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Rectifying faults 

Resetting welding parameters to the factory settings 

 

 

56 

099-005548-EW501 

27.10.2017

 

 

7.3 

Resetting welding parameters to the factory settings 

RESET

+

+

l

0

 

Figure 7-1 

Display 

Setting/selection 

 

Calibration 

The machine will be calibrated for approx 2 seconds each time it is switched on. 

 

Initialising 

Keep the push-button pressed until "InI" is shown on the display. 

7.4 

Display machine control software version 

The query of the software versions only serves to inform the authorised service staff. It is available in the 
machine configuration menu

 > see 5.6 chapter

7.5 

Dynamic power adjustment 

 

 

This requires use of the appropriate mains fuse. 
Observe mains fuse specification > see 8 chapter! 

 

The dynamic power adjustment automatically adjusts the welding performance to an uncritical level for 
the fuse. 

The dynamic power adjustment can be set in two increments in the machine configuration menu using 
parameter "FUS": 20 A, 16 A

 > see 5.6 chapter

The currently selected value will be shown on the "cal" section of the display for three seconds after the 
machine has been switched on. 

 

Summary of Contents for Picomig 185 Synergic TKG

Page 1: ...ating instructions EN Welding machine Picomig 185 Synergic TKG 099 005548 EW501 27 10 2017 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group...

Page 2: ...ervice department on 49 2680 181 0 A list of authorised sales partners can be found at www ewm group com Liability relating to the operation of this equipment is restricted solely to the function of t...

Page 3: ...llation of welding current leads 20 5 1 5 1 Stray welding currents 21 5 1 6 Mains connection 21 5 1 6 1 Mains configuration 22 5 1 7 Shielding gas supply shielding gas cylinder for welding machine 22...

Page 4: ...sal 51 6 1 General 51 6 2 Cleaning 51 6 2 1 Dirt filter 51 6 3 Maintenance work intervals 52 6 3 1 Daily maintenance tasks 52 6 3 2 Monthly maintenance tasks 52 6 3 3 Annual test inspection and testin...

Page 5: ...erved to prevent serious and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning symbol The hazard is also highlighted using a symbol in the page margin...

Page 6: ...off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Correct Numerical value adjustable Menu entry Signal light lights up in green Navigating the menu Signal light flashes gr...

Page 7: ...ety instructions The illustration shows a general example of a welding system Figure 2 1 Item Documentation A 1 Transport cart A 2 Power source A 3 Welding torch A Complete documentation 2 4 Safety in...

Page 8: ...cause the welding voltages to be combined which is not permitted Risk of injury due to improper clothing During arc welding radiation heat and voltage are sources of risk that cannot be avoided The us...

Page 9: ...magnetic 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...

Page 10: ...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 prac...

Page 11: ...sport 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...

Page 12: ...tage Directive LVD Electromagnetic Compatibility Directive EMC Restriction of Hazardous Substance RoHS In case of unauthorised changes improper repairs non compliance with specified deadlines for Arc...

Page 13: ...the protective cap 5 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and torch trigger integrated 6 Park socket polarity selection plug Retainer for the polarity...

Page 14: ...ing Workpiece connection MMA welding Workpiece connection 11 Cooling air inlet 12 Machine control see 4 4 chapter 13 Carrying handle 4 2 Rear view Figure 4 2 Item Symbol Description 0 1 Main switch ma...

Page 15: ...15 4 3 Inside view Figure 4 3 Item Symbol Description 0 1 Sticker JOB List see 11 1 chapter 2 Push button wire inching Potential and gas free inching of the wire electrode through the hose package to...

Page 16: ...1 Collective interference signal light 2 Excess temperature signal light 3 Welding data display 3 digit Displays the welding parameters and the corresponding values see 5 2 chapter 4 Welding parameter...

Page 17: ...s 7 Welding parameter setting dial For setting the welding performance for selecting the JOB welding task and for setting other welding parameters 8 Operating mode button Non latched Latched Spots Int...

