EWM Picotig 200 AC/DC puls 8P TG User manual

Operating instructions
EN
Welding machine
Picotig 200 AC/DC puls 5P TG
Picotig 200 AC/DC puls 8P TG
099-000188-EW501
Observe additional system documents!
10.10.2023

General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read and observe the operating instructions for all system components, especially the sa-
fety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the location where the machine is operated.
• Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and re-
pair the machine.
• Technical changes due to further development in machine technology may lead to a dif-
fering welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers.
Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No
other form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed ac-
cepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and methods
are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this
reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect
installation, improper operation or incorrect usage and maintenance or any actions connected to this in
any way.
© EWM GmbH
Dr. Günter-Henle-Strasse 8
56271 Mündersbach Germany
Tel.: [phone], Fax: -244
Email: [email protected]
www.ewm-group.com
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.
Data security
The user is responsible for backing up data of all changes from the factory setting. The user is liable for
erased personal settings. The manufacturer does not assume any liability for this.

Contents
Notes on using these operating instructions
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1 Contents
1Contents .......................................................................................................................................... 3
2For your safety ............................................................................................................................... 5
2.1 Notes on using these operating instructions .......................................................................... 5
2.2 Explanation of icons ............................................................................................................... 6
2.3 Safety instructions .................................................................................................................. 7
2.4 Transport and installation .................................................................................................... 10
3Intended use ................................................................................................................................. 12
3.1 Applications .......................................................................................................................... 12
3.2 Software version .................................................................................................................. 12
3.3 Documents which also apply ............................................................................................... 12
3.3.1 Warranty ............................................................................................................... 12
3.3.2 Declaration of Conformity ..................................................................................... 12
3.3.3 Welding in environments with increased electrical hazards ................................. 12
3.3.4 Service documents (spare parts and circuit diagrams) ........................................ 12
3.3.5 Calibration/Validation ........................................................................................... 12
3.3.6 Part of the complete documentation ..................................................................... 13
4Machine description – quick overview ...................................................................................... 14
4.1 Front view / rear view ........................................................................................................... 14
4.2 Machine control – Operating elements ................................................................................ 16
4.2.1 Welding data display ............................................................................................ 17
5Design and function ..................................................................................................................... 18
5.1 Transport and installation .................................................................................................... 18
5.1.1 Ambient conditions ............................................................................................... 18
5.1.2 Machine cooling .................................................................................................... 18
5.1.3 Workpiece lead, general ....................................................................................... 19
5.1.4 Transport belt ....................................................................................................... 19
5.1.4.1 Adjusting the length of the carrying strap ............................................. 19
5.1.4.2 Welding torch cooling unit connection .................................................. 19
5.1.5 Notes on the installation of welding current leads ................................................ 20
5.1.6 Stray welding currents .......................................................................................... 22
5.1.7 Mains connection .................................................................................................. 23
5.1.7.1 Mains configuration ............................................................................... 23
5.2 TIG welding .......................................................................................................................... 24
5.2.1 Welding torch and workpiece line connection ...................................................... 24
5.2.1.1 Control lead connection ........................................................................ 25
5.2.2 Shielding gas supply (shielding gas cylinder for welding machine) ..................... 25
5.2.2.1 Connecting the shielding gas supply .................................................... 25
5.2.3 Welding task selection .......................................................................................... 26
5.2.4 AC welding ........................................................................................................... 27
5.2.4.1 AC balance (optimise cleaning effect and penetration characteristics) 27
5.2.5 Gas test – setting the shielding gas volume ......................................................... 27
5.2.6 Arc ignition ............................................................................................................ 28
5.2.6.1 HF ignition ............................................................................................. 28
5.2.6.2 Liftarc .................................................................................................... 28
5.2.6.3 Automatic cut-out .................................................................................. 28
5.2.7 Operating modes (functional sequences) ............................................................ 29
5.2.7.1 Explanation of symbols ......................................................................... 29
5.2.7.2 Non-latched mode ................................................................................. 30
5.2.7.3 Latched mode ....................................................................................... 31
5.2.8 Average value pulse welding ................................................................................ 32
5.2.9 TIG antistick .......................................................................................................... 32
5.2.10 Welding torch (operating variants) ....................................................................... 33
5.2.10.1 Tapping function (tap torch trigger) ....................................................... 33
5.2.10.2 Welding torch mode .............................................................................. 33
5.2.10.3 Up/down speed ..................................................................................... 33
5.2.10.4 Current jump ......................................................................................... 33
5.2.10.5 Standard TIG torch (5-pole) .................................................................. 34
5.2.10.6 TIG up/down torch (8-pole) ................................................................... 36

