EWM Picomig 180 puls TKG Operating Instructions Manual
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EWM Picomig 180 puls TKG Operating Instructions Manual

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Operating instructions
Welding machine
EN
Picomig 180 puls TKG
099-005545-EW501
03.11.2016

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Summary of Contents for EWM Picomig 180 puls TKG

  • Page 1 Operating instructions Welding machine Picomig 180 puls TKG 099-005545-EW501 03.11.2016...

  • Page 2: General Instructions

    +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 Part of the complete documentation ....................8 Safety instructions ..........................
  • Page 4 Resetting welding parameters to the factory settings ..............67 Display machine control software version ..................67 Dynamic power adjustment ......................67 8 Technical data............................68 Picomig 180 puls TKG ......................... 68 9 Accessories ............................69 Options ............................69 Transport systems ........................69 General accessories ........................
  • Page 5 Contents Notes on the use of these operating instructions 099-005545-EW501 03.11.2016...

  • Page 6: For Your Safety

    For your safety Notes on the use of these operating instructions For your safety Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. •...

  • Page 7: Explanation Of Icons

    For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release/tap/tip user must observe. Switch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Numerical value – adjustable Correct Menu entry Signal light lights up in green...

  • Page 8: Part Of The Complete Documentation

    For your safety Part of the complete documentation Part of the complete documentation These operating instructions are part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system.

  • Page 9: Safety Instructions

    For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
  • Page 10 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
  • Page 11 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
  • Page 12 For your safety Safety instructions CAUTION Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •...

  • Page 13: Transport And Installation

    For your safety Transport and installation Transport and installation WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! • Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air! •...

  • Page 14: Intended Use

    Intended use Applications Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate.

  • Page 15: Documents Which Also Apply

    In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product.

  • Page 16: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-005545-EW501 03.11.2016...
  • Page 17 Machine description – quick overview Front view Item Symbol Description Carrying handle Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside. Wire spool inspection window Check wire supply Slide latch, lock for the protective cap...

  • Page 18: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Main switch, machine on/off Connecting nipple G¼, shielding gas connection Mains connection cable with connector plug Cooling air outlet Cooling air inlet 099-005545-EW501 03.11.2016...

  • Page 19: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-3 Item Symbol Description Wire spool holder Wheels Machine feet Wire feed unit Push-button, wire inching Potential- and gas-free inching of the wire electrode through the hose package to the welding torch >...

  • Page 20: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements The setting ranges for the parameter values are summarised in the Parameter overview section > see 12.1 chapter. Figure 4-4 Item Symbol Description “Collective interference” signal light “Excess temperature”...
  • Page 21 Machine description – quick overview Machine control – Operating elements Item Symbol Description JOB- Welding task push-button (JOB) LIST Select the welding 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.

  • Page 22: Design And Function

    Design and function Transport and installation Design and function WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •...

  • Page 23: Machine Cooling

    Design and function Transport and installation 5.1.2 Machine cooling 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 distance of 0.5 m from obstacles! 5.1.3 Workpiece lead, general CAUTION...

  • Page 24: Notes On The Installation Of Welding Current Leads

    Design and function Transport and installation 5.1.4 Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults 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.

  • Page 25: Stray Welding Currents

    Design and function Transport and installation 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 5-3 5.1.4.1 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and...

  • Page 26: Mains Connection

    Design and function Transport and installation 5.1.5 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only operate machine using a socket that has correctly fitted protective earth. • The mains voltage indicated on the rating plate must match the supply voltage.

  • Page 27: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Transport and installation 5.1.6 Shielding gas supply (shielding gas cylinder for welding machine) WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! •...

  • Page 28: Shielding Gas Hose Connection

    Design and function Transport and installation 5.1.6.2 Shielding gas hose connection Figure 5-7 Item Symbol Description Connecting nipple G¼, shielding gas connection • Connect crown nut of the shielding gas line to the G¼“ connecting nipple. 099-005545-EW501 03.11.2016...

  • Page 29: Gas Test - Setting The Shielding Gas Volume

    Design and function Transport and installation Gas test – setting the shielding gas volume 5.1.6.3 CAUTION Electric shocks! When setting the shielding gas quantity, high voltage ignition pulses or open circuit voltage are applied at the welding torch; these can lead to electric shocks and burning on contact.

  • Page 30: Welding Data Display

    Design and function Welding data display Welding data display Figure 5-8 The push-button for the welding parameter display mode is next to the display. Each time the push-button is pressed the display changes to the next parameter. After the last parameter is reached the display continues with the first parameter.

  • Page 31: Setting The Operating Point (Welding Output)

    Design and function Welding data display 5.2.2 Setting the operating point (welding output) 5.2.2.1 Operating point setting via welding current Automatic display mode switching: If the wire speed or the voltage is changed, the display will switch briefly to show the respective parameter.

  • Page 32: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.3.1 Welding torch and workpiece line connection On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used! •...
  • Page 33 Design and function MIG/MAG welding Choose welding current connection socket according to the signal light for the polarity setting! • Select JOB • Polarity selection “+” or polarity selection “-” signal lights show the polarity setting. Figure 5-10 Item Symbol Description Welding torch Welding torch connection (Euro torch connector)

  • Page 34: Wire Feed

    Design and function MIG/MAG welding 5.3.2 Wire feed CAUTION 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 rotating or moving parts or drive components! •...

