EWM PICOTIG 180 AC/DC, PICOTIG 220 DC, PICOTIG 220 AC/DC Operating Instructions Manual

EWM HIGHTEC WELDING GmbH
Dr. Günter - Henle - Straße 8; D-56271 Mündersbach
Phone: [phone]; Fax: [phone]
Internet:

www.ewm.de ; E-mail: [e-mail]

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 compl y 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

[e-mail]

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 modificati ons, which
have not been expressly allowed by E WM,
this declaration will lose its validity.

Par la présente, nous déclarons que la
conception et la construc tion 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 commi ssioning the machine,
notes regarding safety, maintenance and care, technical data as well as informa t ion
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:

SNR:
PROJ:

GEPRÜFT/CONTROL:

Name of Customer / company

Adress

Post code / Place

Country

Stamp / Signature of EWM-distibutor

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 a vailable
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 comple t e ly 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 teleco mmunications 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 gase s 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 occa sionally 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 situatio ns 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 2.5mm2 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 35mm2
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 val ve 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 sock et.

• 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.

5 Commissioning

5/4

Antistick:

If the stick electrode sticks in spite of the arcforcing device, the machine automatically switches
over to the minimum current within about 1 sec, so that overheating of the electrode is prevented. If
the antistick device has been triggered, check the welding current setting and correct if necessary.

After welding, place electrode holder onto insulated base,
switch off welding machine.

Electrode is hot.

5.8 TIG 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.

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).

• Fit tungsten electrode and gas nozzle onto the welding torch
(take into account current load, see torch operating instructions).

• Connect welding torch and workpiece lead.

• Fix workpiece lead with good electrical contact to the workpiece.

• Set the welding process “TIG welding” using the key button. (chap. 3.1; C1)

• Switch on machine at the main switch (G1

).

• Open gas cylinder valve and set recommended gas quantity on the pressure reducer.

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.

5.8.1 TIG welding with liftarc ignition

• Select liftarc ignition type using changeover switch (H1).

• Select operating mode (non-latched / latched) using the key button (chap. 3, D1).

The functional sequences for TIG non-latched and TIG latched are described in chap. 5.12.3.

• Carry out welding (see fig. 5/2)

The arc is ignited on contact with the workpiece:

• Activate torch trigger in accordance with the operating mode selected.

• The torch gas nozzle must be placed with its rim on the ignition point to give a gap of approx. 2-

3 mm between the electrode tip and the workpiece (a).

• Carefully touch the workpiece with tungsten electrode tip. Press torch trigger in accordance with
the operating mode selected.

• The arc ignites when the torch is lifted off and swivelled to its normal position (c).

Fig. 5/2: Liftarc

5 Commissioning

5/5

Finish welding:

• Activate torch trigger in accordance with the operating mode selected.

•

After welding, place electrode holder onto insulated base, switch off welding machine.
Tungsten electrode is hot!

5.8.2 TIG welding with HF ignition

• Select HF ignition type using changeover switch (H1).

• Select operating mode (non-latched / latched) using the key button (chap. 3, D1).

The functional sequences for TIG non-latched and TIG latched are described in chap. 5.12.3.

• Carry out welding

The arc is ignited without contact:

• Activate torch trigger in accordance with the operating mode selected.

• Position the torch at an angle to the edge of the gas nozzle and move the electrode tip by

straightening up the torch, until the arc ignites. (See fig. 5/3)

• After ignition, move the torch into the normal position.

Fig. 5/3: HF ignition

Finish welding:

• Activate torch trigger in accordance with the operating mode selected.

After welding, place electrode holder onto insulated base, switch off welding machine.
Tungsten electrode is hot!

5.8.3 Automatic cut-out

If the arc does not ignite after starting or if the arc is interrupted when the torch is moved
away, an automatic cut-out occurs after 3 sec.
HF, gas and the open circuit voltage (power unit) are switched off.

5 Commissioning

5/6

5.8.4 TIG welding torch, operating variants

The welding process can be controlled with various torch de signs
(TT=torch trigger):

In addition to the operating variants described in chaps. 5.8.4.1 and 5.8.4.2, other variants
can be found in the PICOTIG PRO mode operating instructions.

5.8.4.1 Standard TIG torch, 5-pole connector plug (factory setting)
The welding machine is prepared for these torch types as standard.

Symbol Description Functions Operation with

Welding current on / off TT 1

Standard TIG torch

Design: 1 trigger

Secondary current TT 1 in tapping mode
Welding current on / off TT 1

Secondary current TT 2

Standard TIG torch
Design: 2 triggers

Secondary current TT 1 in tapping mode
Welding current on / off TT 1 (rocker forwards)

Secondary current TT 2 (rocker back)

Standard TIG torch
Design: 2 triggers (MG
rocker)

Secondary current TT 1 (rocker forwards)

in tapping mode

5.8.4.2 TIG Up/Down torch, 8-pole connector plug (optional)
The welding machine is prepared for this torch type as standard.

Symbol Description Functions Operation with

Welding current on / off TT
Secondary current TT in tapping mode

TIG up/down torch
Design: 1 trigger +
2 triggers (rocker)

Increase / reduce
welding current

Rocker forwards / rocker back

The last welding current value set is stored in the memory and is available after switching
on again.

5.8.4.3 TIG potentiometer torch, 8-pole connection plug
For machines with 8-pole connection sockets (optional), it is not possible to differentiate

between TIG up/down torches and potentiometer torches via the torch detection system
Before commissioning, the welding machine must be converted for the TIG potentiom eter

torch.
(see operating instructions for PICOTIG PRO mode, chap. 3.11)

The TIG potentiometer torch can only be used in mode 3.
(see operating instructions for PICOTIG PRO mode, chap. 3.9.2)

Symbol Description Functions Operation with

TIG potentiometer torch
Design: 1 trigger +

1 wheel (potentiometer)

Welding current on / off TT

5.8.5 Tapping operating mode

The tapping mode was included particularly for the secondary current (AMP%) by the use of
a trigger on the welding torch.

Torch with one trigger:

• by tapping (brief pressing and releasing) torch trigger 1

(Repeated tapping switches back to the main current).

Torch with two triggers:

There are two ways of switching to the secondary cu rrent:

• by tapping (see torch with one trigger)

• by pressing down and holding torch trigger 2.

5 Commissioning

5/7

5.8.6 TIG function sequences

All the parameters for the TIG process can be controlled using the key button (F 1) to select the
parameters and the rotary transducer (G1) to set them:

• Main current AMP,

• Down-slope time,

• Gas post-flow time

5.8.6.1 Explanation of symbols

Symbol Meaning

Press torch trigger 1

Release torch trigger 1

AMP

Main current (minimum to maximum current)

I

start

Ignition current

I

end

End-crater current

tUp

Up-slope time

t

Down

Down-slope time
TIG welding process

MMA welding process

Non-latched mode
Latched mode

HF

HF ignition switched on

HF

Liftarc

Gas pre-flows

Gas post-flows

5 Commissioning

5/8

5.8.6.2 TIG non-latched operation

• Adjust the appropriate key buttons or changeover switches to the following settings:

HF

I

I

start

AMP

t

Up

1. 2.

t

Down

I

end

t

Fig. 3/4: Function sequence of TIG non-latched operation

1st step:

• Press and hold torch trigger 1.

