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Contents

Notes on the use of these operating instructions

099-005266-EW501

07.05.2014

5.8.5

Welding data display ..................................................................................................... 41

5.8.5.1

Power-saving mode ....................................................................................... 41

5.8.6

MIG/MAG operating point ............................................................................................. 42

5.8.6.1

Selecting the welding parameter display mode ............................................ 42

5.8.6.2

Operating point setting using material thickness .......................................... 42

5.8.6.3

Arc length correction setting .......................................................................... 42

5.8.7

Further welding parameters .......................................................................................... 43

5.8.7.1

Choke effect / dynamics ................................................................................ 43

5.8.7.2

Gas post-flow time ......................................................................................... 43

5.8.7.3

Spot time ....................................................................................................... 44

5.8.7.4

Pause time (interval operation) ..................................................................... 44

5.8.7.5

Burn-back ...................................................................................................... 45

5.8.7.6

gas pre-flow time ........................................................................................... 45

5.8.8

MIG/MAG functional sequences / operating modes ..................................................... 46

5.8.9

Explanation of signs and functions ............................................................................... 46

5.8.10

Conventional MIG/MAG Welding (GMAW non synergic) ............................................. 51

5.8.10.1

Operating mode ............................................................................................. 51

5.8.11

Welding data display ..................................................................................................... 51

5.8.11.1

Setting the operating point (welding output).................................................. 52

5.8.12

MIG/MAG automatic cut-out ......................................................................................... 52

5.9

MMA welding ................................................................................................................................ 53

5.9.1

Connecting the electrode holder and workpiece lead .................................................. 53

5.9.2

Welding task selection .................................................................................................. 54

5.9.3

Welding current setting ................................................................................................. 55

5.9.4

MMA welding data display ............................................................................................ 55

5.9.4.1

Power-saving mode ....................................................................................... 55

5.9.5

Arcforce......................................................................................................................... 56

5.9.6

Hotstart ......................................................................................................................... 56

5.9.6.1

Hotstart settings ............................................................................................ 57

5.9.7

Antistick......................................................................................................................... 57

5.10

TIG welding .................................................................................................................................. 58

5.10.1

Preparing the TIG welding torch ................................................................................... 58

5.10.2

Welding torch and workpiece line connection .............................................................. 58

5.10.3

Welding task selection .................................................................................................. 59

5.10.4

Welding current setting ................................................................................................. 60

5.10.5

Adjusting the gas post-flow time ................................................................................... 60

5.10.6

Further welding parameters .......................................................................................... 61

5.10.7

TIG welding data display .............................................................................................. 62

5.10.7.1

Power-saving mode ....................................................................................... 62

5.10.8

TIG arc ignition ............................................................................................................. 62

5.10.8.1

Liftarc ignition ................................................................................................ 62

5.10.9

Function sequences/operating modes .......................................................................... 63

5.10.9.1

Legend........................................................................................................... 63

5.10.10

TIG automatic cut-out ................................................................................................... 65

5.11

Machine configuration menu ........................................................................................................ 66

5.11.1

Selecting, changing and saving parameters................................................................. 66

5.11.2

Matching the cable resistance ...................................................................................... 67

Maintenance, care and disposal ......................................................................................................... 69

6.1

General......................................................................................................................................... 69

6.2

Maintenance work, intervals ........................................................................................................ 69

6.2.1

Daily maintenance tasks ............................................................................................... 69

6.2.1.1

Visual inspection ........................................................................................... 69

6.2.1.2

Functional test ............................................................................................... 69

6.2.2

Monthly maintenance tasks .......................................................................................... 69

6.2.2.1

Visual inspection ........................................................................................... 69

6.2.2.2

Functional test ............................................................................................... 69

6.2.3

Annual test (inspection and testing during operation) .................................................. 70

6.3

Maintenance work ........................................................................................................................ 70

6.4

Disposing of equipment ................................................................................................................ 71

6.4.1

Manufacturer's declaration to the end user .................................................................. 71

Содержание Picomig 305 D2 puls

Страница 1: ...uctions Welding machine Picomig 305 D2 puls Picomig 305 D3 puls 099 005266 EW501 07 05 2014 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warranty www ewm group com ...