Contents
Notes on using these operating instructions
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5.2.10.7 Potentiometer torch (8-pole) ................................................................. 38
5.2.10.8 Configuring the TIG potentiometer torch connection ............................ 39
5.2.10.9 RETOX TIG torch (12-pole)................................................................... 40
5.2.11 Expert menu (TIG) ................................................................................................ 41
5.3 MMA welding ........................................................................................................................ 42
5.3.1 Connecting the electrode holder and workpiece lead .......................................... 42
5.3.2 Welding task selection .......................................................................................... 43
5.3.3 Hotstart ................................................................................................................. 43
5.3.4 Antistick................................................................................................................. 43
5.3.5 Average value pulse welding ................................................................................ 44
5.3.6 Expert menu (MMA) .............................................................................................. 44
5.4 Voltage reducing device ....................................................................................................... 45
5.5 Remote control ..................................................................................................................... 45
5.5.1 RT1 19POL ........................................................................................................... 45
5.5.2 RTG1 19POL ........................................................................................................ 45
5.5.3 RTP1 19POL ........................................................................................................ 45
5.5.4 RTP2 19POL ........................................................................................................ 45
5.5.5 RTP3 spotArc 19POL ........................................................................................... 46
5.5.6 RTF1 19POL ......................................................................................................... 46
5.5.7 RTF-X TIG 19Pol .................................................................................................. 46
5.6 Interfaces for automation ..................................................................................................... 46
5.6.1 Remote control connection socket, 19-pole ......................................................... 46
5.7 Access control ...................................................................................................................... 47
5.8 Power-saving mode (Standby) ............................................................................................. 47
5.9 Machine configuration menu ................................................................................................ 48
5.9.1 Selecting, changing and saving parameters......................................................... 48
6Maintenance, care and disposal ................................................................................................. 51
6.1 General................................................................................................................................. 51
6.1.1 Cleaning ................................................................................................................ 51
6.1.2 Dirt filter................................................................................................................. 51
6.2 Maintenance work, intervals ................................................................................................ 52
6.2.1 Daily maintenance tasks ....................................................................................... 52
6.2.2 Monthly maintenance tasks .................................................................................. 52
6.2.3 Annual test (inspection and testing during operation) .......................................... 52
6.3 Disposing of equipment ........................................................................................................ 53
7Rectifying faults............................................................................................................................ 54
7.1 Checklist for rectifying faults ................................................................................................ 54
7.2 Error messages (power source) ........................................................................................... 56
7.3 Resetting welding parameters to the factory settings .......................................................... 57
7.4 Software version of the machine control .............................................................................. 57
8Technical data............................................................................................................................... 58
8.1 Picotig 200 AC/DC ............................................................................................................... 58
9Accessories .................................................................................................................................. 59
9.1 Welding torch cooling system .............................................................................................. 59
9.2 Transport system ................................................................................................................. 59
9.3 Remote controls and accessories ........................................................................................ 59
9.3.1 Connection cables ................................................................................................ 59
9.4 Option for retrofitting ............................................................................................................ 59
9.5 Option for conversion ........................................................................................................... 60
9.5.1 Machine control Comfort ....................................................................................... 60
9.6 Shielding gas supply (shielding gas cylinder for welding machine) ..................................... 60
9.7 General accessories ............................................................................................................ 60
10 Appendix ....................................................................................................................................... 61
10.1 Parameter overview – setting ranges .................................................................................. 61
10.2 Average shielding gas usage ............................................................................................... 62
10.3 Searching for a dealer .......................................................................................................... 63

For your safety
Notes on using these operating instructions
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2 For your safety
2.1 Notes on using these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning sym-
bol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general warn-
ing symbol.
• The risk is explained using a symbol on the edge of the page.
Technical aspects which the user must observe to avoid material or equipment damage.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.

