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Design and function

Transport and installation

099-005542-EW501

24.03.2020

Design and function

WARNING

Risk of injury from electrical voltage!

Contact with live parts, e.g. power connections, can be fatal!

• Observe the safety information on the first pages of the operating instructions!

• Commissioning must be carried out by persons who are specifically trained in handling

power sources!

• Connect connection or power cables while the machine is switched off!

CAUTION

Risk from electrical current!

If welding is carried out alternately using different methods and if a welding torch and

an electrode holder remain connected to the machine, the open-circuit/welding voltage

is applied simultaneously on all cables.

• The torch and the electrode holder should therefore always be placed on an insulated

surface before starting work and during breaks.

Read and observe the documentation to all system and accessory components!

5.1 Transport and installation

WARNING

Risk of accident due to improper transport of machines that must not 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 lifted using 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 non-slip and level, and provide sufficient lighting

for the place of work.

• Safe operation of the machine must be guaranteed at all times.

Equipment damage due to contamination!

Unusually high amounts of dust, acids, corrosive gases or substances can damage the machine

(observe maintenance intervals > see 6.2 chapter).

• Avoid large amounts of smoke, steam, oily fumes, grinding dust and corrosive ambient air!

5.1.1.1 In operation

Temperature range of the ambient air:

• -25 °C to +40 °C (-13 °F to 104 °F)

[1]

Relative humidity:

• up to 50 % at 40 °C (104 °F)
• up to 90 % at 20 °C (68 °F)

5.1.1.2 Transport and storage

Storage in a closed room, temperature range of the ambient air:

• -30 °C to +70 °C (-22 °F to 158 °F)

[1]

Relative humidity

• up to 90 % at 20 °C (68 °F)

[1]

Ambient temperature dependent on coolant! Observe the coolant temperature range of the torch coo-

ling

Содержание Picomig 355 puls TKM

Страница 1: ...Operating instructions EN Welding machine Picomig 355 puls TKM 099 005542 EW501 Observe additional system documents 24 03 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: ...kpiece lead general 24 5 1 4 Welding torch cooling system 24 5 1 4 1 Cooling unit connection 24 5 1 5 Notes on the installation of welding current leads 25 5 1 6 Stray welding currents 26 5 1 7 Mains...

Страница 4: ...s 56 5 6 2 Special parameters in detail 56 5 6 2 1 Ramp time for wire inching P1 56 5 6 2 2 Latched special latched tap start P9 56 5 6 3 Reset to factory settings 57 5 7 Machine configuration menu 58...

Страница 5: ...10 Replaceable parts 73 10 1 Wire feed rollers 73 10 1 1 Wire feed rollers for steel wire 73 10 1 2 Wire feed rollers for aluminium wire 73 10 1 3 Wire feed rollers for cored wire 74 10 1 4 Wire guid...

Страница 6: ...Contents Notes on using these operating instructions 6 099 005542 EW501 24 03 2020...

Страница 7: ...s and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning sym bol The hazard is also highlighted using a symbol in the page margin CAUTION Working or ope...

Страница 8: ...tch off machine Release Switch on machine Press and hold Switch Incorrect Invalid Turn Correct Valid Numerical value adjustable Input Signal light lights up in green Navigation Signal light flashes gr...

Страница 9: ...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 Ite...

Страница 10: ...en taking 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 int...

Страница 11: ...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 12: ...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 13: ...e instructions from the gas manufacturer and any relevant regulations concern ing the use of compressed air Do not attach any element to the shielding gas cylinder valve Prevent the shielding gas cyli...

Страница 14: ...and lock accessory components into the relevant connection socket when the ma chine is switched off Comprehensive descriptions can be found in the operating instructions for the relevant ac cessory co...

Страница 15: ...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 16: ...Machine description quick overview Front view rear view 16 099 005542 EW501 24 03 2020 4 Machine description quick overview 4 1 Front view rear view Figure 4 1...

Страница 17: ...air 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 4 pole connection socket Cooling unit volta...

Страница 18: ...Machine description quick overview Inside view 18 099 005542 EW501 24 03 2020 4 2 Inside view Figure 4 2...

Страница 19: ...nd other operating elements Depending on the machine series additional stickers with information on the replace ment parts and JOB lists will be located on the inside 4 Key button Automatic cutout Wir...

