Operating instructions
Welding machine
GB
Picotig 190 AC/DC 5P TG
Picotig 190 AC/DC 8P TG
099-000151-EW501 18.01.2013
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General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
NOTE
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our
customer service department on +49 2680 181-0.
A list of authorised sales partners can be found at www.ewm-group.com.
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 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 reason,
we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation,
improper operation or incorrect usage and maintenance or any actions connected to this in any way.
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
Subject to technical amendments.
Contents
Notes on the use of these operating instructions
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3
1 Contents
1
Contents..................................................................................................................................................3
2 Safety instructions.................................................................................................................................6
2.1 Notes on the use of these operating instructions ..........................................................................6
2.2 Explanation of icons.......................................................................................................................7
2.3 General..........................................................................................................................................8
2.4 Transport and installation ............................................................................................................12
2.4.1 Ambient conditions.......................................................................................................13
2.4.1.1 In operation...................................................................................................13
2.4.1.2 Transport and storage...................................................................................13
3 Intended use.........................................................................................................................................14
3.1 Applications..................................................................................................................................14
3.1.1 TIG welding ..................................................................................................................14
3.1.2 MMA welding................................................................................................................14
3.2 Documents which also apply .......................................................................................................15
3.2.1 Warranty.......................................................................................................................15
3.2.2 Declaration of Conformity.............................................................................................15
3.2.3 Welding in environments with increased electrical hazards.........................................15
3.2.4 Service documents (spare parts and circuit diagrams)................................................15
3.2.5 Calibration/Validation ...................................................................................................15
4 Machine description – quick overview ..............................................................................................16
4.1 Front view ....................................................................................................................................16
4.2 Rear view.....................................................................................................................................17
4.3 Machine control – Operating elements........................................................................................18
5 Design and function.............................................................................................................................20
5.1 General........................................................................................................................................20
5.2 Workpiece lead, general..............................................................................................................20
5.3 Transport and installation ............................................................................................................21
5.3.1 Adjusting the length of the carrying strap.....................................................................22
5.4 Machine cooling...........................................................................................................................22
5.5 Mains connection.........................................................................................................................23
5.5.1 Mains configuration ......................................................................................................23
5.6 TIG welding..................................................................................................................................24
5.6.1 Welding torch and workpiece line connection..............................................................24
5.6.2 Torch connection options and pin assignments...........................................................25
5.6.3 Shielding gas supply (shielding gas cylinder for welding machine).............................25
5.6.3.1 Connecting the shielding gas supply ............................................................26
5.6.3.2 Setting the shielding gas quantity.................................................................27
5.6.4 Select welding task.......................................................................................................28
5.6.5 Welding data display ....................................................................................................28
5.6.6 Arc ignition....................................................................................................................29
5.6.6.1 HF ignition.....................................................................................................29
5.6.6.2 Liftarc ignition................................................................................................29
5.6.7 Automatic cut-out..........................................................................................................29
5.6.8 Function sequences/operating modes .........................................................................30
5.6.8.1 Explanation of symbols.................................................................................30
5.6.9 TIG runtime parameters...............................................................................................31
5.6.9.1 Non-latched mode.........................................................................................33
5.6.9.2 Latched mode ...............................................................................................34
5.6.10 Welding torch (operating variants) ...............................................................................35
5.6.10.1 Tap torch trigger (tapping function)...............................................................35
5.6.10.2 Torch mode and up/down speed setting.......................................................36
5.6.10.3 Standard TIG torch (5-pole)..........................................................................37
5.6.10.4 TIG up/down torch (8-pole)...........................................................................39
5.6.10.5 Potentiometer torch (8-pole).........................................................................41
5.6.10.6 RETOX TIG torch (12-pole)..........................................................................42
Contents
Notes on the use of these operating instructions
4
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5.7 MMA welding................................................................................................................................43
5.7.1 Connecting the electrode holder and workpiece lead ..................................................43
5.7.2 Hotstart current and Hotstart time ................................................................................44
5.7.3 Antistick.........................................................................................................................44
5.8 Remote control.............................................................................................................................44
5.8.1 Manual remote control RT1 19POL..............................................................................44
5.8.2 RTG1 19POL manual remote control...........................................................................45
5.8.3 Foot-operated remote control RTF1 19POL.................................................................45
5.8.4 Foot-operated remote control RTF2 19POL 5m...........................................................45
5.8.5 Manual remote control RTP1 19POL ...........................................................................45
5.8.6 Manual remote control RTP2 19POL ...........................................................................45
5.8.7 RTP3 spotArc 19POL manual remote control..............................................................45
5.9 Advanced settings........................................................................................................................46
5.9.1 Testing the machine fan ...............................................................................................46
5.9.2 Protecting welding parameters from unauthorised access...........................................47
5.9.2.1 Changing the three-digit machine code ........................................................48
5.9.3 Setting the welding current (absolute/percentage).......................................................49
5.9.4 Selecting the welding current polarity during the ignition phase ..................................50
5.9.5 Choosing the alternating current waveform..................................................................51
5.9.6 Configuring the TIG potentiometer torch connection....................................................52
6 Maintenance, care and disposal.........................................................................................................53
6.1 General.........................................................................................................................................53
6.2 Maintenance work, intervals.........................................................................................................53
6.2.1 Daily maintenance tasks...............................................................................................53
6.2.1.1 Visual inspection ...........................................................................................53
6.2.1.2 Functional test...............................................................................................53
6.2.2 Monthly maintenance tasks..........................................................................................53
6.2.2.1 Visual inspection ...........................................................................................53
6.2.2.2 Functional test...............................................................................................53
6.2.3 Annual test (inspection and testing during operation)..................................................53
6.3 Maintenance work........................................................................................................................54
6.4 Disposing of equipment................................................................................................................54
6.4.1 Manufacturer's declaration to the end user..................................................................54
6.5 Meeting the requirements of RoHS..............................................................................................54
7 Rectifying faults....................................................................................................................................55
7.1 Checklist for rectifying faults ........................................................................................................55
7.2 Machine faults (error messages) .................................................................................................57
7.3 Resetting welding parameters to the factory settings..................................................................58
7.4 Display machine control software version....................................................................................59
8 Technical data.......................................................................................................................................60
8.1 Picotig 190 AC/DC.......................................................................................................................60
9 Accessories ..........................................................................................................................................61
9.1 Remote controls and accessories................................................................................................61
9.1.1 Connection cables........................................................................................................61
9.1.2 Extension cable ............................................................................................................61
9.2 Options.........................................................................................................................................61
9.3 General accessories ....................................................................................................................61
10 Appendix A............................................................................................................................................62
10.1 Overview of EWM branches.........................................................................................................62
Contents
Notes on the use of these operating instructions
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Safety instructions
Notes on the use of these operating instructions
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2 Safety instructions
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
• 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
warning symbol.
