EWM Picomig 355 puls TKM Operating Instructions Manual Download Page 72

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Accessories

General accessories

099-005542-EW501

24.03.2020

9.5 General accessories

Type

Designation

Item no.

AK300

Wire spool adapter K300

094-001803-00001

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

Summary of Contents for Picomig 355 puls TKM

Page 1: ...Operating instructions EN Welding machine Picomig 355 puls TKM 099 005542 EW501 Observe additional system documents 24 03 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: ...kpiece lead general 24 5 1 4 Welding torch cooling system 24 5 1 4 1 Cooling unit connection 24 5 1 5 Notes on the installation of welding current leads 25 5 1 6 Stray welding currents 26 5 1 7 Mains...

Page 4: ...s 56 5 6 2 Special parameters in detail 56 5 6 2 1 Ramp time for wire inching P1 56 5 6 2 2 Latched special latched tap start P9 56 5 6 3 Reset to factory settings 57 5 7 Machine configuration menu 58...

Page 5: ...10 Replaceable parts 73 10 1 Wire feed rollers 73 10 1 1 Wire feed rollers for steel wire 73 10 1 2 Wire feed rollers for aluminium wire 73 10 1 3 Wire feed rollers for cored wire 74 10 1 4 Wire guid...

Page 6: ...Contents Notes on using these operating instructions 6 099 005542 EW501 24 03 2020...

Page 7: ...s 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 ope...

Page 8: ...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 9: ...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 Ite...

Page 10: ...en taking 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 int...

Page 11: ...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 12: ...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 13: ...e instructions from the gas manufacturer and any relevant regulations concern ing the use of compressed air Do not attach any element to the shielding gas cylinder valve Prevent the shielding gas cyli...

Page 14: ...and lock accessory components into the relevant connection socket when the ma chine is switched off Comprehensive descriptions can be found in the operating instructions for the relevant ac cessory co...

Page 15: ...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 16: ...Machine description quick overview Front view rear view 16 099 005542 EW501 24 03 2020 4 Machine description quick overview 4 1 Front view rear view Figure 4 1...

Page 17: ...air 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 4 pole connection socket Cooling unit volta...

Page 18: ...Machine description quick overview Inside view 18 099 005542 EW501 24 03 2020 4 2 Inside view Figure 4 2...

Page 19: ...nd 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 Wir...

Page 20: ...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 8 chapter 5 Display JOB Sh...

Page 21: ...s 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 ro...

Page 22: ...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 23: ...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 24: ...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 25: ...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 26: ...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 27: ...ins plug socket and lead must be checked by a qualified electrician on a regular basis When operating the generator always ensure it is earthed as stipulated in the operating instructions The network...

Page 28: ...ng 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 scr...

Page 29: ...upply 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 de...

Page 30: ...nder valve Open the pressure regulator Switch on the power source at the main switch Trigger gas test see 5 1 10 1 chapter function welding voltage and wire feed motor remain switched off no accidenta...

Page 31: ...alloyed 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 ele...

Page 32: ...ket 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 th...

Page 33: ...otentiometer for wire feed speed with potentiometers for wire feed speed and arc length correction Figure 5 13 5 2 4 Wire feed CAUTION Risk of injury due to moving parts The wire feeders are equipped...

Page 34: ...pport 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 ch...

Page 35: ...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 36: ...Wire 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 whit...

Page 37: ...he contact pressure of the front rollers in wire feed direction to a higher value The inching speed is infinitely adjustable by simultaneously pressing the wire inching push button and turning the wir...

Page 38: ...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 MA...

Page 39: ...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 40: ...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 41: ...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 Shiel...

Page 42: ...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 43: ...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 44: ...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 45: ...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 46: ...12 Expert menu MIG MAG The Expert menu has adjustable parameters stored that don t require regular setting The number of pa rameters shown may be limited e g if a function is deactivated 2s 2s Figure...

Page 47: ...rode or to move welded work pieces Figure 5 32 Item Symbol Description 0 1 Polarity selector plug welding current cable Connect to the park socket 2 Electrode holder 3 Workpiece Insert the polarity se...

Page 48: ...ing electrode types at low current strengths with a short arc in particular Figure 5 34 Display Setting selection Arcforce correction Increase value harder arc Decrease value softer arc 5 3 4 Hotstart...

Page 49: ...e 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 50: ...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 51: ...1 24 03 2020 51 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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...function Special parameters advanced settings 099 005542 EW501 24 03 2020 57 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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...ircuit Check welding circuit for short circuit put down welding torch isolated 59 Machine incompatible Check machine usage 60 Software update required Inform Service Categories legend resetting the er...

Page 67: ...W501 24 03 2020 67 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 68: ...s 68 099 005542 EW501 24 03 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 69: ...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 70: ...on 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 Fa...

Page 71: ...rolly 55 6 Transport cart assembled 090 008825 00000 9 3 Remote control connecting and extension cable 9 3 1 19 pole connection Type Designation Item no R10 19POL Remote control 090 008087 00000 RG10...

Page 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...Appendix Searching for a dealer 099 005542 EW501 24 03 2020 77 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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