EWM HIGHTEC WELDING GmbH

Dr. Günter - Henle - Straße 8; D-56271 Mündersbach

Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244 Internet: www.ewm.de ; E-mail: info@ewm.de

Operating instructions GB

Welding machines for TIG and MMA welding

These operating instructions must be read before commissioning. Failure to do so may be dangerous.

Machine may only be operated by personnel familiar with the appropriate safety regulations.

The machines bear the conformity mark and thus comply with the

• EC Low Voltage Guideline (73/23/EEC) • EC EMV Directive (89/336/EEC)

In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments with an increased electrical hazard.

© 2008 Subject to alteration! Art. Nr.: 099-002004-EWM01 Stand: 15.02.2008

Originaldokument

liegt jedem Gerät bei!

Original document

is enclosed with each machine!

Document original

est joint à toute machine!

EG - KonformitätserklärungEU - 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 8D - 56271 Mündersbach – Germanyinfo@ewm.de

Hiermit erklären wir, daß dasnachstehend bezeichnete Gerät inseiner Konzeption und Bauart sowie inder von uns in Verkehr gebrachtenAusführung den grundlegendenSicherheits-anforderungen der untengenannten EG- Richtlinien entspricht.Im Falle von unbefugtenVeränderungen, unsachgemäßenReparaturen und / oder unerlaubtenUmbauten, die nicht ausdrücklich vonEWM autorisiert sind, verliert dieseErklärung ihre Gültigkeit.

We herewith declare that the machinedescribed below meets the standard safetyregulations of the EU- guidelinesmentionned below in its conception andconstruction, as well as in the design putinto circulation by us. In case ofunauthorized changes, improper repairsand / or unauthorized modifications, whichhave not been expressly allowed by EWM,this declaration will lose its validity.

Par la présente, nous déclarons que laconception et la construction ainsi que lemodèle, mis sur le marché par nous, del´appareil décrit ci - dessouscorrespondent aux directivesfondamentales de sécurité de la U.E.mentionnées ci- dessous. En cas dechangements non autorisés, deréparations inadéquates et / ou demodifications prohibeés, qui n´ont pas étéautorisés expressément par EWM, cettedéclaration 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:

keinenoneaucune

Zutreffende EG - Richtlinien:Applicable EU - guidelines:Directives de la U.E. applicables:

EG - Niederspannungsrichtlinie (73/23/EWG)EU - low voltage guidelineDirective de la U.E. pour basses tensionsEG- EMV- Richtlinie (89/336/EWG)EU- EMC guidelineU.E.- EMC directive

Angewandte harmonisierte Normen:Used co-ordinated norms:Normes harmonisées appliquées:

EN 60974 / IEC 60974 / VDE 0544EN 50199 / VDE 0544 Teil 206

Hersteller - Unterschrift:Signature of manufacturer:Signature du fabricant:

Michael Szczesny , Geschäftsführermanaging directorgérant

05.2000

Dear customer,

Congratulations! You have chosen a quality product from EWM HIGHTEC WELDING GmbH.

EWM machines provide results of the highest perfection thanks to their PREMIUM quality. Therefore we are happy to provide you with a full 3-year warranty according to our operating instructions.

We develop and produce quality! From individual components to the final product, we retain sole responsibility for our machines.

In all their high-tech components, our welding machines embody future-oriented advanced technology at the utmost level of quality. Each of our products is carefully checked; we guarantee that the material and processing of our products is faultless.

These operating instructions contain everything about commissioning the machine, notes regarding safety, maintenance and care, technical data as well as information regarding the warranty. Please heed all these notes to ensure many years of safe operation of the machine.

Thank you for the trust that you have placed in us. We look forward to a long-term partnership with you in the spirit of “ONCE EWM – ALWAYS EWM”.

Yours sincerely,

EWM HIGHTEC WELDING GmbH

Bernd Szczesny

Executive management

Machine and Company Data

Please enter the EWM machine data and your company’s data in the appropriate fields.

CE

EWM HIGHTEC WELDING GMBHD-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

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Stamp / Signature of EWM-distibutor

Date of purchase

Table of contents Page

Contents/1

Safety instructions ............................................................................................................................. S/1 For your safety ........................................................................................................................... S/1 Transport and set-up.................................................................................................................. S/4 Notes on the use of these operating instructions....................................................................... S/4

1 Technical data ...........................................................................................................................1/1

2 Description of the machine......................................................................................................2/1

3 Function specification ..............................................................................................................3/1 3.1 Machine control units T2.10 and T2.15 ...........................................................................3/1 3.2 Remote control..................................................................................................................3/4 3.3 Other setting options.........................................................................................................3/5

3.3.1 TIG welding parameters.......................................................................................3/5 3.3.2 MMA welding parameters ....................................................................................3/5

4 Quick start – the fastest way to weld ......................................................................................4/1

5 Commissioning .........................................................................................................................5/1 5.1 Area of application ............................................................................................................5/1

5.1.1 Proper usage........................................................................................................5/1 5.2 Setting up the welding machine........................................................................................5/1 5.3 Mains connection..............................................................................................................5/1 5.4 Welding machine cooling system .....................................................................................5/1 5.5 Connections ......................................................................................................................5/1

5.5.1 Workpiece lead ....................................................................................................5/2 5.5.2 Electrode holder ...................................................................................................5/2 5.5.3 TIG welding torch ................................................................................................5/2 5.5.4 Shielding gas supply ............................................................................................5/2

5.6 General setting instructions ..............................................................................................5/3 5.7 MMA welding ....................................................................................................................5/3 5.8 TIG welding.......................................................................................................................5/4

5.8.1 TIG welding with liftarc ignition ............................................................................5/4 5.8.2 TIG welding with HF ignition ................................................................................5/5 5.8.3 Automatic cut-out .................................................................................................5/5 5.8.4 TIG welding torch, operating variants ..................................................................5/6

