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Rectifying faults

Checklist for rectifying faults

099-005545-EW501

17.12.2020

Rectifying faults

All products are subject to rigorous production checks and final checks. If, despite this, something fails to

work at any time, please check the product using the following flowchart. If none of the fault rectification

procedures described leads to the correct functioning of the product, please inform your authorised dea-

ler.

7.1 Checklist for rectifying faults

The correct machine equipment for the material and process gas in use is a fundamental

requirement for perfect operation!

Legend

Symbol

Description



Fault/Cause



Remedy

Collective interference signal light illuminates



Excess temperature, welding machine



Allow the machine to cool down whilst still switched on



Welding current monitoring device triggered (stray welding currents flowing across the protective e-

arth). The error must be reset by switching the machine off and on again.



Welding wire is touching electrically conductive casing parts (check wire guide, has the welding

wire sprung off the wire spool?).



Check for a correct mounting of the welding lead. Fit the feeder clamp of the welding lead as

close as possible to the arc.

Excess temperature signal light illuminates



Excess temperature, welding machine



Allow the machine to cool down whilst still switched on

Functional errors



Mains fuse triggers - unsuitable mains fuse



Set up recommended mains fuse

> see 8 chapter



Machine does not start up after switching on (device fan and possibly coolant pump have no function).



Connect the control cable of the wire feeder.



All machine control signal lights are illuminated after switching on



No machine control signal light 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.

Содержание Picomig 180 puls TGE

Страница 1: ...Operating instructions EN Welding machine Picomig 180 puls TKG 099 005545 EW501 Observe additional system documents 17 12 2020...

Страница 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...

Страница 3: ...neral 22 5 1 4 Notes on the installation of welding current leads 22 5 1 5 Stray welding currents 24 5 1 6 Mains connection 25 5 1 6 1 Mains configuration 25 5 1 7 Shielding gas supply shielding gas c...

Страница 4: ...ing 52 6 1 2 Dirt filter 52 6 2 Maintenance work intervals 53 6 2 1 Daily maintenance tasks 53 6 2 2 Monthly maintenance tasks 53 6 2 3 Annual test inspection and testing during operation 53 6 3 Dispo...

Страница 5: ...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...

Страница 6: ...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...

Страница 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...

Страница 8: ...temperatures 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 excessi...

Страница 9: ...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 user...

Страница 10: ...placement 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...

Страница 11: ...on 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 powe...

Страница 12: ...e supplied and our information regarding warranty maintenance and testing at www ewm group com 3 3 2 Declaration of Conformity This product corresponds in its design and construction to the EU directi...

Страница 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 show...

Страница 14: ...Machine description quick overview Front view 14 099 005545 EW501 17 12 2020 4 Machine description quick overview 4 1 Front view Figure 4 1...

Страница 15: ...ion MMA welding Workpiece connection 5 Machine feet 6 Main Switch Switching the machine on or off 7 Mains connection cable with connector plug 8 Cooling air inlet 9 Wheels 10 Connection thread G Shiel...

Страница 16: ...Machine description quick overview Inside view 16 099 005545 EW501 17 12 2020 4 2 Inside view Figure 4 2...

Страница 17: ...cap Cover for the wire feed 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 i...

Страница 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 6 chapter 5 Display JOB Sho...

Страница 19: ...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 corr...

Страница 20: ...ng 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 Nom...

Страница 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 machi...

Страница 22: ...se structural parts of the workpiece as welding current return lead 5 1 4 Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc fli...

Страница 23: ...23 Use an individual welding lead to the workpiece for each welding machine Figure 5 2 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Always keep lea...

Страница 24: ...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...

Страница 25: ...e system with two conductors and an earthed neutral conductor Figure 5 5 Legend Item Designation Colour code L Outer conductor brown N Neutral conductor blue PE Protective conductor green yellow Inser...

Страница 26: ...sure regulator to the gas cylinder 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 the gas hose conne...

Страница 27: ...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...

Страница 28: ...e 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 Preparatio...

Страница 29: ...er integrated 3 Workpiece 4 welding current connection socket MIG MAG welding Workpiece connection 5 Polarity selector plug welding current cable Internal welding current cable for central connection...

Страница 30: ...d manner and injure persons Before mains connection set up the complete wire guide system from the wire spool to the welding torch Check wire guide at regular intervals Keep all casing covers or prote...

Страница 31: ...ng results due to faulty wire feeding Wire feed rolls must be suitable for the diameter of the wire and the material Check the label of the rolls whether they fit the wire diameter If necessary turn o...

Страница 32: ...veyed but will still slip through if the wire spool jams Set the contact pressure of the front rollers in wire feed direction to a higher value Figure 5 12 Item Symbol Description 0 1 Adjusting nut 2...

Страница 33: ...onsisting of welding process type of material wire diameter and type of shiel ding gas are pre defined for all common welding tasks Simple JOB selection from a list of pre defined JOBs sticker on the...