For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release / Tap / Tip
Switch off machine
Release
Switch on machine
Press and hold
Incorrect / Invalid
Switch
Correct / Valid
Turn
Input
Numerical value – adjustable
Navigation
Signal light lights up in green
Output
Signal light flashes green
Time representation (e.g.: wait 4 s / ac-
tuate)
Signal light lights up in red
Interruption in the menu display (other
setting options possible)
Signal light flashes red
Tool not required/do not use
Signal light lights up in blue
Tool required/use
Signal light flashes blue

For your safety
Safety instructions
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2.3 Safety instructions
WARNING
Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
• Carefully read the safety instructions in this manual!
• Observe the accident prevention regulations and any regional regulations!
• Inform persons in the working area that they must comply with the regulations!
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low vol-
tages can cause a shock and lead to accidents.
• Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
• Always place torches and electrode holders on an insulated surface!
• Wear the full personal protective equipment (depending on the application)!
• The machine may only be opened by qualified personnel!
• The device must not be used to defrost pipes!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a techni-
cal specialist may interconnect the sources as per standard IEC 60974-9:2010: Installa-
tion and use and German Accident Prevention Regulation BVG D1 (formerly VBG 15) or
country-specific regulations.
Before commencing arc welding, a test must verify that the equipment cannot exceed
the maximum permitted open circuit voltage.
• Only qualified personnel may connect the machine.
• When taking individual power sources out of operation, all mains and welding current leads
must be safely disconnected from the welding system as a whole. (Hazard due to reverse
polarity voltage!)
• Do not interconnect welding machines with pole reversing switch (PWS series) or machines
for AC welding since a minor error in operation can cause the welding voltages to be com-
bined, which is not permitted.
Risk of injury due to radiation or heat!
Arc radiation can lead to skin and eye injuries.
Contact with hot workpieces and sparks can lead to burns.
• Use hand shield or welding helmet with the appropriate safety level (depends on the appli-
cation).
• Wear dry protective clothing (e.g. hand shield, gloves, etc.) in accordance with
the applicable regulations of your country.
• Persons who are not directly involved should be protected with a welding curtain or suitable
safety screen against radiation and the risk of blinding!

For your safety
Safety instructions
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WARNING
Risk of injury due to improper clothing!
During arc welding, radiation, heat and voltage are sources of risk that cannot be
avoided. The user has to be equipped with the complete personal protective equipment
at all times. The protective equipment has to include:
• Respiratory protection against hazardous substances and mixtures (fumes and vapours);
otherwise implement suitable measures such as extraction facilities.
• Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and
heat.
• Dry welding clothing (shoes, gloves and body protection) to protect against warm environ-
ments with conditions comparable to ambient temperatures of 100 °C or higher and arcing
and work on live components.
• Hearing protection against harming noise.
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during
welding, there is a risk of flames.
• Be watchful of potential sources of fire in the working area!
• Do not carry any easily inflammable objects, e.g. matches or lighters.
• Ensure suitable fire extinguishers are available in the working area!
• Thoroughly remove any residue of flammable materials from the workpiece prior to starting
to weld.
• Only further process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!

