition
HF
Liftarc (contact ignition)
O1
19-pole connection socket Remote control connection (option)
3 Function specification
3/1
3.1 Machine control T 2.10 and T 2.15
AMP
secsec
sec
sec
AMPAMP
S
AMP
VOLT
T 2.10
A1
G1
K1
F1
J1
I1
H1
D1
C1
B1
Fig. 3/1: T 2.10 (PICOTIG 220 DC)
AMP
secsec
sec
sec
AMPAMP
T 2.15
DC
S
AMP
VOLT
AC
A1
L1
G1
K1
F1
J1
E1
I1
H1
D1
C1
B1
S
Fig. 3/2: T 2.15 (PICOTIG 180; 220 AC/DC)
3 Function specification
3/2
Item Symbol Description
A1
Three-figure display (on when the machine is ready for operation)
Depending on the setting on the key button (B1), displays the welding current
and welding voltage. Display of error messages (see chap. 7)
Display of the welding parameter values
for the TIG process (F1):
Main current (H1),
Down-slope time (I1):
Gas post-flow time (J1):
Select the relevant signal lights using key buttons from top to bottom.
B1
AMP
VOLT
Display switching:
AMP
Welding current display
VOLT
Welding voltage display
C1
Welding process:
MMA welding
TIG welding
D1
Operating modes (TIG):
non-latched
latched
E1
DC
AC
T 2.15 only
DC
TIG direct current welding
AC
TIG alternating current welding
F1
Key buttons for selecting the welding parameter signal lights
for the TIG process:
Main current (H1), down-slope time (I1), gas post-flow time (J1)
G1
sec
AMPAMP
Rotary transducer for setting all parameters for the TIG process (F1).
During the welding process, the LEDs H1 to J1 show the progress of the welding sequence, e.g.
during the gas post-flow, LED J1 will be on.
Welding parameter signal lights can be selected via key buttons
H1
AMP
Main current (TIG):
I min -220A; 1A increments.
Main current (MMA):
I min - 180A; 1A increments.
I1
secsec
Down-slope time (TIG):
0.1s - 20.0s; 0.1s increments.
The Down-Slope time can be set separately for non-latched and latched.
J1
secsec
Gas post-flow time (TIG):
0.1s - 20.0s; 0.1s increments.
3 Function specification
3/3
Item Symbol Description
K1
Excess temperature
Thermal monitors in the power unit trigger at excess temperature and the
excess temperature control lamp comes on. After cooling, welding can proceed
without any further measures.
Collective interference:
If the collective interference signal light is on, the power unit is automatically
switched off. Because some interference is short-term and one-off (e.g. mains
voltage surges), the signal light will go out again and the welding machine is
ready for welding. If the collective interference signal light continues to be on
after an appropriate waiting time, see the chapter on troubleshooting.
Water deficiency (optional):
Indicates a water deficiency in welding machines cooled by liquids.
L1
SS
T 2.15 only:
Indicates that welding is possible in environments with increased electrical risks
(e.g. in boilers).
If the LED is off, the machine must be switched off and the service department
must be informed.
3 Function specification
3/4
3.2 Remote control
Only the remote controls described in these operating instructions should be
connected.
Only plug and lock the remote control unit into the remote control connection socket
and only when the machine is switched off.
For remote controls without cables, a remote control connection cable should be used.
See the operating instructions on the remote control for more detailed information.
Foot-operated remote control RTF 1 Manual remote control RT1
Functions:
Welding current
"ON/OFF" (switches
on after the pedal
has been pressed).
Infinitely adjustable
welding current (in
%) depending on the
preselected main
current or I
1
of the
welding machine.
Functions:
Infinitely adjustable welding
current (in %) depending on
the welding current I
1
preselected on the welding
machine.
When the foot-operated remote control
RTF 1 is connected, the machine
switches automatically to non latched
operation. The up- and down-slopes are
switched off.
RTP 1 manual remote control RTP 2 manual remote control
Functions:
TIG / MMA
Pulse / spot / normal
The percentage settings
of the main and
secondary current
depending on the
preselected welding
current I
1
of the welding
machine.
Pulse, spot and break
times are infinitely
adjustable.
TIG AC pulses special is
not possible.
Functions:
TIG / MMA
Pulse / spot / normal
The percentage settings of
the main and secondary
current depending on the
preselected welding current I
1
of the welding machine.
Frequency and spot times
infinitely adjustable.
Coarse adjustment of the
cycle frequency.