5.8.4.1 Standard TIG torch, 5-pole connector plug (factory setting)..............5/6 5.8.4.2 TIG Up/Down torch, 8-pole connector plug (optional) .......................5/6

5.8.5 Tapping operating mode ......................................................................................5/6 5.8.6 TIG function sequences .......................................................................................5/7

5.8.6.1 Explanation of symbols ......................................................................5/7 5.8.6.2 TIG non-latched operation .................................................................5/8 5.8.6.3 TIG latched operation.........................................................................5/9

5.9 Cooling unit function specification (optional) ..................................................................5/10 5.9.1 Coolant error ......................................................................................................5/10

6 Maintenance and care...............................................................................................................6/1

7 3-Year Warranty.........................................................................................................................7/1

8 Operating problems, causes and remedies ...........................................................................8/1

9 Spare parts list ..........................................................................................................................9/1

10 Accessories, options ..............................................................................................................10/1 10.1 Standard TIG torch .........................................................................................................10/1 10.2 TIG Up/Down torch .........................................................................................................10/1 10.3 Electrode holder / workpiece lead...................................................................................10/1 10.4 General accessories .......................................................................................................10/1 10.5 Remote control / connection cable .................................................................................10/1

11 Circuit diagrams......................................................................................................................11/1

Safety instructions

S/1

For your safety

Observe accident prevention regulations! Ignoring the following safety procedures can be fatal!

Proper usage This machine has been manufactured according to the latest developments in technology and current regulations and standards. It is to be operated only for the use for which it was designed (see chapter Commissioning/Area of application). Improper usage However, this machine may be a hazard to persons, animals and property if it is • not used as directed • used by unskilled persons who have not been trained • modified or converted improperly

Our operating instructions will provide you with an introduction into the safe use of the machine. Therefore please read them carefully and only start work when you are familiar with them. Any person involved in the operation, maintenance and repair of this machine must read and follow these operating instructions, especially the safety precautions. Where appropriate, this should be confirmed by signature. Furthermore, the • relevant accident prevention regulations, • generally accepted safety regulations, • local regulations, etc. must be observed.

Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves. • Protect eyes and face with protective visor.

Electric shocks can be fatal! • Do not touch any live parts in or on the machine! • The machine may only be connected to correctly earthed sockets. • Only operate with intact connection lead including protective conductor and safety plug. • An improperly repaired plug or damaged mains cable insulation can cause electric shocks. • The machine may only be opened by qualified and authorised specialist staff. • Disconnect from the mains before opening. Switching off is not sufficient. Wait for 2 minutes until the

capacitors have discharged. • Always put down welding torch, stick electrode holder in an insulated condition. • The machine must not be used to defrost pipes!

Even touching low voltages can cause you to get a shock and lead to accidents, so: • Protect yourself from falling before working on platforms or scaffolding. • During welding ensure that you operate earth tongs, torch and workpiece correctly, and not in ways for

which they are not intended. Do not touch live parts with bare skin. • Only replace electrodes when wearing dry gloves. • Never use torches or earth cables with damaged insulation.

Smoke and gases can lead to breathing difficulties and poisoning. • Do not breathe in smoke and gases. • Ensure that there is sufficient fresh air. • Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can be

converted into poisonous phosgene by ultraviolet radiation.

Safety instructions

S/2

Workpiece, flying sparks and droplets are hot! • Keep children and animals well away from the working area. Their behaviour is unpredictable. • Move containers with inflammable or explosive liquids away from the working area. There is a danger

of fire and explosion. • Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of

explosions when apparently harmless substances develop high pressures in enclosed containers by heating.

Take care to avoid fire hazards • Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when parts

are glowing or hot slag is present. • A constant check must be kept on whether fire hazards have arisen in the working area. • Highly inflammable objects, such as matches and cigarette lighters for example, must not be carried in

trouser pockets. • You must ensure that fire extinguishing equipment - appropriate for the welding process - is available

close to the welding work area and that this equipment can be accessed easily. • Containers in which fuels or lubricants have been present must be thoroughly cleaned before welding

begins. It is not sufficient simply for the receptacle to be empty. • After a workpiece has been welded, it must only be touched or brought into contact with inflammable

material when it has cooled down sufficiently. • Loose welding connections can completely destroy protective conductor systems of interior

installations and cause fires. Before beginning welding work, ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source.

Noise exceeding 70 dBA can cause permanent hearing damage! • Wear suitable earmuffs or plugs. • Ensure that other people who spend time in the working area are not inconvenienced by the noise.

Interference by electrical and electromagnetic fields is possible e.g. from the welding machine or from the high-voltage pulses of the ignition unit. • As laid down in Electromagnetic Compatibility Standard EN 50199, the machines are intended for use

in industrial areas; if they are operated in residential environments, for example, problems may occur in ensuring electromagnetic compatibility.

• The functioning of heart pacemakers can be adversely affected when you are standing near the welding machine.

• It is possible that electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the welding site could malfunction.

• Other mains supply leads, control leads, signal and telecommunications leads above, under and near the welding device may be subject to interference.

Electromagnetic interference must be reduced to a level that no longer constitutes interference. Possible reduction measures: • Welding machines must be serviced regularly. (see Chap. Maintenance and care) • Welding leads should be as short as possible and run closely together on or near to the ground. • Selective shielding of other leads and equipment in the environment can reduce radiation.

Repair and modifications may only carried out by authorised, trained, specialist staff. The warranty becomes null and void in the event of unauthorised interference.

Safety instructions

S/3

Transport and installation

The machines may only be transported and operated in an upright position.

Before carrying away or moving, pull out mains plug and place on the machine.

When setting up the machine, resistance to tilting is only guaranteed up to an angle of 15° (as specified in EN 60974).