For your safety
Safety instructions
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CAUTION
Smoke and gases!
Smoke and gases may lead to shortness of breath and poisoning! The ultraviolet radia-
tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso-
nous phosgene.
• Ensure sufficient fresh air!
• Keep solvent vapours away from the arc beam field!
• Wear suitable respiratory protection if necessary!
• To prevent the formation of phosgene, residues of chlorinated solvents on workpieces must
first be neutralised using appropriate measures.
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
According to IEC 60974-10, welding machines are divided into two classes of
electromagnetic compatibility (the EMC class can be found in the Technical
data) > see 8 chapter:
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas, inclu-
ding residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the
surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding system
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
Electromagnetic fields!
The power source can create electrical or electromagnetic fields that may impair the
function of electronic systems such as EDP and CNC devices, telecommunication,
power and signal lines as well as pacemakers and defibrillators.
• Follow the maintenance instructions > see 6.2 chapter!
• Unwind the welding leads completely!
• Shield radiation-sensitive equipment or facilities appropriately!
• The function of pacemakers may be impaired (seek medical advice if necessary).

For your safety
Transport and installation
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CAUTION
Obligations of the operator!
The respective national directives and laws must be complied with when operating the
machine!
• Implementation of national legislation relating to framework directive 89/391/EEC on the int-
roduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
• In particular, directive 89/655/EEC concerning the minimum safety and health requirements
for the use of work equipment by workers at work.
• The regulations applicable to occupational safety and accident prevention in the country
concerned.
• Setting up and operating the machine as per IEC 60974.-9.
• Brief the user on safety-conscious work practices on a regular basis.
• Regularly inspect the machine as per IEC 60974.-4.
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode hold-
ers, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the ma-
chine is switched off.
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of the
operator, where necessary in consultation with the mains network operator, to ensure that the
machine can be connected.
2.4 Transport and installation
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause seri-
ous injuries!
• Observe the instructions from the gas manufacturer and any relevant regulations concern-
ing the use of compressed air!
• Do not attach any element to the shielding gas cylinder valve!
• Prevent the shielding gas cylinder from heating up.

For your safety
Transport and installation
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CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
• Disconnect all supply lines before transport!
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10° (ac-
cording to IEC 60974-1).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Risk of accidents due to incorrectly installed leads!
Incorrectly installed leads (mains, control and welding leads or intermediate hose pack-
ages ) can present a tripping hazard.
• Lay the supply lines flat on the floor (avoid loops).
• Avoid laying the leads on passage ways.
Risk of injury from heated coolant and its connections!
The coolant used and its connection or connection points can heat up significantly
during operation (water-cooled version). When opening the coolant circuit, escaping
coolant may cause scalding.
• Open the coolant circuit only when the power source or cooling unit is switched off!
• Wear proper protective equipment (protective gloves)!
• Seal open connections of the hose leads with suitable plugs.
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant ac-
cessory components.
• Accessory components are detected automatically after the power source is switched on.
Protective dust caps protect the connection sockets and therefore the machine against dirt and
damage.
• The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
• The cap must be replaced if faulty or if lost!

Intended use
Applications
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and stand-
ards applicable for use in industry and trade. It may only be used for the welding proce-
dures indicated at the rating plate. Hazards may arise for persons, animals and material
objects if the equipment is not used correctly. No liability is accepted for any damages
arising from improper usage!
• The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
3.1 Applications
Arc welding machine for TIG DC and AC welding with lift arc (touch starting) or HF ignition (contactless)
and MMA welding as secondary process. It may be possible to expand the functionality by using acces-
sories (see the documentation in the relevant chapter).
3.2 Software version
The software version of the machine control can be displayed in the machine configuration menu
(menu Srv) > see 5.9 chapter.
3.3 Documents which also apply
3.3.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information regarding
warranty, maintenance and testing at www.ewm-group.com!
3.3.2 Declaration of Conformity
This product corresponds in its design and construction to the EU directives listed in the decla-
ration. The product comes with a relevant declaration of conformity in the original.
The manufacturer recommends carrying out the safety inspection according to national and in-
ternational standards and guidelines every 12 months (from commissioning).
3.3.3 Welding in environments with increased electrical hazards
Power sources with this marking can be used for welding in an environment with increased
electrical hazard (e.g. boilers). For this purpose, appropriate national or international regulations
must be followed. The power source must not be placed in the danger zone!
3.3.4 Service documents (spare parts and circuit diagrams)
WARNING
No improper repairs and modifications!
To prevent injuries and damage to the machine, only competent personnel (authorised
service personnel) are allowed to repair or modify the machine.
Unauthorised manipulations will invalidate the warranty!
• Instruct competent personnel (authorised service personnel) to repair the machine.
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.3.5 Calibration/Validation
An original certificate is enclosed with the product. The manufacturer recommends calibration / validation
at intervals of 12 months (from commissioning).