• The gas pre-flow time passes.

• 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 in the adjusted up-slope time to the main current AMP.

2

nd

step:

• Release torch trigger 1.

• The main current falls in the adjusted down-slope time to the end-crater current I

end

(minimum

current).

• The main current reaches the end-crater current I

end

, the arc extinguishes.

• The gas post-flow time set passes.

If the 1st torch trigger is pressed during the down-slope time, the welding current returns to
the main current AMP set.

5 Commissioning

5/9

5.8.6.3 TIG latched operation

• Adjust the appropriate key buttons or changeover switches to the following settings:

HF

I

I

start

AMP

I

end

t

Up

t

Down

t

AMP%

1. 2. 3. 4.

Fig. 3/5: TIG latched function sequence

Step 1

• Press torch trigger 1, the gas pre-flow time passes.

• 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 in the adjusted up-slope time to the main current AMP.

(Secondary current AMP% see chap. 3.1)

Step 3

• Press torch trigger 1.

• The main current falls in the adjusted down-slope time to the end-crater current I

end

(minimum

current).

4

th

step

• Release torch trigger 1, the arc extinguishes.

• The gas post-flow time set begins.

Immediate termination of the welding procedure without down-slope and end-crater
current:

• Briefly press the 1st torch trigger (3rd and 4th step).

The current falls to zero and the gas post-flow time begins.

5 Commissioning

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5.9 Cooling unit function specification (optional)

A functional test is performed on the cooling module after the welding machine has been switched
on.

The coolant pump and the fan are switched on.
When the pump is running, there is a sufficient coolant level and enough through-put, the co oling
module is switched off.

If the through-put is not sufficient a coolant error is reported and the pump runs for a maximum of 2
minutes so that the operator can top up the coolant.

The cooling module is switched on at the start of the TIG welding process.
After the welding process has stopped, the water pump and fan continue to run for a further 5
minutes and then switch off.

5.9.1 Coolant error

If there is no through-put for longer than 2.5 seconds during the welding operation e.g. because of
a lack of coolant, pump failure or a burst or leaking hose:

• an error message is issed (chap. 3, K1: Water deficiency LED)

• and the welding process is ended in a controlled manner

(coolant pump and power unit of the welding machine are swit ched off).

When the welding process is re-started, the coolant error is reset and the cooling module is
switched on. If still no through-put has built up after 2.5 seconds, the cooling module is switched
off, the water deficiency LED (chap. 3, K1) comes on and the welding process is ended in a
controlled manner.

6 Maintenance and care

6/1

6.1 General

Under the indicated environmental conditions and no rmal operating conditions, this machine is
largely maintenance-free and requires minimum care. However, a number of points should be
observed to guarantee fault-free operation of your welding machine. Among these are regular
cleaning and checking as described below, depending on the level of contamination in the
environment and the usage time of the welding machine.

Cleaning, testing and repairing of the welding machines may only be carried out by competent,
capable personnel. A capable person is one who, due to training, knowledge and experience, is
able to recognise the dangers that can occur during testing of welding power sources as well as
possible subsequent damage and who is able to implement the required safety procedures.

In the event of failure to comply with any one of the following tests, the machine must not be
operated again until it has been repaired and a new test has been carried out.

6.2 Cleaning

Before cleaning, carefully disconnect the machine from the mains. PULL OUT THE MAINS PLUG.
(Switching off or pulling out the fuse does not provide adequate insulation protection)
Wait 2 minutes until the capacitors are discharged. Remove the casing cover.

The individual components should be handled as follows:
Power source: Depending on the amount of dust, blow out power source u sing oil- and moisture-

free compressed air.
Electronics: Do not blast electronic components or circuit boards with compressed air but instead

use suction from a vacuum cleaner for cleaning purpose s.

6.3 Repetition Test conforming to E VDE 0544-207, conforming to the
German Ordinance on Operational Safety

In addition to the regulations on the repetition test mentioned here, the relevant laws and
regulations in the country of use must be observed.

The repetition test must be conducted in accordance with E VDE 0544-207 “Repetition Test on Arc
Welding Equipment”. The draft standard summarises all the necessary test points specifically for
welding machines as already cited together in the VDE 0702 “Repetition Test for Electrical
Devices”, with the addition of special application notes and different limit values.

Unfortunately, many test devices for VDE 0702 are not completely suitable due to the special
conditions in inverter arc welding machines!

Recommendation: Ask your test engineer whether he is performing the test in accorda nce with E
VDE 0544-207, the measuring equipment conforms to VDE0404-2 and the frequency response is
being evaluated in accordance with DIN EN 61010-1 Appendix A – Measuring Circuit A1. Have this
confirmed in writing if necessary.

EWM as a manufacturer has specified a separate test device and provides its EWM dealers with
the necessary support to conduct a repetition test to E VDE 0544-207 correctly.

If the repetition test is not conducted in accordance with the standards and / or not at the
prescribed intervals, the right to claim under the warranty lapses!

The following description of the repetition test is only a brief overview of the products to be
tested. For details on the test points or in the event of any queries, please read E VDE 0544-207.

6 Maintenance and care

6/2

6.3.1 Test intervals and scope

A quarterly partial test and an annual extensive test are to be carried out. The extensive test must
also be carried out each time that repairs are made; in the case of heavy use, the period can be
reduced (e.g. to 6 months when used at construction sites). In the extensive test, the machine must
be opened and cleaned according to the section entitled “Cleaning”. Only exterior cleanin g is
required for the partial test.

Partial test Full test
a) Visual check a) Visual check

b) Electrical test: measurement of Protective

conductor resistance

b) Electrical test: measurement of

• Protective conductor resistance

• Insulation resistance

• Leakage currents

• Open circuit voltage

c) Functional test c) Functional test

6.3.2 Documentation of the test

The result of the test must be documented to show the following clearly:

• Identify the tested machines,

• The date of the test

• The time of the next test and

• The results
for later reference. The machine must be marked if the test is successful (e.g. with a test plate).

This plate must include the date of the next repetition test.

6.3.3 Visual inspection

Given below are the main points in the full test. The points to be tested with the machine open are
not required for the partial test.

1. Torch/stick electrode holder, welding current return lead clamp

2. Leads including plugs and couplings

3. Open plugs and couplings

4. Casing

5. Open casing

6. Special features of the welding power sources for plasma cutting

7. Operating, message, safety and adjustment devices

8. Other, general condition

6.3.4 Measurement of protective conductor resistance

Measure between the plug earthed contact and accessible metal parts, e.g. casing screws. During
the measurement, the connection lead must be moved across the entire length, but especially
close to the casing and plug inputs. This should uncover any interruptions in the protective
conductor. All conductive parts of the casing accessible from outside should also be tested to
ensure a correct PE connection for safety class I.

The resistance must not exceed a mains connection lead 0.3 Ω up to 5m in length. For longer
leads, the permissible value increases by 0.1 Ω per 7.5m of lead.

6 Maintenance and care

6/3

6.3.5 Measurement of insulation resistance

The mains switch must be on before the insulation in the interior of the machine through to the
transformer can be checked. If a mains contactor is fitted, this should be bridged or the
measurement must be carried out on both sides.

