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For your safety

Part of the complete documentation

099-005548-EW501

27.10.2017

7

2.3

Part of the complete documentation

These operating instructions are 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 system components, especially the safety instructions!

The illustration shows a general example of a welding system.

Figure 2-1

Item Documentation

A.1

Transport cart

A.2

Power source

A.3

Welding torch

A

Complete documentation

2.4

Safety instructions

WARNING

Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!

•  Carefully read the safety instructions in this manual!
•  Observe the accident prevention regulations and any regional regulations!
•  Inform persons in the working area that they must comply with the regulations!

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Содержание Picomig 185 Synergic TKG

Страница 1: ...ating instructions EN Welding machine Picomig 185 Synergic TKG 099 005548 EW501 27 10 2017 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group...

Страница 2: ...ervice department on 49 2680 181 0 A list of authorised sales partners can be found at www ewm group com Liability relating to the operation of this equipment is restricted solely to the function of t...

Страница 3: ...llation of welding current leads 20 5 1 5 1 Stray welding currents 21 5 1 6 Mains connection 21 5 1 6 1 Mains configuration 22 5 1 7 Shielding gas supply shielding gas cylinder for welding machine 22...

Страница 4: ...sal 51 6 1 General 51 6 2 Cleaning 51 6 2 1 Dirt filter 51 6 3 Maintenance work intervals 52 6 3 1 Daily maintenance tasks 52 6 3 2 Monthly maintenance tasks 52 6 3 3 Annual test inspection and testin...

Страница 5: ...erved to prevent serious and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning symbol The hazard is also highlighted using a symbol in the page margin...

Страница 6: ...off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Correct Numerical value adjustable Menu entry Signal light lights up in green Navigating the menu Signal light flashes gr...

Страница 7: ...ety instructions The illustration shows a general example of a welding system Figure 2 1 Item Documentation A 1 Transport cart A 2 Power source A 3 Welding torch A Complete documentation 2 4 Safety in...

Страница 8: ...cause the welding voltages to be combined which is not permitted Risk of injury due to improper clothing During arc welding radiation heat and voltage are sources of risk that cannot be avoided The us...

Страница 9: ...magnetic compatibility of class A machines difficulties can arise in these areas due to interference not only in the supply lines but also in the form of radiated interference Class B machines fulfil...

Страница 10: ...The regulations applicable to occupational safety and accident prevention in the country concerned Setting up and operating the machine as per IEC 60974 9 Brief the user on safety conscious work prac...

Страница 11: ...sport the machine on level solid ground Secure add on parts using suitable equipment Risk of accidents due to incorrectly installed leads Incorrectly installed leads mains control and welding leads or...

Страница 12: ...tage Directive LVD Electromagnetic Compatibility Directive EMC Restriction of Hazardous Substance RoHS In case of unauthorised changes improper repairs non compliance with specified deadlines for Arc...

Страница 13: ...the protective cap 5 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and torch trigger integrated 6 Park socket polarity selection plug Retainer for the polarity...

Страница 14: ...ing Workpiece connection MMA welding Workpiece connection 11 Cooling air inlet 12 Machine control see 4 4 chapter 13 Carrying handle 4 2 Rear view Figure 4 2 Item Symbol Description 0 1 Main switch ma...

Страница 15: ...15 4 3 Inside view Figure 4 3 Item Symbol Description 0 1 Sticker JOB List see 11 1 chapter 2 Push button wire inching Potential and gas free inching of the wire electrode through the hose package to...

Страница 16: ...1 Collective interference signal light 2 Excess temperature signal light 3 Welding data display 3 digit Displays the welding parameters and the corresponding values see 5 2 chapter 4 Welding parameter...

Страница 17: ...s 7 Welding parameter setting dial For setting the welding performance for selecting the JOB welding task and for setting other welding parameters 8 Operating mode button Non latched Latched Spots Int...

Страница 18: ...a crane 5 1 1 Ambient conditions T he machine must not be operated in the open air and must only be set up and operated on a suitable stable and level base The operator must ensure that the ground is...

Страница 19: ...ons on a daily basis and lock by 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 le...

Страница 20: ...with HF igniter TIG for as long as possible 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...

Страница 21: ...transport vehicle or crane frames unless they are insulated Always put welding torches and electrode holders on an insulated surface when they are not in use Figure 5 5 5 1 6 Mains connection DANGER...

Страница 22: ...curing of shielding gas cylinders can cause serious injuries Place shielding gas cylinder into the designated holder and secure with fastening elements chain belt Attach the fastening elements within...

Страница 23: ...er 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 gas hose connection crown nut onto the output side...

Страница 24: ...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 25: ...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 knobs of the control waiting for abo...

Страница 26: ...o torch connector side Carefully insert the welding torch connector with as yet too long a liner into the Euro torch connector and secure with a crown nut Cut off the liner with a liner cutter see 9 c...

Страница 27: ...ive 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...

Страница 28: ...sing standardised basket coils DIN 8559 see 9 chapter Figure 5 11 Item Symbol Description 0 1 Carrier pin For fixing the wire spool 2 Knurled nut For fixing the wire spool Loosen knurled nut from spoo...

Страница 29: ...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...

Страница 30: ...Wire feed roll overview table Material Diameter Colour code Groove form mm inch Steel Stainless steel Brazing 0 6 023 monochrome light pink V groove 0 8 030 white 0 8 0 9 1 0 030 035 040 bicolour whit...