Pulse/pause ratio (balance)
adjustable from 10% to 90%.
TIG AC pulses special is not
possible
For remote controls RTP 1 and RTP 2, adjust the following settings on the appropriate
changeover switch:
3 Function specification
3/5
3.3 Other setting options
In addition to the settings already described, other settings can be made using the T 2.10
or T 2.15. These settings are described in detail in the PICOTIG PRO mode operating
instructions.
The following values are set at the factory.
3.3.1 TIG welding parameters
Parameters Factory setting
Main current 100A
Secondary current 49%
Down-slope time 0.1sec
End-crater current 30%
Gas post-flow time 5.0sec
Tungsten electrode diameter 2.4mm
AC balance -10%
AC frequency 80Hz
Gas pre-flow time 0.2sec
Ignition current 20%
Up-slope time 0.3sec
Alternating current waveform square
3.3.2 MMA welding parameters
Parameters Factory setting
Main current 100A
Hotstart current 150%
Hotstart time 0.1sec
4 Quick start – the fastest way to weld
4/1
Pre
p
arations Settin
g
Fault elimination
Plug in the mains plug.
(Remember fuse!)
Set the welding process
SS
LED S - safety sign (PICOTIG 180; 220
AC/DC only):
If the LED is off, call the service dept.
+
Plug in the workpiece lead, lock
and attach live to the workpiece.
Select the operating mode.
Excess temperature LED is on:
Duty cycle exceeded >
allow the machine to cool down
-
Insert the torch welding current plug
DC
AC
Select the current type.
(PICOTIG 180; 220 AC/DC only)
LED water deficiency (optional):
For operation with a cooling module,
the LED indicates a water deficiency in
water cooled welding machine
Connect torch trigger plug.
Connect shielding gas supply, set gas
flow.
sec
AMPAMP
Select all adjustable welding
parameters for the TIG process using
the key button and set the rotary
transducer:
Main current AMP, down-slope time,
gas post-flow time.
LED collective interference:
Power unit is switched off. Some faults
are short-term, one-off faults and the
collective interference signal light will
go off again and the welding machine
will be ready for welding once more.
If the signal light does not go of, see
chap. 7.
Switch on machine at the main switch
HF
HF
Set the ignition type:
HF ignition
Liftarc (contact ignition)
5 Commissioning
5/1
5.1 Area of application
5.1.1 Proper usage
These welding machines are suitable exclusively for TIG and MMA welding.
Any other use is regarded as "improper" and no liability is assumed for any damage arising
therefrom.
We can only guarantee smooth and trouble-free operation of the machines when used in
conjunction with the welding torches and accessories from our range.
MMA directff current welding for rutile and basic coated electrodes.
TIG direct current and alternating current welding with HF ignition or liftarc for
DC: Unalloyed, low-alloy and high-alloy steels, copper, nickel-based alloys and special metals.
AC: Aluminium and aluminium alloys
5.2 Setting up the welding machine
Follow the safety instructions on the opening pages entitled "For your safety".
Set up the machine so that there is sufficient space to adjust the operating elements.
Ensure that the machine is set up in a stable position and is appropriately secured.
5.3 Mains connection
The operating voltage shown on the rating plate must match the mains voltage.
For mains fuse protection, please refer to the technical data (chap. 1).
Insert mains plug into the appropriate socket when the machine is switched off.
5.4 Welding machine cooling system
To achieve the optimum duty cycle of the power components, ensure that the following conditions
are met:
Ensure that the working area is adequately ventilated,
Do not obstruct the air inlets and outlets on the machine,
No metal parts, dust or other foreign bodies are permitted to enter the machine.
5.5 Connections
Fig. 5 / 1 Connections
5 Commissioning
5/2
5.5.1 Workpiece lead
Insert cable plug of the workpiece lead and lock by turning to the right.
TIG welding: Welding current socket “+” (C1)
MMA welding: Welding current socket “+” (C1)
The polarity depends on the instructions from the electrode manufacturer given on the
electrode packaging.
Remove paint, rust and dirt from clamping and welding areas with a wire brush. The
workpiece clamp must be mounted near the welding point and must be fixed in such a way
that it cannot come loose of its own accord.
Structural parts, pipes, rails etc. may not be used as return leads for the welding current
unless they are the workpiece themselves.
A perfect current connection must be ensured for welding benches and appliances.
5.5.2 Electrode holder
Insert cable plug of the electrode holder into the welding current socket ( “-” D1) and lock by
turning to the right.
