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EWM Picomig 305 puls TKM, Operating Instructions Manual

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EWM Picomig 305 puls TKM Operating Instructions Manual Download Page 64

Rectifying faults 

Resetting welding parameters to the factory settings 

 

 

64 

099-005639-EW501 

04.06.2020

 

 

7.4  Resetting welding parameters to the factory settings 

RESET

+

+

+

l

0

l

0

 

Figure 7-2 

Display 

Setting/selection 

 

Code of machine control 

 

 

Initialisation complete 

All customised welding parameters haven been overwritten by the factory settings. 

 

Summary of Contents for Picomig 305 puls TKM

Page 1: ...Operating instructions EN Welding machine Picomig 305 puls TKM 099 005639 EW501 Observe additional system documents 04 06 2020...

Page 2: ...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 f...

Page 3: ...iece lead general 22 5 1 4 Welding torch cooling system 22 5 1 4 1 Cooling unit connection 22 5 1 5 Notes on the installation of welding current leads 23 5 1 6 Stray welding currents 24 5 1 7 Mains co...

Page 4: ...rs 52 5 6 2 Special parameters in detail 52 5 6 2 1 Ramp time for wire inching P1 52 5 6 2 2 Latched special latched tap start P9 52 5 6 3 Reset to factory settings 53 5 7 Machine configuration menu 5...

Page 5: ...10 Replaceable parts 70 10 1 Wire feed rollers 70 10 1 1 Wire feed rollers for steel wire 70 10 1 2 Wire feed rollers for aluminium wire 70 10 1 3 Wire feed rollers for cored wire 71 10 1 4 Wire guid...

Page 6: ...Contents Notes on using these operating instructions 6 099 005639 EW501 04 06 2020...

Page 7: ...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...

Page 8: ...mplete 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 sy...

Page 9: ...aking 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 interco...

Page 10: ...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 c...

Page 11: ...ed 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 s...

Page 12: ...e of compressed air Do not attach any element to the shielding gas cylinder valve Prevent the shielding gas cylinder from heating up CAUTION Risk of accidents due to supply lines During transport atta...

Page 13: ...witched 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 switc...

Page 14: ...information regarding warranty maintenance and testing at www ewm group com 3 2 2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the d...

Page 15: ...Machine description quick overview Front view rear view 099 005639 EW501 04 06 2020 15 4 Machine description quick overview 4 1 Front view rear view Figure 4 1...

Page 16: ...r outlet 10 Machine feet 11 External wire feed inlet Pre cut casing inlet for external wire feed 12 8 pole connection socket Cooling unit control lead 13 Connection thread G Shielding gas connection i...

Page 17: ...Machine description quick overview Inside view 099 005639 EW501 04 06 2020 17 4 2 Inside view Figure 4 2...

Page 18: ...itional stickers with information on the replace ment parts and JOB lists will be located on the inside 4 Key button Automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fus...

Page 19: ...elding task from the welding task list JOB LIST The list can be found inside the protective cap on the wire feeder and in the appendix to these operating instructions 7 Welding parameter setting dial...

Page 20: ...ing 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 No...

Page 21: ...ot 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 lift...

Page 22: ...s 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...

Page 23: ...ith 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 A...

Page 24: ...y are insulated Always put welding torches and electrode holders on an insulated surface when they are not in use Figure 5 5 5 1 7 Mains connection DANGER Hazards caused by improper mains connection A...

Page 25: ...earthed neutral conductor a three phase system with three conductors of which any one can be earthed e g the outer conductor Figure 5 6 Legend Item Designation Colour code L1 Outer conductor 1 brown L...

Page 26: ...r of the transport handle Insert the welding torch into the welding torch holder as shown 5 1 9 Shielding gas supply shielding gas cylinder for welding machine WARNING Risk of injury due to improper h...

Page 27: ...ure 5 8 Item Symbol Description 0 1 Pressure regulator 2 Output side of the pressure regulator 3 Shielding gas cylinder 4 Cylinder valve Before connecting the pressure regulator to the gas cylinder op...

Page 28: ...switched off no accidental arc ignition Set the relevant gas quantity for the application on the pressure regulator Setting instructions Welding process Recommended shielding gas quantity MAG welding...

Page 29: ...zing soft wire electrodes high alloy wire electrodes or aluminium materials Preparation for connecting welding torches with a spiral guide Check that the capillary tube is correctly positioned in rela...

Page 30: ...elding torches with one rotary knob one rocker or one pair of buttons only must be configured on the machine control appropriately For this purpose set the FRC special parameter to the corresponding a...

Page 31: ...port Before you start working always check the wire spool is securely fastened Standard D300 wire spool holder can be used Adapters are required when using standardised basket coils DIN 8559 see 9 5 c...

Page 32: ...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 33: ...hite 0 8 0 9 1 0 031 035 039 bicolour white blue 1 0 1 2 039 047 blue red 1 4 055 monochrome green 1 6 063 black 2 0 079 grey 2 4 094 brown 2 8 110 light green 3 2 126 purple Aluminium 0 8 031 bicolou...

Page 34: ...e inching push button and turning the wire speed rotary knob The left display shows the wire feed speed selected the right display shows the current motor current of the wire feed mechanism Depending...

Page 35: ...direction to increase the braking effect Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation 5 2 3 Definition of MIG MA...

Page 36: ...ed settings apply to all JOBs Throttling 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 J...

Page 37: ...ration and directionally stable arc Excellent root and sidewall fusion Secure welding also with very long stick outs Reduced undercuts Manual and automated applications You can make use of these prope...