The insulation resistance must not be less than:

Input power circuit
(mains)

against Welding current circuit and

electronics

5 MΩ at test voltage 1000V=

Input power circuit
(mains)

against Casing (PE)

2.5 MΩ at test voltage 500V =

Welding current
circuit and
electronics

against Casing (PE)

2.5 MΩ at test voltage 500V =

6.3.6 Measuring the leakage current (protective conductor and contact current)

These measurements cannot be carried out with a normal multimeter. Even test devices for
VDE 0702 (especially older devices) are generally only intended for 50/60Hz. With inverter welding
machines, however, significantly higher frequencies occur, which can interfere with some
measuring devices, and results in others measuring the frequency incorrectly.

Test devices must meet the requirements of VDE 0404-2. For the frequency response
measurement, please refer to DIN EN 61010-1 Appendix A – Measuring Circuit A1.

For these measurements the welding machine must be switched on and supplying open circuit
voltage.

1. Protective conductor current: <3.5mA

2. Contact current from welding sockets separately to PE: <10mA

3. Contact current of accessible, conductive parts not connected to PE, to PE: <0.5mA

6.3.7 Measuring the open circuit voltage

6u8F

10nF

0...5k

0k2

1k0

1N 4007

Measuring circuit to DIN EN 60974-1

Connect the measuring circuit to the welding current
sockets. The voltmeter must display mean values and
must have an internal resistance ≥ 1 MΩ. During the
measurement, adjust the potentiometer from 0 kΩ to 5 kΩ.
The voltage measured should not deviate from that given
on the rating plate by more than +/- 5% and must not be
greater than 113V (for machines with VRD: 35V).

6.3.8 Function test of the welding machine

Safety devices, selector switches and command units (if fitted) and the entire machine or the entire
system for arc welding, must be functioning perfectly.

1. Main switch

2. Emergency stop devices

3. Danger reduction devices

4. Gas solenoid valve

5. Message and control lamps

6. Command devices and selector switches (including remote controls)

7. Locks

6 Maintenance and care

6/4

6.4 Repair Work

Repair and maintenance work may only be performed by qualified and authorised specialist staff;
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 o rigin al 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.

We hereby confirm that the servicing and maintenance guidelines given above, and the repetition test described
above, have been conducted correctly in accordance with E VDE 0544 207.

Date / Stamp / Signature of EWM sales partner

Date / Stamp / Signature of EWM sales partner

Date of next repetition test

Date of next repetition test

Date / Stamp / Signature of EWM sales partner

Date / Stamp / Signature of EWM sales partner

Date of next repetition test

Date of next repetition test

Date / Stamp / Signature of EWM sales partner

Date / Stamp / Signature of EWM sales partner

Date of next repetition test

Date of next repetition test

7 3-Year Warranty

7/1

7.1 General Validity

3 year warranty

on all new EWM machines:

• Power sources

• Wire feeds

• Cooling units

• Trolley

1 year warranty

on remote controls and used EWM machines.

6 month warranty

on spare parts supplied separately (e.g. circuit boards, ignition units).

Replaceable parts are components that are subject to mechanical ageing (e.g. motors, gears,
pumps, fans, WF rollers, wheels, solenoid valves, etc.) and are thus excluded from the warranty.

This information applies regardless of statutory warranty rights and is based on our General
Terms and Conditions as well as our accompanying Warranty Regulations.

7 3-Year Warranty

7/2

7.2 Warranty Declaration

Your 3-year Warranty

Regardless of statutory warranty rights and based o n our General Terms and Conditions, EWM
HIGHTEC WELDING GmbH provides a 3-year warranty for its welding products starting on the
date of purchase. Different warranty periods apply for accessories and spare parts; please see the
“General Validity” section for these periods. Wearing parts are of course exempt from the warranty.

EWM guarantees the error-free condition of our products in terms of materials and processing. If
the product proves to be defective in terms of materials or processing within the warranty period,
you have the right to free repair or to replacement by an appropriate product, at our discretion. In
this case, the returned product becomes the property of EWM when it reaches Mündersba ch or our
premises.

Note

Only machines that are inspected and maintained regularly function correctly in the long term. For
this reason, please ensure that all the points given in your operating instructions are followed,
especially in the “Maintenance and Care” chapter.

Making a Claim

When making a claim under the warranty, please contact only your EWM-authorised sales partner.

Exclusion of Warranty

The warranty does not apply to products that are damaged due to accident s, misuse, improper
operation, incorrect installation, use of force, disregard of the specifications and operating
instructions, insufficient maintenance (see “Maintenance and Care” chapter), exterior influenc es,
natural disasters or personal misfortunes. Furthermore, it is not valid in the case of improper
changes, repairs or modifications. In addition, a claim against the warranty does not exist in the
case of partially or completely dismantled products and interventions by persons who are not
authorised by EWM, as well as in the case of normal wear.

Limitation

All claims regarding fulfilment or non-fulfilment on the part of EWM from this declaration in
connection with this product are limited as follows to the replacement of the actual damages.
EWM’s liability originating from this declaration in connection with this product is strictly limited to
the amount that the purchaser originally paid for the original purchase. This limitation does not
apply to personal injuries or damage to property caused by negligent behaviour on the part o f
EWM. In no way will EWM be responsible for lost profits, indirect or subsequent damage. EWM is
not liable for damages based on the claims of third parties.

Place of Jurisdiction

If the person making the order is a business person, the sole place of jurisdiction for all disputes
resulting directly or indirectly from the contractual relationship shall be the headquarters or the
branch office of the supplier, at the discretion of the supplier. The purchaser gains ownership of the
products supplied as replacements within the framework of the warranty adjustment at the time of
the exchange.

8 Operating problems, causes and remedies

8/1

8.1 Error messages

• In the event of a machine error, an error code (see table below) is shown on the display (chap.

3, A1).

• If multiple errors occur, they should be rectified in sequence.

Error message Possible cause Remedy
"E1" Water fault

Occurs only when the water cooler
(optional) is connected.

Ensure that sufficient water pressure
can be generated. (e.g. top up water)

"E2" Temperature fault Allow machine to cool down.
"E3" Electronics error Switch the machine off and back on

again.
If the fault persists, inform the service
department.

"E4" see "E3" see "E3"
"E5" see "E3" see "E3"
"E6" Calibration error in the voltage

detection.

Switch off the machine, place the
torch in an insulated position and
switch the machine back on.
If the fault persists, inform the service
department.

"E7" Calibration error in the current

detection.

Switch off the machine, place the
torch in an insulated position and
switch the machine back on.
If the fault persists, inform the service
department.

"E8" Fault in one of the electronics supply

voltages or excess temperature of
the welding transformer.

Allow machine to cool down. If the
error message continues to be
displayed, 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 excess voltage Switch the machine off and back on

again.
If the fault persists, inform the service
department.

