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EWM Picomig 305 Synergic TKM, Operating Instructions Manual

The EWM Picomig 305 Synergic TKM is a versatile and efficient welding machine that guarantees exceptional performance. To easily operate this equipment, be sure to download and read the detailed Operating Instructions Manual available for free on our website. Unlock the machine's full potential by following the step-by-step instructions in the manual. Experience seamless welding with the EWM Picomig 305 Synergic TKM.

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Contents 

Notes on using these operating instructions 

 

099-005640-EW501 

04.06.2020

 

3

 

 

1 

Contents 

1

 

Contents .................................................................................................................................................. 3

 

2

 

For your safety ....................................................................................................................................... 6

 

2.1

 

Notes on using these operating instructions .................................................................................. 6

 

2.2

 

Explanation of icons ....................................................................................................................... 7

 

2.3

 

Part of the complete documentation .............................................................................................. 8

 

2.4

 

Safety instructions .......................................................................................................................... 9

 

2.5

 

Transport and installation ............................................................................................................ 12

 

3

 

Intended use ......................................................................................................................................... 14

 

3.1

 

Applications .................................................................................................................................. 14

 

3.2

 

Documents which also apply ....................................................................................................... 14

 

3.2.1

 

Warranty ....................................................................................................................... 14

 

3.2.2

 

Declaration of Conformity ............................................................................................. 14

 

3.2.3

 

Welding in environments with increased electrical hazards ......................................... 14

 

3.2.4

 

Service documents (spare parts and circuit diagrams) ................................................ 14

 

3.2.5

 

Calibration/Validation.................................................................................................... 14

 

4

 

Machine description – quick overview .............................................................................................. 15

 

4.1

 

Front view / rear view ................................................................................................................... 15

 

4.2

 

Inside view ................................................................................................................................... 17

 

4.3

 

Machine control – Operating elements ........................................................................................ 18

 

4.3.1

 

Welding data display .................................................................................................... 20

 

4.3.2

 

Polarity setting .............................................................................................................. 20

 

5

 

Design and function ............................................................................................................................. 21

 

5.1

 

Transport and installation ............................................................................................................ 21

 

5.1.1

 

Ambient conditions ....................................................................................................... 21

 

5.1.1.1

 

In operation ................................................................................................... 21

 

5.1.1.2

 

Transport and storage ................................................................................... 21

 

5.1.2

 

Machine cooling ............................................................................................................ 21

 

5.1.3

 

Workpiece 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 connection .......................................................................................................... 24

 

5.1.7.1

 

Mains configuration ....................................................................................... 25

 

5.1.8

 

Welding torch holder ..................................................................................................... 26

 

5.1.9

 

Shielding gas supply (shielding gas cylinder for welding machine) ............................. 27

 

5.1.9.1

 

Pressure regulator connection ...................................................................... 27

 

5.1.9.2

 

Shielding gas hose connection ..................................................................... 28

 

5.1.9.3

 

Shielding gas volume settings ...................................................................... 28

 

5.1.9.4

 

Gas test ......................................................................................................... 29

 

5.1.9.5

 

Purge hose package ..................................................................................... 29

 

5.2

 

MIG/MAG welding ........................................................................................................................ 29

 

5.2.1

 

Welding torch and workpiece line connection .............................................................. 29

 

5.2.2

 

MIG/MAG function torch ............................................................................................... 31

 

5.2.3

 

MIG/MAG Push/Pull welding torch ............................................................................... 31

 

5.2.4

 

Wire feed ...................................................................................................................... 31

 

5.2.4.1

 

Inserting the wire spool ................................................................................. 31

 

5.2.4.2

 

Changing the wire feed rollers ...................................................................... 33

 

5.2.4.3

 

Inching the wire electrode ............................................................................. 34

 

5.2.4.4

 

Spool brake setting ....................................................................................... 36

 

5.2.5

 

Definition of MIG/MAG welding tasks ........................................................................... 36

 

5.2.6

 

Welding task selection .................................................................................................. 37

 

5.2.7

 

Welding power (operating point) .................................................................................. 37

 

5.2.7.1

 

Selecting the welding parameter display mode ............................................ 37

 

5.2.7.2

 

Operating point setting using material thickness .......................................... 38

 

5.2.7.3

 

Arc length ...................................................................................................... 38

 

5.2.8

 

forceArc / forceArc puls ................................................................................................ 38

 

5.2.9

 

rootArc/rootArc puls ...................................................................................................... 39

 

Summary of Contents for Picomig 305 Synergic TKM

Page 1: ...Operating instructions EN Welding machine Picomig 305 Synergic TKM 099 005640 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 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...