• The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at the edge of the page.
NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.
Safety instructions
Explanation of icons
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2.2 Explanation of icons
Symbol Description
Press
Do not press
Turn
Switch
l
0
Switch off machine
l
0
Switch on machine
ENTER (enter the menu)
NAVIGATION (Navigating in the menu)
EXIT (Exit the menu)
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use
Safety instructions
General
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2.3 General
DANGER
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
• Observe the maintenance instructions! (see Maintenance and Testing chapter)
• Unwind welding leads completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if
necessary).
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Electric shock!
Welding machines use high voltages which can result in potentially fatal electric 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 surf ace!
• The unit should only be opened by specialist staff after the mains plug has been unplugged!
• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!
WARNING
Risk of injury due to radiation or heat!
Arc radiation results in injury to skin and eyes.
Contact with hot workpieces and sparks results in burns.
• Use welding shield or welding helmet with the appropriate safety level (depending on the
application)!
• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
• Protect persons not involved in the work against arc beams and the risk of glare using
safety curtains!
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressur e
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by weldi ng or cutting!
Safety instructions
General
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WARNING
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent
vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to
the ultraviolet radiation of the arc!
• Ensure that there is sufficient fresh air!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
• Check for fire hazards in the working area!
• Do not carry any easily flammable objects such as matches or lighters.
• Keep appropriate fire extinguishing equipment to hand in the working area!
• Thoroughly remove any residue of flammable substances from the workpiece before
starting welding.
• Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
• Connect welding leads correctly!
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
Danger when coupling multiple power sources
!
Coupling multiple power sources in parallel or in series
has to be carried out by
qualified personnel and in accordance with the manufacturer's guidelines. Before
bringing the power sources into service for arc welding operations, a test has to verify
that they cannot exceed the maximum allowed open circuit voltage.
• Connection of the machine may be carried out by qualified personnel only!
• When decommissioning individual power sources, all mains and welding current leads
have
to be safely disconnected from the welding system as a whole. (danger due to inverse
voltages)!
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
Safety instructions
General
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CAUTION
Obligations of the operator!
The respective national directives and laws must be observed for operation of the
machine!
• National implementation of the framework directive (89/391/EWG), as well as the
associated individual directives.
• In particular, directive (89/655/EWG), on the minimum regulations for safety and health
protection when staff members use equipment during work.
• The regulations regarding work safety and accident prevention for the resp ective country.
• Setting up and operating the machine according to IEC 60974-9.
• Check at regular intervals that users are working in a safety-conscious way.
• Regular checks of the machine according to IEC 60974-4.
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power source s, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of
products!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Damage to the machine due to stray welding 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 wo rkpiece!
• Set up, attach or suspend all conductive power source components like casing, transport
vehicle and crane frames so they are insulated!
• Do not place any other electronic devices such as drillers or angle g rind ers, etc., on the
power source, transport vehicle or crane frames unless they are insulated!
• Always put welding torches and electrode holders on an insulated surface when they are
not in use!
Mains connection
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by ta king current from the mains
network. For some types of machines, connection restrictions or requirement s relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of
the operator, where necessary in consultation with the mains network operator, to ensure that
the machine can be connected.
Safety instructions
General
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11
CAUTION
EMC Machine Classification
In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic
compatibility classes (see technical data):
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas,
including residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits 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 neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding equipment
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
Safety instructions
Transport and installation
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2.4 Transport and installation
WARNING
Incorrect handling of shielding gas cylinders!
Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.
• Observe the instructions from the gas manufacturer and in any relevant regulations
concerning the use of compressed air!
• Place shielding gas cylinders in the holders provided for them and secure with fixing
devices.
• Avoid heating the shielding gas cylinder!
Risk of accident due to 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
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, -3, -10).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
• Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
Safety instructions
Transport and installation
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2.4.1 Ambient conditions
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!
• 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.
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities 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 distance of 0.5 m from obstacles!
2.4.1.1 In operation
Temperature range of the ambient air:
• -20 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.4.1.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -25 °C to +55 °C
Relative air humidity
• Up to 90% at 20 °C
Intended use
Applications
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3 Intended use
This machine has been manufactured according to the latest developments in technology and current
regulations and standards. It must only be operated in line with the instructions on correct us age.
WARNING
Hazards due to improper usage!
Hazards may arise for persons, animals and material objects if the equipment is not
used correctly. No liability is accepted for any damages arising from improper usage!
• The equipment must only be used in line with proper usage and by trained or expert staff!
• Do not modify or convert the equipment improperly!
3.1 Applications
3.1.1 TIG welding
TIG welding with alternating or direct current. Arc ignition optionally by means of 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 pool. There is no external protection; any protection against the
atmosphere comes from the electrode.
Intended use
Documents which also apply
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15
3.2 Documents which also apply
3.2.1 Warranty
NOTE
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
3.2.2 Declaration of Conformity
The designated machine conforms to EC Directives and standards in terms of its design
and construction:
• EC Low Voltage Directive (2006/95/EC),
• EC EMC Directive (2004/108/EC),
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.
3.2.3 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 repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.2.5 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuri ng equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months
Machine description – quick overview
Front view
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4 Machine description – quick overview
4.1 Front view
NOTE
The maximum possible machine configuration is given in the text description.
If necessary, the optional connection may need to be retrofitted (see "Accessories"
chapter).
Figure 4-1
Item Symbol Description 0
1
Machine control
See Machine control – operating elements chapter
2
Connection socket, "+" welding current
• TIG: Connection for workpiece lead
• MMA: Electrode holder or workpiece lead connection
3
Connection socket, 5-pole/8-pole/12-pole
5-pole: Standard TIG torch control lead
8-pole: TIG Up/Down or potentiometer torch control lead
12-pole: Control lead for TIG up/down torch with display
4
G¼” connecting nipple, “-” welding current
Shielding gas connection (with yellow insulating cap) for TIG welding torch
5
Connection socket, "-" welding current
• TIG: TIG welding torch connection
• MMA: Electrode holder or workpiece lead connection
6 Cooling air inlet
Machine description – quick overview
Rear view
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4.2 Rear view
Figure 4-2
Item Symbol Description 0
1
Carrying handle
2
Carrying strap
3
HF
HF
Ignition type changeover switch
HF
= Liftarc (contact ignition)
HF
= HF ignition
4
Main switch, machine on/off
5 Mains connection cable
6
Machine feet
7 Cooling air outlet
8
G¼” connecting nipple
Shielding gas connection on the pressure regulator.
9
Connection socket, 19-pole
Remote control connection
Machine description – quick overview
Machine control – Operating elements
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4.3 Machine control – Operating elements
AMP
sec
secsec
AMP
DC
AC
sec
AMP%
T 2.36
S
S
6
7
3 42
12
11
10
5
9
8
AMP
VOLT
1
Figure 4-3
Item Symbol Description 0
1
Switch display button
AMP Welding current display
VOLT Welding voltage display
2
Welding process button
MMA welding
TIG welding
3
Operating mode button
Non-latched
Latched
4
Welding current polarity button
DC welding with negative polarity at the torch (or electrode holder) with
respect to the workpiece.
