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EWM Picomig 305 puls TKM, Руководство по эксплуатации

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Design and function 

MIG/MAG welding 

 

099-005639-EW501 

04.06.2020

 

41

 

 

Spot welding 

 

Figure 5-28 

Start 

•  Press and hold torch trigger. 
•  Shielding gas is expelled (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. 

 

Содержание Picomig 305 puls TKM

Страница 1: ...Operating instructions EN Welding machine Picomig 305 puls TKM 099 005639 EW501 Observe additional system documents 04 06 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: ...iece lead general 22 5 1 4 Welding torch cooling system 22 5 1 4 1 Cooling unit connection 22 5 1 5 Notes on the installation of welding current leads 23 5 1 6 Stray welding currents 24 5 1 7 Mains co...

Страница 4: ...rs 52 5 6 2 Special parameters in detail 52 5 6 2 1 Ramp time for wire inching P1 52 5 6 2 2 Latched special latched tap start P9 52 5 6 3 Reset to factory settings 53 5 7 Machine configuration menu 5...

Страница 5: ...10 Replaceable parts 70 10 1 Wire feed rollers 70 10 1 1 Wire feed rollers for steel wire 70 10 1 2 Wire feed rollers for aluminium wire 70 10 1 3 Wire feed rollers for cored wire 71 10 1 4 Wire guid...

Страница 6: ...Contents Notes on using these operating instructions 6 099 005639 EW501 04 06 2020...

Страница 7: ...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 warn...

Страница 8: ...mplete documentation This document is 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 sy...

Страница 9: ...aking individual power sources out of operation all mains and welding current leads must be safely disconnected from the welding system as a whole Hazard due to reverse polarity voltage Do not interco...

Страница 10: ...fire extinguishers are available in the working area Thoroughly remove any residue of flammable materials from the workpiece prior to starting to weld Only further process workpieces after they have c...

Страница 11: ...ed out Recommendations for reducing interference emission Mains connection e g additional mains filter or shielding with a metal tube Maintenance of the arc welding system Welding leads should be as s...

Страница 12: ...e of compressed air Do not attach any element to the shielding gas cylinder valve Prevent the shielding gas cylinder from heating up CAUTION Risk of accidents due to supply lines During transport atta...

Страница 13: ...witched off Comprehensive descriptions can be found in the operating instructions for the relevant ac cessory components Accessory components are detected automatically after the power source is switc...

Страница 14: ...information regarding warranty maintenance and testing at www ewm group com 3 2 2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the d...

Страница 15: ...Machine description quick overview Front view rear view 099 005639 EW501 04 06 2020 15 4 Machine description quick overview 4 1 Front view rear view Figure 4 1...

Страница 16: ...r outlet 10 Machine feet 11 External wire feed inlet Pre cut casing inlet for external wire feed 12 8 pole connection socket Cooling unit control lead 13 Connection thread G Shielding gas connection i...

Страница 17: ...Machine description quick overview Inside view 099 005639 EW501 04 06 2020 17 4 2 Inside view Figure 4 2...

Страница 18: ...itional stickers with information on the replace ment parts and JOB lists will be located on the inside 4 Key button Automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fus...

Страница 19: ...elding task from the welding task list JOB LIST The list can be found inside the protective cap on the wire feeder and in the appendix to these operating instructions 7 Welding parameter setting dial...

Страница 20: ...ing Hold values after welding MIG MAG Parameter Nominal values Actual values Hold values Welding current 1 Material thickness Wire feed speed Welding voltage 1 traditional MIG MAG TIG MMA Parameter No...

Страница 21: ...ot be lifted Do not lift or suspend the machine The machine can drop and cause injuries The handles straps or brackets are suitable for transport by hand only The machine must not be suspended or lift...

Страница 22: ...s and leads can heat up and cause burns when touched Check welding current connections on a daily basis and lock by turning to the right when necessary Clean workpiece connection thoroughly and secure...

Страница 23: ...ith HF igniter TIG for as long as pos sible in parallel with a distance of 20 cm to avoid HF sparkover Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences A...

Страница 24: ...y are insulated Always put welding torches and electrode holders on an insulated surface when they are not in use Figure 5 5 5 1 7 Mains connection DANGER Hazards caused by improper mains connection A...