Страница 2: ...pment No other form of liability regardless of type shall be accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are observed during installation operation usage and maintenance of the equipment An incorrectly performed installation can result i...

Страница 3: ...erview 16 4 1 Front view 16 4 2 Rear view 18 4 3 Inside view 19 4 4 Machine control Operating elements 20 5 Design and function 22 5 1 Installation 23 5 2 Machine cooling 24 5 3 Workpiece lead general 24 5 4 Welding torch holder 25 5 5 Notes on the installation of welding current leads 26 5 6 Mains connection 28 5 6 1 Mains configuration 28 5 7 Shielding gas supply shielding gas cylinder for weldi...

Страница 4: ...ing 55 5 9 4 MMA welding data display 55 5 9 4 1 Power saving mode 55 5 9 5 Arcforce 56 5 9 6 Hotstart 56 5 9 6 1 Hotstart settings 57 5 9 7 Antistick 57 5 10 TIG welding 58 5 10 1 Preparing the TIG welding torch 58 5 10 2 Welding torch and workpiece line connection 58 5 10 3 Welding task selection 59 5 10 4 Welding current setting 60 5 10 5 Adjusting the gas post flow time 60 5 10 6 Further weldi...

Страница 5: ...ctory settings 76 7 4 1 Resetting a single JOB 76 7 4 2 Resetting all JOBs 77 8 Technical data 78 8 1 Picomig 305 puls D2 78 8 2 Picomig 305 puls D3 79 9 Accessories 80 9 1 General accessories 80 9 2 Options 80 9 3 Transport systems 80 10 Replaceable parts 81 10 1 Wire feed rollers 81 10 1 1 Wire feed rollers for steel wire 81 10 1 2 Wire feed rollers for aluminium wire 81 10 1 3 Wire feed rollers...

Страница 6: ...ol 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 warning symbol The risk is explained using a symbol on the edge of the page CAUTION Working and operating procedures which must be followed precisely to avoid damaging or destroying t...

Страница 7: ...ress Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exit the menu 4 s Time display example wait 4s press Interruption in the menu display other setting options possible Tool not required do not use Tool required use ...

Страница 8: ...ks and burns on contact Even low voltages can cause you to get a shock and lead to accidents Do not touch any live parts in or on the machine Connection cables and leads must be free of faults Switching off alone is not sufficient Place welding torch and stick electrode holder on an insulated surface The unit should only be opened by specialist staff after the mains plug has been unplugged Only we...

Страница 9: ... accidents if these safety instructions are not observed Non observance of these safety instructions is potentially fatal Carefully read the safety information in this manual Observe the accident prevention regulations in your country Inform persons in the working area that they must observe the regulations Danger when coupling multiple power sources Coupling multiple power sources in parallel or ...

Страница 10: ...g currents Stray welding currents can destroy protective earth conductors damage equipment and electronic devices and cause overheating of components leading to fire Make sure all welding leads are securely connected and check regularly Always ensure a proper and secure electrical connection to the workpiece Set up attach or suspend all conductive power source components like casing transport vehi...

Страница 11: ...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 must consider the following see also EN 60974 10 Appendix A Mains control signal and telecommunication lines Radios and televisions Computers and other control systems Safety equipment The health of neighbouring persons especi...

Страница 12: ...uitable for transport by hand only The machine may not be lifted by crane or suspended CAUTION Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to IEC 60974 1 Set up and transport the machine on level solid ground Secure add on parts using suitable equipme...

Страница 13: ...ities of dust acid corrosive gases or substances may damage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambient conditions Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Keep the cooling air inlet and outlet clear Observe the minimum distan...

Страница 14: ...Welding with cored wire electrodes consisting of a metal casing and a powder core As with MIG MAG standard welding the arc is protected from the atmosphere by shielding gas The gas is supplied either externally gas shielded cored wires or produced in the arc by means of the powder core self shielding cored wires 3 1 2 2 rootArc Short arc with perfect weld modelling capabilities for effortless gap ...

Страница 15: ...ed with the unit 3 2 3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be used in environments with an increased electrical hazard 3 2 4 Service documents spare parts and circuit diagrams DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repaired or mod...