Страница 20: ...button Welding current Material thickness Wire feed speed Press for 2 s to put the machine into power saving mode Activate one of the operating elements to reactivate see 5 8 chapter 5 Display JOB Sh...

Страница 21: ...s button For selecting the parameters to be set Also for entering and exiting the menus for ad vanced settings Choke effect dynamics Gas post flow time Spot time Pause time 10 Arc length correction ro...

Страница 22: ...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 23: ...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 24: ...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 25: ...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 26: ...heck that all welding current connections are firmly secured and electrical connections are in perfect condition Set up attach or suspend all conductive power source components such as casing trans po...

Страница 27: ...ins plug socket and lead must be checked by a qualified electrician on a regular basis When operating the generator always ensure it is earthed as stipulated in the operating instructions The network...

Страница 28: ...ng is part of the machine s scope of delivery Figure 5 7 Item Symbol Description 0 1 Crossmember of the transport handle 2 Torch holder 3 Fixing screws x 4 4 Fan type lock washers Use the mounting scr...

Страница 29: ...upply from the shielding gas cylinder to the welding torch is a fun damental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch being de...

Страница 30: ...nder valve Open the pressure regulator Switch on the power source at the main switch Trigger gas test see 5 1 10 1 chapter function welding voltage and wire feed motor remain switched off no accidenta...

Страница 31: ...alloyed wire electrodes steel Use a chrome nickel liner when welding hard high alloy wire electrodes CrNi Use a plastic or teflon liner when welding or brazing soft wire electrodes high alloy wire ele...

Страница 32: ...ket and lock in place by turning to the right Insert the central plug for the welding torch into the central connector and screw together with crown nut Insert cable plug on the workpiece lead into th...

Страница 33: ...otentiometer for wire feed speed with potentiometers for wire feed speed and arc length correction Figure 5 13 5 2 4 Wire feed CAUTION Risk of injury due to moving parts The wire feeders are equipped...

Страница 34: ...pport 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 ch...

Страница 35: ...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 36: ...Wire feed roll overview table Material Diameter Colour code Groove form mm inch Steel Stainless steel Brazing 0 6 024 monochrome light pink V groove 0 8 031 white 0 8 0 9 1 0 031 035 039 bicolour whit...

Страница 37: ...he contact pressure of the front rollers in wire feed direction to a higher value The inching speed is infinitely adjustable by simultaneously pressing the wire inching push button and turning the wir...

Страница 38: ...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 5 Definition of MIG MA...

Страница 39: ...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 40: ...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 41: ...applicable intermediate hose packages Avoid loops 5 2 10 Operating modes functional sequences 5 2 10 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Shiel...

Страница 42: ...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 43: ...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 44: ...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 45: ...er 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...

Страница 46: ...12 Expert menu MIG MAG The Expert menu has adjustable parameters stored that don t require regular setting The number of pa rameters shown may be limited e g if a function is deactivated 2s 2s Figure...

Страница 47: ...rode or to move welded work pieces Figure 5 32 Item Symbol Description 0 1 Polarity selector plug welding current cable Connect to the park socket 2 Electrode holder 3 Workpiece Insert the polarity se...

Страница 48: ...ing electrode types at low current strengths with a short arc in particular Figure 5 34 Display Setting selection Arcforce correction Increase value harder arc Decrease value softer arc 5 3 4 Hotstart...

Страница 49: ...e minimum current within approx one se cond This prevents the electrode from annealing Check the welding current setting and correct for the welding task in hand Figure 5 36 5 3 6 Expert menu MMA The...

Страница 50: ...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 51: ...1 24 03 2020 51 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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...function Special parameters advanced settings 099 005542 EW501 24 03 2020 57 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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...ircuit Check welding circuit for short circuit put down welding torch isolated 59 Machine incompatible Check machine usage 60 Software update required Inform Service Categories legend resetting the er...

Страница 67: ...W501 24 03 2020 67 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 68: ...s 68 099 005542 EW501 24 03 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 69: ...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 70: ...on H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 4 25 C to 40 C Machine cooling Torch cooling Fan AF gas Wire feed speed 0 5 m min to 25m min Fa...

Страница 71: ...rolly 55 6 Transport cart assembled 090 008825 00000 9 3 Remote control connecting and extension cable 9 3 1 19 pole connection Type Designation Item no R10 19POL Remote control 090 008087 00000 RG10...

Страница 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...Appendix Searching for a dealer 099 005542 EW501 24 03 2020 77 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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