Страница 25: ...earthed neutral conductor a three phase system with three conductors of which any one can be earthed e g the outer conductor Figure 5 6 Legend Item Designation Colour code L1 Outer conductor 1 brown L...

Страница 26: ...r of the transport handle Insert the welding torch into the welding torch holder as shown 5 1 9 Shielding gas supply shielding gas cylinder for welding machine WARNING Risk of injury due to improper h...

Страница 27: ...ure 5 8 Item Symbol Description 0 1 Pressure regulator 2 Output side of the pressure regulator 3 Shielding gas cylinder 4 Cylinder valve Before connecting the pressure regulator to the gas cylinder op...

Страница 28: ...switched off no accidental arc ignition Set the relevant gas quantity for the application on the pressure regulator Setting instructions Welding process Recommended shielding gas quantity MAG welding...

Страница 29: ...zing 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 rela...

Страница 30: ...elding 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 corresponding a...

Страница 31: ...port Before you start working always check the wire spool is securely fastened Standard D300 wire spool holder can be used Adapters are required when using standardised basket coils DIN 8559 see 9 5 c...

Страница 32: ...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 33: ...hite 0 8 0 9 1 0 031 035 039 bicolour white blue 1 0 1 2 039 047 blue red 1 4 055 monochrome green 1 6 063 black 2 0 079 grey 2 4 094 brown 2 8 110 light green 3 2 126 purple Aluminium 0 8 031 bicolou...

Страница 34: ...e inching push button and turning the wire speed rotary knob The left display shows the wire feed speed selected the right display shows the current motor current of the wire feed mechanism Depending...

Страница 35: ...direction to increase the braking effect Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation 5 2 3 Definition of MIG MA...

Страница 36: ...ed settings apply to all JOBs Throttling effect dynamics gas post flow time gas pre flow time and wire burn back correction are stored for each JOB individually Changes are stored permanently in the J...

Страница 37: ...ration and directionally stable arc Excellent root and sidewall fusion Secure welding also with very long stick outs Reduced undercuts Manual and automated applications You can make use of these prope...

Страница 38: ...f applicable intermediate hose packages Avoid loops 5 2 8 Operating modes functional sequences 5 2 8 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Shiel...

Страница 39: ...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 40: ...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 41: ...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 42: ...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 43: ...tting selection Gas pre flow time Burn back correction 5 3 MMA welding 5 3 1 Connecting the electrode holder and workpiece lead CAUTION Risk of crushing and burns When changing stick electrodes there...

Страница 44: ...ill be based on the in formation of the electrode manufacturer on the electrode packaging 5 3 2 Welding task selection Select MMA JOB 128 see 11 1 chapter You can only change the JOB number when no we...

Страница 45: ...Current t Time Figure 5 35 5 3 5 Antistick The Antistick feature prevents the electrode from annealing Should the electrode stick despite the Arcforce feature the machine automatically switches to the...

Страница 46: ...on Figure 5 38 Item Symbol Description 0 1 Welding torch 2 Polarity selector plug welding current cable Internal welding current cable for central connection welding torch Connection socket for weldin...

Страница 47: ...1 04 06 2020 47 5 4 3 Welding task selection Select TIG JOB 127 You can only change the JOB number when no welding current is flowing 3s Figure 5 39 5 4 4 Adjusting the gas post flow time 3s Figure 5...

Страница 48: ...wn may be limited e g if a function is deactivated 2s 2s Figure 5 41 Display Setting selection Gas pre flow time Ignition current as percentage dependent on main current Upslope time to main current D...

Страница 49: ...o normal position Complete the welding task Remove the torch from the workpiece so that the arc extinguishes 5 4 7 Operating modes functional sequences 5 4 7 1 Legend Symbol Meaning Press torch trigge...

Страница 50: ...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 51: ...torch trigger is released during the downslope time The welding current drops to zero and the gas post flow time begins 5 5 Remote control The remote controls are operated on the 19 pole remote contr...

Страница 52: ...mponents with a single pair of but tons or a rocker only 1 3 8 No remote control encoding 10 15 No remote control encoding 5 6 2 Special parameters in detail 5 6 2 1 Ramp time for wire inching P1 The...