The polarity depends on the instructions from the electrode manufacturer given on the
electrode packaging.
Clamp stick electrode into electrode holder. Caution: Risk of injury from crushing!
Always put down stick electrode holder in an insulated position.
5.5.3 TIG welding torch
We can only guarantee the perfect functioning of our machines when used with our range of
welding torches.
TIG welding torches with shielded torch trigger control leads should not be connected (see
torch operating instructions).
Always put down welding torch when insulated.
Prepare welding torch according to the welding task in hand (see operating instructions for
the torch).
Fit tungsten electrode and gas nozzle onto the welding torch
(observe current load, see torch operating instructions).
Insert the welding current plug in socket "-" (D1) and lock by turning to the right.
Insert the torch trigger plug in the socket (B1) and tighten.
Screw shielding gas connection of the welding torch tightly onto the connection nipple G¼ (A1
)
(welding current potential "-").
For water cooled torches (optional):
Engage the rapid-action closure nipple of the TIG torch in the rapid-action closure coupling for
the coolant supply (blue) and return (red) lines of the cooling module.
5.5.4 Shielding gas supply (shielding gas cylinder to the welding machine)
No impurities must be allowed to enter the shielding gas supply, as these would otherwise
cause blockages in the shielding gas supply. Before connecting the pressure reducer to
the gas cylinder, open the cylinder valve briefly to blow out any dirt.
All shielding gas connections must be gastight.
Place shielding gas cylinder in the retainer provided for it and secure with chains.
Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to
blow out any dirt present.
Connection:
Mount the pressure reducer on the gas cylinder valve.
Screw the gas hose gastight to the pressure reducer and connecting nipple G ¼" on the rear of
the welding machine (F1).
Adjustment:
Switch on machine at the main switch (G1
).
Select the TIG welding process using the key button (chap. 3, C1).
5 Commissioning
5/3
Select latched mode with the key button (chap. 3, D1).
During the adjustment, the open-circuit voltage is applied to the torch electrode (when the
torch trigger has been pressed).
Press and release the torch trigger.
Slowly open the gas cylinder valve.
Set the required amount of shielding gas on the pressure reducer, about 4 - 15 l/min depending
on the current strength and the material.
Rule of thumb for gas flow rate:
Diameter of gas nozzle in mm corresponds to gas flow in l/min.
Example: 7 mm gas nozzle corresponds to 7 l/min gas flow.
5.6 General setting instructions
Set welding current:
The setting of the welding current depends first and foremost on the material, the thickness of
the metal to be welded and the seam preparation.
The welding current is corrected until such time as a perfect weld is guaranteed.
Other practical and theoretical descriptions of MMA and TIG welding can be found in the
MMA and TIG textbooks. These are available from us on request.
5.7 MMA welding
Follow the safety instructions on the opening pages entitled "For your safety".
If welding is carried out alternately using TIG or MMA and if both a welding torch and an
electrode holder are connected to the machine, the open-circuit/welding voltage is applied
simultaneously to both.
The torch and the electrode holder should therefore always be placed on an insulated
surface before starting work and during breaks.
When replacing spent or new stick electrodes, always switch off the machine at the main
switch.
Always use insulated tongs to remove used stick electrodes or to move welded
workpieces. Always put the electrode holder down when insulated.
Connect workpiece lead and electrode holder.
The polarity depends on the type of electrode to be welded.
Fix workpiece lead with good electrical contact to the workpiece.
Insert mains plug into correctly earthed socket.
Set the welding process “MMA welding” using the key button. (chap. 3.1; C1)
Clamp stick electrode into electrode holder. Caution: Risk of injury from crushing!
Switch on machine at the main switch (G1
).
Set welding current.
Hold the protective screen in front of your face and, using the tip of the stick electrode, scrape
over the workpiece (as if you were striking a match).
The machine has a hotstart device.
During the ignition procedure the current is increased to improve ignition of the electrode.
As soon as the arc has ignited, try to maintain a distance from the workpiece equivalent to the
diameter of the stick electrode being used.
During welding, the distance should remain as constant as possible.
The stick electrode inclination should be 20 to 30°.
Arcforcing:
Shortly before the electrode threatens to stick, the arcforcing device sets an increased current
designed to prevent the electrode from sticking.
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EWM PICOTIG 220 DC Operating Instructions Manual

Category
Welding System
Type
Operating Instructions Manual
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