EWM Picomig 180 Synergic TKG Operating Instructions Manual Download Page 1

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Operating instructions

Welding machine

Picomig 180 Synergic TKG

099-005546-EW501 Observe additional system documents!

7.12.2020

Summary of Contents for Picomig 180 Synergic TKG

Page 1: ...Operating instructions EN Welding machine Picomig 180 Synergic TKG 099 005546 EW501 Observe additional system documents 7 12 2020...

Page 2: ...uthorised 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 fo...

Page 3: ...eral 22 5 1 4 Notes on the installation of welding current leads 22 5 1 5 Stray welding currents 24 5 1 6 Mains connection 25 5 1 6 1 Mains configuration 25 5 1 7 Shielding gas supply shielding gas cy...

Page 4: ...g 52 6 1 2 Dirt filter 52 6 2 Maintenance work intervals 53 6 2 1 Daily maintenance tasks 53 6 2 2 Monthly maintenance tasks 53 6 2 3 Annual test inspection and testing during operation 53 6 3 Disposi...

Page 5: ...s and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning symbol The hazard is also highlighted using a symbol in the page margin CAUTION Working or oper...

Page 6: ...tch off machine Release Switch on machine Press and hold Switch Incorrect Invalid Turn Correct Valid Numerical value adjustable Input Signal light lights up in green Navigation Signal light flashes gr...

Page 7: ...cal specialist may interconnect the sources as per standard IEC 60974 9 2010 Installation and use and German Accident Prevention Regulation BVG D1 formerly VBG 15 or country specific regulations Befor...

Page 8: ...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 excessiv...

Page 9: ...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...

Page 10: ...placement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the machine is switched off Requirements for connection to the public...

Page 11: ...n 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...

Page 12: ...nformation 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 de...

Page 13: ...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...

Page 14: ...Machine description quick overview Front view 14 099 005546 EW501 7 12 2020 4 Machine description quick overview 4 1 Front view Figure 4 1...

Page 15: ...ion MMA welding Workpiece connection 5 Machine feet 6 Main Switch Switching the machine on or off 7 Mains connection cable with connector plug 8 Cooling air inlet 9 Wheels 10 Connection thread G Shiel...

Page 16: ...Machine description quick overview Inside view 16 099 005546 EW501 7 12 2020 4 2 Inside view Figure 4 2...

Page 17: ...cap Cover for the wire feed mechanism and other operating elements Depending on the machine series additional stickers with information on the replacement parts and JOB lists will be located on the in...

Page 18: ...s the welding parameters and the corresponding values see 4 3 1 chapter 4 Welding parameter display mode power saving mode push button Welding current Material thickness Wire feed speed Press for 2 s...

Page 19: ...for setting other welding parameters 8 Operating mode button Non latched Latched Spots Interval 9 Runtime parameters button For selecting the parameters to be set Also for entering and exiting the men...

Page 20: ...ng Hold values after welding MIG MAG Parameter Nominal values Actual values Hold values Welding current 1 Material thickness Wire feed speed Welding voltage 1 traditional MIG MAG TIG MMA Parameter Nom...

Page 21: ...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 machi...

Page 22: ...use structural parts of the workpiece as welding current return lead 5 1 4 Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc fl...

Page 23: ...3 Use an individual welding lead to the workpiece for each welding machine Figure 5 2 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Always keep lead...

Page 24: ...heck that all welding current connections are firmly secured and electrical connections are in perfect condition Set up attach or suspend all conductive power source components such as casing transpor...

Page 25: ...system with two conductors and an earthed neutral conductor Figure 5 5 Legend Item Designation Colour code L Outer conductor brown N Neutral conductor blue PE Protective conductor green yellow Insert...

Page 26: ...sure regulator to the gas cylinder open the cylinder valve briefly to blow out any dirt Tighten the pressure regulator screw connection on the gas bottle valve to be gas tight Screw the gas hose conne...

Page 27: ...Gas test push button on the machine control welding voltage and wire feed motor remain switched off no unintentional ignition of the arc Shielding gas flows for around 25 seconds or until the button i...

Page 28: ...e electrodes or aluminium materials Preparation for connecting welding torches with a spiral guide Check that the capillary tube is correctly positioned in relation to the central connector Preparatio...

Page 29: ...r integrated 3 Workpiece 4 welding current connection socket MIG MAG welding Workpiece connection 5 Polarity selector plug welding current cable Internal welding current cable for central connection w...

Page 30: ...manner and injure persons Before mains connection set up the complete wire guide system from the wire spool to the welding torch Check wire guide at regular intervals Keep all casing covers or protec...

Page 31: ...g results due to faulty wire feeding Wire feed rolls must be suitable for the diameter of the wire and the material Check the label of the rolls whether they fit the wire diameter If necessary turn or...

Page 32: ...eyed but will still slip through if the wire spool jams Set the contact pressure of the front rollers in wire feed direction to a higher value Figure 5 12 Item Symbol Description 0 1 Adjusting nut 2 F...

Page 33: ...onsisting of welding process type of material wire diameter and type of shielding gas are pre defined for all common welding tasks Simple JOB selection from a list of pre defined JOBs sticker on the m...

Page 34: ...ttling effect dynamics gas post flow time gas pre flow time and wire burn back correction are stored for each JOB individually Changes are stored permanently in the JOB that is currently selected If r...

Page 35: ...c settings are now completed Other welding parameters have already been set optimally in the factory they can however be modified to suit individual requirements 5 2 6 Further welding parameters Prese...