Страница 31: ...rotary knob The left display shows the wire feed speed selected the right display shows the current motor current of the wire feed mechanism Figure 5 13 Item Symbol Description 0 1 Welding wire 2 Wir...

Страница 32: ...3 2 5 Spool brake setting Figure 5 15 Item Symbol Description 0 1 Allen screw Securing the wire spool retainer and adjustment of the spool brake Tighten the Allen screw 8 mm in the clockwise directio...

Страница 33: ...with the JOB list see 11 1 chapter 3s Figure 5 16 Validity of the settings Spot time pause time and wire feed speed settings apply to all JOBs Throttling effect dynamics gas post flow time gas pre fl...

Страница 34: ...t have to change the display mode before setting the parameter Figure 5 18 5 3 5 3 Arc length correction setting Setting range 5 V to 5 V Figure 5 19 The basic settings are now completed Other weldin...

Страница 35: ...Operating modes functional sequences 5 3 7 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Shielding gas flowing I Welding output Wire electrode is being...

Страница 36: ...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 37: ...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 38: ...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 39: ...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 40: ...holder and workpiece lead Figure 5 26 Item Symbol Description 0 1 Electrode holder 2 Workpiece 3 Connection socket for welding current Electrode holder or workpiece lead connection 4 Connection socke...

Страница 41: ...t This makes it easier to weld large drop melting electrode types at low current strengths with a short arc in particular Figure 5 28 Display Setting selection Arcforce correction Increase value harde...

Страница 42: ...ER NAVIGATION 2s EXIT 2s Figure 5 30 Display Setting selection Hotstart current Hotstart time 5 4 5 Antistick The Antistick feature prevents the electrode from annealing Should the electrode stick des...

Страница 43: ...Dinse torch connector Welding current shielding gas and torch trigger integrated 3 Workpiece 4 Connection socket welding current TIG welding Workpiece connection 5 Polarity selector plug welding curre...

Страница 44: ...election Select TIG JOB 127 see 11 1 chapter You can only change the JOB number when no welding current is flowing 3s Figure 5 33 5 5 4 Adjusting the gas post flow time Preselection Select TIG JOB 127...

Страница 45: ...setting ranges for the parameter values are summarised in the Parameter overview section see 12 1 chapter Preselection Select TIG JOB 127 see 5 5 3 chapter ENTER EXIT NAVIGATION 2s 2s Figure 5 35 Dis...

Страница 46: ...2 3 mm between the electrode tip and the workpiece The arc ignites and the welding current is increased depending on the operating mode set to the ignition or main current set c Lift off the torch and...

Страница 47: ...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 48: ...s and hold torch trigger The main current falls in the set downslope time to the end crater current Iend 4th cycle Release torch trigger arc is extinguished Gas post flow time elapses The welding proc...

Страница 49: ...x 2 seconds each time it is switched on Exit the menu Exit Machine configuration Settings for machine functions and parameter display Dynamic power adjustment see 7 5 chapter Time based power saving m...

Страница 50: ...4 chapter for a prolonged time or by setting a parameter in the machine configuration menu time controlled power saving mode see 5 6 chapter When power saving mode is activated the machine displays sh...

Страница 51: ...der 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 re...

Страница 52: ...ly tighten if necessary Remove any spatter Clean the wire feed rollers on a regular basis depending on the degree of soiling 6 3 2 Monthly maintenance tasks Visual inspection Casing damage front rear...

Страница 53: ...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 54: ...5 3 2 4 chapter Check settings and correct if necessary Worn wire rolls Check and replace if necessary Wire feed motor without supply voltage automatic cutout triggered by overloading Reset triggered...

Страница 55: ...place the electrode holder in an insulated position and switch the machine back on If the error persists notify service department E15 Error in on of the electronics supply voltages Switch the machine...

Страница 56: ...tware versions only serves to inform the authorised service staff It is available in the machine configuration menu see 5 6 chapter 7 5 Dynamic power adjustment This requires use of the appropriate ma...

Страница 57: ...kVA 5 5 kVA Recommended generator rating 8 0 kVA Frequency 50 60 Hz Mains fuse safety fuse slow blow 16 A 1 cos efficiency 0 99 86 Workpiece lead minimum 25 mm2 Ambient temperature 25 C to 40 C Machi...

Страница 58: ...00000 CA D200 Centering adapter for 5 kg spools 094 011803 00000 ADAPTER EZA DINSE ZA Adapter for welding torches with Dinse connector to Euro central connector on the machine 094 016765 00000 9 2 Opt...

Страница 59: ...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 stain...

Страница 60: ...cored wire 092 002848 00014 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 se...

Страница 61: ...pendix A JOB List 099 005548 EW501 27 10 2017 61 11 Appendix A 11 1 JOB List We recommend using the characteristics for 1 0 mm solid wire electrodes also for the 0 9 mm solid wire electrodes Figure 11...

Страница 62: ...0 1 20 0 s Pause time interval 1 0 0 1 20 0 s Wire burn back 0 50 50 TIG Gas pre flow time 0 5 0 0 5 0 s Ignition current 20 1 200 Up slope time 1 0 0 0 20 0 s Down slope time 1 0 0 0 20 0 s End curre...

Страница 63: ...Appendix C Overview of EWM branches 099 005548 EW501 27 10 2017 63 13 Appendix C 13 1 Overview of EWM branches...

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