"E11" Excess voltage Switch off the machine and check the

mains oltage

9 Spare parts list

9/1

PICOTIG 180 AC/DC: in Bearbeitung/ in preparation

Abb. 8/1: Vorderseite; Fig. 8/1: front view

Item Designation Description PICOTIG 180; 220

A1

Griffstange Hand grip 094-007501-00003

B1

Halterung für Griffstange Hand grip mount 094-007383-00003

C1

Gehäusewinkel Casing angle 094-007900-00002

D1

Steuerung T2.15 komplett

(PICOTIG 180; 220 AC/DC)

Control T2.15 complete

(PICOTIG 180; 220 AC/DC)

040-000632-00000

Ohne Abb.
No figure

Steuerung T2.10 komplett

(PICOTIG 220 DC)

Control T2.10 complete

(PICOTIG 220 DC)

040-000633-00000

Drehknopf Rotary dial 074-000315-00000

E1

Drehknopfdeckel Rotary dial cap 074-000315-00001

F1

Anschlußbuchse Connection socket 074-000232-00000

G1

Anschlußbuchse 5-polig Connection socket, 5-pole 074-000233-00000
Anschlußnippel G1/4 Connection nipple, G1/4 094-002695-00001
Isolierstück Insulation piece 094-000075-00000
Druckscheibe Pressure washer 094-000076-00000
Mutter M20 M20 nut 094-000068-00000

H1

Fächerscheibe Fan-type lock washer 094-006516-00000

I1

Gummifüße Rubber feet 094-001718-00001

9 Spare parts list

9/2

Abb. 8/2 Rückseite / Fig. 8/2 rear view

Item Designation Description

PICOTIG 180; 220

A2

Kippschalter Toggle switch 094-001898-00000

B2

Anschlußbuchse 8-polig (Option) Connection socket, 8-pole

(optional)

094-006904-00000

C2

Netzschalter Mains switch 094-008045-00000

D2

Anbau Gehäuse (Option) Housing extension (optional) 094-006861-00000
Abdeckkappe (Option) Cap (optional) 094-006862-00000
Buchseneinsatz (Option) Socket insert (optional) 094-007943-00000
Kabeldurchführung Cable bushing 094-007871-00000

E2

Gegenmutter Counter nut 094-007878-00000

F2

Magnetventil G1/4 Solenoid valve, G1/4 094-005497-00001

G2

Netzkabel Mains cable 094-005142-00001

H2

Anschlußbuchse 19-polig Connection socket 19-pole 094-003064-00000

9 Spare parts list

9/3

A3

G3

F3

B3
C3

D3

E3

Abb. 8/3: linke Seite; Fig. 8/3: left side (PICOTIG 220 DC)

Item

Designation

Description

PICOTIG 220 DC

A3

Drossel-Hochsetzsteller Choke power factor correction 044-002685-00000

B3

Haupttrafo Main transformer 092-001560-00001

C3

Lüfter Fan 094-007861-00000

D3

Sekundärdioden Secondary diode 044-002312-00000

E3

LEM-Wandler LF205-S/SP1 LEM-converter LF205-S/SP1 044-002691-00000

F3

PCB Spannungsverdoppler SV2/1 PCB voltage doubler SV2/1 040-000533-00000

G3

PCB Brennertasterfilter BTF1 PCB torch trigger filter BTF1 040-000545-00000

9 Spare parts list

9/4

A4

H4

G4

F4

B4

C4
D4

E4

Abb 8/4: rechte Seite; Fig. 8/4: right side (PICOTIG 220 DC)

Item

Designation

Description

PICOTIG 220 DC

A4

Steuerung T200/1 PICOTIG T200/1 PICOTIG control 040-000631-00000

B4

Steuerung T201/2 DC T201/2 DC control 042-000653-00000

C4

PCB Zündgerät HFAC4 PCB ignition unit HFAC4 040-000622-00000

D4

Steuerung DC 220 Control DC 220 040-000587-00000

E4

HF-Drossel HF choke 072-000536-00000

F4

Frontblech Front panel 094-008002-00005

G4

Bodenblech Floor panel 094-007705-00003

H4

Rückblech Rear panel 094-007706-00003

9 Spare parts list

9/5

A5

H5

G5

F5

B5
C5

D5
E5

Abb. 8/5: linke Seite; Fig. 8/5: left side (PICOTIG 220 AC/DC)

Item

Designation

Description

PICOTIG 220

AC/DC

A5

Drossel-Hochsetzsteller Choke power factor correction 044-002685-00000

B5

Haupttrafo Main transformer 092-001560-00001

C5

Lüfter Fan 094-007861-00000

D5

Sekundärdioden (4x)
BYT200 PIV400

Secondary diodes (4 x)
BYT200 PIV400

044-002601-00000

E5

Wechselrichter-Module (4x)
GA200SA60S

Inverse rectifier modules (4 x)
GA200SA60S

074-000600-00000

F5

LEM-Wandler LF205-S/SP1 LEM-converter LF205-S/SP1 044-002691-00000

G5

Wechselrichtertreiberstufe TRF5 Inverse rectifier dri ve r stage

TRF5

040-000618-00000

H5

PCB Brennertasterfilter BTF1 PCB torch trigger filter BTF1 040-000545-00000

9 Spare parts list

9/6

A6

G6

H6

F6

B6

C6

D6

E6

Abb. 8/6: rechte Seite; Fig. 8/6: right side (PICOTIG 220 AC/DC)

Item

Designation

Description

PICOTIG 220

AC/DC

A6

PCB Schweißelektronik T200/1 PICOTIG PCB welding electronics T200/1

PICOTIG

040-000631-00000

B6

PCB Tastatur T201/2 PCB key board T201/2 042-000653-00000

C6

PCB Zündgerät HF AC4 PCB ignition unit HF AC4 040-000622-00000

D6

Frontblech Front panel 094-008002-00005

E6

HF Drossel HF choke 072-000536-00000

F6

Gehäuse Bodenblech Floor panel casing 094-007705-00003

G6

PCB Power Sinus DC 220 PCB Power Sinus DC 220 040-000587-00000

H6

Rückblech Rear panel 094-007706-00003

10 Accessories, options

10/1

10.1 Standard TIG torch

Designation, description Item No.

WIG torch 26 GD, 4m, two triggers 094-000538-00000
WIG torch 20 WD, 4m, two triggers 094-000487-00000

10.2 TIG Up/Down torch

Designation, description Item No.

Opt. 8-pole connection socket for potentiometer and Up/Down torch 092-001530-00000
WIG torch 26 Up-Down GD, 4m 094-007549-00000
WIG torch 20 Up-Down WD, 4m 094-007535-00000

10.3 Electrode holder / workpiece lead

Designation, description Item No.

Electrode holder, 35mm2, 4m 092-000052-00000
Workpiece lead, 35mm2, 4m, pole binder 092-000008-00000

10.4 General accessories

Designation, description Item No.

Opt. cooling unit connection option 092-001708-00000
COOL20 U20 air-cooling unit 090-008104-00102
TROLLY 31-2 construction site transport vehicle 090-008160-00000
Adapter for earthing contact coupling to plug CEE16A 092-000812-00000
8-pole to 5-pole adapter for standard TIG torch 092-000940-00000
Adapter for TIG torch with central connector to TIG machines with decentral

connection

094-008284-00000

DM2 pressure reducer flowmeter 16l/min 094-001980-00000
ADAP1 thread adapter G1/4 to G1/8 094-001650-00000
KF 23E-10 coolant 9.3l (-10 ° frost protection)

094-000530-00000

KF 23E-200 coolant 200l (-10 ° frost protection)

094-000530-00001

KF 37E-10 coolant 9.3l (-20 ° frost protection)

094-006256-00000

10.5 Remote control / connection cable

Designation, description Item No.