Page 3: ...rkpiece 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 connection 24 5 1 7 1 Mains configuration 25 5 1 8 Welding torch holder 26 5 1 9 Shielding gas supply shielding gas cylinder for welding machine 27 5 1 9 1 Pressure regulator connection 27 5 1 9 2 Sh...

Page 4: ...ters 53 5 6 2 Special parameters in detail 53 5 6 2 1 Ramp time for wire inching P1 53 5 6 2 2 Latched special latched tap start P9 53 5 6 3 Reset to factory settings 54 5 7 Machine configuration menu 55 5 7 1 Selecting changing and saving parameters 55 5 7 2 Aligning the cable resistance 56 5 7 3 Power saving mode Standby 57 6 Maintenance care and disposal 58 6 1 General 58 6 1 1 Cleaning 58 6 1 ...

Page 5: ...0 10 Replaceable parts 71 10 1 Wire feed rollers 71 10 1 1 Wire feed rollers for steel wire 71 10 1 2 Wire feed rollers for aluminium wire 71 10 1 3 Wire feed rollers for cored wire 72 10 1 4 Wire guide 72 11 Appendix 73 11 1 JOB List 73 11 2 Parameter overview setting ranges 74 11 3 Searching for a dealer 75 ...

Page 6: ...us 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 i...

Page 7: ...itch 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 green Output Signal light lights up in red Time representation e g wait 4 s actuate Signal light flashes red Interruption in the menu display other setting options possible Tool not required do not use...

Page 8: ...f 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 2 1 Item Documentation A 1 Conversion instructions for optional equipment A 2 Power source A 3 Cooling unit voltage converter tool box etc A 4 Transport cart A 5 Welding torch A 6 Remote control A 7 Control...

Page 9: ...t 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 ...

Page 10: ...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 t...

Page 11: ...ied 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...

Page 12: ...se 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 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...

Page 13: ...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 o...

Page 14: ...ding 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 decla ration The product comes with a relevant declaration of conformity in the original 3 2 3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be ...

Page 15: ...Machine description quick overview Front view rear view 099 005640 EW501 04 06 2020 15 4 Machine description quick overview 4 1 Front view rear view Figure 4 1 ...

Page 16: ...ir 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 inlet 14 4 pole connection socket Cooling unit voltage supply 15 Welding current cable polarity selection Welding current to Euro torch connector torch for polarity selection MIG MAG Connection socket...

Page 17: ...ed mechanism and other operating elements Depending on the machine series additional 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 fuse 5 Push button wire inching Potential and gas free inching of the wire electrode through the hose package to the welding t...

Page 18: ... button Welding current Material thickness Wire feed speed Press for 2 s to put the machine into power saving mode Activate one of the operating elements to reactivate see 5 7 3 chapter 5 Display JOB Shows the currently selected welding task JOB number 6 JOB LIST Welding task push button JOB Select the welding task from the welding task list JOB LIST The list can be found inside the protective cap...

Page 19: ... Spots Interval 9 Runtime parameters button For selecting the parameters to be set Also for entering and exiting the menus for ad vanced settings Choke effect dynamics Gas post flow time Spot time Pause time 10 Arc length correction rotary dial 11 Push button gas test rinse hose package see 5 1 9 chapter 12 Signal light polarity setting 13 Signal light polarity setting ...

Page 20: ...ding 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 Nominal values Actual values Hold 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 kno...

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 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 ...

Page 22: ...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 Welding torch cooling system 5 1 4 1 Cooling unit connection Figure 5 1 Item Symbol Description 0 1 Cooling module 2 4 pole connection socket Cooling unit voltage supply 3 8 pole connection socket Cooling unit control lead I...

Page 23: ...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 in termediate hose package torch lead Figure 5 2 Use an individual welding lead to the workpiece for each weldi...

Page 24: ...ey 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 An improper mains connection can cause injuries or damage property The connection mains plug or cable the repair or voltage adjustment of the device must be carried out by a qualified electrician in 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 L2 Outer conductor 2 black L3 Outer conductor 3 grey N Neutral conductor blue PE Protective conductor green yellow Insert mains plug of the switched off machine into the appropriate socket ...

Page 26: ...ing is part of the machine s scope of delivery Figure 5 7 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 screws to screw the torch holder onto the crossmember of the transport handle Insert the welding torch into the welding torch holder as shown ...

Page 27: ...supply from the shielding gas cylinder to the welding torch is a fun damental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch being destroyed Always re fit the yellow protective cap when not using the shielding gas connection All shielding gas connections must be gas tight 5 1 9 1 Pressure regulator connection Figure 5 8 Item Symbo...

Page 28: ...linder valve Open the pressure regulator Switch on the power source at the main switch Trigger gas test see 5 1 9 4 chapter function welding voltage and wire feed motor remain 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 Wire diameter x 11 5 l m...