Alternating current welding (alternating current waveform can be set)
5 AMP
Main current signal light
Imin to Imax (1 A increments)
6 AMP% Secondary current (TIG)
Setting range 1 % to 100 % (1 % increments). Percentage of the main current.
7 sec
Down-slope time (TIG)
0.00 s to 20.0 s (0.1 s increments).
The down-slope time can be set separately for non-l atched and latched.
8 sec Gas post-flow time (TIG)
Setting ranges: 0.1 s to 20.0 s (0.1 s increments).
9
Select welding parameters button
This button is used to select the welding parameters depending on the welding process
and operating mode used.
Machine description – quick overview
Machine control – Operating elements
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Item Symbol Description 0
10
Welding parameter setting rotary dial
Setting currents, times and parameters.
11
S
Error/status indicators
Collective interference signal light
Water deficiency signal light (welding torch cooling )
Excess temperature signal light
S
safety sign signal light
12
Three-figure LED display
Welding parameter display (see also chap. “Welding data display”).
Design and function
General
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5 Design and function
5.1 General
WARNING
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
• Follow safety instructions on the opening pages of the operating instructions.
• Commissioning may only be carried out by persons who have the relevant expertise of
working with arc welding machines!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
CAUTION
Risk of burns on 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 turn ing 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 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 in sulated
surface before starting work and during breaks.
CAUTION
Using protective dust caps!
Protective dust caps protect the connection sockets and ther efore the machine against
dirt and damage.
• The protective dust cap must be fitted if there is no accessory component being operated
on that connection.
• The cap must be replaced if faulty or if lost!
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!
Design and function
Transport and installation
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5.3 Transport and installation
WARNING
Risk of accident due to 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!
• 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.
CAUTION
Damage to the machine due to improper transport!
The machine can be damaged by tensile or lateral forces if it is set
down or picked up in a non-vertical position!
• Do not drag the machine horizontally on the machine feet!
• Always pick up the machine vertically and set it down carefully.
Design and function
Machine cooling
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5.3.1 Adjusting the length of the carrying strap
NOTE
To demonstrate adjustment, lengthening the strap is shown in the figure. To shorten,
the strap's loops must be inched in the opposite direction.
Figure 5-1
5.4 Machine cooling
To obtain an optimal duty cycle from the power components, the following precautions should be
observed:
• Ensure that the working area is adequately ventilated.
• Do not obstruct the air inlets and outlets of the machine.
• Do not allow metal parts, dust or other objects to get into the machine.
Design and function
Mains connection
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5.5 Mains connection
DANGER
Hazard caused by improper mains connection!
An improper mains connection can cause injuries or damage property!
• Only use machine with a plug socket that has a correctly fitted protective conductor.
• If a mains plug must be fitted, this may only be carried out by an electrician in accordance
with the relevant national provisions or regulations!
• Mains plug, socket and lead must be checked regularly by an electrician!
• When operating 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
NOTE
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 conductor blue
PE Protective conductor green-yellow
CAUTION
Operating voltage - mains voltage!
The operating voltage shown on the rating plate must be consistent with the mains
voltage, in order to avoid damage to the machine!
• For mains fuse protection, please refer to the “Technical data” chapter!
• Insert mains plug of the switched-off machine into the appropriate socket.
Design and function
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5.6 TIG welding
5.6.1 Welding torch and workpiece line connection
NOTE
Prepare welding torch according to the welding task in hand (see operating instructions
for the torch).
Figure 5-3
Item Symbol Description 0
1
Welding torch
2
Welding torch hose package
3
Connection socket, "-" welding current
Welding current lead connection for TIG welding torch
4
G¼" connecting nipple
TIG welding torch shielding gas connection
5
Connection socket, 5-pole/8-pole/12-pole
5-pole: Standard TIG torch control lead
8-pole: TIG Up/Down or potentiometer torch control lead
12-pole: Control lead for TIG up/down torch with display
6
Workpiece
7
Connection socket for "+" welding current
Workpiece lead connection
• Insert the welding current plug on the welding torch into the welding current connection socket and
lock by turning to the right.
• Remove yellow protective cap on G¼ connecting nipple.
• Screw welding torch shielding gas connection tightly onto the G¼" connection nipple.
• Insert the welding torch control lead plug into the connection socket for the welding torch control lead
(5-pole with standard torch, 8-pole with up/down or potentiometer torch and 12-pole with up/down
torch with LED display) and tighten.
• Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by
turning to the right.
Design and function
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5.6.2 Torch connection options and pin assignments
Figure 5-4
5.6.3 Shielding gas supply (shielding gas cylinder for welding machine)
WARNING
Incorrect handling of shielding gas cylinders!
Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.
• Observe the instructions from the gas manufacturer and in any relevant regulations
concerning the use of compressed air!
• 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 being destroyed.
• Always re-fit the yellow protective cap when not using the shielding gas connection.
• All shielding gas connections must be gas tight.
NOTE
Before connecting the pressure regulator to the gas cylinder, open the cylinder valve
briefly to expel any dirt.
Design and function
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5.6.3.1 Connecting the shielding gas supply
• Place the shielding gas cylinder into the relevant cylinder bracket.
• Secure the shielding gas cylinder using a securing chain.
4
3
2
1
Figure 5-5
Item Symbol Description 0
1
Pressure regulator
2
Shielding gas cylinder
3
Output side of the pressure regulator
4
Cylinder valve
NOTE
Before connecting the pressure regulator to the gas cylinder, open the cylinder valve
briefly to expel any dirt.
• Tighten the 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 5-6
Item Symbol Description 0
1
Connecting nipple G¼, shielding gas connection
• Connect crown nut of the shielding gas line to the G¼“ connecting nipple.
Design and function
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5.6.3.2 Setting the shielding gas quantity
CAUTION
Electric shocks!
When setting the shielding gas quantity, high voltage ignition pulses or open circuit
voltage are 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.
• Press the torch trigger and set the shielding gas quantity with the flow gauge of the pressure regulator.
NOTE
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 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!
Design and function
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5.6.4 Select welding task
The welding task is selected using the buttons on the machine control on the welding machine .
Signal lights (LED) display the welding parameter selection.
Set the welding task in the following order:
Item Symbol Description 0
1
Welding process button
MMA welding
TIG welding
2
Welding current polarity button
DC welding with negative polarity at the torch (or electrode holder) with
respect to the workpiece.
Alternating current welding (alternating current waveform can be set)
3
Operating mode button
Non-latched
Latched
4
Select welding parameters button
This button is used to select the welding parameters depending on the welding process
and operating mode used.