RTF1 foot-operated remote control current On/Off 5m, 19-pole 094-006680-00000
RT1 H remote control current without cable 090-008097-00000
RT1 H remote control spot/pulse without cable 090-008098-00000
RTP2 H remote control spot/pulse without cable 090-008099-00000
RA5M19 connection cable 5m 19-pole 092- 001470-00005
RA10M19 connection cable 10m 19-pole 092-001470-00010
RA20M19 connection cable 20m 19-pole 092-001470-00020

11 Circuit diagrams

11/1

11.1 PICOTIG 180 AC/DC

230V/240V

50/60Hz

N

L1

AC

DC

A1-

4x

E3E1

A2

M

A1

T1-

TP

TM

HF-Drossel

PE

22nF

PE

-U2

Flachbandkabel 26polig

Flachbandkabel 16polig

P

M

X2/1

X3/1

X4/1

TRP

TRM

M

PE

V3-V4

V5-V6

V7-V8

Stromwandler

1234

-M+

+U2

1 2

S1-

X2/10

X2/4

X2/1

X2/3

X2/2

X2/7

X2/5
X2/6

X2/8
X2/9

X2/16

X2/13

X2/11
X2/12

X2/14
X2/15

X2/19

X2/17
X2/18

X2/20
X2/21

X2/23

X2/22

X2/24

X2/26

X2/25

T3

T1
T4
T2

IP+

IP­REL
I10A
+7V
+7V
+15V
+15V

+24V
+24V

0V1

0V1

0V1

0V1

NC

-15V
Temp

0V2

0V2

NC
NC

UZWK

~

~

+

-

+

X2-

A2-

H F A C 5

X1/1

X1/4

X1/2

X1/3

X1/6

X1/5

X2/1

X2/2

HF-P

+15V/HF

0V/HF

HF-N

NC

+24V/HF

R1-R2

V1-V2

R3-R4

Ringkerne Toroides

D C 1 8 0

A3-

T R F 5

X2/2

X3/2

X4/2

X1/7

X1/1

X1/6

X1/5

X1/2
X1/3
X1/4

X1/13

X1/12

X1/11

X1/9

X1/8

X1/10

X1/15

X1/14

X1/16

NC

NC

+15V1

0V1

NC
NC

AC-STOER
Temp-Sek

T2S

T1SH

T2SH

T1S

HVA
HVB
HVB

HVA

2x2n2F

A7-

X9-

X7-

LF205-S

PE

Ringkern

A 42

B

52

C

52

D

62

E 22

F 62

EL

W

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

Änderung-4:

Änderung-3:

Änderung-2:

Änderung-1:

12.02.2008

17.11.2006

NIEDENTHAL

NIEDENTHAL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

1

PICOTIG 180 AC/DC

4522-01

Zeichnungsnummer:

ELEK-GERAET, 230V TRAGBAR

11 Circuit diagrams

11/2

Stecker X2

Stecker X1 Stecker X12

X9/7

X9/8

X9/9

X9/10

Stecker X9

X9/1

X9/4

X9/6

X9/5

X9/2

X9/3

IH-Down

Uref 10V

Poti UD/ein

PE

X1/5

X1/9

X1/10

X1/7

X1/8

X1/6

X1/3

X1/4

0V

0V

NC

NC

UP

X1/1

X1/2

BRT2

BRT1

2-BT

WIG-Brenner

Doppeltaster

X3/1

X3/3

X3/4

X3/2

X2/7

X2/8

X2/3

X2/4

X2/5

X2/6

1

2

1-BT

5

3

4

mit

X2/2

X2/1

X7/10

X7/9

X7/8

X7/3

X7/5
X7/6

X7/4

X7/7

X7/2

X7/1

Poti UD/ein

Up

7

8

IH-Down

Uref 10V

0V

563

4

BT1

BT2

1

2

Steuersatz

Wechselrichter

Trafo

Up-Down Brenner:

-

-

+

+

BFGHD

E

C

10k

A

B

FHG

D

E

C

A

BT1 BT2

UpDown

Poti Brenner:

oder

Stecker X6

Peripherie

Stecker X10

X5/6

X5/4
X5/5

X5/3

X5/2

X5/1

+24V Lüfter

Lüfter

NC

NC

0V2

0V2

Temp

-15V

NC

UZWK

0V1

0V1

0V1

0V1

+24V

+24V

+15V

+15V

+7V

+7V

I10A

REL

IP-

IP+

T3

T2

T4

T1

X2/1

X2/2

X2/3

X2/4

X2/5

X2/6

X2/7

X2/8

X2/9

X2/10

X2/11

X2/12

X2/13

X2/14

X2/15

X2/16

+24V Gasrelais
0V/HF
HF-N
0VHF
+24V/HF
NC
+15V-LEM
NC

-U2
Gas-Relais
HF/LIFTARC
HF-P
+15V/HF
HF-Bereit

-15V-LEM
M
NC
+U2

+15V
+15V2
PTC+
PTC-

X3/26

X3/25

X3/24

X3/23

X3/22

X3/21

X3/20

X3/19

X3/18

X3/17

X3/16

X3/15

X3/14

X3/13

X3/12

X3/11

X3/10

X3/9

X3/8

X3/7

X3/6

X3/5

X3/4

X3/3

X3/2

X3/1

-15V

-15V

+15V

+15V

+5V1

+5V1

0V1

0V1

+10V Uref.

+10V Uref.

0V-ANG

0V-ANG

OE

Analog C

Analog B

Analog A

Drehgeber A

Drehgeber B

Drehgeber A

Drehgeber B

CLK1

CLK1

seriell Ein

seriell Aus

seriell Ein

seriell Aus

X10/1
X10/2
X10/3
X10/4
X10/5
X10/6
X10/7
X10/8
X10/9
X10/10

T3

T2

T4

T1

Stecker X11

Zusatzansteuerung

Stecker X8

Stecker X7 Stecker X4

Stecker X5

HF ein/aus

PE21

Gas

A4-

X4/10

X4/9

X4/8

X4/7

X4/6

X4/5

X4/4

X4/3

X4/2

X4/1

X4/11
X4/12
X4/13
X4/14
X4/15
X4/16
X4/17
X4/18

X8/1
X8/2

Flachbandkabel 26polig

2

1

+24V

+

-

T 2 0 0 / 1

Lüfter

Bedienfeld

Stecker X3

Brennertaster

Seriell-InterfaceProgrammierstecker FernreglerWasserkühler

X11/1
X11/2
X11/3
X11/4

X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8
X1/9

X12/4

X12/3

X12/2

X12/1

X6/18

X6/17

X6/16

X6/15

X6/14

X6/13

X6/12

X6/11

X6/10

X6/9

X6/8

X6/7

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

S5-

Y1-

X8-

M1-

Lüfter

X1/3

X1/1

X1/2

X1/4

X1/5

X1/6

X1/7

X1/8

X1/9

X1/10

X1/11

Stecker X1

Bedienfeld

X1/23

X1/12

X1/13

X1/14

X1/15

X1/16

X1/17

X1/20

X1/18

X1/19

X1/21

X1/22

X1/26

X1/24

X1/25

Flachbandkabel

26polig

-15V

-15V

+15V

+15V

+5V1

+5V1

0V1

0V1

+10V Uref.