Secure the gas cylinder! • Place shielding gas cylinders in the holders provided for them and secure with safety chains. • Take care when handling cylinders; do not throw or heat, guard against them toppling over. • When moving by crane, take off the gas cylinder from the welding machine.

Ambient conditions The welding machine must not be used in a location with risk of explosion For usage, the following conditions must be kept: Temperature range of the ambient air

• During welding: -10°C to +40°C

• During transport and storage -25°C to +55°C. Relative air humidity

• up to 50% at 40°C;

• up to 90% at 20°C.

The ambient air must be free of unusual amounts of dust, acids, corrosive gases or substances, etc., assuming these are not produced by the welding process. Examples of unusual operating conditions:

• unusual corrosive smoke,

• vapour,

• excessive oil vapour,

• unusual vibrations or jolts,

• excessive quantities of dust such as grinding dust etc.,

• severe weather conditions,

• unusual conditions near the coast or on board ship.

When setting up the machine, ensure a free inlet and outlet of air. The machine is tested to protection class IP23, i.e.:

• Protection against penetration of solid foreign bodies ∅ > 12mm,

• Protection against water spray up to an angle of 60° to the vertical.

Safety instructions

S/4

Notes on the use of these operating instructions These operating instructions are arranged into chapters.

To help you find your way around more quickly, in the margins you will occasionally see symbols along with the sub-headings. These symbols refer to particularly important passages of text which are graded as follows depending on their importance:

Please note: Technical features which users must observe.

Warning: Working and operating procedures which must be followed precisely to avoid damaging or destroying the machine.

Caution: Working and operating procedures which must be followed precisely to avoid risk to persons and includes the "Warning" symbol. Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet points, e.g.:

• Insert the welding current lead socket into the relevant socket and lock.

Symbol Description

Press

Do not press

Turn

Switch

1 Technical data

1/1

PICOTIG 180 AC/DC PICOTIG 220 DC PICOTIG 220 AC/DC

Setting range: Welding current / welding voltage TIG MMA

5A - 180A 10,1V - 17,2V

5A - 140A 20,2V - 25,6V

3A (5A AC) -220A / 10,1V -18,8V 5A - 180A /

20,2V - 27,2V

Max. welding current for TIG MMA TIG MMA TIG MMA

20ºC ambient temperature: 40%DC 45%DC 50%DC 60%DC 100%DC 40°C ambient temperature: 35%DC 40%DC 50%DC 60%DC 100%DC

------ ------ ------ 180A 150A

------ 180A ------ 150A 120A

------ ------ 140A 130A 110A

------ ------ 140A 130A 110A

220A ------ ------ 180A 150A

220A ------ ------ 160A 130A

------ 180A ------ 160A 140A

180A ------ ------ 140A 110A

220A ------ ------ 180A 150A

220A ------ ------ 160A 130A

------180A------160A140A

180A------------140A110A

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

secsecAMPAMP S

AMP

VOLT

T 2.10

A1

G1

K1

F1

J1

I1

H1

D1C1B1

Fig. 3/1: T 2.10 (PICOTIG 220 DC)

AMP

secsec

secsecAMPAMP

T 2.15

DC

S

AMP

VOLT

AC

A1 L1

G1

K1

F1

J1

E1

I1

H1

D1C1B1

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

secAMPAMP

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 I1 of the welding machine.

Functions:

• Infinitely adjustable welding current (in %) depending on the welding current I1 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 I1 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 I1 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

Preparations Setting 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.

secAMPAMP

• Select all adjustable welding parameters for the TIG process using the key button and set the rotary transducer:

• Main current AMP, down-slope time, gas post-flow time.

LED collective interference:

• Power unit is switched off. Some faults are short-term, one-off faults and the collective interference signal light will go off again and the welding machine will be ready for welding once more. If the signal light does not go of, see chap. 7.

• Switch on machine at the main switch

HF

HF • Set the ignition type: HF ignition Liftarc (contact ignition)

5 Commissioning

5/1

5.1 Area of application

5.1.1 Proper usage These welding machines are suitable exclusively for TIG and MMA welding. Any other use is regarded as "improper" and no liability is assumed for any damage arising therefrom.

We can only guarantee smooth and trouble-free operation of the machines when used in conjunction with the welding torches and accessories from our range.

• MMA directff current welding for rutile and basic coated electrodes.

• TIG direct current and alternating current welding with HF ignition or liftarc for DC: Unalloyed, low-alloy and high-alloy steels, copper, nickel-based alloys and special metals. AC: Aluminium and aluminium alloys

5.2 Setting up the welding machine

Follow the safety instructions on the opening pages entitled "For your safety".

Set up the machine so that there is sufficient space to adjust the operating elements.

Ensure that the machine is set up in a stable position and is appropriately secured.

5.3 Mains connection

The operating voltage shown on the rating plate must match the mains voltage.

For mains fuse protection, please refer to the technical data (chap. 1).

• Insert mains plug into the appropriate socket when the machine is switched off.

5.4 Welding machine cooling system To achieve the optimum duty cycle of the power components, ensure that the following conditions are met:

• Ensure that the working area is adequately ventilated,

• Do not obstruct the air inlets and outlets on the machine,

• No metal parts, dust or other foreign bodies are permitted to enter the machine.

5.5 Connections

Fig. 5 / 1 Connections

5 Commissioning

5/2

5.5.1 Workpiece lead • Insert cable plug of the workpiece lead and lock by turning to the right.

TIG welding: Welding current socket “+” (C1)

MMA welding: Welding current socket “+” (C1)

The polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

Remove paint, rust and dirt from clamping and welding areas with a wire brush. The workpiece clamp must be mounted near the welding point and must be fixed in such a way that it cannot come loose of its own accord. Structural parts, pipes, rails etc. may not be used as return leads for the welding current unless they are the workpiece themselves. A perfect current connection must be ensured for welding benches and appliances.

