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Rectifying faults

Checklist for rectifying faults

72

099-005313-EW501

02.09.2015

7

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
dealer.

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

Wire feed problems



Contact tip blocked



Clean, spray with anti-spatter spray and replace if necessary



Setting the spool brake - See 5.7.4.5 Spool brake setting chapter





Check settings and correct if necessary



Setting pressure units - See 5.7.4.4 Inching the wire electrode 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 worn cores

Functional errors



Machine control without displaying the signal lights after switching on



Phase failure > check mains connection (fuses)



No welding performance



Phase failure > check mains connection (fuses)



Connection problems





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





Tighten contact tip correctly

Mains fuse triggers



Unsuitable mains fuse



Set up recommended mains fuse.

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Содержание Picomig 305 D3 puls

Страница 1: ...ions EN Welding machine Picomig 305 D3 puls TKG Picomig 305 D3 Synergic TKG 099 005313 EW501 02 09 2015 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit...

Страница 2: ...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 m...

Страница 3: ...Service documents spare parts and circuit diagrams 15 3 2 5 Calibration Validation 15 4 Machine description quick overview 16 4 1 Front view 16 4 2 Rear view 18 4 3 Inside view 19 4 4 Machine control...

Страница 4: ...t 51 5 8 MMA welding 52 5 8 1 Connecting the electrode holder and workpiece lead 52 5 8 2 Welding task selection 53 5 8 3 Welding current setting 53 5 8 4 MMA welding data display 53 5 8 5 Arcforce 54...

Страница 5: ...ges power source 73 7 3 Resetting welding parameters to the factory settings 75 7 4 Resetting JOBs welding tasks to the factory settings 76 7 4 1 Resetting a single JOB 76 7 4 2 Resetting all JOBs 77...

Страница 6: ...e 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 i...

Страница 7: ...rve Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exi...

Страница 8: ...hocks 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 Swit...

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 preve...

Страница 10: ...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 sec...

Страница 11: ...ard 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 foll...

Страница 12: ...itable 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 d...

Страница 13: ...ties 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 ambie...

Страница 14: ...optimum welding results when joining unalloyed low allow and high alloy steels and aluminium thanks to controlled droplet transfer and targeted adapted heat input 3 1 2 1 forceArc puls Effective exten...

Страница 15: ...is enclosed 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 elect...

Страница 16: ...Machine description quick overview Front view 16 099 005313 EW501 02 09 2015 4 Machine description quick overview 4 1 Front view Figure 4 1...

Страница 17: ...or for transport 7 Machine feet 8 Welding current cable polarity selection Welding current to Euro torch connector torch for polarity selection MIG MAG Connection socket for welding current Self shiel...

Страница 18: ...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...

Страница 19: ...on 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 wir...

Страница 20: ...elding data display 3 digit Displays the welding parameters and the corresponding values 2 Signal light JOB List Illuminates upon display or selection of the JOB number 3 Key button JOB List Selection...

Страница 21: ...ges See 5 6 Shielding gas supply shielding gas cylinder for welding machine chapter 10 Welding type push button for machine versions with pulsed arc welding procedures only standard MIG MAG welding pu...

Страница 22: ...nt 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 cloc...

Страница 23: ...and brackets are suitable for transport by hand only The machine may not be lifted by crane or suspended CAUTION Installation site The machine must not be operated in the open air and must only be set...

Страница 24: ...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 parall...

Страница 25: ...02 09 2015 25 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 Alw...

Страница 26: ...uctions The resulting network has to be suitable for operating devices according to protection class 1 5 5 1 Mains configuration The machine may be connected to a three phase system with four conducto...

Страница 27: ...elding 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...

Страница 28: ...eat rinsing process several times 5 6 2 1 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...

Страница 29: ...trodes steel Use a chrome nickel liner when welding hard high alloy wire electrodes CrNi Use a liner to weld or braze soft wire electrodes high alloy wire electrodes or aluminium materials Preparation...

Страница 30: ...connection welding torch Connection socket for welding current Insert the central plug for the welding torch into the central connector and screw together with crown nut Insert the plug of the workpie...

Страница 31: ...ge correction Welding torches with one rotary knob one rocker or one pair of buttons only must be configured on the machine control appropriately For this purpose set the FRC special parameter to the...

Страница 32: ...ome 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 wo...

Страница 33: ...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 34: ...code Groove form mm inch Steel Stainless steel Brazing 0 6 023 monochrome light pink V groove 0 8 030 white 0 9 1 0 035 040 blue 1 2 045 red 1 4 052 green 1 6 060 black 2 0 080 grey 2 4 095 brown 2 8...

Страница 35: ...intervals 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 hig...

Страница 36: ...the welding torch outlet A prerequisite for the automatic inching process is the correct preparation of the wire guide especially in the capillary and wire guide tube area The contact pressure has to...

Страница 37: ...5 Welding data display Diagram 5 12 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 pa...

Страница 38: ...re used here to set the wire speed and the welding voltage Operating element Action Result Increase or reduce welding performance via the wire speed parameter Operating element Action Result Set the w...

Страница 39: ...the polarity selction plug if necessary 5 7 7 Welding task selection The settings for the respective welding parameters are defined by the different JOBs The right JOB can be determined quickly with t...