+10V Uref.

0V-ANG

0V-ANG

OE

Analog C

Analog B

Analog A

Drehgeber A

Drehgeber B

Drehgeber A

Drehgeber B

CLK1

CLK1

seriell Ein

seriell Aus

seriell Ein

seriell Aus

A5-

X5- X5-

Poti UD/ein

Up

IH-Down

Uref 10V

BT2

0V

BT1

Poti UD/ein

Up

IH-Down

Uref 10V

BT20VBT1

X5-

B1

B T F - 1

A6-

NC0V0VNCUref. 10V

Poti. UD/ein

IH-DownUpBRT2

BRT1

EMU1

TRST

EM0

TD0

VCC

TDI

GND

TMS

NC

TCK

NC

+5V

TXD DSP

NC

TXD UC

0V

RXD DSP

NC

RXD UC

NC

0V1

+15V1

NCNCNC

NC

T2SH

T1SH

T2S

T1S

Temp-Sek

AC-STOER

HVB

HVB

HVA

HVA

16polig

Flachbandkabel

PE

Flachbandkabel 10polig

E 1 10

rt

sw

PE

T 2 1 0

A

B

C

D

E

F

G

H

J

K

L

M

NPR

S

TUV

PE

IGR0

Poti IH

Poti IL

Polwendung PWS

Uref.+10V

Isoll

Puls Freq.

0V

+15V

IGR0

FR-Typ1

FR-Typ2

FR-Typ3

FR Str./Stp.

FR WIG/Elek.

FR MIG ein/aus

0V

-15V

X4-

Meld. Wasserkühler

Rel. Pumpe

Rel. Lüfter

+15V

0V

-15V

0V

FR MIG ein/aus

IGR0

FR STR/STP

FR-Typ2
FR-Typ3

FR-Typ1

+15V

0V

Puls Freq.

Isoll

Uref. 10V

Poti IL

Poti IH

IGR0

FR WIG/ELEK

Polwendung PWS

Option: Fernregler

Wassermangel

Ringkern

2

PE

2n2F

C1-

1

A 41

C

71

1 6B

1 9D

1 11F

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

Änderung-4:

Änderung-3:

Änderung-2:

Änderung-1:

12.02.2008

17.11.2006

NIEDENTHAL

NIEDENTHAL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

2

PICOTIG 180 AC/DC

4522-01

Zeichnungsnummer:

ELEK-GERAET, 230V TRAGBAR

11 Circuit diagrams

11/3

11.2 PICOTIG 220 DC

230V/240V

50/60Hz

N

L1

AC

DC

6x

PE

PFC

E3E1

A2

M

A1

TP

TM

HF-Drossel

LF205-S

2x2n2F

PE

22nF

PE

H F A C 5

A2-

Flachbandkabel 26polig

X1/1

X1/4

X1/2

X1/3

X1/6

X1/5

DR0 GR+

P

M

PE

Stromwandler

1234

-M+

-U2

1 2

X1/2

X1/3

X1/1

X11-

X6-

D C 2 1 0

A1-

S1-

Option Wasserkühlung!

X1-

X10-

Kühlgerät

L1-

X2/10

X2/4

X2/1

X2/3

X2/2

X2/7

X2/5
X2/6

X2/8
X2/9

X2/16

X2/13

X2/11
X2/12

X2/14
X2/15

X2/19

X2/17
X2/18

X2/20
X2/21

X2/23

X2/22

X2/24

X2/26

X2/25

T3

T1

T4

T2

IP+

IP­REL
I10A
+7V
+7V

+15V
+15V
+24V
+24V

0V1

0V1

0V1

0V1

NC

-15V

Temp

0V2
0V2

NC
NC

UZWK

T1-

X2-

35412

NCPENC

230V

0V

1

2

Ringkern

Ringkerne Toroides

HF-P

+15V/HF

0V/HF

HF-N

NC

+24V/HF

X2/1

X2/2

R1-

V1-

R2-

A1~

-EL

W+

A3-

S V 2 / 1

EL

W

A7-

+U2

X7-X9-

+

V2-

A 32

C

52

B 52

D 62

E 62

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

Änderung-4:

Änderung-3:

Änderung-2:

Änderung-1:

12.02.2008

22.11.2006

NIEDENTHAL

NIEDENTHAL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

1

PICOTIG 220 DC

4529-01

Zeichnungsnummer:

ELEK-GERAET, 230V TRAGBAR

11 Circuit diagrams

11/4

A5-

T 2 0 0 / 1

A6-

PE

BRT1

BRT2

UP

NCNC0V

0V

Poti UD/ein

Uref 10V

IH-Down

X1/2

X1/1

X1/4

X1/3

X1/6

X1/8

X1/7

X1/10

X1/9

X1/5

X2/1

X2/2

X2/6

X2/5

X2/4

X2/3

X2/8

X2/7

X3/2

X3/4

X3/3

X3/1

BT2

BT1

0V

Uref 10V

IH-Down

Up

Poti UD/ein

2143658

7

4

3

5

2

1

B1-

B

FHG

D

E

C

AA

C

E

DHGFB

X5-

X5-X5-

BT1

0V

Up

Poti UD/ein

IH-Down

Uref 10V

BT2

BT1

0V

Up

BT2

Uref 10V

IH-Down

Poti UD/ein

Bedienfeld

M1-

1

2

PE

X8-

4

3

S5-

X11/4

X11/3

X11/2

X11/1

X1/26

X1/25

X1/24

X1/23

X1/22

X1/21

X1/20

X1/19

X1/18

X1/17

X1/16

X1/15

X1/14

X1/13

X1/12

X1/11

X1/10

X1/9

X1/8

X1/7

X1/6

X1/5

X1/4

X1/3

X1/2

X1/1

X1/1

X1/3

X1/2

X1/4

X1/5

seriell Aus

seriell Ein

CLK1

seriell Ein

seriell Aus

X1/6

X1/7

X1/8

X1/9

X1/10

X1/11

X1/12

X1/13

CLK1

Drehgeber B

Drehgeber A

Drehgeber B

Analog A

Analog C

Analog B

Drehgeber A

Stecker X1

X1/15

X1/16

X1/17

X1/20

X1/19

X1/21

X1/18

0V-ANG

+10V Uref.

0V-ANG

0V1

+5V1

0V1

+10V Uref.

X1/23

X1/24

X1/25

PE

X1/26

+15V

-15V

+15V

-15V

X1/22

+5V1

Bedienfeld

X1/14

OE

-

+

sw

rt

1

2

X8/2

X8/1

A4-

Stecker X3

Gas

26polig

Flachbandkabel

Lüfter

Stecker X8

Zusatzansteuerung

Stecker X11

T1
T4
T2
T3

seriell Aus

seriell Ein

seriell Aus

seriell Ein

CLK1

CLK1

Drehgeber B

Drehgeber A

Drehgeber B

Drehgeber A

Analog A

Analog B

Analog C

OE

0V-ANG

0V-ANG

+10V Uref.