5
Welding parameter setting rotary dial
Setting currents, times and parameters.
5.6.5 Welding data display
The welding data display shows all relevant welding parameters and their values depending on the
selection made. Next to the controller display is an "arrow key" for selecting between welding current and
voltage.
Other parameter displays are described later in this chapter.
Design and function
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5.6.6 Arc ignition
5.6.6.1 HF ignition
Figure 5-7
The arc is started without contact from high-voltage ignition pulses.
a) Position the welding torch in welding position over the workpiece (distance between the electrode tip
and workpiece should be approx. 2-3mm).
b) Press the torch trigger (high voltage ignition pulses ignite the arc).
c) Ignition current flows, and the welding process is continued depending on the operating mode
selected.
End the welding process: Release or press the torch trigger depending on the operating mode
selected.
5.6.6.2 Liftarc ignition
a) b) c)
Figure 5-8
The arc is ignited on 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, dependin g on the
operating mode set, to the ignition or main current set.
c) Lift off the torch and swivel to the normal position.
Ending the welding process: Release or press the torch trigger depending on the operating mode
selected.
5.6.7 Automatic cut-out
NOTE
The automatic cut-out function will be triggered by two conditions during the welding
process:
During the ignition phase (ignition fault)
• If there is no welding current within 3s after starting the welding.
During the welding phase (arc interruption)
• If the arc is interrupted for longer than 3s.
In both cases, the welding machine ends the ignition or welding process immediately.
Design and function
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5.6.8 Function sequences/operating modes
The parameters for the function sequence are set using the “Select welding parameters” button and the
“Welding parameter setting” rotary dial.
AMP
sec
secsec
AMP
DC
AC
sec
AMP%
T 2.36
S
S
AMP
VOLT
2
1
Figure 5-9
Item Symbol Description 0
1
Select welding parameters button
This button is used to select the welding parameters depending on the welding process
and operating mode used.
2
Welding parameter setting rotary dial
Setting currents, times and parameters.
5.6.8.1 Explanation of symbols
Symbol Meaning
Press torch trigger 1
Release torch trigger 1
I
Current
t
Time
Gas pre-flows
I
start
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 main current (AMP) to secondary current (AMP%)
ts2
TIG pulses: Slop time from secondary current (AMP%) to main current (AMP)
t
Down
Down-slope time
I
end
End-crater current
Gas post-flows
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5.6.9 TIG runtime parameters
Figure 5-10
Display Setting/selection
Main current I1 (AMP)
Main current setting
Secondary current (AMP%)
Setting range in percent: 1% to 100% (depending on main current).
Setting range, absolute: Imin to Imax.
Downslope time
0.00 s to 20.0 s (0.1 s increments). The downslope time can be set separately for latched
and non-latched operation.
End-crater current
Setting range in percent: depending on main current
Setting range, absolute: Imin to Imax.
Gas post-flow time
Setting range: 0.1 s to 20.0 s (0.1 s increments).
Diameter of tungsten electrode/ignition optimisation
1 mm to 4 mm or larger (0.1 mm increments)
Alternating current balance (AC)
Max. setting range: -30% to +30% (1% increments).
Optimisation of cleaning and fusion penetration.
Alternating current frequency (AC)
Setting range: 50 Hz to 200 Hz (1 Hz increments).
Constriction and stabilisation of the arc: The cleaning effect increases with a higher
frequency. Particularly thin panels (welding with a low current), anodised sheet
aluminium or highly contaminated articles for welding can b e welded and cleaned
perfectly at a higher frequency.
Design and function
TIG welding
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Display Setting/selection
Gas pre-flow time
Setting range: 0.1 s to 5.0 s (0.1 s increments)
Ignition current
Setting range in percent: depending on main current
Setting range, absolute: Imin to Imax.
Upslope time to main current
Setting: 0.0 sec. to 20.0 sec. (factory setting 1.0 sec.)
Design and function
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5.6.9.1 Non-latched mode
I
I
start
AMP
t
Up
1. 2.
t
Down
I
end
t
AMP%
Figure 5-11
1st cycle:
• Press and hold torch trigger 1.
• The gas pre-flow time elapses.
• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.
• The welding current flows and immediately assumes the value set for the ignition current I
start
.
• HF is switched off.
• The welding current increases with the adjusted up-slope time to the main current AMP.
Switching from main current AMP to secondary current AMP%:
Press torch trigger 2 or Tap torch trigger 1
2nd cycle:
• Release torch trigger 1.
• The main current falls in the set down-slope time to the
end-crater current I
end
(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 end-crater current I
end
, the arc extinguishes.
• The set gas post-flow time elapses.
NOTE
When the foot-operated remote control RTF is connected, the machine switches
automatically to non-latched operation.
The up- and down-slopes are switched off.
Design and function
TIG welding
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5.6.9.2 Latched mode
I
I
start
AMP
I
end
t
Up
t
Down
t
1. 2. 3. 4.
AMP%
Figure 5-12
Step 1
• Press torch trigger 1, the gas pre-flow time elapses.
• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.
• Welding current flows and immediately assumes the ignition current value set (search arc at minimum
setting). HF is switched off.
Step 2
• Release torch trigger 1.
• The welding current increases with the set up-slope time to the main current AMP.
Switching from main current AMP to secondary current AMP%:
Press torch trigger 2 or Tap torch trigger 1
Step 3
• Press torch trigger 1.
• The main current drops with the set down-slope time to the end-crater current I
end
(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.
NOTE
When the foot-operated remote control RTF is connected, the machine switches
automatically to non-latched operation.
The up- and down-slopes are switched off.
To use the alternative welding start (tapping start) a double-digit torch mode (11-x) has
to be set at the welding machine control. The number of torch modes available depends
on the machine type. For single-digit torch modes (1-x) this function is disabled.
Design and function
TIG welding
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5.6.10 Welding torch (operating variants)
Different 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
BRT 1
Press torch trigger
BRT 1
Tap torch trigger
BRT 2
Tap and press torch trigger
5.6.10.1 Tap torch trigger (tapping function)
NOTE
Swiftly tap the torch trigger to change the function.
The torch mode set determines the operating mode of the tapping function.