Intended use
Documents which also apply
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3.3.6 Part of the complete documentation
This document is part of the complete documentation and valid only in combination with all other
parts of these instructions! Read and observe the operating instructions for all system
components, especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 3-1
Item
Documentation
A.1
Transport vehicle
A.2
Power source
A.3
Cooling unit
A.4
Welding torch
A.5
Remote control
A.6
Control
A
Complete documentation

Machine description – quick overview
Front view / rear view
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4 Machine description – quick overview
4.1 Front view / rear view
Figure 4-1

Machine description – quick overview
Front view / rear view
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Item
Symbol
Description 0
1
Transport elements
Transport handle and transport belt > see 5.1.4 chapter
2
Machine control > see 4.2 chapter
3
Connection socket (welding torch control cable) > see 5.2.1.1 chapter
4
Connection socket, “+” welding current
How to connect the accessories depends on the welding procedure. Please observe
the connection description for the corresponding welding procedure > see 5 chapter.
5
Cooling air inlet
6
8-pole connection socket
Cooling unit control lead
7
Ignition type changeover switch > see 5.2.6 chapter
= ------ Liftarc (contact ignition)
= ------ HF ignition
8
Main Switch
Switching the machine on or off.
9
Cooling air outlet
10
Machine feet
11
Mains connection cable > see 5.1.7 chapter
12
Connection thread - G¼"
Shielding gas connection (inlet)
13
4-pole connection socket
Cooling unit voltage supply
14
Connection socket, 19-pole
Remote control connection
15
Connection socket, “-” welding current
How to connect the accessories depends on the welding procedure. Please observe
the connection description for the corresponding welding procedure > see 5 chapter.
16
Connection thread - G¼"
Shielding gas connection (outlet)

Machine description – quick overview
Machine control – Operating elements
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4.2 Machine control – Operating elements
Figure 4-2
Item
Symbol
Description 0
1
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 4.2.1 chapter
2
Error/status displays
----------- Collective interference signal light
--------- Water deficiency signal light (welding torch cooling)
--------- Excess temperature signal light
--------- S sign signal light
VRD ----- voltage reduction device (VRD) > see 5.4 chapter
3
AMP
Main current signal light
Imin to Imax (1 A increments)
4
AMP%
Secondary current (TIG)
5
Welding parameter setting rotary dial
Setting currents, times and parameters.
6
Select welding parameters button
This button is used to select the welding parameters depending on the welding process
and operating mode used.
7
sec
Down-slope time (TIG)
8
Signal light, gas post-flow time
9
Welding current polarity push-button
-------- DC welding with negative polarity at the torch (or electrode holder) with
respect to the workpiece.
-- Alternating current welding/alternating current forms > see 5.2.4 chapter

Machine description – quick overview
Machine control – Operating elements
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Item
Symbol
Description 0
10
Pulsed welding push-button
TIG ------- pulsed welding > see 5.2.8 chapter
MMA ----- pulsed welding > see 5.3.5 chapter
11
Operating mode/power-saving mode push-button
-------- Non-latched
------ Latched
Press for 2 s to put the machine into power-saving mode. To reactivate, activate one of
the operating elements > see 5.8 chapter.
12
Welding procedure push-button
-------- MMA welding
--------- TIG welding
13
Display switching push-button
AMP ----- Welding current display
kW -------- Welding performance display (both signal lights are illuminated)
VOLT ---- Welding voltage display
4.2.1 Welding data display
The following welding parameters can be displayed before (nominal values), during (actual values) or af-
ter welding (hold values):
Parameter
Nominal values
Actual values
Hold values
Welding current