+10V Uref.

0V1

0V1

+5V1

+5V1

+15V

+15V

-15V

-15V

X3/1

X3/2

X3/3

X3/4

X3/5

X3/6

X3/7

X3/8

X3/9

X3/10

X3/11

X3/12

X3/13

X3/14

X3/15

X3/16

X3/17

X3/18

X3/19

X3/20

X3/21

X3/22

X3/23

X3/24

X3/25

X3/26

+24V

Lüfter

PTC-

PTC+

+15V2

+15VX12/1
X12/2
X12/3
X12/4

+U2

NC

M

-15V-LEM

HF-Bereit

+15V/HF

HF-P

HF/LIFTARC

Gas-Relais

-U2

NC

+15V-LEM

NC

+24V/HF

0VHF

HF-N

0V/HF

+24V GasrelaisX6/1
X6/2
X6/3
X6/4
X6/5
X6/6
X6/7
X6/8
X6/9
X6/10
X6/11
X6/12
X6/13
X6/14
X6/15
X6/16
X6/17
X6/18

HVA

HVA

HVB

HVB

AC-STOER

Temp-Sek

T1S

T2S

T1SH

T2SH

NCNCNC

NC

+15V1

0V1 X2/16

X2/15

X2/14

X2/13

X2/12

X2/11

X2/10

X2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

T1

T4

T2

T3

IP+

IP-

REL

I10A

+7V

+7V

+15V

+15V

+24V

+24V

0V1

0V1

0V1

0V1

UZWK

NC

-15V

Temp

0V2

0V2

NC

NC

Lüfter

+24V Lüfter

Peripherie

Stecker X6

Poti Brenner:

Down Up

BT2BT1

10k

+

+

-

-

Up-Down Brenner:

Brennertaster

Trafo

Wechselrichter

Steuersatz

Flachbandkabel 10polig

mit

1-BT

Doppeltaster

WIG-Brenner

2-BT

BRT1

BRT2UpIH-Down

Poti. UD/ein

Uref. 10V

X9/3

X9/2

X9/5

X9/6

X9/4

X9/1

NC0V0V

Stecker X9

X9/10

X9/9

X9/8

X9/7

NC

Stecker X12

Stecker X1

Stecker X2

Y1-

X4/18

X4/17

X4/16

X4/15

X4/14

X4/13

X4/12

X4/11

X4/1
X4/2
X4/3
X4/4
X4/5
X4/6
X4/7
X4/8
X4/9
X4/10

X10/10

X10/9

X10/8

X10/7

X10/6

X10/5

X10/4

X10/3

X10/2

X10/1

X5/1
X5/2
X5/3

X5/5

X5/4

X5/6

X7/1
X7/2

X7/7

X7/4

X7/6

X7/5

X7/3

X7/8
X7/9
X7/10

Seriell-Interface

Stecker X10Stecker X7

PE

Stecker X5

Fernregler

Stecker X4

Programmierstecker

A

B

C

D

E

F

G

H

J

K

L

M

NPR

S

TUV

PE

IGR0

Poti IH

Poti IL

Polwendung PWS

Uref.+10V

Isoll

Puls Freq.

0V

+15V

IGR0

FR-Typ1

FR-Typ2

FR-Typ3

FR Str./Stp.

FR WIG/Elek.

FR MIG ein/aus

0V

-15V

X4-

Option: Fernregler

Ringkern

2

PE

2n2F

C1-

1

A

B

C

D

E

F

G

H

Pumpe

Lüfter

+15V

Wassermangel

Wasserkühler

0V

NC

NC

X3-

Ringkern

n=?Wdg.

Option: Wasserkühlung

TRST

NC

RXD UC

NC

RXD DSP

0V

TXD UC

NC

TXD DSP

+5V

TCK

NC
TMS
GND

TDI
VCC
TD0
EM0

EMU1

Wasserkühler

B T F - 1

Flachbandkabel 26polig

HF ein/aus

0V

Pumpe

Lüfter

+15V

Wassermangel

Wasserkühler

1 6

B

1 9D

1 11E

A 41

C

71

T 2 1 0

oder

FR MIG ein/aus

Polwendung PWS

Poti IL

Poti IH

IGR0

Uref.+10V

Isoll

Puls. Freq.

0V
+15V
IGR0

FR-Typ1
FR-Typ2
FR-Typ3

FR-Str./Stp.

FR WIG/Elek.

0V

-15V

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

Änderung-4:

Änderung-3:

Änderung-2:

Änderung-1:

12.02.2008

22.11.2006

NIEDENTHAL

NIEDENTHAL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

2

PICOTIG 220 DC

4529-01

Zeichnungsnummer:

ELEK-GERAET, 230V TRAGBAR

11 Circuit diagrams

11/5

11.3 PICOTIG 220 AC/DC

230V/240V

50/60Hz

N

L1

AC

DC

A1-

4x

E3E1

A2

M

A1

T1-

TP

TM

HF-Drossel

PE

22nF

PE

-U2

Flachbandkabel 26polig

Flachbandkabel 16polig

P

M

X2/1

X3/1

X4/1

TRP

TRM

M

PE

V3-V4

V5-V6

V7-V8

Stromwandler

123 4

-M+

+U2

1 2

S1-

X2/10

X2/4

X2/1

X2/3

X2/2

X2/7

X2/5
X2/6

X2/8
X2/9

X2/16

X2/13

X2/11
X2/12

X2/14
X2/15

X2/19

X2/17
X2/18

X2/20
X2/21

X2/23

X2/22

X2/24

X2/26

X2/25

T3

T1
T4
T2

IP+

IP­REL
I10A
+7V
+7V
+15V
+15V

+24V
+24V

0V1

0V1

0V1

0V1

NC

-15V

Temp

0V2

0V2

NC
NC

UZWK

~

~

+

-

+

X2-

A2-

H F A C 5

X1/1

X1/4

X1/2

X1/3

X1/6

X1/5

X2/1

X2/2

HF-P

+15V/HF

0V/HF

HF-N

NC

+24V/HF

R1-R2

V1-V2

R3-R4

Ringkerne Toroides

D C 1 8 0

A3-

X2/2

X3/2

X4/2

X1/7

X1/1

X1/6

X1/5

X1/2
X1/3
X1/4

X1/13

X1/12

X1/11

X1/9

X1/8

X1/10

X1/15

X1/14

X1/16

NC

NC

+15V1

0V1

NC
NC

AC-STOER

Temp-Sek

T2S

T1SH

T2SH

T1S

HVA

HVB
HVB

HVA

2x2n2F

A7-

X9-

X7-

PE

Ringkern

A

42

B

62

C 52

D 62

E

22

F

62

EL

W

T R F 5

LF205-S

X10-

1

1

X10-

2

2

X10-

X1-

PE

PE1342

230V0VNC

NC

Kühlgerät

Option Wasserkühlung!