Design and function
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5.6.10.2 Torch mode and up/down speed setting
The user has the modes 1 to 4 and modes 11 to 14 available. Modes 11 to 14 include the same function
options as 1 to 4, but without tapping function 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).
l
0
Figure 5-13
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)
Increase value = rapid current change
Reduce value = slow current change
Exit the menu
Exit
Design and function
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5.6.10.3 Standard TIG torch (5-pole)
Standard torch with one torch trigger:
Diagram Operating
elements
Explanation of symbols
BRT1 = Torch trigger 1 (welding current on/off;
secondary current via tapping function)
Functions mode Operating
elements
Welding current On/Off
BRT 1
Secondary current (Latched mode)
1
(factory-set)
BRT 1
Standard torch with two torch triggers:
Diagram Operating
elements
Explanation of symbols
BRT1 = torch trigger 1
BRT2 = torch trigger 2
Functions mode Operating
elements
Welding current On/Off
BRT 1
Secondary current
BRT 2
Secondary current (tapping mode) / (latched mode)
1
(factory-set)
BRT 1
Welding current On/Off
BRT 1
Secondary current (tapping mode) / (latched mode)
BRT 1
Up function
BRT 2
Down function
3
BRT 2
Design and function
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Standard torch with one rocker (MG rocker, two torch triggers)
Diagram Operating
elements
Explanation of symbols
BRT 1 = torch trigger 1
BRT 2 = torch trigger 2
Functions mode Operating
elements
Welding current On/Off
BRT 1
Secondary current
BRT 2
Secondary current (tapping mode) / (latched mode)
1
(factory-set)
BRT 1
Welding current On/Off
BRT 1
+
BRT 2
Secondary current (tapping mode)
BRT 1
+
BRT 2
Up function
BRT 1
Down function
2
BRT 2
Welding current On/Off
BRT 1
Secondary current (tapping mode) / (latched mode)
BRT 1
Up function
BRT 2
Down function
3
BRT 2
Design and function
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5.6.10.4 TIG up/down torch (8-pole)
Up/down torch with one torch trigger
Diagram Operating
elements
Explanation of symbols
TT 1 = torch trigger 1
Functions Mode Operating
elements
Welding current on/off
BRT 1
Secondary current (tapping mode) / (latched mode)
BRT 1
Increase welding current, infinite adjustment (up function)
Up
Reduce welding current, infinite adjustment (down function)
1
(factory-
set)
Down
Welding current on/off
BRT 1
Secondary current (tapping mode)
2
BRT 1
Welding current on/off
BRT 1
Secondary current (tapping mode) / (Latched mode)
BRT 1
Increase welding current by an increment (see chapter "Setting the first
increment in modes 4 and 14")
Up
Reduce welding current by an increment (see chapter "Setting the first
increment in modes 4 and 14")
4
Down
Design and function
TIG welding
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Up/down torch with two torch triggers
Diagram Operating
elements
Explanation of symbols
TT 1 = torch trigger 1 (left)
TT 2 = torch trigger 2 (right)
Functions Mode Operating
elements
Welding current on/off
BRT 1
Secondary current
BRT 2
Secondary current (tapping mode) / (latched mode)
BRT 1
Increase welding current, infinite adjustment (up function)
Up
Reduce welding current, infinite adjustment (down function)
1
(factory-
set)
Down
Welding current on/off
BRT 1
Secondary current
BRT 2
Secondary current (tapping mode)
2
BRT 1
Welding current on/off
BRT 1
Secondary current
BRT 2
Secondary current (tapping mode)
BRT 1
Increase welding current by an increment (see chapter "Setting the
first increment in modes 4 and 14")
Up
Reduce welding current by an increment (see chapter "Setting the
first increment in modes 4 and 14")
4
Down
Design and function
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5.6.10.5 Potentiometer torch (8-pole)
NOTE
The welding machine needs to be configured for operation with a potentiometer torch
(see chap. "Configuring TIG potentiometer torch")
Potentiometer torch with one torch trigger:
Diagram Operating
elements
Explanation of symbols
BRT 1 = torch trigger 1
Functions Mode Operating
elements
Welding current On/Off
BRT 1
Secondary current (tapping mode)
BRT 1
Increase welding current, infinite adjustment
Reduce welding current, infinite adjustment
3
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/Off
BRT 1
Secondary current
BRT 2
Secondary current (tapping mode)
BRT 1
Increase welding current, infinite adjustment
Reduce welding current, infinite adjustment
3
Design and function
TIG welding
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5.6.10.6 RETOX TIG torch (12-pole)
NOTE
For operation with this welding torch, the welding machine must be equipped with the
retrofit option "ON 12POL RETOX TIG" (12-pole torch connection socket)!
Diagram Operating elements Explanation of symbols
888
BRT 1
BRT 3
BRT 4
BRT 2
TT= torch trigger
Functions Mode Operating
elements
Welding current on/off TT 1
Secondary current
TT 2
Secondary current (tapping function)
TT 1 (tapping)
Increase welding current (up function)
TT 3
Reduce welding current (down function)
1
(ex works)
TT 4
Welding current on/off TT 1
Secondary current
TT 2
Secondary current (tapping function)
2
TT 1 (tapping)
Welding current on/off TT 1
Secondary current
TT 2
Secondary current (tapping function)
3
TT 1 (tapping)
Welding current on/off TT 1
Secondary current
TT 2
Secondary current (tapping function)
TT 1 (tapping)
Increase welding current (up function)
TT 3
Reduce welding current (down function)
4
TT 4
Design and function
MMA welding
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5.7 MMA welding
CAUTION
Risk of being crushed or burnt.
When replacing spent or new stick electrodes
• Switch off machine at the main switch
• Wear appropriate safety gloves
• Use insulated tongs to remove spent stick electrodes or to move welded workpieces and
• Always put the electrode holder down on an insulated surface.
Shielding gas connection!
During MMA welding open circuit voltage is applied at the shielding gas connection
(G¼" connecting nipple).
• Place yellow insulating cap on the G¼" connection nipple (protects against electrical
voltage and dirt).
5.7.1 Connecting the electrode holder and workpiece lead
NOTE
Polarity depends on the instructions from the electrode manufacturer given on the
electrode packaging.
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
5
Connecting nipple G¼, shielding gas 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 plug of the workpiece lead into either the "+" or "-" welding current connection socket and
lock by turning to the right.
Design and function
Remote control
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5.7.2 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
Figure 5-15
Display Setting/selection
Main current I1 (AMP)
Main current setting
Hotstart current
Hotstart current setting
Hotstart time
Hotstart time setting
5.7.3 Antistick
Anti-stick prevents the electrode from annealing.
If the electrode sticks in spite of the Arcforce device, the
machine automatically switches over to the minimum
current within about 1 second to prevent the electrode
from overheating. Check the welding current setting
and correct according to the welding task!
Figure 5-16
5.8 Remote control
NOTE
Insert the remote control control cable into the 19-pole connection socket for remote
control connection and lock.
5.8.1 Manual remote control RT1 19POL
Functions
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
Design and function
Remote control
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5.8.2 RTG1 19POL manual remote control
Functions
• Infinite setting of the welding current (0% to 100%) depending on the main current
preselected at the welding machine
5.8.3 Foot-operated remote control RTF1 19POL
Functions
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Start/stop welding operation (TIG)
ActivArc welding is not possible in combination with the foot-operated remote control.