5.5.2 Electrode holder • Insert cable plug of the electrode holder into the welding current socket ( “-” D1) and lock by

turning to the right.

The polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

Clamp stick electrode into electrode holder. Caution: Risk of injury from crushing! Always put down stick electrode holder in an insulated position.

5.5.3 TIG welding torch

We can only guarantee the perfect functioning of our machines when used with our range of welding torches. TIG welding torches with shielded torch trigger control leads should not be connected (see torch operating instructions). Always put down welding torch when insulated. Prepare welding torch according to the welding task in hand (see operating instructions for the torch).

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

• Insert the welding current plug in socket "-" (D1) and lock by turning to the right.

• Insert the torch trigger plug in the socket (B1) and tighten.

• Screw shielding gas connection of the welding torch tightly onto the connection nipple G¼ (A1) (welding current potential "-").

• For water cooled torches (optional): Engage the rapid-action closure nipple of the TIG torch in the rapid-action closure coupling for the coolant supply (blue) and return (red) lines of the cooling module.

5.5.4 Shielding gas supply (shielding gas cylinder to the welding machine)

No impurities must be allowed to enter the shielding gas supply, as these would otherwise cause blockages in the shielding gas supply. Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to blow out any dirt. All shielding gas connections must be gastight.

• Place shielding gas cylinder in the retainer provided for it and secure with chains.

• Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to blow out any dirt present.

Connection: • Mount the pressure reducer on the gas cylinder valve.

• Screw the gas hose gastight to the pressure reducer and connecting nipple G ¼" on the rear of the welding machine (F1).

Adjustment: • Switch on machine at the main switch (G1). • Select the TIG welding process using the key button (chap. 3, C1).

5 Commissioning

5/3

• Select latched mode with the key button (chap. 3, D1).

During the adjustment, the open-circuit voltage is applied to the torch electrode (when the torch trigger has been pressed).

• Press and release the torch trigger.

• Slowly open the gas cylinder valve.

• Set the required amount of shielding gas on the pressure reducer, about 4 - 15 l/min depending on the current strength and the material.

Rule of thumb for gas flow rate:

Diameter of gas nozzle in mm corresponds to gas flow in l/min. Example: 7 mm gas nozzle corresponds to 7 l/min gas flow.

5.6 General setting instructions Set welding current:

• The setting of the welding current depends first and foremost on the material, the thickness of the metal to be welded and the seam preparation.

• The welding current is corrected until such time as a perfect weld is guaranteed.

Other practical and theoretical descriptions of MMA and TIG welding can be found in the MMA and TIG textbooks. These are available from us on request.

5.7 MMA welding

Follow the safety instructions on the opening pages entitled "For your safety".

If welding is carried out alternately using TIG or MMA and if both a welding torch and an electrode holder are connected to the machine, the open-circuit/welding voltage is applied simultaneously to both.

The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks.

When replacing spent or new stick electrodes, always switch off the machine at the main switch.

Always use insulated tongs to remove used stick electrodes or to move welded workpieces. Always put the electrode holder down when insulated.

• Connect workpiece lead and electrode holder. The polarity depends on the type of electrode to be welded.

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

• Insert mains plug into correctly earthed socket.

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

• Clamp stick electrode into electrode holder. Caution: Risk of injury from crushing!

• Switch on machine at the main switch (G1). • Set welding current.

• Hold the protective screen in front of your face and, using the tip of the stick electrode, scrape over the workpiece (as if you were striking a match).

The machine has a hotstart device. During the ignition procedure the current is increased to improve ignition of the electrode.

• As soon as the arc has ignited, try to maintain a distance from the workpiece equivalent to the diameter of the stick electrode being used.

During welding, the distance should remain as constant as possible. The stick electrode inclination should be 20 to 30°.

Arcforcing:

Shortly before the electrode threatens to stick, the arcforcing device sets an increased current designed to prevent the electrode from sticking.

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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

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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.

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5.8.4 TIG welding torch, operating variants The welding process can be controlled with various torch designs (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 potentiometer 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 current:

• by tapping (see torch with one trigger)

• by pressing down and holding torch trigger 2.

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5.8.6 TIG function sequences All the parameters for the TIG process can be controlled using the key button (F1) 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)

Istart Ignition current

Iend End-crater current

tUp Up-slope time

tDown 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

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5.8.6.2 TIG non-latched operation

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

HF

I

Istart

AMP

tUp

1. 2.

tDown

Iend

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 Istart.

• HF is switched off.

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

2nd step:

• Release torch trigger 1.

• The main current falls in the adjusted down-slope time to the end-crater current Iend (minimum current).

• The main current reaches the end-crater current Iend, 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.

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5.8.6.3 TIG latched operation

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

HF

I

Istart

AMP

Iend

tUp tDown

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 Iend (minimum current).

4th 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.

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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 cooling 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 switched 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 normal 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 using 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 purposes.

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 accordance 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

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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 cleaning 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

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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

6u8F10nF

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 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.

