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Replaceable parts 

Wire feed rollers 

 

 

44 

099-005682-EW501 

7.9.2022

 

 

10  Replaceable parts 

Performance specifications and guarantee only in connection with original spare and replacement 

parts! 

10.1  Wire feed rollers 

10.1.1  Wire feed rollers for steel wire 

Type 

Designation 

Item no. 

FE 4R 0.6 MM/0.023 INCH 

LIGHT PINK 

Drive roll set, 37 mm, 4 rolls, V-groove for steel, 

stainless steel and brazing 

092-002770-00006 

FE 4R 0.8-1.0MM / 0.03-0.04 

INCH BLUE/WHITE 

Drive roll set, 37 mm, 4 rolls, V-groove for steel, 

stainless steel and brazing 

092-002770-00009 

FE 4R 1.0-1.2MM / 0.04-0.045 

INCH BLUE/RED 

Drive roll set, 37 mm, 4 rolls, V-groove for steel, 

stainless steel and brazing 

092-002770-00011 

FE 4R 1.4 MM/0.052 INCH 

GREEN 

Drive roll set, 37 mm, 4 rolls, V-groove for steel, 

stainless steel and brazing 

092-002770-00014 

FE 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, 

stainless steel and brazing 

092-002770-00020 

FE 4R 2.4 MM/0.095 INCH 

BROWN 

Drive roll set, 37 mm, 4 rolls, V-groove for steel, 

stainless steel and brazing 

092-002770-00024 

FE 4R 2.8 MM/0.11 INCH 

LIGHT GREEN 

Drive roll set, 37 mm, 4 rolls, V-groove for steel, 

stainless steel and brazing 

092-002770-00028 

FE 4R 3.2 MM/0.12 INCH 

VIOLET 

Drive roll set, 37 mm, 4 rolls, V-groove for steel, 

stainless steel and brazing 

092-002770-00032 

 

10.1.2  Wire feed rollers for aluminium wire 

Type 

Designation 

Item no. 

AL 4R 0.8 MM/0.03 INCH 

WHITE/YELLOW 

Drive roll set, 37 mm, for aluminium 

092-002771-00008 

AL 4R 1.0 MM/0.04 INCH 

BLUE/YELLOW 

Drive roll set, 37 mm, for aluminium 

092-002771-00010 

AL 4R 1.2 MM/0.045 INCH 

RED/YELLOW 

Drive roll set, 37 mm, for aluminium 

092-002771-00012 

AL 4R 1.6 MM/0.06 INCH 

BLACK/YELLOW 

Drive roll set, 37 mm, for aluminium 

092-002771-00016 

AL 4R 2.0 MM/0.08 INCH 

GREY/YELLOW 

Drive roll set, 37 mm, for aluminium 

092-002771-00020 

AL 4R 2.4 MM/0.095 INCH 

BROWN/YELLOW 

Drive roll set, 37 mm, for aluminium 

092-002771-00024 

AL 4R 2.8 MM/0.110 INCH 

LIGHT GREEN/YELLOW 

Drive roll set, 37 mm, for aluminium 

092-002771-00028 

AL 4R 3.2 MM/0.125 INCH 

VIOLET/YELLOW 

Drive roll set, 37 mm, for aluminium 

092-002771-00032 

 

Summary of Contents for Picomig 225 puls TKG

Page 1: ...Operating instructions EN Welding machine Picomig 225 puls TKG Picomig 225 Synergic TKG 099 005682 EW501 Observe additional system documents 7 9 2022...

Page 2: ...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...

Page 3: ...ion of welding current leads 19 5 1 5 Stray welding currents 20 5 1 6 Welding torch holder 21 5 1 7 Mains connection 22 5 1 7 1 Mains configuration 22 5 1 8 Shielding gas supply shielding gas cylinder...

Page 4: ...parameters to the factory settings 41 8 Technical data 42 8 1 Picomig 225 42 9 Accessories 43 9 1 Transport system 43 9 2 Options 43 9 3 General accessories 43 10 Replaceable parts 44 10 1 Wire feed r...

Page 5: ...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 oper...

Page 6: ...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...

Page 7: ...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 Befo...

Page 8: ...emperatures 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...

Page 9: ...s 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 use...

Page 10: ...lacement 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...

Page 11: ...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: ...mation refer to the Warranty registration brochure supplied and our information regarding warranty maintenance and testing at www ewm group com 3 2 2 Declaration of Conformity This product corresponds...

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 rear view 14 099 005682 EW501 7 9 2022 4 Machine description quick overview 4 1 Front view rear view Figure 4 1...

Page 15: ...Cooling air outlet 10 External wire feed inlet Pre cut casing inlet for external wire feed 11 Connection thread G Shielding gas connection inlet 12 Welding current cable polarity selection Welding cur...

Page 16: ...on the machine series additional stickers with information on the replace ment parts and JOB lists will be located on the inside 2 Slide latch lockfor the protective cap 3 Wire spool inspection window...