5.8.4 Foot-operated remote control RTF2 19POL 5m
Functions
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Start/stop welding operation (TIG)
ActivArc welding is not possible in combination with the foot-operated remote control.
5.8.5 Manual remote control RTP1 19POL
RTP2
Functions
• TIG/MMA
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Pulse/spot/normal
• Pulse, spot and break times are infinitely adjustable.
5.8.6 Manual remote control RTP2 19POL
RTP2
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 frequenc y.
• Pulse/pause ratio (balance) adjustable from 10% to 90%.
5.8.7 RTP3 spotArc 19POL manual remote control
RTP2
Functions
• TIG / MMA.
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Pulse / SpotArc spots / normal
• Frequency and spot time infinitely adjustable.
• Coarse adjustment of the pulse frequency.
• Pulse/pause ratio (balance) adjustable from 10% to 90%.
Design and function
Advanced settings
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5.9 Advanced settings
NOTE
ENTER (enter the menu)
• Switch off machine at the main switch
• Press and hold the "welding parameters" button and switch the machine on again at the
same time.
NAVIGATION (navigating in the menu)
• Parameters are selected by pressing the "welding parameters" button.
• Set or change the parameters by turning the "welding parameter setting" rotary dial.
EXIT (leave the menu)
• Select the "Elt" menu item.
• Press the "welding parameters" button (settings will be applied, machine changes to the
ready-to-operate status).
5.9.1 Testing the machine fan
The machine fan can be switched on at the machine controls so that you can check that it is wo rking
correctly.
l
0
Figure 5-17
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
Design and function
Advanced settings
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5.9.2 Protecting welding parameters from unauthorised access
NOTE
The machine code is set to the factory setting of 000 after each reset (see chapter
"Resetting welding parameters to the factory setting".
See chapter "Changing the three-digit machine code" for information on how to change
this code).
To protect against unauthorised or unintentional changes to the welding parameters, you can lock the
machine controls with a software key (3-digit machine code).
If the access lock is active, only the following parameters can be changed:
• Welding current (within a previously defined range).
• Switch display.
• Switch welding parameters (JOBs)
l
0
Figure 5-18
Display Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Exit the menu
Exit
Error
Error message after entering an incorrect machine code
Machine code
Querying the three-digit machine code (000 to 999), user input
Switch off
Switching off machine function
Switch on
Switching on machine function
Design and function
Advanced settings
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5.9.2.1 Changing the three-digit machine code
In this menu you can change the 3-digit machine code.
After entering and confirming the old code, you can enter a new code.
The correct machine code is necessary for activating and deactivating the access lock!
l
0
Figure 5-19
Display Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Machine code
Confirming the old machine 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 code
• Machine code entered correctly
• Prompt for entering the new machine code
Exit the menu
Exit
Design and function
Advanced settings
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5.9.3 Setting the welding current (absolute/percentage)
The welding currents for start current, secondary current, end current and hotstart current ca n be set as
percentages (factory setting) or absolute values.
If absolute current display is set, the "AMP" signal light for the main current is lit in addition to the
respective "AMP%" signal light. However, in percentage display mode, only the respective "AMP%" signal
light is lit.
l
0
Figure 5-20
Display Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Settings
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). Example: Main current setting to 120A and secondary current to 50%
results in an absolute secondary current of 60A.
Welding current display, absolute
Absolute representation of all welding currents in amperes
Exit the menu
Exit
Design and function
Advanced settings
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5.9.4 Selecting the welding current polarity during the ignition phase
Selection of welding current polarity during ignition phase, until the arc stabilises. It always switches over
to DC- polarity after a few milliseconds.
l
0
Figure 5-21
Display Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Settings
Settings for machine functions and parameter displays
Negative welding current polarity during the ignition phase
Positive welding current polarity during the ignition phase
Exit the menu
Exit
Design and function
Advanced settings
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5.9.5 Choosing the alternating current waveform
l
0
Figure 5-22
Display Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised 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 selected settings
Exit the menu
Exit
Design and function
Advanced settings
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5.9.6 Configuring the TIG potentiometer torch connection
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Risk of injury due to electrical voltage after switching off!
Working on an open machine can lead to fatal injuries!
Capacitors are loaded with electrical voltage during operation. Voltage remains present
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 h ave 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, please see the standard operating instructions fo r the welding
machine.
When connecting a potentiometer torch, jumper JP1 on PCB T200/1 inside the welding machine
should be unplugged.
Welding torch configuration Setting
Prepared for TIG standard or up/down torch (factory setting) : JP1
Prepared for potentiometer torches JP1
A
B
C
D
E
F
G
H
Poti-Brenner
10k
B2-
Uref.+10V
0V
0V
BT1
BT2
IH-Down
Up
Poti/UD ein
Figure 5-23
NOTE
For this torch type the welding machine has to be set to torch mode 3, see chapter
"Setting torch mode and Up/Down speed".
Maintenance, care and disposal
General
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6 Maintenance, care and disposal
DANGER
Risk of injury from electric shock!
Cleaning machines that are not disconnected from the mains can lead to serious
injuries!
• Disconnect the machine completely from the mains.
• Remove the mains plug!
• Wait for 4 minutes until the capacitors have discharged!
6.1 General
When used in the specified environmental conditions and under normal operating condition s, this
machine is largely maintenance-free and requires a minimum of care.
There are some points, which should be observed, to guarantee fault-free operation of your welding
machine. Among these are regular cleaning and checking as descri bed below, depending on the pollution
level of the environment and the length of time the unit is in use.
6.2 Maintenance work, intervals
6.2.1 Daily maintenance tasks
6.2.1.1 Visual inspection
• Mains supply lead and its strain relief
• Gas tubes and their switching equipment (solenoid valve)
• Other, general condition
6.2.1.2 Functional test
• Welding current cables (check that they are fitted correctly and secured)
• Gas cylinder securing elements
• Operating, message, safety and adjustment devices (Functional test)
6.2.2 Monthly maintenance tasks
6.2.2.1 Visual inspection
• Casing damage (front, rear and side walls)
• Transport elements (strap, lifting lugs, handle)
6.2.2.2 Functional test
• Selector switches, command devices, emergency stop devices, voltage re ducing devices, message
and control lamps
6.2.3 Annual test (inspection and testing during operation)
NOTE
The welding machine may only be tested by competent, capable personsl.
A capable person is one who, because of his training, knowledge and experience, is
able to recognise the dangers that can occur while testing welding power sources as
well as possible subsequent damage and who is able to implement the required safety
procedures.
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition
to the regulations on testing given here, the relevant local laws and regulations must also be observed.
Maintenance, care and disposal
Maintenance work
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6.3 Maintenance work
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service 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.
6.4 Disposing of equipment
NOTE
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and
electronic components, which must be disposed of.
• Do not dispose of in household waste!
• Observe the local regulations regarding disposal!