Страница 34: ...ttling 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 r...

Страница 35: ...ic settings are now completed Other welding parameters have already been set optimally in the factory they can however be modified to suit individual requirements 5 2 6 Further welding parameters Pres...

Страница 36: ...ode 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 7 2 Automatic cut out Once the fault periods have elapsed the aut...

Страница 37: ...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...

Страница 38: ...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...

Страница 39: ...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...

Страница 40: ...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...

Страница 41: ...holder 2 Connection socket for welding current Electrode holder or workpiece lead connection 3 Polarity selector plug welding current cable Connect to the park socket 4 Workpiece 5 Connection socket...

Страница 42: ...weld large drop melting electrode types at low current strengths with a short arc in particular Figure 5 26 Display Setting selection Arcforce correction Increase value harder arc Decrease value softe...

Страница 43: ...he electrode from annealing Should the electrode stick despite the Arcforce feature the machine au tomatically switches to the minimum current within approx one second This prevents the electrode from...

Страница 44: ...ding Workpiece connection 5 Polarity selector plug welding current cable Internal welding current cable for central connection welding torch Connection socket for welding current Insert the central pl...

Страница 45: ...ing task selection Select TIG JOB 127 You can only change the JOB number when no welding current is flowing 3 s Figure 5 31 5 4 4 Adjusting the gas post flow time Preselection Select TIG JOB 127 see 5...

Страница 46: ...meters The setting ranges for the parameter values are summarised in the Parameter overview sec tion see 11 2 chapter Preselection Select TIG JOB 127 see 5 4 3 chapter 2s 2s Figure 5 33 Display Settin...

Страница 47: ...ed Latched t Time tUp Upslope time tDown Downslope time Istart Ignition current Iend End crater current 5 4 6 2 Automatic cut out Once the fault periods have elapsed the automatic cut out stops the we...

Страница 48: ...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...

Страница 49: ...t 2nd cycle Release torch trigger Welding current increases to the main current in the set upslope time 3rd cycle Press and hold torch trigger The main current falls in the set downslope time to the e...

Страница 50: ...between electrode tip and workpiece is approx 2 3 mm arc ignites current increases to the set main current c Lift the torch off and bring into normal position Complete the welding task Remove the tor...

Страница 51: ...nges to the service menu should be agreed with the authorised service person nel Software version of the machine control Version display 5 6 Power saving mode Standby You can activate the power saving...

Страница 52: ...ce 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 s...

Страница 53: ...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 ele...

Страница 54: ...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...

Страница 55: ...Welding wire is touching electrically conductive casing parts check wire guide has the welding wire sprung off the wire spool Check for a correct mounting of the welding lead Fit the feeder clamp of...

Страница 56: ...ck settings and correct if necessary Setting pressure units see 5 2 2 3 chapter Check settings and correct if necessary Worn wire rolls Check and replace if necessary Kinked hose packages Extend and l...

Страница 57: ...d position and switch the ma chine back on If the error persists notify service department E15 Error in one of the electronics supply voltages Switch the machine off and on again If the error persists...

Страница 58: ...are versions only serves to inform the authorised service staff It is available in the machine configuration menu see 5 5 chapter 7 5 Dynamic power adjustment This requires use of the appropriate main...

Страница 59: ...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 25 C to 40 C Machine co...

Страница 60: ...394 002910 00030 G1 G1 4 R 3M Gas hose 094 000010 00003 ADAPTER EZA DINSE ZA Adapter for welding torches with Dinse connector to Euro central connector on the machine 094 016765 00000 9 2 Options Typ...

Страница 61: ...0 1 2 Drive rollers 37 mm steel 092 000842 00000 FE 2DR4R 1 2 1 6 Drive rollers 37 mm steel 092 000843 00000 FE AL 2GR4R SF Pressure rollers smooth 37 mm 092 000414 00000 10 1 2 Wire feed rollers for...

Страница 62: ...or cored wire 092 000411 00000 URUE ROE 2DR4R 1 4 1 6 2 0 2 4 SF Conversion kit 37 mm 4 roller drive for cored wire 092 000412 00000 URUE ROE 2DR4R 2 8 3 2 SF Conversion kit 37 mm 4 roller drive for c...

Страница 63: ...odes Figure 11 1 MIG MAG pulse arc welding can be selected with JOBs 6 34 42 74 75 76 82 83 84 90 91 110 111 114 and 115 If an attempt is made to set another JOB to pulse noP no Pulse appears briefly...

Страница 64: ...rent 20 1 200 Up slope time 1 0 0 0 20 0 s Down slope time 1 0 0 0 20 0 s End current 20 1 200 Gas post flow time 4 0 0 0 20 0 s MMA Arcforce correction 0 10 10 Hot start current 120 50 200 Hot start...

Страница 65: ...Appendix Searching for a dealer 099 005545 EW501 17 12 2020 65 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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