Welding voltage



Welding power



When the hold values are displayed after welding and the settings are then changed (e.g. welding cur-
rent), the display will switch to the relevant nominal values.
 not possible
 possible

Design and function
Transport and installation
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5 Design and function
WARNING
Risk of injury from electrical voltage!
Contact with live parts, e.g. power connections, can be fatal!
• Observe the safety information on the first pages of the operating instructions!
• Commissioning must be carried out by persons who are specifically trained in handling
power sources!
• Connect connection or power cables while the machine is switched off!
Read and observe the documentation to all system and accessory components!
5.1 Transport and installation
WARNING
Risk of accident due to improper transport of machines that must not be lifted!
Do not lift or suspend the machine! The machine can drop and cause injuries! The
handles, straps or brackets are suitable for transport by hand only!
• The machine must not be suspended or lifted using a crane.
Damage to the machine due to improper transport!
The machine can be damaged by tensile or lateral forces if it is set down or picked up in a non-
vertical position!
• Do not drag the machine horizontally on the machine feet!
• Always pick up the machine vertically and set it down carefully.
5.1.1 Ambient conditions
The machine must not be operated in the open air and must only be set up and operated on a
suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient lighting
for the place of work.
• Safe operation of the machine must be guaranteed at all times.
Equipment damage due to contamination!
Unusually high amounts of dust, acids, corrosive gases or substances can damage the machine
(observe maintenance intervals > see 6.2 chapter).
• Avoid large amounts of smoke, steam, oily fumes, grinding dust and corrosive ambient air!
In operation
Temperature range of the ambient air:
• -25 °C to +40 °C (-13 °F to 104 °F)
Relative humidity:
• up to 50 % at 40 °C (104 °F)
• up to 90 % at 20 °C (68 °F)
Transport and storage
Storage in a closed room, temperature range of the ambient air:
• -30 °C to +70 °C (-22 °F to 158 °F)
Relative humidity
• up to 90 % at 20 °C (68 °F)
5.1.2 Machine cooling
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!

Design and function
Transport and installation
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19
5.1.3 Workpiece lead, general
CAUTION
Risk of burning due to incorrect welding current connection!
If the welding current plugs (machine connections) are not locked or if the workpiece
connection is contaminated (paint, corrosion), these connections and leads can heat up
and cause burns when touched!
• Check welding current connections on a daily basis and lock by turning to the right when
necessary.
• Clean workpiece connection thoroughly and secure properly. Do not use structural parts of
the workpiece as welding current return lead!
5.1.4 Transport belt
5.1.4.1 Adjusting the length of the carrying strap
To demonstrate adjustment, lengthening the strap is shown in the figure. To shorten, the strap's
loops must be inched in the opposite direction.
Figure 5-1
5.1.4.2 Welding torch cooling unit connection
Figure 5-2
Item
Symbol
Description 0
1
8-pole connection socket
Cooling unit control lead
2
5-pole connection socket
Cooling unit voltage supply

Design and function
Transport and installation
20
099-000188-EW501
10.10.2023
Item
Symbol
Description 0
3
Cooling module
• Insert and lock the 8-pole control lead plug on the cooling unit into the 8-pole connection socket on the
welding machine.
• Insert and lock the 5-pole supply plug on the cooling unit into the 5-pole connection socket on the
welding machine.
5.1.5 Notes on the installation of welding current leads
• Incorrectly installed welding current leads can cause faults in the arc (flickering).
• Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long
and as close as possible in parallel.
• Lay the workpiece lead and hose package of power sources with HF igniter (TIG) for as long as pos-
sible in parallel with a distance of 20 cm to avoid HF sparkover.
• Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences
• Always keep leads as short as possible! For optimum welding results max. 30 m (welding lead + inter-
mediate hose package + torch lead).
Figure 5-3