Страница 16: ...Machine description quick overview Front view 16 099 005266 EW501 07 05 2014 4 Machine description quick overview 4 1 Front view Figure 4 1 ...

Страница 17: ...o or Dinse torch connector Welding current shielding gas and torch trigger integrated 9 Machine feet 10 Park socket polarity selection plug Retainer for the polarity selection plug in MMA mode or for transport 11 Connection socket welding current MIG MAG cored wire welding Workpiece connection TIG welding Workpiece connection MMA welding Workpiece connection 12 welding current connection socket MI...

Страница 18: ...EW501 07 05 2014 4 2 Rear view Figure 4 2 Item Symbol Description 0 1 Main switch machine on off 2 Connecting nipple G shielding gas connection 3 Cooling air outlet 4 External wire feed inlet Pre cut casing inlet for external wire feed 5 Mains connection cable ...

Страница 19: ...ion 0 1 Key button Automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse 2 Button Wire inching For inching the wire electrode when changing the wire spool The welding wire is inched into the tube package with the current off and without the gas being expelled 3 Wire spool holder 4 Wire feed unit ...

Страница 20: ...t Illuminates upon display or selection of the JOB number 3 Key button JOB List Selection of the welding task JOB from the JOB list 4 Collective interference signal light 5 Excess temperature signal light 6 Signal light polarity setting 7 Signal light polarity setting 8 Push button welding parameter display mode Welding current Welding voltage Material thickness Wire feed speed Press for 2 s to pu...

Страница 21: ...lding type MIG MAG standard welding MIG MAG pulse arc welding 11 Operating mode button Non latched Latched Spots Interval 12 Welding parameter setting dial For setting the welding performance for selecting the JOB welding task and for setting other welding parameters 13 Arc length correction rotary dial 14 Runtime parameters button For selecting the parameters to be set Also for entering and exiti...

Страница 22: ...ent connection If the welding current connections are not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by turning in clockwise direction if necessary Risk of injury due to moving parts The wire feeders are equipped with moving parts which can trap hands hair clothing or tools and thus injure persons Do not reach into r...

Страница 23: ...f machines that may not be lifted Do not lift or suspend the machine The machine can fall down and cause injuries The handles and brackets are suitable for transport by hand only The machine may not be lifted by crane or suspended CAUTION Damage due to supply lines not being disconnected During transport supply lines which have not been disconnected mains supply leads control leads etc may cause h...

Страница 24: ...not allow metal parts dust or other objects to get into the machine 5 3 Workpiece lead general CAUTION Risk of burns due to incorrect connection of the workpiece lead Paint rust and dirt on the connection restrict the power flow and may lead to stray welding currents Stray welding currents may cause fires and injuries Clean the connections Fix the workpiece lead securely Do not use structural part...

Страница 25: ...g is part of the machine s scope of delivery Figure 5 1 Item Symbol Description 0 1 Crossmember of the transport handle 2 Torch holder 3 Fan type lock washers 4 Fixing screws x 4 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 ...

Страница 26: ...s in the arc flickering Lay the workpiece lead and hose package of power sources without HF igniter MIG MAG for as long and as close as possible in parallel Lay the workpiece lead and hose package of power sources 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 i...

Страница 27: ...05 2014 27 NOTE Use an individual welding lead to the workpiece for each welding machine Figure 5 3 NOTE Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Always keep leads as short as possible Lay any excess cable lengths in meanders Figure 5 4 ...

Страница 28: ...network has to be suitable for operating devices according to protection class 1 5 6 1 Mains configuration NOTE The machine may be connected to a three phase system with four conductors and an earthed neutral conductor a three phase system with three conductors of which any one can be earthed e g the outer conductor Figure 5 5 Legend Item Designation Colour code L1 Outer conductor 1 brown L2 Outer...

Страница 29: ...ding torch is a fundamental 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 NOTE Before connecting the pressure regulator to the gas cylinder open the cylinder valve briefly to expel an...

Страница 30: ...at rinsing process several times 5 7 3 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11 5 l min MIG brazing Wire diameter x 11 5 l min MIG welding aluminium Wire diameter x 13 5 l min 100 argon TIG Gas nozzle diameter in mm corresponds to l min gas throughput Helium rich gas mixtures require a higher gas volume The table below can...