Page 29: ...loyed wire electrodes steel Use a chrome nickel liner when welding hard high alloy wire electrodes CrNi Use a plastic or teflon liner when welding or brazing 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 relation to the central connector Preparation for c...

Page 30: ...cket and lock in place by turning to the right Insert the central plug for the welding torch into the central connector and screw together with crown nut Insert cable plug on the workpiece lead into the welding current socket and lock by turning to the right Some wire electrodes e g self shielding cored wire are welded using negative polarity In this case the welding current lead should be connect...

Page 31: ...pped with moving parts which can trap hands hair clothing or tools and thus injure persons Do not reach into rotating or 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 very high speeds and if conveyed incorrectly may escape in an uncontrolled manner...

Page 32: ... 5 chapter Figure 5 14 Item Symbol Description 0 1 Carrier pin For fixing the wire spool 2 Knurled nut For fixing the wire spool Unlock and open protective flap Loosen knurled nut from spool holder Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore Fasten wire spool using knurled nut Figure 5 15 Abspulrichtung der Schweißdrahtspule beachten ...

Page 33: ...ixing 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 Fold the closure brackets outwards by 90 Unfasten pressure units and fold out clamping units and pressure rollers will automatically flip up wards Remove the wire feed rollers from the roller support Se...

Page 34: ...white 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 bicolour white yellow U groove 0 9 1 0 035 039 blue 1 2 047 red 1 6 063 black 2 0 079 grey 2 4 094 brown 2 8 110 light green 3 2 126 purple Flux cored wire 0 8 031 bicolour white orange V groove knurled 0 9...

Page 35: ...re 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 on the design of the device the wire feed mechanism may be reversed Figure 5 17 Item Symbol Description 0 1 Welding wire 2 Wire feed nipple 3 Guide tube 4 Adjusting nut Extend and lay out the torch h...

Page 36: ...e 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 5 Definition of MIG MAG welding tasks This machine range features simple operation with a very wide range of functions JOBs welding tasks consisting of welding process type of material wire diameter and type of shiel ding...

Page 37: ...eed 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 JOB that is currently selected If required these parameter values can be reset to the factory settings see 5 6 3 chapter 5 2 7 Welding power operating point 5 2 7 1 Selecting the welding parameter dis...

Page 38: ...tration 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 properties after selecting the forceArc process see 5 2 6 chapter As with pulse arc welding it is important to make sure of a good welding current connection Keep welding current cables as short as possib...

Page 39: ... applicable intermediate hose packages Avoid loops 5 2 10 Operating modes functional sequences 5 2 10 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Shielding gas flowing I Welding output Wire electrode 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 10 2 Automatic cut ...

Page 40: ...ng 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 Step 2 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses ...

Page 41: ...uns 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 cycle Press torch trigger no effect 4 cycle Release torch trigger Wire feed motor stops Arc is extinguished after the pre selected wire burn back time elapses Gas post flow time elapses ...

Page 42: ...gas 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 after the spot time elapses Arc is extinguished after the wire burn back time elapses Gas post flow time elapses Premature termination Release torch trigger ...

Page 43: ...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 gas post flow time elapses If the pause time is less than 3 s wire creep only takes place in the first spot phase When the torch trigger is released the welding process is also ended even before the spo...

Page 44: ...etting 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 is a risk of crushing and burns Wear appropriate and dry protective gloves Use an insulated pair of tongs to remove the used stick electrode or to move welded work pieces Figure 5 32 Item Symbol Desc...

Page 45: ...will 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 welding current is flowing 3s Figure 5 33 5 3 3 Arcforce During the welding process arcforce prevents the electrode sticking in the weld pool with increases in current This makes it easier to weld larg...

Page 46: ... 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 minimum current within approx one se cond This prevents the electrode from annealing Check the welding current setting and correct for the welding task in hand Figure 5 36 5 3 6 Expert menu MMA The ...

Page 47: ...ion 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 welding current 3 Workpiece Insert the central plug for the welding torch into the central connector and screw together with crown nut Insert the polarity selection plug into the welding current connection...

Page 48: ...EW501 04 06 2020 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 40 Display Setting selection Gas post flow time ...

Page 49: ...own 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 Downslope time The downslope time can be set separately for latched and non latched operation End crater current Setting range in percent depending on main current Setting range absolute Imin to Imax ...

Page 50: ...to 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 trigger Release torch trigger I Welding current Gas pre flows Gas post flows Non latched Latched t Time tUp Upslope time tDown Downslope time Istart Ignition current Iend End crater current 5 4 7 2 Automat...

Page 51: ...value 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 end crater current Iend If the torch trigger is pressed again during the downslope time the welding current returns to the set main current The main current reaches the end crater current Iend the arc...