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

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7.2 Warranty Declaration Your 3-year Warranty

Regardless of statutory warranty rights and based on 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 Mündersbach 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 accidents, misuse, improper operation, incorrect installation, use of force, disregard of the specifications and operating instructions, insufficient maintenance (see “Maintenance and Care” chapter), exterior influences, 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 of 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

A3G3

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

G4F4

B4

C4D4

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

A5H5

G5

F5

B5

C5D5

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 driver 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 094-000538-00000WIG 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 092-001530-00000WIG torch 26 Up-Down GD, 4m 094-007549-00000WIG 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

E3

E1

A2M

A1

T1-

TPTM

HF-D

rossel

PE

22nF

PE

-U2

Flachbandkabel 26poligFlachbandkabel 16polig

PM

X2/1

X3/1

X4/1

TRP

TRMM

PE

V3-V

4

V5-V

6

V7-V

8

Strom

wandler

12

34

-M

+

+U21

2

S1-

X2/10

X2/4

X2/1

X2/3

X2/2

X2/7

X2/5X2/6

X2/8X2/9

X2/16

X2/13

X2/11X2/12

X2/14X2/15

X2/19

X2/17

X2/18

X2/20

X2/21

X2/23X2/22

X2/24

X2/26

X2/25

T3

T1T4T2

IP+

IP-RELI10A

+7V+7V

+15V

+15V+24V

+24V0V10V1

0V10V1

NC-15V

Temp0V20V2

NCNC

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/H

F

0V/H

FH

F-NNC

+24V/H

F

R1-R

2

V1-V

2

R3-R

4

Ringkerne Toroides

D C

1 8 0

A3-

T R F 5

X2/2

X3/2

X4/2

X1/7

X1/1

X1/6X1/5

X1/2

X1/3X1/4

X1/13

X1/12X1/11

X1/9X1/8

X1/10

X1/15X1/14

X1/16

NC

NC

+15V10V1

NCNC

AC-STOERTemp-Sek

T2S

T1SHT2SH

T1S

HVAHVB

HVB

HVA

2x2n2FA7-

X9-X7-

LF205-S

PE

Ringkern

A 42

B5

2

C 52

D 62

E 22

F 62

EL

W

Datum

:N

ame:

gezeichnet:geprüft:

Freigabe:Ä

nderung-4:Ä

nderung-3:Ä

nderung-2:Ä

nderung-1:12.02.2008

17.11.2006

NIED

ENTH

AL

NIED

ENTH

AL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any w

ayor com

municated or forw

arded to third partiesw

ithout our express permission!

1

PICO

TIG 180 A

C/D

C4522-01

Zeichnungsnumm

er:

ELEK-G

ERA

ET, 230V TRA

GB

AR

11 Circuit diagrams

11/2

Stecker X

2

Stecker X

1S

tecker X12

X9/7

X9/8

X9/9

X9/10

Stecker X

9

X9/1

X9/4

X9/6

X9/5

X9/2

X9/3

IH-D

own

Uref 10V

Poti U

D/ein

PE

X1/5

X1/9

X1/10

X1/7

X1/8

X1/6

X1/3

X1/4

0V0V NCNC

UP

X1/1

X1/2

BR

T2B

RT1

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

53 4

mit

X2/2

X2/1

X7/10X7/9X7/8

X7/3

X7/5X7/6

X7/4

X7/7

X7/2X7/1

Poti U

D/einU

p78

IH-D

own

Uref 10V

0V

56 34

BT1

BT2

12

Steuersatz

Wechselrichter

Trafo

Up-D

own B

renner:

- -

+ +BFGH DE C

10k

ABFH G DE C A

BT1

BT2

Up

Dow

n

Poti B

renner:

oder

Stecker X

6P

eripherie

Stecker X

10

X5/6

X5/4X5/5

X5/3X5/2X5/1

+24V Lüfter

Lüfter

NCNC0V20V2Temp-15VNCUZWK0V10V10V10V1+24V+24V+15V+15V+7V+7VI10ARELIP-IP+T3T2T4T1

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 Gasrelais0V/HFHF-N0VHF+24V/HFNC+15V-LEMNC-U2Gas-RelaisHF/LIFTARCHF-P+15V/HFHF-Bereit-15V-LEMMNC+U2

+15V+15V2PTC+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

X3/10X

3/9X

3/8X

3/7X

3/6X

3/5X

3/4X

3/3X

3/2X

3/1

-15V-15V+15V+15V+5V

1+5V

10V

10V

1+10V

Uref.

+10V U

ref.0V

-AN

G0V

-AN

GO

EA

nalog CA

nalog BA

nalog AD

rehgeber AD

rehgeber BD

rehgeber AD

rehgeber BC

LK1

CLK

1seriell E

inseriell A

usseriell E

inseriell A

us

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

T3T2T4T1S

tecker X11

ZusatzansteuerungS

tecker X8

Stecker X

7S

tecker X4

Stecker X

5

HF ein/aus

PE

2 1

Gas

A4-

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

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

X8/1X8/2

Flachbandkabel 26polig

2 1+24V +-

T 2 0 0 / 1

Lüfter

Bedienfeld

Stecker X

3

Brennertaster

Seriell-Interface

Program

mierstecker

FernreglerW

asserkühler

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

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

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

X12/4X12/3X12/2X12/1

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

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 X

1B

edienfeld

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

Flachbandkabel26polig

-15V-15V+15V+15V+5V

1+5V

10V

10V

1+10V

Uref.

+10V U

ref.0V

-AN

G0V

-AN

GO

EA

nalog CA

nalog BA

nalog AD

rehgeber AD

rehgeber BD

rehgeber AD

rehgeber BC

LK1

CLK

1seriell E

inseriell A

usseriell E

inseriell A

us

A5-

X5-X5-

Poti U

D/ein

Up

IH-D

own

Uref 10V

BT2

0V

BT1

Poti U

D/ein

Up

IH-D

own

Uref 10V

BT20V

BT1

X5-

B1

B T F - 1

A6-

NC

0V 0V NC

Uref. 10V

Poti. U

D/ein

IH-D

own

Up

BR

T2B

RT1

EMU1TRSTEM0TD0VCCTDI

GNDTMSNC

TCK

NC+5V

TXD DSPNC

TXD UC0V

RXD DSPNC

RXD UCNC

0V1

+15V1

NC

NC

NC

NC

T2SH

T1SH

T2ST1S

Temp-S

ekA

C-S

TOE

RH

VB

HV

BH

VA

HV

A

16poligFlachbandkabel

PE

Flachbandkabel 10polig

E1

10

rtsw

PE

T 2 1 0

ABCDEFGHJKLMNPRSTUV

PEIGR

0

Poti IH

Poti IL

Polw

endung PW

S

Uref.+10V

Isoll

Puls Freq.