Page 17: ...cumentation to all system and accessorycomponents 5 1 Transport and installation WARNING Risk of accident due to impropertransport of machines that must not be lifted Do not lift or suspend the machin...

Page 18: ...ion results in a reduction in performance and equipment damage Observe the ambient conditions Keep the cooling air inlet and outlet clear Observe the minimum distanceof 0 5 m from obstacles 5 1 3 Work...

Page 19: ...h 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 Alw...

Page 20: ...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 trans po...

Page 21: ...g is part of the machine s scope of delivery Figure 5 5 Item Symbol Description 0 1 Crossmember of the transport handle 2 Torch holder 3 Fixing screws x 4 4 Fan type lock washers Use the mounting scre...

Page 22: ...erate machine using a socket that has correctly fitted protective earth Mains plug socket and lead must be checked by a qualified electrician on a regular basis When operating the generator always ens...

Page 23: ...upply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch being des...

Page 24: ...no unintentional ignition of the arc Shielding gas flows for around 25 seconds or until the button is pressed again Repeat rinsing process several times Setting instructions Welding process Recommend...

Page 25: ...g welding torches with a spiral guide Check that the capillary tube is correctly positioned in relation to the central connector Preparation for connecting welding torches with a liner Push forward th...

Page 26: ...moving parts or drive 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 v...

Page 27: ...ool bore Fasten wire spool using knurled nut Figure 5 11 Observe the unwinding direction of the wire spool 5 2 2 2 Changing the wire feed rollers Figure 5 12 Item Symbol Description 0 1 Tommy The tomm...

Page 28: ...0 clockwise or anti clockwise tommy locks into place Fold the closure brackets outwards by 90 Unfasten pressure units and fold out clamping units and pressure rollers will automatically flip up wards...

Page 29: ...ire feed roll overview table Material Diameter Colour code Groove form mm inch Steel Stainless steel Brazing 0 6 024 monochrome light pink V groove 0 8 031 white 0 8 0 9 1 0 031 035 039 bicolour white...

Page 30: ...sure on the adjusting nuts of the feed roll tensioners so that the wire electrode is fed but slips when the wire spool is blocked The inching speed is infinitelyadjustable by simultaneously pressing t...

Page 31: ...gure 5 14 5 2 2 4 Spool brake setting Figure 5 15 Item Symbol Description 0 1 Allen screw Securing the wire spool retainer and adjustment of thespool brake Tighten the Allen screw 8 mm in the clockwis...

Page 32: ...n 0 1 Polarity selector plug welding current cable Connect to the park socket 2 Electrode holder 3 Workpiece Insert the polarity selection plug in the park socket and lock in place by turning to the r...

Page 33: ...elector plug welding current cable Internal welding current cable for central connection welding torch Connection socket for welding current 3 Workpiece Insert the central plug for the welding torch i...

Page 34: ...autions Follow the maintenance instructions see 6 3 chapter If any of the test requirements below are not met the unit must not be put back into opera tion until it has been repaired and tested again...

Page 35: ...ction points are omitted Repairer Check and clean the welding torch Deposits in the welding torch may cause short circuits impair the welding result and lead to welding torch damage Check wire drive w...

Page 36: ...l protective caps when not in use Gas test that the solenoid valve opens and closes properly Checking operating signalling and indicator lights protective devices and actuators Check wire feed roll ho...

Page 37: ...em separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private households can be disposed of free of ch...

Page 38: ...form service staff as necessary If multipleerrors occur these are displayed in succession Error message Possible cause Remedy E 0 Start signal set in the event of er rors Do not press the torch trigge...

Page 39: ...ion detach current lead from degaussing 7 3 Checklist for rectifying faults The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation Leg...

Page 40: ...fasten the contact tip and contact tip holder Wire feed problems Contact tip blocked Clean and if necessary replace Setting the spool brake see 5 2 2 4 chapter Check settings and correct if necessary...

Page 41: ...ers to the factory settings All customised welding parameters that are stored will be replaced by the factory settings RESET l 0 Figure 7 1 Display Setting selection Calibration The machine will be ca...

Page 42: ...n class protection classification H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 4 25 C to 40 C Machine cooling Torch cooling Fan AF gas Wire fee...

Page 43: ...03 D 0002 Crane suspension for Picomig 180 185 D3 305 D3 Phoenix and Taurus 355 compact drive 4 092 002549 00000 ON TH TG 03 TG 04 TG 11 R Torch holder right 092 002699 00000 CA D200 Centering adapter...

Page 44: ...ainless steel and brazing 092 002770 00020 FE 4R 2 4 MM 0 095 INCH BROWN Drive roll set 37 mm 4 rolls V groove for steel stainless steel and brazing 092 002770 00024 FE 4R 2 8 MM 0 11 INCH LIGHT GREEN...

Page 45: ...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 set 37 mm 4 rolls V groove knu...

Page 46: ...endix Searching for a dealer 46 099 005682 EW501 7 9 2022 11 Appendix 11 1 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldw...

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