Страница 31: ...e a chrome nickel liner when welding hard high alloy wire electrodes CrNi Use a plastic core to weld or braze 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 connecting welding torches with a plastic core Pu...

Страница 32: ...ector Welding current shielding gas and torch trigger 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 welding torch Connection socket for welding current Insert the central plug for the welding torch into the central connector and screw together with ...

Страница 33: ...r Welding current shielding gas and torch trigger integrated 3 Workpiece 4 Connection socket welding current MIG MAG cored wire welding 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 plug for the welding torch into the central connector and screw togethe...

Страница 34: ... secured wire spool If the wire spool is not secured properly it may come loose from the wire spool holder and fall to the ground causing damage to the machine and injuries Securely fasten the wire spool to the wire spool holder using the knurled nut Before you start working always check the wire spool is securely fastened Figure 5 9 Item Symbol Description 0 1 Carrier pin For fixing the wire spoo...

Страница 35: ...e and the material Check the roller label to verify that the rollers are suitable for the wire diameter Turn or change if necessary use V groove rollers with for steel wires and other hard wires use U groove rollers for aluminium wires and other soft alloyed wires Slide new drive rollers into place so that the diameter of the wire used is visible on the drive roller Screw the drive rollers in plac...

Страница 36: ...ntervals Keep all casing covers or protective caps closed during operation Risk of injury due to welding wire escaping from the welding torch The welding wire can escape from the welding torch at high speed and cause bodily injury including injuries to the face and eyes Never direct the welding torch towards your own body or towards other persons CAUTION Extensive wear due to incorrect contact pre...

Страница 37: ... wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe Press the clamping element with the pressure roller back downwards and fold the wire units back up again wire electrode should be in the groove on the drive roller Set the contact pressure with the adjusting nuts of t...

Страница 38: ...fined JOBs sticker on the machine The required process parameters are calculated by the system depending on the operating point specified single dial operation via wire speed rotary dial Conventional welding task definition using wire speed and welding voltage is also possible NOTE The welding task definition described below applies when defining MIG MAG and cored wire welding tasks Pay attention ...

Страница 39: ... Si1 steel 3 Shielding gas type 80 90 Ar 4 Wire diameter 0 8 mm A B 2 mm Determine welding task JOB Set JOB 6 Set operating point via panel thickness VOLT AM P Wire Gas M aterial JOB LIST DY N m min AM P 0 1 1 2 2 3 3 4 4 5 5 t2 t1 M 1 81 S 2 0 JOB 6 VOLT AM P Wire Gas M aterial JOB LIST DYN m min AM P 0 1 1 2 2 3 3 4 4 5 5 t2 t1 M 1 81 S 6 4 3 2 1 6 Figure 5 13 ...

Страница 40: ...t is flowing Operating element Action Result Display 1 x Select JOB list LED is on Set JOB number Wait 3 s until the setting has been applied 5 8 4 2 Operating mode Operating element Action Result n x Selecting the operating mode The LED indicates the selected operating mode Non latched operation Latched operation Spots Interval operation 5 8 4 3 Welding type MIG MAG standard pulse arc welding Ope...

Страница 41: ...rent Material thickness Wire speed Welding voltage After welding you can change back to the nominal values by pressing the buttons or using the dials on the controls or by briefly pressing the torch trigger 5 8 5 1 Power saving mode The power saving function can be activated either by pressing the button for a longer time see chapter Machine description Short overview or by setting a parameter in ...

Страница 42: ...5 8 6 2 Operating point setting using material thickness The process of setting the operating point by means of the panel thickness parameter is described as an example below Operating element Action Result Display Increase or reduce welding performance via the panel thickness parameter Display example 2 0 mm 5 8 6 3 Arc length correction setting Operating element Action Result Arc length correcti...

Страница 43: ...Choke effect dynamics Operating element Action Result Display n x Selecting the parameter to be set The LED indicates the parameter selected Parameter value set Choke effect dynamics Gas post flow time Spot time Pause time interval operation Set choke effect dynamics Setting range 40 Arc hard and narrow deeper fusion penetration 40 Arc soft and wide 5 8 7 2 Gas post flow time Operating element Act...