0V

+15V

IGR

0

FR-Typ1

FR-Typ2

FR-Typ3

FR S

tr./Stp.

FR W

IG/E

lek.

FR M

IG ein/aus

0V-15V

X4-

Meld. Wasserkühler

Rel. PumpeRel. Lüfter

+15V

0V

-15V0V

FR MIG ein/aus

IGR0

FR STR/STP

FR-Typ2FR-Typ3

FR-Typ1

+15V0V

Puls Freq.Isoll

Uref. 10V

Poti ILPoti IHIGR0

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

:N

ame:

gezeichnet:geprüft:

Freigabe:Ä

nderung-4:Ä

nderung-3:Ä

nderung-2:Ä

nderung-1:12.02.2008

17.11.2006

NIED

ENTH

AL

NIED

ENTH

AL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any w

ayor com

municated or forw

arded to third partiesw

ithout our express permission!

2

PICO

TIG 180 A

C/D

C4522-01

Zeichnungsnumm

er:

ELEK-G

ERA

ET, 230V TRA

GB

AR

11 Circuit diagrams

11/3

11.2 PICOTIG 220 DC

230V/240V

50/60Hz

N L1

AC

DC

6x

PE

PFC

E3

E1

A2M

A1

TPTM

HF-D

rossel

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

DR

0G

R+

PM

PE

Strom

wandler

12

34

-M

+

-U21

2

X1/2

X1/3

X1/1

X11-

X6-

D C

2 1 0A

1-

S1-

Option W

asserkühlung!

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

X2/11X2/12

X2/14X2/15

X2/19

X2/17X2/18

X2/20X2/21

X2/23X2/22

X2/24

X2/26X2/25

T3

T1

T4T2

IP+IP-

RELI10A+7V

+7V+15V

+15V+24V+24V

0V10V1

0V10V1

NC-15VTemp

0V20V2

NCNC

UZWK

T1-

X2-

35 4 12

NC

PE

NC

230V

0V12

Ringkern

Ringkerne Toroides

HF-P

+15V/H

F0V

/HF

HF-NN

C

+24V/H

F

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

B5

2

D 62

E 62

Datum

:N

ame:

gezeichnet:geprüft:

Freigabe:Ä

nderung-4:Ä

nderung-3:Ä

nderung-2:Ä

nderung-1:12.02.2008

22.11.2006

NIED

ENTH

AL

NIED

ENTH

AL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any w

ayor com

municated or forw

arded to third partiesw

ithout our express permission!

1

PICO

TIG 220 D

C4529-01

Zeichnungsnumm

er:

ELEK-G

ERA

ET, 230V TRA

GB

AR

11 Circuit diagrams

11/4

A5-

T 2 0 0 / 1

A6-

PE BR

T1B

RT2U

P

NC

NC0V 0V

Poti U

D/ein

Uref 10V

IH-D

own

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-D

own

Up

Poti U

D/ein

2 14 36 58 7

43 521

B1-

BFH G DE C AACE DH G F B

X5- X

5-X

5-B

T1

0VUp

Poti U

D/ein

IH-D

own

Uref 10V

BT2

BT1

0VUp

BT2

Uref 10V

IH-D

own

Poti U

D/ein

Bedienfeld

M1-

12PE

X8-4 3 S

5-

X11/4

X11/3X11/2X11/1

X1/26X1/25

X1/24X1/23X1/22

X1/21X1/20X1/19

X1/18X1/17

X1/16X1/15X1/14

X1/13X1/12

X1/11X1/10X1/9

X1/8X1/7

X1/6X1/5X1/4

X1/3X1/2X1/1

X1/1

X1/3

X1/2

X1/4

X1/5

seriell Aus

seriell Ein

CLK

1

seriell Ein

seriell Aus

X1/6

X1/7

X1/8

X1/9

X1/10

X1/11

X1/12

X1/13

CLK

1

Drehgeber B

Drehgeber A

Drehgeber B

Analog A

Analog C

Analog B

Drehgeber A

Stecker X

1

X1/15

X1/16

X1/17

X1/20

X1/19

X1/21

X1/18

0V-A

NG

+10V U

ref.0V

-AN

G

0V1

+5V1

0V1

+10V U

ref.

X1/23

X1/24

X1/25

PE

X1/26

+15V

-15V+15V

-15V

X1/22

+5V1

Bedienfeld

X1/14

OE

- +

sw rt

12

X8/2

X8/1

A4-

Stecker X

3

Gas

26poligFlachbandkabel

LüfterS

tecker X8

ZusatzansteuerungS

tecker X11

T1T4T2

T3seriell A

usseriell E

inseriell A

us

seriell Ein

CLK

1

CLK

1D

rehgeber BD

rehgeber A

Drehgeber B

Drehgeber A

Analog A

Analog B

Analog C

OE

0V-A

NG

0V-A

NG

+10V U

ref.+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

+24VLüfter

PTC-

PTC++15V2+15VX12/1

X12/2X12/3

X12/4

+U2

NCM-15V-LEM

HF-Bereit+15V/HF

HF-PHF/LIFTARCGas-Relais

-U2NC

+15V-LEMNC+24V/HF

0VHFHF-N

0V/HF+24V GasrelaisX6/1

X6/2

X6/3X6/4

X6/5X6/6X6/7

X6/8X6/9

X6/10X6/11X6/12

X6/13X6/14

X6/15X6/16X6/17

X6/18

HV

AH

VA

HV

B

HV

BA

C-S

TOE

R

Temp-S

ekT1ST2S

T1SH

T2SHNC

NC

NC

NC

+15V1

0V1

X2/16

X2/15

X2/14

X2/13

X2/12

X2/11

X2/10X

2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

T1T4T2

T3IP+IP-

RELI10A

+7V+7V+15V

+15V+24V

+24V0V10V1

0V10V1

UZWKNC-15V

Temp0V20V2

NCNC

Lüfter+24V

Lüfter

Peripherie

Stecker X

6

Poti B

renner:

Dow

nU

p

BT2

BT1

10k

++

--

Up-D

own B

renner:

Brennertaster

Trafo

Wechselrichter

Steuersatz

Flachbandkabel 10polig

mit

1-BT

Doppeltaster

WIG

-Brenner2-B

T

BR

T1B

RT2

Up

IH-D

own

Poti. U

D/ein

Uref. 10V

X9/3

X9/2

X9/5

X9/6

X9/4

X9/1

NC

0V0V

Stecker X

9

X9/10

X9/9

X9/8

X9/7

NC

Stecker X

12S

tecker X1

Stecker X

2

Y1-

X4/18X4/17

X4/16X4/15

X4/14X4/13X4/12

X4/11

X4/1

X4/2X4/3X4/4

X4/5X4/6

X4/7X4/8X4/9

X4/10

X10/10

X10/9X10/8X10/7

X10/6X10/5

X10/4X10/3X10/2

X10/1

X5/1

X5/2X5/3

X5/5

X5/4

X5/6

X7/1X7/2

X7/7

X7/4

X7/6X7/5

X7/3

X7/8X7/9

X7/10

Seriell-Interface

Stecker X

10S

tecker X7

PE

Stecker X

5

FernreglerS

tecker X4

Program

mierstecker

ABCDEFGHJKLMNPRSTUV

PEIGR

0

Poti IH

Poti IL

Polw

endung PW

S

Uref.+10V

Isoll

Puls Freq.

0V

+15V

IGR

0

FR-Typ1

FR-Typ2

FR-Typ3

FR S

tr./Stp.

FR W

IG/E

lek.

FR M

IG ein/aus

0V-15V

X4-

Option: Fernregler

Ringkern

2

PE

2n2F

C1-

1

ABCDEFGH

Pum

pe

Lüfter

+15V

Wasserm

angel

Wasserkühler

0VNCNC

X3-

Ringkern

n=?Wdg.

Option: W

asserkühlung

TRST

NCRXD UC

NC

RXD DSP0V

TXD UCNC

TXD DSP

+5V

TCK

NCTMSGND

TDI

VCCTD0EM0

EMU1

Wasserkühler

B T F - 1

Flachbandkabel 26polig

HF ein/aus

0V

Pumpe

Lüfter

+15V

WassermangelWasserkühler

1 6B

1 9D

1 11E

A 41

C 71

T 2 1 0oder

FR MIG ein/aus

Polwendung PWS

Poti IL

Poti IH

IGR0

Uref.+10VIsoll

Puls. Freq.

0V

+15VIGR0

FR-Typ1

FR-Typ2

FR-Typ3

FR-Str./Stp.FR WIG/Elek.

0V

-15V

Datum

:N

ame:

gezeichnet:geprüft:

Freigabe:Ä

nderung-4:Ä

nderung-3:Ä

nderung-2:Ä

nderung-1:12.02.2008

22.11.2006

NIED

ENTH

AL

NIED

ENTH

AL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any w

ayor com

municated or forw

arded to third partiesw

ithout our express permission!

2

PICO

TIG 220 D

C4529-01

Zeichnungsnumm

er:

ELEK-G

ERA

ET, 230V TRA

GB

AR

11 Circuit diagrams

11/5

11.3 PICOTIG 220 AC/DC

230V/240V

50/60Hz

N L1

AC

DC

A1-

4x

E3

E1

A2M

A1

T1-

TPTM

HF-D

rossel

PE

22nF

PE

-U2

Flachbandkabel 26poligFlachbandkabel 16polig

PM

X2/1

X3/1

X4/1

TRP

TRMM

PE

V3-V

4

V5-V

6

V7-V

8

Strom

wandler

12

34

-M

+

+U21

2

S1-

X2/10

X2/4

X2/1

X2/3X2/2

X2/7

X2/5X2/6

X2/8X2/9

X2/16

X2/13

X2/11

X2/12

X2/14

X2/15

X2/19

X2/17X2/18

X2/20X2/21

X2/23

X2/22

X2/24

X2/26X2/25

T3

T1T4

T2

IP+IP-

REL

I10A+7V+7V

+15V+15V

+24V+24V

0V1

0V10V1

0V1

NC

-15VTemp

0V2

0V2NC

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/H

F0V

/HF

HF-NN

C

+24V/H

F

R1-R

2

V1-V

2

R3-R

4

Ringkerne Toroides

D C

1 8 0

A3-

X2/2

X3/2

X4/2

X1/7

X1/1

X1/6X1/5

X1/2X1/3

X1/4

X1/13X1/12

X1/11

X1/9X1/8

X1/10

X1/15

X1/14

X1/16

NC

NC+15V1

0V1

NCNC

AC-STOER

Temp-Sek

T2ST1SHT2SH

T1S

HVA

HVBHVB

HVA

2x2n2FA7-

X9-X7-

PE

Ringkern

A 42

B6

2

C 52

D 62

E 22

F 62

EL

W

T R F 5

LF205-S

X10- 11

X10- 22

X10-X

1-

PE

PE

134 2230V

0VNC

NCKühlgerät

Option W

asserkühlung!

Datum

:N

ame:

gezeichnet:geprüft:

Freigabe:Ä

nderung-4:Ä

nderung-3:Ä

nderung-2:Ä

nderung-1:12.02.2008

17.11.2006

NIED

ENTH

AL

NIED

ENTH

AL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any w

ayor com

municated or forw

arded to third partiesw

ithout our express permission!