6.4.1 Manufacturer's declaration to the end user
• According to European provisions (guideline 2002/96/EG of the European Parliament and the Council
of January, 27th 2003), used electric and electronic equipment may no longer be placed in u nsorted
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 system s provided for this
purpose.
• According to German law (law governing the distribution, taking b ack and environmentally correct
disposal of electric and electronic equipment (ElektroG) from 16.03.2005), used machines are to be
placed in a collection system separate from unsorted municipal waste. The public wa ste management
utilities (communities) have created collection points at which used equipment from private households
can be disposed of free of charge.
• Information about giving back used equipment or about collections can be obtained from the
respective municipal administration office.
• EWM participates in an approved waste disposal and recycling system and is registered in the Used
Electrical Equipment Register (EAR) under number WEEE DE 57686922.
• In addition to this, returns are also possible throughout Europe via EWM sales partners.
6.5 Meeting the requirements of RoHS
We, EWM HIGHTEC Welding GmbH Mündersbach, hereby co nfirm that all products supplied by us which
are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).
Rectifying faults
Checklist for rectifying faults
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7 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 you r autho rised
dealer.
7.1 Checklist for rectifying faults
NOTE
The correct machine equipment for the material and process gas in use is a
fundamental requirement for perfect operation!
Legend Symbol Description
a
Fault/Cause
#
Remedy
Functional errors
a Machine control without displaying the signal lights after switching on
# Phase failure > check mains connection (fuses)
a No welding performance
# Phase failure > check mains connection (fuses)
a Various parameters cannot be set
# Entry level is blocked, disable access lock (see chapter entitled "Lock welding parameters
against unauthorised access")
a Connection problems
# Make control lead connections and check that they are fitted correctly.
No arc ignition
a Incorrect ignition type setting.
# Set ignition type changeover switch to the HF ignition setting.
Bad arc ignition
a Material inclusions in the tungsten electrode due to contact with filler material or workpiece
# Regrind or replace the tungsten electrode
a 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
a Loose welding current con nections
# Tighten power connections on the torch and/or on the workpiece
# Tighten contact tip correctly
a Overload
# Check and correct welding current setting
# Use a more powerful welding torch
Rectifying faults
Checklist for rectifying faults
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Unstable arc
a Material inclusions in the tungsten electrode due to contact with filler material or workpiece
# Regrind or replace the tungsten electrode
a Incompatible parameter settings
# Check settings and correct if necessary
Pore formation
a Inadequate or missing gas shielding
# Check shielding gas setting and replace shielding gas cylinde r if necessary
# Shield welding site with protective screens (draughts affect the welding result)
# Use gas lens for aluminium applications and high-alloy steels
a Unsuitable or worn welding torch equipment
# Check size of gas nozzle and replace if necessary
a Condensation (hydrogen) in the gas tube
# Purge hose package with gas or replace
Rectifying faults
Machine faults (error messages)
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7.2 Machine faults (error messages)
NOTE
A welding machine error is indicated by the collective fault signal lamp (A1) lighting up
and an error code (see table) being displayed in the machine control display. In the
event of a machine error, the power unit shuts down.
• Document machine errors and inform service staff as necessary.
Error message Possible cause Remedy
E1 Water fault
Only occurs if a water cooling
unit is connected.
Ensure that sufficient water pressure can be built
up. (e.g. top up water)
E2 Temperature error Allow machine to cool down.
E3 Electronics error Switch ma chine off and on again.
If the fault persists, inform the service
department.
E4 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 electronics
supply voltages or excess
temperature of the welding
transformer.
Allow machine to cool down. If the error message
persists, switch the machine off and back on
again.
If the fault persists, inform the service
department.
E9 Low voltage Switch off the machine and check the mains
voltage.
E10 Secondary overvoltage Switch machine off and on again.
If the fault persists, inform the service
department.
E11 Overvoltage Switch off the machine and check the mains
voltage.
E12 VRD (open circuit voltage
reduction error)
Inform Service
Rectifying faults
Resetting welding parameters to the factory settings
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7.3 Resetting welding parameters to the factory settings
NOTE
All customised welding parameters that are stored will be replaced by the factory
settings.
RESET
DC
AC
l
0
Figure 7-1
Display Setting/selection
Input confirmation
User entries are applied, release button(s).
Rectifying faults
Display machine control software version
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59
7.4 Display machine control software version
NOTE
The query of the software versions only serves to inform the authorised service staff!
l
0
Figure 7-2
Display Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Service menu
Service settings
Exit the menu
Exit
Software version of the machine control
Version display (example 014 = version 14)
Technical data
Picotig 190 AC/DC
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8 Technical data
NOTE
Performance specifications and guarantee only in connection with original spare and
replacement parts!
8.1 Picotig 190 AC/DC
Setting range TIG MMA
Welding current
DC
AC
3 A-190 A
5 A-190 A
5 A-140 A
5 A-140 A
Welding voltage 10.1 V-17.6 V 20.2 V-25.6 V
Duty cycle (DC) at 25 °C
50% DC - 140 A
60% DC 190 A 130 A
100% DC 150 A 110 A
Duty cycle (DC) at 40 °C
40% DC 190 A -
50% DC - 140 A
60% DC 150 A 130 A
100% DC 120 A 110 A
Load alternation
10 min. (60% DC
∧
6 min. welding, 4 min. pause)
Open circuit voltage (DC) 43 V
Mains voltage (tolerances) 1 x 230 V (-40% to +15%)
Frequency 50/60 Hz
Mains fuse 1 x 16 A (safety fuse, slow-blow)
Mains connection lead H07RN-F3G2.5
Max. connected load 5.6 kVA 6.0 kVA
Recommended generator rating 8.1 kVA
cosϕ
0,94
Insulation class/protection classification F/IP 23
Ambient temperature
-20 °C to +40 °C
Machine cooling Fan
Torch cooling Gas
Workpiece lead 35 mm2
Dimensions L x W x H 600 x 205 x 415 mm
Weight 18 kg
EMC class A
Constructed to standards IEC 60974-1, -3, -10
/
Accessories
Remote controls and accessories
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9 Accessories
NOTE
Performance-dependent accessories like torches, workpiece leads, electrode holders or
intermediate hose packages are available from your authorised dealer.
9.1 Remote controls and accessories
Type Designation Item no.
RT1 19POL Remote control current 090-008097-00000
RTG1 19POL Remote control, current 090-008106-00000
RTF1 19POLE 5M Foot-operated remote control current with
connection cable
094-006680-00000
RTF2 19POL 5 m Foot-operated remote control current with
connection cable
090-008764-00000
RTP1 19POL Remote control spot welding / pulses 090-008098-00000
RTP2 19POL Remote control spot welding / pulses 090-008099-00000
RTP3 spotArc 19POL spotArc remote control for spot welding / pulses 090-008211-00000
9.1.1 Connection cables
RA5 19POL 5M Remote control e.g. connection cable 092-001470-00005
RA10 19POL 10M Remote control e.g. connection cable 092-001470-00010
RA20 19POL 20M Remote control e.g. connection cable 092-001470-00020
9.1.2 Extension cable
RV5M19 19POLE 5M Extension cable 092-000857-00000
RV5M19 19POLE 10M Extension cable 092-000857-00010
RV5M19 19POLE 15M Extension cable 092-000857-00015
RV5M19 19POLE 20M Extension cable 092-000857-00020
9.2 Options
Type Designation Item no.