Страница 44: ...lue set Choke effect dynamics Gas post flow time Spot time Pause time interval operation Setting the stop time Setting range 0 1 s to 20 0 s in increments of 0 1 s 5 8 7 4 Pause time interval operation Operating element Action Result Display n x Selecting the parameter to be set The LED indicates the parameter selected Parameter value set Choke effect dynamics Gas post flow time Spot time Pause ti...

Страница 45: ...m min AM P DYN t2 t1 DYN t2 t1 Figure 5 15 Display Setting selection Burn back correction 0 to 499 of the burn back time specified in the JOB 5 8 7 6 gas pre flow time Preselection Select a MIG MAG JOB see chapter Selecting MIG MAG welding tasks ENTER 3 s EXIT 3 s NAVIGATION m min AM P DYN t2 t1 DYN t2 t1 Figure 5 16 Display Setting selection Gas pre flow time 0 0 s to 20 0 s 0 1 s increments ...

Страница 46: ...nces operating modes 5 8 9 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 ...

Страница 47: ...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 ...

Страница 48: ...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 ...

Страница 49: ...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 ...

Страница 50: ...e feed speed increases to the set nominal value The wire feed stops after 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 tri...

Страница 51: ... latched operation Latched operation Spots Interval operation 5 8 11 Welding data display Diagram 5 21 The button for the welding parameter display mode is next to the display Each time the button is pressed the display changes to the next parameter After the last parameter is reached the display continues with the first parameter The display shows Nominal values before welding Actual values durin...

Страница 52: ...mance via the wire speed parameter Operating element Action Result Set the welding voltage Setting range 5 V to 35 V NOTE Automatic display mode switching If the wire speed or the voltage is changed the display will switch briefly to show the respective parameter This means that you don t have to change the display mode before setting the parameter If the display mode is set to display the welding...

Страница 53: ...ece 3 Connection socket for welding current Electrode holder or workpiece lead connection 4 Connection socket welding current Electrode holder or workpiece lead connection 5 Polarity selector plug welding current cable Connect to the park socket Insert the polarity selection plug in the park socket and lock in place by turning to the right Insert cable plug of the electrode holder into either the ...

Страница 54: ...ection 0 1 Welding process MMA A B Determine welding task JOB Set JOB 128 Set welding current JOB 128 VOLT AM P Wire Gas M aterial JOB LIST DYN m min AM P 0 1 1 2 2 3 3 4 4 5 5 t2 t1 M 1 81 S 100 VOLT AM P Wire Gas M aterial JOB LIST DYN m min AM P 0 1 1 2 2 3 3 4 4 5 5 t2 t1 M 1 81 S 128 1 Figure 5 23 ...

Страница 55: ...tches between welding current and welding voltage The display shows Nominal values before welding Actual values during welding Hold values after welding Parameter Nominal values Actual values Hold values Welding current Welding voltage The display switches back from hold values to actual values for approximately 5 s after welding is finished 5 9 4 1 Power saving mode The power saving function can ...

Страница 56: ...strengths with a short arc in particular Operating element Action Result Display 1 x Select DYN setting LED is on Parameter value setting Arc forcing setting for electrode types Setting range 40 to 40 Negative values Rutile Values around zero Basic Positive values Rutilecellulose 5 9 6 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current a ...

Страница 57: ...n Hotstart current 0 to 200 of the welding current 1 increments Hotstart time 0 0 s to 20 0 s 0 1 s increments 5 9 7 Antistick Anti stick prevents the electrode from annealing If the electrode sticks in spite of the Arcforce device the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating Check the welding current setting and cor...

Страница 58: ...r 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 current cable Internal welding current cable for central connection welding torch Connection socket for welding current Insert the central plug for the welding torch into the central connector and screw ...

Страница 59: ...lection 0 1 Welding process TIG A B Determine welding task JOB Set JOB 127 Set welding current JOB 127 VOLT AM P Wire Gas M aterial JOB LIST DYN m min AM P 0 1 1 2 2 3 3 4 4 5 5 t2 t1 M 1 81 S 127 VOLT AM P Wire Gas M aterial JOB LIST DYN m min AM P 0 1 1 2 2 3 3 4 4 5 5 t2 t1 M 1 81 S 100 1 Figure 5 29 ...