1

PICO

TIG 220 A

C/D

C

4524-01Zeichnungsnum

mer:

ELEK-G

ERA

ET, 230V TRA

GB

AR

11 Circuit diagrams

11/6

Stecker X

2

Stecker X

1S

tecker X12

X9/7

X9/8

X9/9

X9/10

Stecker X

9

X9/1

X9/4

X9/6

X9/5

X9/2

X9/3

IH-D

own

Uref 10V

Poti U

D/ein

PE

X1/5

X1/9

X1/10

X1/7

X1/8

X1/6

X1/3

X1/4

0V0V NCNC

UP

X1/1

X1/2

BR

T2B

RT1

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

53 4

mit

X2/2

X2/1

X7/10X7/9X7/8

X7/3

X7/5X7/6

X7/4

X7/7

X7/2X7/1

Poti U

D/einU

p78

IH-D

own

Uref 10V

0V

56 34

BT1

BT2

12

Steuersatz

Wechselrichter

Trafo

Up-D

own B

renner:

- -

+ +BFGH DE C

10k

ABFH G DE C A

BT1

BT2

Up

Dow

n

Poti B

renner:

oder

Stecker X

6P

eripherie

Stecker X

10

X5/6

X5/4X5/5

X5/3X5/2X5/1

+24V Lüfter

Lüfter

NCNC0V20V2Temp-15VNCUZWK0V10V10V10V1+24V+24V+15V+15V+7V+7VI10ARELIP-IP+T3T2T4T1

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 Gasrelais0V/HFHF-N0VHF+24V/HFNC+15V-LEMNC-U2Gas-RelaisHF/LIFTARCHF-P+15V/HFHF-Bereit-15V-LEMMNC+U2

+15V+15V2PTC+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+5V

1+5V

10V

10V

1+10V

Uref.

+10V U

ref.0V

-AN

G0V

-AN

GO

EA

nalog CA

nalog BA

nalog AD

rehgeber AD

rehgeber BD

rehgeber AD

rehgeber BC

LK1

CLK

1seriell E

inseriell A

usseriell E

inseriell A

us

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

T3T2T4T1S

tecker X11

ZusatzansteuerungS

tecker X8

Stecker X

7S

tecker X4

Stecker X

5

HF ein/aus

PE

2 1

Gas

A4-

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

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

X8/1X8/2

Flachbandkabel 26polig

2 1+24V +-

T 2 0 0 / 1

Lüfter

Bedienfeld

Stecker X

3

Brennertaster

Seriell-Interface

Program

mierstecker

Wasserkühler

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

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

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

X12/4X12/3X12/2X12/1

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

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 X

1B

edienfeld

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

Flachbandkabel26polig

-15V-15V+15V+15V+5V

1+5V

10V

10V

1+10V

Uref.

+10V U

ref.0V

-AN

G0V

-AN

GO

EA

nalog CA

nalog BA

nalog AD

rehgeber AD

rehgeber BD

rehgeber AD

rehgeber BC

LK1

CLK

1seriell E

inseriell A

usseriell E

inseriell A

us

X5-X5-

Poti U

D/ein

Up

IH-D

own

Uref 10V

BT20V

BT1

Poti U

D/ein

Up

IH-D

own

Uref 10V

BT2

0V

BT1

X5-

B1

B T F - 1

A6-

NC

0V 0V NC

Uref. 10V

Poti. U

D/ein

IH-D

own

Up

BR

T2B

RT1

EMU1TRSTEM0TD0VCCTDI

GNDTMSNC

TCK

NC+5V

TXD DSPNC

TXD UC0V

RXD DSPNC

RXD UCNC

0V1

+15V1

NC

NC

NC

NC

T2SH

T1SH

T2ST1S

Temp-S

ekA

C-S

TOE

RH

VB

HV

BH

VA

HV

A

16poligFlachbandkabel

PE

Flachbandkabel 10polig

E1

10

rtsw

PE

A 41

C 71

1 6B

1 9D

1 11F

ABCDEFGHJKLMNPRSTUV

PEIGR

0

Poti IH

Poti IL

Polw

endung PW

S

Uref.+10V

Isoll

Puls Freq.

0V

+15V

IGR

0

FR-Typ1

FR-Typ2

FR-Typ3

FR S

tr./Stp.

FR W

IG/E

lek.

FR M

IG ein/aus

0V-15V

X4-

Meld. Wasserkühler

Rel. PumpeRel. Lüfter

+15V

0V

-15V0V

FR MIG ein/aus

IGR0

FR STR/STP

FR-Typ2FR-Typ3

FR-Typ1

+15V0V

Puls Freq.Isoll

Uref. 10V

Poti ILPoti IHIGR0

FR WIG/ELEK

Polwendung PWS

Option: Fernregler

Wassermangel

Ringkern

ABCDEFGH

Pum

pe

Lüfter

+15V

Wasserm

angel

Wasserkühler

0VNCNC

X3-

Ringkern

n=?Wdg.

Option: W

asserkühlung

2

PE

2n2F

C1-

1

A5-

T 2 1 0

Fernregler

Datum

:N

ame:

gezeichnet:geprüft:

Freigabe:Ä

nderung-4:Ä

nderung-3:Ä

nderung-2:Ä

nderung-1:12.02.2008

17.11.2006

NIED

ENTH

AL

NIED

ENTH

AL

Blatt: /2

This drawing is protected by copyright.

It may not be reproduced or utilised in any w

ayor com

municated or forw

arded to third partiesw

ithout our express permission!

2

PICO

TIG 220 A

C/D

C

4524-01Zeichnungsnum

mer:

ELEK-G

ERA

ET, 230V TRA

GB

AR