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

Änderung-4:

Änderung-3:

Änderung-2:

Änderung-1:

12.02.2008

17.11.2006

NIEDENTHAL

NIEDENTHAL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

1

PICOTIG 220 AC/DC

4524-01

Zeichnungsnummer:

ELEK-GERAET, 230V TRAGBAR

11 Circuit diagrams

11/6

Stecker X2

Stecker X1 Stecker X12

X9/7

X9/8

X9/9

X9/10

Stecker X9

X9/1

X9/4

X9/6

X9/5

X9/2

X9/3

IH-Down

Uref 10V

Poti UD/ein

PE

X1/5

X1/9

X1/10

X1/7

X1/8

X1/6

X1/3

X1/4

0V

0VNCNC

UP

X1/1

X1/2

BRT2

BRT1

2-BT

WIG-Brenner

Doppeltaster

X3/1

X3/3

X3/4

X3/2

X2/7

X2/8

X2/3

X2/4

X2/5

X2/6

1

2

1-BT

5

3

4

mit

X2/2

X2/1

X7/10

X7/9

X7/8

X7/3

X7/5
X7/6

X7/4

X7/7

X7/2

X7/1

Poti UD/ein

Up

7

8

IH-Down

Uref 10V

0V

563

4

BT1

BT2

1

2

Steuersatz

Wechselrichter

Trafo

Up-Down Brenner:

-

-

+

+

BFGHD

E

C

10k

A

B

FHG

D

E

C

A

BT1 BT2

UpDown

Poti Brenner:

oder

Stecker X6

Peripherie

Stecker X10

X5/6

X5/4
X5/5

X5/3

X5/2

X5/1

+24V Lüfter

Lüfter

NC

NC

0V2

0V2

Temp

-15V

NC

UZWK

0V1

0V1

0V1

0V1

+24V

+24V

+15V

+15V

+7V

+7V

I10A

REL

IP-

IP+

T3

T2

T4

T1

X2/1

X2/2

X2/3

X2/4

X2/5

X2/6

X2/7

X2/8

X2/9

X2/10

X2/11

X2/12

X2/13

X2/14

X2/15

X2/16

+24V Gasrelais
0V/HF
HF-N
0VHF
+24V/HF
NC
+15V-LEM
NC

-U2
Gas-Relais
HF/LIFTARC
HF-P
+15V/HF
HF-Bereit

-15V-LEM
M
NC
+U2

+15V
+15V2
PTC+
PTC-

X3/26

X3/25

X3/24

X3/23

X3/22

X3/21

X3/20

X3/19

X3/18

X3/17

X3/16

X3/15

X3/14

X3/13

X3/12

X3/11

X3/10

X3/9

X3/8

X3/7

X3/6

X3/5

X3/4

X3/3

X3/2

X3/1

-15V

-15V

+15V

+15V

+5V1

+5V1

0V1

0V1

+10V Uref.

+10V Uref.

0V-ANG

0V-ANG

OE

Analog C

Analog B

Analog A

Drehgeber A

Drehgeber B

Drehgeber A

Drehgeber B

CLK1

CLK1

seriell Ein

seriell Aus

seriell Ein

seriell Aus

X10/1
X10/2
X10/3
X10/4
X10/5
X10/6
X10/7
X10/8
X10/9
X10/10

T3

T2

T4

T1

Stecker X11

Zusatzansteuerung

Stecker X8

Stecker X7 Stecker X4Stecker X5

HF ein/aus

PE21

Gas

A4-

X4/10

X4/9

X4/8

X4/7

X4/6

X4/5

X4/4

X4/3

X4/2

X4/1

X4/11
X4/12
X4/13
X4/14
X4/15
X4/16
X4/17
X4/18

X8/1
X8/2

Flachbandkabel 26polig

2

1

+24V

+

-

T 2 0 0 / 1

Lüfter

Bedienfeld

Stecker X3

Brennertaster

Seriell-InterfaceProgrammierstecker Wasserkühler

X11/1
X11/2
X11/3
X11/4

X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8
X1/9

X12/4

X12/3

X12/2

X12/1

X6/18

X6/17

X6/16

X6/15

X6/14

X6/13

X6/12

X6/11

X6/10

X6/9

X6/8

X6/7

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

S5-

Y1-

X8-

M1-

Lüfter

X1/3

X1/1

X1/2

X1/4

X1/5

X1/6

X1/7

X1/8

X1/9

X1/10

X1/11

Stecker X1

Bedienfeld

X1/23

X1/12

X1/13

X1/14

X1/15

X1/16

X1/17

X1/20

X1/18

X1/19

X1/21

X1/22

X1/26

X1/24

X1/25

Flachbandkabel

26polig

-15V

-15V

+15V

+15V

+5V1

+5V1

0V1

0V1

+10V Uref.

+10V Uref.

0V-ANG

0V-ANG

OE

Analog C

Analog B

Analog A

Drehgeber A

Drehgeber B

Drehgeber A

Drehgeber B

CLK1

CLK1

seriell Ein

seriell Aus

seriell Ein

seriell Aus

X5- X5-

Poti UD/ein

Up

IH-Down

Uref 10V

BT2

0V

BT1

Poti UD/ein

Up

IH-Down

Uref 10V

BT2

0V

BT1

X5-

B1

B T F - 1

A6-

NC0V0VNCUref. 10V

Poti. UD/ein

IH-DownUpBRT2

BRT1

EMU1

TRST

EM0

TD0

VCC

TDI

GND

TMS

NC

TCK

NC

+5V

TXD DSP

NC

TXD UC

0V

RXD DSP

NC

RXD UC

NC

0V1

+15V1

NCNCNC

NC

T2SH

T1SH

T2S

T1S

Temp-Sek

AC-STOER

HVB

HVB

HVA

HVA

16polig

Flachbandkabel

PE

Flachbandkabel 10polig

E 1 10

rt

sw

PE

A

41

C 71

1 6

B

1 9

D

1 11

F

A

B

C

D

E

F

G

H

J

K

L

M

NPR

S

TUV

PE

IGR0

Poti IH

Poti IL

Polwendung PWS

Uref.+10V

Isoll

Puls Freq.

0V

+15V

IGR0

FR-Typ1

FR-Typ2

FR-Typ3

FR Str./Stp.

FR WIG/Elek.

FR MIG ein/aus

0V

-15V

X4-

Meld. Wasserkühler

Rel. Pumpe

Rel. Lüfter

+15V

0V

-15V

0V

FR MIG ein/aus

IGR0

FR STR/STP

FR-Typ2
FR-Typ3

FR-Typ1

+15V

0V

Puls Freq.

Isoll

Uref. 10V

Poti IL

Poti IH

IGR0

FR WIG/ELEK

Polwendung PWS

Option: Fernregler

Wassermangel

Ringkern

A

B

C

D

E

F

G

H

Pumpe

Lüfter

+15V

Wassermangel

Wasserkühler

0V

NC

NC

X3-

Ringkern

n=?Wdg.

Option: Wasserkühlung

2

PE

2n2F

C1-

1

A5-

T 2 1 0

Fernregler

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

Änderung-4:

Änderung-3:

Änderung-2:

Änderung-1:

12.02.2008

17.11.2006

NIEDENTHAL

NIEDENTHAL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

2

PICOTIG 220 AC/DC

4524-01

Zeichnungsnummer:

ELEK-GERAET, 230V TRAGBAR