Страница 53: ...function Special parameters advanced settings 099 005639 EW501 04 06 2020 53 5 6 3 Reset to factory settings All special parameters saved by the user will be overwritten by the factory settings l 0 F...

Страница 54: ...lection Lead resistance 1 Lead resistance for the first welding circuit 0 m 60 m 8 m ex works Time based power saving mode see 5 8 chapter Time to activation of the power saving mode in case of inacti...

Страница 55: ...ater cooled welding torch With other hose package lengths it is ne cessary to carry out a voltage correction to optimise welding properties The voltage correction value can be set close to zero by mea...

Страница 56: ...contact tip on a clean purged location on the workpiece and then press the torch trigger for approx 2 seconds A short circuit current will flow briefly which is used to determine and display the new c...

Страница 57: ...ight to claim under warranty is void In all service matters always consult the dealer who supplied the machine Return deliveries of defective equipment subject to warranty may only be made through you...

Страница 58: ...rollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks Visual inspection Casing damage front rear and side walls Wheels and their securing elements Transport el...

Страница 59: ...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 60: ...s illuminated after switching on No welding power Phase failure check mains connection fuses Machine restarts continuously Wire feeder without function System does not start up Make control lead conne...

Страница 61: ...tage Check the mains voltages and compare with the connection voltages of the welding ma chine 2 Mains undervoltage 3 Excess temperature of welding machine Allow the machine to cool down mains switch...

Страница 62: ...oltages 58 Short circuit Check welding circuit for short circuit put down welding torch isolated 59 Machine incompatible Check machine usage 60 Software update required Inform Service Category legend...

Страница 63: ...W501 04 06 2020 63 7 3 Welding parameter calibration In case of deviations between the welding parameters set on the front panel remote control and those shown on the welding machine this function all...

Страница 64: ...s 64 099 005639 EW501 04 06 2020 7 4 Resetting welding parameters to the factory settings RESET l 0 l 0 Figure 7 2 Display Setting selection Code of machine control Initialisation complete All customi...

Страница 65: ...he RESET will be done after pressing the button The menu will be ended when no changes are done after 3 sec JOB number example The shown JOB will be set to ex works 7 5 2 Resetting all JOBs All custom...

Страница 66: ...tage 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 4 25 C to 40 C Mach...

Страница 67: ...Technical data Picomig 305 TKM 099 005639 EW501 04 06 2020 67 4 Ambient temperature dependent on coolant Observe coolant temperature range...

Страница 68: ...e control 090 008087 00000 RG10 19POL 5M Remote control to set the wire speed and welding voltage correction 090 008108 00000 RA5 19POL 5M Remote control e g connection cable 092 001470 00005 RA10 19P...

Страница 69: ...001 CA D200 Centering adapter for 5 kg spools 094 011803 00000 16A 5POLE CEE Mains plug 094 000712 00000 DM 842 Ar CO2 230bar 30l D Pressure regulator with manometer 394 002910 00030 G1 G1 4 R 3M Gas...

Страница 70: ...tainless steel and brazing 092 002770 00020 FE 4R 2 4 MM 0 095 INCH BROWN Drive roll set 37 mm 4 rolls V groove for steel stainless steel and brazing 092 002770 00024 FE 4R 2 8 MM 0 11 INCH LIGHT GREE...

Страница 71: ...4 FUEL 4R 1 6 MM 0 06 INCH BLACK ORANGE Drive roll set 37 mm 4 rolls V groove knurled for flux cored wire 092 002848 00016 FUEL 4R 2 0 MM 0 08 INCH GREY ORANGE Drive roll set 37 mm 4 rolls V groove kn...

Страница 72: ...MAG pulse arc welding can be selected with JOBs 6 9 34 36 42 44 74 76 78 80 82 84 86 88 90 92 94 96 110 112 114 116 118 120 122 124 179 206 207 235 238 and 254 If an attempt is made to set another JO...

Страница 73: ...Gas pre flow time 0 5 0 0 20 0 s Ignition current 0 0 20 0 s Up slope time 1 0 0 20 0 s Down slope time 0 0 20 0 s End current 20 1 200 Gas post flow time 0 5 0 0 20 0 s MMA Hot start current 0 0 20...

Страница 74: ...Appendix Searching for a dealer 74 099 005639 EW501 04 06 2020 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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