Page 52: ...e 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 control connection socket analogue 5 6 Special parameters advanced settings Special parameters P1 to Pn are applied for customer specific configuration of machine functions This allows the user maximum fl...

Page 53: ...omponents 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 wire inching starts with a speed 1 0 m min for 2 secs It is subsequently increased to a ramp function to 6 0 m min The ramp time can be set between two ranges During wire inching the speed can be cha...

Page 54: ...d function Special parameters advanced settings 54 099 005640 EW501 04 06 2020 5 6 3 Reset to factory settings All special parameters saved by the user will be overwritten by the factory settings l 0 Figure 5 46 ...

Page 55: ...ction Lead resistance 1 Lead resistance for the first welding circuit 0 mΩ 60 mΩ 8 mΩ ex works Time based power saving mode see 5 7 3 chapter Time to activation of the power saving mode in case of inactivity Setting disabled or numerical value 5 60 min Only qualified service personnel may change the parameters Service menu Any changes to the service menu should be agreed with the authorised servic...

Page 56: ...water 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 means of realigning the cable resistance It is recommended to align the electric cable resistance after replacing accessories such as torches or intermediate hose packages In case a second wire feeder i...

Page 57: ...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 cable resistance The value can be between 0 mΩ and 40 mΩ The new value is immediately saved without requiring further confirmation If no value is shown on the right hand display then measurement failed...

Page 58: ...right 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 your dealer When replacing parts use only original spare parts When ordering spare parts please quote the machine type serial number and item number of the machine as well as the type designation and it...

Page 59: ...d 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 elements strap lifting lugs handle Check coolant tubes and their connections for impurities Functional test Selector switches command devices emergency stop devices voltage reducing devices message and...

Page 60: ...er 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 governing the distribution taking back and environmentally correct dis posal of electric and electronic equipment ElektroG used machines are to be placed in a collection system separate from unsorted...

Page 61: ...is 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 connections and check that they are fitted correctly Loose welding current connections Tighten power connections on the torch and or on the workpiece Properly fasten the contact tip and contact tip holder...

Page 62: ...ltage 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 to 1 4 Coolant error Fill coolant Turn on pump shaft coolant pump Check overcurrent trip of air cooling unit 5 Wire feeder tachometer error Check the wire feeder tachometer generator sends no signal ...

Page 63: ...voltages 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 resetting the error a The error message disappears when the error is eliminated b The error message can be reset by pressing a pushbutton Resetting the machine errors is only possible with the listed...

Page 64: ...40 EW501 04 06 2020 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 allows for easy alignment B A B A B A B A A l 0 B A Figure 7 1 ...

Page 65: ...gs 099 005640 EW501 04 06 2020 65 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 ...

Page 66: ...The 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 customised welding parameters that are stored will be replaced by the factory settings 3s 3s 3s Figure 7 4 Display Setting selection RESET to factory settings The RESET will be done after pressing the butt...

Page 67: ...tage category Ⅰ Ⅲ 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 Machine cooling Torch cooling Fan AF gas Wire feed speed 0 5 m min to 25m min Factory installed roll equipment 1 0 1 2 mm for steel wire Drive 4 rollers 37 mm Wire spool diameter Standardised wire spo...

Page 68: ...Technical data Picomig 305 TKM 68 099 005640 EW501 04 06 2020 4 Ambient temperature dependent on coolant Observe coolant temperature range ...

Page 69: ...te 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 19POL 10m Remote control e g connection cable 092 001470 00010 RA20 19POL 20m Remote control e g connection cable 092 001470 00020 RV5M19 19POLE 5M Extension cable 092 000857 00000 RV5M19 19POL 10M Exte...

Page 70: ...0001 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 hose 094 000010 00003 DSP Sharpener for liner 094 010427 00000 Cutter Hose cutter 094 016585 00000 voltConverter 230 400 Voltage converter 090 008800 00502 ...

Page 71: ...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 brazin...

Page 72: ... 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 knurled for flux cored wire 092 002848 00020 FUEL 4R 2 4 MM 0 095 INCH BROWN ORANGE Drive roll set 37 mm 4 rolls V groove knurled for flux cored wire 092 002848 00024 10 1 4 Wire guide Type Designation I...

Page 73: ...G 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 JOB to pulse noP no Pulse appears briefly on the display and the machine is reset to default ...

Page 74: ... 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 0 Hot start time 0 5 0 1 20 0 s Basic parameters independent of procedure Calibration Exit menu Machine configuration Remote control encoding 0 0 15 Wire inching ramp time 1 0 1 Tapping start for latc...

Page 75: ...Appendix Searching for a dealer 099 005640 EW501 04 06 2020 75 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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