Страница 40: ...d 5 7 8 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 Actio...

Страница 41: ...ory settings chapter 5 7 9 1 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 effe...

Страница 42: ...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 7 9 4 Pause time interval operation O...

Страница 43: ...EXIT 3 s NAVIGATION m min AMP Figure 5 13 Display Setting selection Burn back correction 0 to 499 of the burn back time specified in the JOB 5 7 9 6 gas pre flow time Preselection Select a MIG MAG JOB...

Страница 44: ...i Ar 91 99 251 12 0 252 12 0 253 6 0 You can make use of these properties after selecting the forceArc process See 5 7 7 Welding task selection chapter As with pulse arc welding it is important to mak...

Страница 45: ...t formation and secure sidewall fusion Un alloyed and low alloy steels Manual and automated applications rootArc welding up to Wire mm 0 6 0 8 0 9 1 1 2 1 6 Material Gas JOB JOB JOB JOB JOB JOB Steel...

Страница 46: ...es operating modes 5 7 12 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 cre...

Страница 47: ...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 48: ...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 49: ...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 50: ...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...

Страница 51: ...number Wait 3 s until the setting has been applied 5 7 13 1 Operating mode Operating element Action Result n x Selecting the operating mode The LED indicates the selected operating mode Non latched o...

Страница 52: ...piece 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 w...

Страница 53: ...al for the welding parameter settings Operating element Action Result Display Set welding current current nominal value 5 8 4 MMA welding data display Diagram 5 22 The button for the welding parameter...

Страница 54: ...strengths with a short arc in particular Operating element Action Result Display 1 x Select DYN setting LED is on Parameter value setting Arc force setting for electrode types Setting range 40 to 40 N...

Страница 55: ...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 8 7 Antistick Anti stick prevents the electrode from annealing If the electrode sticks i...

Страница 56: ...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 57: ...D is on Set JOB number Wait 3 s until the setting has been applied 5 9 3 1 Welding current setting Set the welding current with the rotary dial for the welding parameter settings Operating element Act...

Страница 58: ...ter ENTER 3 s EXIT 3 s NAVIGATION m min AMP DYN t2 t1 DYN t2 t1 Figure 5 27 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 curren...

Страница 59: ...mately 5 s after welding is finished 5 9 6 TIG arc ignition 5 9 6 1 Liftarc ignition Figure 5 29 The arc is ignited on contact with the workpiece a Carefully place the torch gas nozzle and tungsten el...

Страница 60: ...Function sequences operating modes 5 9 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 t...

Страница 61: ...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 62: ...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 63: ...e transport handle Insert the welding torch into the welding torch holder as shown 5 11 Power saving mode Standby The power saving function can be activated either by pressing the button for a longer...

Страница 64: ...hine functions This allows the user maximum flexibility in optimising their requirements These settings are not configured directly on the machine control since a regular setting of the parameters is...

Страница 65: ...r accessory components with a single pair of buttons or a rocker only 5 13 1 1 Special parameters in detail Ramp time for wire inching P1 The wire inching starts with a speed 1 0 m min for 2 secs It i...

Страница 66: ...special parameters saved by the user will be overwritten by the factory settings Operating element Action Result Display left right Switch off welding machine Press and hold push button Switch on weld...

Страница 67: ...ssing 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...

Страница 68: ...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...

Страница 69: ...welding systems with a second power circuit if two wire feeders are to be operated from a single power source for example a second alignment with parameter rL2 must be performed 3 Alignment measureme...

Страница 70: ...number of the spare part 6 1 General When used in the specified environmental conditions and under normal operating conditions this machine is largely maintenance free and requires a minimum of care T...

Страница 71: ...an Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be collected separately The symbol depicting a was...

Страница 72: ...k settings and correct if necessary Setting pressure units See 5 7 4 4 Inching the wire electrode chapter Check settings and correct if necessary Worn wire rolls Check and replace if necessary Wire fe...

Страница 73: ...wire feeder speedometer is not issuing a signal M3 51 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...

Страница 74: ...ilure Check mains voltages Legend 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 mach...

Страница 75: ...02 09 2015 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 c...

Страница 76: ...ks 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 press...

Страница 77: ...all JOBs 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...

Страница 78: ...es 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 3 kVA...

Страница 79: ...ting and extension cable 9 2 1 19 pole connection Type Designation Item no R10 19POL Remote control 090 008087 00000 RG10 19POL 5M Remote control to set the wire speed and welding voltage correction 0...

Страница 80: ...azing 092 002770 00008 FE 4R 1 0 MM 0 04 INCH BLUE Drive roll set 37 mm 4 rolls V groove for steel stainless steel and brazing 092 002770 00010 FE 4R 1 2 MM 0 045 INCH RED Drive roll set 37 mm 4 rolls...

Страница 81: ...urled for flux cored wire 092 002848 00008 FUEL 4R 1 0 MM 0 04 INCH BLUE ORANGE Drive roll set 37 mm 4 rolls V groove knurled for flux cored wire 092 002848 00010 FUEL 4R 1 2 MM 0 045 INCH RED ORANGE...

Страница 82: ...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 no...

Страница 83: ...Appendix B Overview of EWM branches 099 005313 EW501 02 09 2015 83 12 Appendix B 12 1 Overview of EWM branches...

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