Страница 60: ...it 3 s until the setting has been applied 5 10 4 Welding current setting Set the welding current with the rotary dial for the welding parameter settings Operating element Action Result Display Set welding current current nominal value 5 10 5 Adjusting the gas post flow time Operating element Action Result Display 1 x Select setting for gas post flow time LED is on parameter value setting Setting t...

Страница 61: ...sks ENTER 3 s EXIT 3 s NAVIGATION m min AM P DYN t2 t1 DYN t2 t1 Figure 5 30 Display Setting selection Gas pre flow time 0 0 s to 20 0 s 0 1 s increments Ignition current 0 to 200 of the welding current 1 increments Upslope time 0 0 s to 20 0 s 0 1 s increments Downslope time 0 0 s to 20 0 s 0 1 s increments End current 0 to 200 of the welding current 1 increments ...

Страница 62: ... menu time based power saving mode When power saving mode is activated both machine displays show the horizontal digit in the centre of the display only Pressing any operating element e g tapping the torch trigger deactivates power saving mode and the machine is ready for welding again 5 10 8 TIG arc ignition 5 10 8 1 Liftarc ignition Figure 5 32 The arc is ignited on contact with the workpiece a ...

Страница 63: ...9 Function sequences operating modes 5 10 9 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 ...

Страница 64: ...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...

Страница 65: ...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 process is terminated immediately if the torch trigger is released during the downslope time The welding current drops to zero and the gas post flow time begins 5 10 10 TIG automatic cut out NOTE The weldin...

Страница 66: ...ressing the sequence parameter push button Set or change the parameters by turning the welding parameter setting rotary knob EXIT Exit the menu Press the gas test flushing push button switch machine off and on again ENTER EXIT NAVIGATION l 0 DYN t2 t1 DYN t2 t1 m min AMP Figure 5 35 Display Setting selection Lead resistance 1 Lead resistance for the first welding circuit 0 mΩ 60 mΩ 8 mΩ ex works O...

Страница 67: ...er cooled welding torch With other hose package lengths it is necessary to carry out a voltage correction to optimise welding properties The voltage correction value can be set close to zero by means of re matching the cable resistance It is recommended to match the electric cable resistance after replacing accessories such as torches or intermediate hose packages In case a second wire feeder is u...

Страница 68: ... welding systems with a second power circuit if two wire feeders are to be operated from a single power source for example a second balancing with parameter rL2 must be performed 3 Balancing measurement Applying slight pressure put the welding torch in place with the contact tip on a clean purged location on the workpiece and then press the torch trigger for approx 2 seconds Short circuit current ...

Страница 69: ...lt free operation of your welding machine Among these are regular cleaning and checking as described below depending on the pollution level of the environment and the length of time the unit is in use 6 2 Maintenance work intervals 6 2 1 Daily maintenance tasks Clean the wire feed rollers on a regular basis depending on the degree of soiling 6 2 1 1 Visual inspection Mains supply lead and its stra...

Страница 70: ...ce and Testing Warranty A periodic test according to IEC 60974 4 Periodic inspection and test has to be carried out In addition to the regulations on testing given here the relevant local laws and regulations must also be observed 6 3 Maintenance work Repair and maintenance work may only be performed by qualified authorised personnel otherwise the right to claim under warranty is void In all servi...

Страница 71: ...ided for this purpose According to German law law governing the distribution taking back and environmentally correct disposal of electric and electronic equipment ElektroG from 16 03 2005 used machines are to be placed in a collection system separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private h...

Страница 72: ...es 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 fuse rear of the power source by pressing the key button Kinked hose packages Extend and lay out the torch hose package Wire guide core or spiral is dirty or worn Clean core or spiral replace kinked or wor...

Страница 73: ...Wire feeder speedometer error Check the wire feeder speedometer is not issuing a signal M3 00 defective inform Service Error 6 gas x Shielding gas error Check shielding gas supply for machines with shielding gas monitoring Error 7 Se Vol x Secondary excess voltage Inverter error inform Service Error 8 no PE x Earth fault between welding wire and earth line Phoenix 330 only Separate the connection ...