Page 18: ...a crane 5 1 1 Ambient conditions T he 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...

Page 19: ...ons 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 le...

Page 20: ...with HF igniter TIG for as long as possible 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 A...

Page 21: ...transport vehicle or crane frames unless they are insulated Always put welding torches and electrode holders on an insulated surface when they are not in use Figure 5 5 5 1 6 Mains connection DANGER...

Page 22: ...curing of shielding gas cylinders can cause serious injuries Place shielding gas cylinder into the designated holder and secure with fastening elements chain belt Attach the fastening elements within...

Page 23: ...er 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 gas hose connection crown nut onto the output side...

Page 24: ...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 25: ...values Welding current Welding voltage After the welding the display switches form hold values to nominal values by pressing the push buttons or turning the rotary knobs of the control waiting for abo...

Page 26: ...o torch connector side Carefully insert the welding torch connector with as yet too long a liner into the Euro torch connector and secure with a crown nut Cut off the liner with a liner cutter see 9 c...

Page 27: ...ive components Keep casing covers or protective caps closed during operation Risk of injury due to welding wire escaping in an unpredictable manner Welding wire can be conveyed at very high speeds and...

Page 28: ...sing standardised basket coils DIN 8559 see 9 chapter Figure 5 11 Item Symbol Description 0 1 Carrier pin For fixing the wire spool 2 Knurled nut For fixing the wire spool Loosen knurled nut from spoo...

Page 29: ...xing the clamping unit and setting the pressure 4 Clamping unit 5 Wire feed roller see the Wire feed roller overview table Rotate the tommy by 90 clockwise or anti clockwise tommy locks into place Fol...

Page 30: ...Wire feed roll overview table Material Diameter Colour code Groove form mm inch Steel Stainless steel Brazing 0 6 023 monochrome light pink V groove 0 8 030 white 0 8 0 9 1 0 030 035 040 bicolour whit...

Page 31: ...rotary knob The left display shows the wire feed speed selected the right display shows the current motor current of the wire feed mechanism Figure 5 13 Item Symbol Description 0 1 Welding wire 2 Wir...

Page 32: ...3 2 5 Spool brake setting Figure 5 15 Item Symbol Description 0 1 Allen screw Securing the wire spool retainer and adjustment of the spool brake Tighten the Allen screw 8 mm in the clockwise directio...

Page 33: ...with the JOB list see 11 1 chapter 3s Figure 5 16 Validity of the settings Spot time pause time and wire feed speed settings apply to all JOBs Throttling effect dynamics gas post flow time gas pre fl...

Page 34: ...t have to change the display mode before setting the parameter Figure 5 18 5 3 5 3 Arc length correction setting Setting range 5 V to 5 V Figure 5 19 The basic settings are now completed Other weldin...

Page 35: ...Operating modes functional sequences 5 3 7 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Shielding gas flowing I Welding output Wire electrode is being...

Page 36: ...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 37: ...ns 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...

Page 38: ...as 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 af...

Page 39: ...ter 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 ga...

Page 40: ...holder and workpiece lead Figure 5 26 Item Symbol Description 0 1 Electrode holder 2 Workpiece 3 Connection socket for welding current Electrode holder or workpiece lead connection 4 Connection socke...

Page 41: ...t This makes it easier to weld large drop melting electrode types at low current strengths with a short arc in particular Figure 5 28 Display Setting selection Arcforce correction Increase value harde...

Page 42: ...ER NAVIGATION 2s EXIT 2s Figure 5 30 Display Setting selection Hotstart current Hotstart time 5 4 5 Antistick The Antistick feature prevents the electrode from annealing Should the electrode stick des...

Page 43: ...Dinse torch connector Welding current shielding gas and torch trigger integrated 3 Workpiece 4 Connection socket welding current TIG welding Workpiece connection 5 Polarity selector plug welding curre...