Page 38: ...f applicable intermediate hose packages Avoid loops 5 2 8 Operating modes functional sequences 5 2 8 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Shiel...

Page 39: ...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 40: ...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 41: ...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 42: ...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 43: ...tting selection Gas pre flow time Burn back correction 5 3 MMA welding 5 3 1 Connecting the electrode holder and workpiece lead CAUTION Risk of crushing and burns When changing stick electrodes there...

Page 44: ...ill be based on the in formation of the electrode manufacturer on the electrode packaging 5 3 2 Welding task selection Select MMA JOB 128 see 11 1 chapter You can only change the JOB number when no we...

Page 45: ...Current t Time Figure 5 35 5 3 5 Antistick The Antistick feature prevents the electrode from annealing Should the electrode stick despite the Arcforce feature the machine automatically switches to the...

Page 46: ...on Figure 5 38 Item Symbol Description 0 1 Welding torch 2 Polarity selector plug welding current cable Internal welding current cable for central connection welding torch Connection socket for weldin...

Page 47: ...1 04 06 2020 47 5 4 3 Welding task selection Select TIG JOB 127 You can only change the JOB number when no welding current is flowing 3s Figure 5 39 5 4 4 Adjusting the gas post flow time 3s Figure 5...

Page 48: ...wn may be limited e g if a function is deactivated 2s 2s Figure 5 41 Display Setting selection Gas pre flow time Ignition current as percentage dependent on main current Upslope time to main current D...

Page 49: ...o normal position Complete the welding task Remove the torch from the workpiece so that the arc extinguishes 5 4 7 Operating modes functional sequences 5 4 7 1 Legend Symbol Meaning Press torch trigge...

Page 50: ...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 51: ...torch trigger is released during the downslope time The welding current drops to zero and the gas post flow time begins 5 5 Remote control The remote controls are operated on the 19 pole remote contr...

Page 52: ...mponents with a single pair of but tons or a rocker only 1 3 8 No remote control encoding 10 15 No remote control encoding 5 6 2 Special parameters in detail 5 6 2 1 Ramp time for wire inching P1 The...

Page 53: ...function Special parameters advanced settings 099 005639 EW501 04 06 2020 53 5 6 3 Reset to factory settings All special parameters saved by the user will be overwritten by the factory settings l 0 F...

Page 54: ...lection Lead resistance 1 Lead resistance for the first welding circuit 0 m 60 m 8 m ex works Time based power saving mode see 5 8 chapter Time to activation of the power saving mode in case of inacti...

Page 55: ...ater cooled welding torch With other hose package lengths it is ne cessary to carry out a voltage correction to optimise welding properties The voltage correction value can be set close to zero by mea...

Page 56: ...contact tip on a clean purged location on the workpiece and then press the torch trigger for approx 2 seconds A short circuit current will flow briefly which is used to determine and display the new c...

Page 57: ...ight 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 you...

Page 58: ...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 el...

Page 59: ...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 60: ...s illuminated after switching on No welding power Phase failure check mains connection fuses Machine restarts continuously Wire feeder without function System does not start up Make control lead conne...

Page 61: ...tage Check the mains voltages and compare with the connection voltages of the welding ma chine 2 Mains undervoltage 3 Excess temperature of welding machine Allow the machine to cool down mains switch...

Page 62: ...oltages 58 Short circuit Check welding circuit for short circuit put down welding torch isolated 59 Machine incompatible Check machine usage 60 Software update required Inform Service Category legend...

Page 63: ...W501 04 06 2020 63 7 3 Welding parameter calibration In case of deviations between the welding parameters set on the front panel remote control and those shown on the welding machine this function all...

Page 64: ...s 64 099 005639 EW501 04 06 2020 7 4 Resetting welding parameters to the factory settings RESET l 0 l 0 Figure 7 2 Display Setting selection Code of machine control Initialisation complete All customi...

Page 65: ...he RESET will be done after pressing the button The menu will be ended when no changes are done after 3 sec JOB number example The shown JOB will be set to ex works 7 5 2 Resetting all JOBs All custom...

Page 66: ...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 4 25 C to 40 C Mach...

Page 67: ...Technical data Picomig 305 TKM 099 005639 EW501 04 06 2020 67 4 Ambient temperature dependent on coolant Observe coolant temperature range...

Page 68: ...e control 090 008087 00000 RG10 19POL 5M Remote control to set the wire speed and welding voltage correction 090 008108 00000 RA5 19POL 5M Remote control e g connection cable 092 001470 00005 RA10 19P...

Page 69: ...001 CA D200 Centering adapter for 5 kg spools 094 011803 00000 16A 5POLE CEE Mains plug 094 000712 00000 DM 842 Ar CO2 230bar 30l D Pressure regulator with manometer 394 002910 00030 G1 G1 4 R 3M Gas...

Page 70: ...tainless 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 GREE...

Page 71: ...4 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 kn...

Page 72: ...MAG pulse arc welding can be selected with JOBs 6 9 34 36 42 44 74 76 78 80 82 84 86 88 90 92 94 96 110 112 114 116 118 120 122 124 179 206 207 235 238 and 254 If an attempt is made to set another JO...

Page 73: ...Gas pre flow time 0 5 0 0 20 0 s Ignition current 0 0 20 0 s Up slope time 1 0 0 20 0 s Down slope time 0 0 20 0 s End current 20 1 200 Gas post flow time 0 5 0 0 20 0 s MMA Hot start current 0 0 20...

Page 74: ...Appendix Searching for a dealer 74 099 005639 EW501 04 06 2020 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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