Страница 74: ...gend for categories error reset a The error message will disappear once the error has been rectified b The error message can be reset by pressing a key button Welding machine control Key button RC1 RC2 Expert CarExpert Progress M3 11 alpha Q Concept Basic Basic S Synergic Synergic S Progress M3 71 Picomig 305 not possible c The error message can only be reset by switching the machine off and on ag...

Страница 75: ... 07 05 2014 75 7 3 Resetting welding parameters to the factory settings RESET l 0 VOLT AMP DYN t2 t1 VOLT AMP DYN t2 t1 l 0 Figure 7 1 Display Setting selection Code of machine control Initialisation complete All customised welding parameters haven been overwritten by the factory settings ...

Страница 76: ...sks to the factory settings 7 4 1 Resetting a single JOB EXIT RESET ENTER 3 s 3 s 3 s JOB LIST JOB LIST Figure 7 2 Display Setting selection Reset to factory settings 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 ...

Страница 77: ...l JOBs NOTE All customised welding parameters that are stored will be replaced by the factory settings ENTER 3 s EXIT RESET 3 s 3 s JOB LIST JOB LIST Figure 7 3 Display Setting selection Reset to factory settings The RESET will be done after pressing the button The menu will be ended when no changes are done after 3 sec ...

Страница 78: ...e Open circuit voltage 93 V Mains voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 16 A Mains connection lead H07RN F4G2 5 Max connected load 11 0 kVA 8 3 kVA 12 1 kVA Recommended generator rating 16 4 kVA cosϕ 0 99 Insulation class protection classification F IP 23 Ambient temperature 25 C to 40 C Machine torch cooling Fan gas Welding torch connection ...

Страница 79: ... 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 16 A Mains connection lead H07RN F4G2 5 Max connected load 11 0 kVA 8 3 kVA 12 1 kVA Recommended generator rating 16 3 kVA cosϕ 0 99 Insulation class protection classification F IP 23 Ambient temperature 25 C to 40 C Machine torch cooling Fan gas Welding torch connection Euro torch connector Wire feed speed 1 m min to 20 m min Stand...

Страница 80: ...al accessories Type Designation Item no 5POLE CEE 16A M Machine plug 094 000712 00000 DM AR MIX 35L MIN Manometer pressure regulator 094 000009 00000 G1 G1 4 R 3M Gas hose 094 000010 00003 SPL Sharpener for plastic liners 094 010427 00000 HC PL Hose cutter 094 016585 00000 9 2 Options Type Designation Item no ON MF XX5 Dirt filter 092 002662 00000 9 3 Transport systems Type Designation Item no Tro...

Страница 81: ...092 000841 00000 FE 2DR4R 1 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 Pressure rollers smooth 37mm 092 000844 00000 10 1 2 Wire feed rollers for aluminium wire Type Designation Item no AL 4ZR4R 0 8 1 0 Twin rollers 37 mm for aluminium 092 000869 00000 AL 4ZR4R 1 0 1 2 Twin rollers 37 mm for aluminium 092 000848 00000 AL...

Страница 82: ...m 092 000846 00000 URUE AL 4ZR4R 1 2 1 6 Conversion kit 37mm 4 roller drive for aluminium 092 000847 00000 URUE AL 4ZR4R 2 4 3 2 Conversion kit 37mm 4 roller drive for aluminium 092 000868 00000 URUE ROE 2DR4R 0 8 0 9 0 8 0 9 Conversion kit 37mm 4 roller drive for cored wire 092 000830 00000 URUE ROE 2DR4R 1 0 1 2 1 4 1 6 Conversion kit 37mm 4 roller drive for cored wire 092 000831 00000 URUE ROE ...

Страница 83: ...OTE MIG 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 96 110 111 114 115 118 119 122 123 206 and 207 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 standard ...

Страница 84: ...Appendix B Overview of EWM branches 84 099 005266 EW501 07 05 2014 12 Appendix B 12 1 Overview of EWM branches ...

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