Page 36: ...de is being conveyed Wire creep Wire burn back Gas pre flows Gas post flows Non latched Latched t Time t1 Spot time t2 Pause time 5 2 7 2 Automatic cut out Once the fault periods have elapsed the auto...

Page 37: ...g gas is expelled gas pre flows Wire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Change over to pre selected wire speed S...

Page 38: ...s at creep speed Arc ignites when the wire electrode makes contact with the workpiece Welding current flows Wire feed speed increases to the set nominal value 2 cycle Release torch trigger no effect 3...

Page 39: ...s pre flows Arc ignites after the wire electrode makes contact with the workpiece at creep speed Welding current flows Wire feed speed increases to the set nominal value The wire feed stop welding aft...

Page 40: ...er the spot time elapses Arc is extinguished after the wire burn back time elapses The process is repeated when the pause time is over End Release torch trigger wire feed stops arc is extinguished gas...

Page 41: ...holder 2 Connection socket for welding current Electrode holder or workpiece lead connection 3 Polarity selector plug welding current cable Connect to the park socket 4 Workpiece 5 Connection socket...

Page 42: ...weld large drop melting electrode types at low current strengths with a short arc in particular Figure 5 26 Display Setting selection Arcforce correction Increase value harder arc Decrease value softe...

Page 43: ...he electrode from annealing Should the electrode stick despite the Arcforce feature the machine automatically switches to the minimum current within approx one second This prevents the electrode from...

Page 44: ...ding Workpiece connection 5 Polarity selector plug welding current cable Internal welding current cable for central connection welding torch Connection socket for welding current Insert the central pl...

Page 45: ...ing task selection Select TIG JOB 127 You can only change the JOB number when no welding current is flowing 3 s Figure 5 31 5 4 4 Adjusting the gas post flow time Preselection Select TIG JOB 127 see 5...

Page 46: ...meters The setting ranges for the parameter values are summarised in the Parameter overview section see 11 2 chapter Preselection Select TIG JOB 127 see 5 4 3 chapter 2s 2s Figure 5 33 Display Setting...

Page 47: ...ed Latched t Time tUp Upslope time tDown Downslope time Istart Ignition current Iend End crater current 5 4 6 2 Automatic cut out Once the fault periods have elapsed the automatic cut out stops the we...

Page 48: ...alue set for the starting current Istart Welding current increases to the main current in the set upslope time 2nd cycle Release torch trigger The main current falls in the set downslope time to the e...

Page 49: ...t 2nd cycle Release torch trigger Welding current increases to the main current in the set upslope time 3rd cycle Press and hold torch trigger The main current falls in the set downslope time to the e...

Page 50: ...between electrode tip and workpiece is approx 2 3 mm arc ignites current increases to the set main current c Lift the torch off and bring into normal position Complete the welding task Remove the torc...

Page 51: ...anges to the service menu should be agreed with the authorised service personnel Software version of the machine control Version display 5 6 Power saving mode Standby You can activate the power saving...

Page 52: ...e 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 sp...

Page 53: ...rollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks Visual inspection Casing damage front rear and side walls Wheels and their securing elements Transport ele...

Page 54: ...on wheels indicates that the equipment must be collected separately This machine has to be disposed of or recycled in accordance with the waste separation systems in use According to German law law g...

Page 55: ...elding wire is touching electrically conductive casing parts check wire guide has the welding wire sprung off the wire spool Check for a correct mounting of the welding lead Fit the feeder clamp of th...

Page 56: ...k settings and correct if necessary Setting pressure units see 5 2 2 3 chapter Check settings and correct if necessary Worn wire rolls Check and replace if necessary Kinked hose packages Extend and la...

Page 57: ...position and switch the machine back on If the error persists notify service department E15 Error in one of the electronics supply voltages Switch the machine off and on again If the error persists n...

Page 58: ...are versions only serves to inform the authorised service staff It is available in the machine configuration menu see 5 5 chapter 7 5 Dynamic power adjustment This requires use of the appropriate main...

Page 59: ...tage category Contamination level 3 Insulation class protection classification H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 25 C to 40 C Machin...

Page 60: ...394 002910 00030 G1 G1 4 R 3M Gas hose 094 000010 00003 ADAPTER EZA DINSE ZA Adapter for welding torches with Dinse connector to Euro central connector on the machine 094 016765 00000 9 2 Options Typ...

Page 61: ...1 2 Drive rollers 37 mm steel 092 000842 00000 FE 2DR4R 1 2 1 6 Drive rollers 37 mm steel 092 000843 00000 FE AL 2GR4R SF Pressure rollers smooth 37 mm 092 000414 00000 10 1 2 Wire feed rollers for a...

Page 62: ...or cored wire 092 000411 00000 URUE ROE 2DR4R 1 4 1 6 2 0 2 4 SF Conversion kit 37 mm 4 roller drive for cored wire 092 000412 00000 URUE ROE 2DR4R 2 8 3 2 SF Conversion kit 37 mm 4 roller drive for c...

Page 63: ...odes Figure 11 1 MIG MAG pulse arc welding can be selected with JOBs 6 34 42 74 75 76 82 83 84 90 91 110 111 114 and 115 If an attempt is made to set another JOB to pulse noP no Pulse appears briefly...

Page 64: ...ent 20 1 200 Up slope time 1 0 0 0 20 0 s Down slope time 1 0 0 0 20 0 s End current 20 1 200 Gas post flow time 4 0 0 0 20 0 s MMA Arcforce correction 0 10 10 Hot start current 120 50 200 Hot start t...

Page 65: ...Appendix Searching for a dealer 099 005546 EW501 7 12 2020 65 11 3 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide...

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