ON 12pol Retox TIG 190/230 Optional retrofit 12-pole connection socket, torch 092-002519-00000
ON Filter TIG 190-270 Retrofit option, dirt filter for air inlet 092-002551-00000
9.3 General accessories
Type Designation Item no.
ADAP SCHUKO/16ACEE Earth contact coupling/CEE16A plug 092-000812-00000
DM1 35L/MIN Manometer pressure regulator 094-000009-00000
GH 2X1/4'' 2M Gas hose 094-000010-00001
ADAP 8-5 POL 8 to 5-pole adapter 092-000940-00000
Appendix A
Overview of EWM branches
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10 Appendix A
10.1 Overview of EWM branches
EWM HIGHTEC WELDING GmbH
Dr. Günter-Henle-Straße 8
56271 Mündersbach · Germany
Tel: +49 2680 181-0 · Fax: -244
www.ewm-group.com · info@ewm-group.com
EWM HIGHTEC WELDING (Kunshan) Ltd.
10 Yuanshan Road, Kunshan · New & High-tech Industry Development Zone
Kunshan · Jiangsu · 215300 · People´s Republic of China
Tel: +86 512 57867-188 · Fax: -182
www.ewm-kunshan.cn · info@ewm-kunshan.cn
EWM HIGHTEC WELDING GmbH
Fichtenweg 1
4810 Gmunden · Austria · Tel: +43 7612 778 02-0 · Fax: -20
www.ewm-gmunden.at · info@ewm-gmunden.at
EWM HIGHTEC WELDING UK Ltd.
Unit 2B Coopies Way · Coopies Lane Industrial Estate
Morpeth · Northumberland · NE61 6JN · Great Britain
Tel: +44 1670 505875 · Fax: -514305
www.ewm-morpeth.co.uk · info@ewm-morpeth.co.uk
EWM HIGHTEC WELDING (Kunshan) Ltd.
10 Yuanshan Road, Kunshan · New & High-tech Industry Development Zone
Kunshan · Jiangsu · 215300 · People´s Republic of China
Tel: +86 512 57867-188 · Fax: -182
www.ewm-kunshan.cn · info@ewm-kunshan.cn
EWM HIGHTEC WELDING Sales s.r.o. / Prodejní a poradenské centrum
Tyršova 2106
256 01 Benešov u Prahy · Czech Republic
Tel: +420 317 729-517 · Fax: -712
www.ewm-benesov.cz · info@ewm-benesov.cz
EWM HIGHTEC WELDING FZCO / Regional Office Middle East
LOB 21 G 16 · P.O. Box 262851
Jebel Ali Free Zone · Dubai, UAE · United Arab Emirates
Tel: +971 48870-322 · Fax: -323
www.ewm-dubai.ae · info@ewm-dubai.ae
EWM HIGHTEC WELDING AUTOMATION GmbH
Boxbachw
eg 4
08606 Oelsnitz/V. · Germany
Tel: +49 37421 20-300 · Fax: -318
www
.ewm-automation.de · info@ewm-automation.de
EWM HIGHTEC WELDING s.r.o.
Tr. 9. k
vetna 718 / 31
407 53 Ji íkov · Czech Republicř
Tel: +420 412 358-551 · Fax: -504
www.ewm-jirikov.cz · info@ewm-jirikov.cz
Production, Sales and Service
Sales and Service Germany
Sales and Service International
Plants Branches More than 300 EWM sales partners worldwide
Headquarters
EWM HIGHTEC WELDING GmbH
Dr. Günter-Henle-Straße 8
56271 Mündersbach · Germany
Tel: +49 2680 181-0 · Fax: -244
www.ewm-group.com · info@ewm-group.com
Technology centre
EWM HIGHTEC WELDING GmbH
Forststr.7-13
56271 Mündersbach · Germany
Tel: +49 2680 181-0 · Fax: -144
www.ewm-group.com · info@ewm-group.com
EWM HIGHTEC WELDING GmbH
Vertriebs- und Technologiezentrum
Grünauer Fenn 4
14712 Rathenow · Tel: +49 3385 49402-0 · Fax: -20
www.ewm-rathenow.de · info@ewm-rathenow.de
EWM HIGHTEC WELDING GmbH
Lindenstraße 1a
38723 Seesen-Rhüden ·
Tel: +49 5384 90798-0 · Fax: -20
www.ewm-seesen.de · info@ewm-seesen.de
EWM HIGHTEC WELDING GmbH
Sachsstraße 28
50259 Pulheim · Tel: +49 2234 697-047 · Fax: -048
www.ewm-pulheim.de · info@ewm-pulheim.de
EWM HIGHTEC WELDING GmbH
In der Florinskaul 14-16
56218 Mülheim-Kärlich · Tel: +49 261 988898-0 · Fax: -20
www.ewm-muelheim-kaerlich.de · info@ewm-muelheim-kaerlich.de
EWM HIGHTEC WELDING GmbH
Sälzerstr. 20
56235 Ransbach-Baumbach · Tel: +49 261 2623 9276-0 · Fax: -244
www.ewm-ransbach-baumbach.de · info@ewm-ransbach-baumbach.de
EWM HIGHTEC WELDING GmbH
Eiserfelder Straße 300
57080 Siegen · Tel: +49 271 3878103-0 · Fax: -9
www.ewm-siegen.de · info@ewm-siegen.de
EWM HIGHTEC WELDING GmbH
Vertriebs- und Technologiezentrum
Draisstraße 2a
69469 Weinheim ·Tel: +49 6201 84557-0 · Fax: -20
www.ewm-weinheim.de · info@ewm-weinheim.de
EWM Schweißtechnik Handels GmbH
Rittergasse 1
89143 Blaubeuren · Tel: +49 7344 9191-75 · Fax: -77
www.ewm-blaubeuren.de · info@ewm-blaubeuren.de
EWM Schweißtechnik Handels GmbH
Heinkelstraße 8
89231 Neu-Ulm · Tel: +49 731 7047939-0 · Fax: -15
www.ewm-neu-ulm.de · info@ewm-neu-ulm.de
EWM HIGHTEC WELDING AUTOMATION GmbH
Steinfeldstrasse 15
90425 Nürnberg · Tel: +49 911 3841-727 · Fax: -728
www.ewm-automation.de · info@ewm-automation.de
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