Page 44: ...election Select TIG JOB 127 see 11 1 chapter You can only change the JOB number when no welding current is flowing 3s Figure 5 33 5 5 4 Adjusting the gas post flow time Preselection Select TIG JOB 127...

Page 45: ...setting ranges for the parameter values are summarised in the Parameter overview section see 12 1 chapter Preselection Select TIG JOB 127 see 5 5 3 chapter ENTER EXIT NAVIGATION 2s 2s Figure 5 35 Dis...

Page 46: ...2 3 mm between the electrode tip and the workpiece The arc ignites and the welding current is increased depending on the operating mode set to the ignition or main current set c Lift off the torch and...

Page 47: ...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 48: ...s and hold torch trigger The main current falls in the set downslope time to the end crater current Iend 4th cycle Release torch trigger arc is extinguished Gas post flow time elapses The welding proc...

Page 49: ...x 2 seconds each time it is switched on Exit the menu Exit Machine configuration Settings for machine functions and parameter display Dynamic power adjustment see 7 5 chapter Time based power saving m...

Page 50: ...4 chapter for a prolonged time or by setting a parameter in the machine configuration menu time controlled power saving mode see 5 6 chapter When power saving mode is activated the machine displays sh...

Page 51: ...der 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 re...

Page 52: ...ly tighten if necessary Remove any spatter Clean the wire feed rollers on a regular basis depending on the degree of soiling 6 3 2 Monthly maintenance tasks Visual inspection Casing damage front rear...

Page 53: ...r 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...

Page 54: ...5 3 2 4 chapter Check settings and correct if necessary Worn wire rolls Check and replace if necessary Wire feed motor without supply voltage automatic cutout triggered by overloading Reset triggered...

Page 55: ...place the electrode holder in an insulated position and switch the machine back on If the error persists notify service department E15 Error in on of the electronics supply voltages Switch the machine...

Page 56: ...tware versions only serves to inform the authorised service staff It is available in the machine configuration menu see 5 6 chapter 7 5 Dynamic power adjustment This requires use of the appropriate ma...

Page 57: ...kVA 5 5 kVA Recommended generator rating 8 0 kVA Frequency 50 60 Hz Mains fuse safety fuse slow blow 16 A 1 cos efficiency 0 99 86 Workpiece lead minimum 25 mm2 Ambient temperature 25 C to 40 C Machi...

Page 58: ...00000 CA D200 Centering adapter for 5 kg spools 094 011803 00000 ADAPTER EZA DINSE ZA Adapter for welding torches with Dinse connector to Euro central connector on the machine 094 016765 00000 9 2 Opt...

Page 59: ...4R 1 6 MM 0 06 INCH BLACK Drive roll set 37 mm 4 rolls V groove for steel stainless steel and brazing 092 002770 00016 FE 4R 2 0 MM 0 08 INCH GREY Drive roll set 37 mm 4 rolls V groove for steel stain...

Page 60: ...cored wire 092 002848 00014 FUEL 4R 1 6 MM 0 06 INCH BLACK ORANGE Drive roll set 37 mm 4 rolls V groove knurled for flux cored wire 092 002848 00016 FUEL 4R 2 0 MM 0 08 INCH GREY ORANGE Drive roll se...

Page 61: ...pendix A JOB List 099 005548 EW501 27 10 2017 61 11 Appendix A 11 1 JOB List We recommend using the characteristics for 1 0 mm solid wire electrodes also for the 0 9 mm solid wire electrodes Figure 11...

Page 62: ...0 1 20 0 s Pause time interval 1 0 0 1 20 0 s Wire burn back 0 50 50 TIG Gas pre flow time 0 5 0 0 5 0 s Ignition current 20 1 200 Up slope time 1 0 0 0 20 0 s Down slope time 1 0 0 0 20 0 s End curre...

Page 63: ...Appendix C Overview of EWM branches 099 005548 EW501 27 10 2017 63 13 Appendix C 13 1 Overview of EWM branches...

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