  • Page 35: Inserting The Wire Spool

    Design and function MIG/MAG welding 5.3.2.2 Inserting the wire spool CAUTION Risk of injury due to incorrectly secured wire spool. If the wire spool is not secured properly, it may come loose from the wire spool support and fall to the ground, causing damage to the machine and injuries. •...

  • Page 36: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.3.2.3 Changing the wire feed rollers Unsatisfactory welding results due to faulty wire feeding! Wire feed rollers must be suitable for the diameter of the wire and the material. • Check the roller label to verify that the rollers are suitable for the wire diameter. Turn or change if necessary! •...

  • Page 37: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.3.2.4 Inching the wire electrode Figure 5-13 Item Symbol Description Adjusting nut Feed roll tensioner Fixing the clamping unit and setting the pressure. Clamping unit Knurled screw Pressure roller Drive roller Wire feed nipple Guide tube •...

  • Page 38: Spool Brake Setting

    Design and function MIG/MAG welding 5.3.2.5 Spool brake setting Figure 5-14 Item Symbol Description Allen screw Securing the wire spool retainer and adjustment of the spool brake • Tighten the Allen screw (8 mm) in the clockwise 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! 099-005545-EW501...

  • Page 39: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.3.3 Definition of MIG/MAG welding tasks This machine range features simple operation with a very wide range of functions. • JOBs (welding tasks consisting of welding process, type of material, wire diameter and type of shielding gas) are pre-defined for all common welding tasks.

  • Page 40: Welding Task Selection

    Design and function MIG/MAG welding 5.3.4 Welding task selection The settings for the respective welding parameters are defined by the different JOBs. The right JOB can be determined quickly with the JOB list > see 11.1 chapter. Figure 5-15 Item Symbol Description JOB- Welding task push-button (JOB)

  • Page 41: Further Welding Parameters

    Design and function MIG/MAG welding 5.3.5 Further welding parameters • Preselection: Select a MIG/MAG JOB > see 5.3.4 chapter. ENTER NAVIGATION EXIT Figure 5-16 Display Setting/selection Gas pre-flow time Burn-back correction 099-005545-EW501 03.11.2016...

  • Page 42: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.3.6 MIG/MAG functional sequences / operating modes 5.3.6.1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Shielding gas flowing Welding output Wire electrode is being conveyed Wire creep Wire burn-back Gas pre-flows Gas post-flows Non-latched...
  • Page 43 Design and function MIG/MAG welding Non-latched mode Figure 5-17 Step 1 • Press and hold torch trigger. • Shielding 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. •...
  • Page 44 Design and function MIG/MAG welding Latched mode Figure 5-18 1. cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed” • Arc ignites when the wire electrode makes contact with the workpiece Welding current flows •...
  • Page 45 Design and function MIG/MAG welding Spot welding Figure 5-19 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. •...
  • Page 46 Design and function MIG/MAG welding Interval Figure 5-20 Start • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). Sequence • Arc ignites after the wire electrode makes contact with the workpiece at creep speed. • Welding current flows. •...

  • Page 47: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Design and function MIG/MAG welding 5.3.7 Conventional MIG/MAG Welding (GMAW non synergic) You can only change the JOB number when no welding current is flowing. Figure 5-21 Item Symbol Description JOB- Welding task push-button (JOB) LIST Select the welding 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.

  • Page 48: Mma Welding

    Design and function MMA welding MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •...

  • Page 49: Welding Task Selection

    Design and function MMA welding 5.4.2 Welding task selection • Select MMA JOB 128 > see 11.1 chapter. You can only change the JOB number when no welding current is flowing. Figure 5-23 Item Symbol Description JOB- Welding task push-button (JOB) LIST Select the welding task from the welding task list (JOB-LIST).

  • Page 50: Arcforce

    Design and function MMA welding 5.4.2.1 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current. This makes it easier to weld large-drop melting electrode types at low current strengths with a short arc in particular.

  • Page 51: Hotstart Settings

    Design and function MMA welding 5.4.3.1 Hotstart settings The setting ranges for the parameter values are summarised in the Parameter overview section > see 12.1 chapter. • Select MMA JOB 128 > see 5.4.2 chapter. ENTER NAVIGATION EXIT Figure 5-26 Display Setting/selection Hot start current...

  • Page 52: Tig Welding

    Design and function TIG welding TIG welding 5.5.1 Preparing the TIG welding torch The TIG welding torch is to be equipped to suit the relevant welding task! • Fit suitable tungsten electrodes and • an appropriate shielding gas nozzle. • Observe the operating instructions for the TIG welding torch! 5.5.2 Welding torch and workpiece line connection...

  • Page 53: Welding Task Selection

    Design and function TIG welding 5.5.3 Welding task selection • Select TIG JOB 127 > see 11.1 chapter. You can only change the JOB number when no welding current is flowing. Figure 5-29 Item Symbol Description JOB- Welding task push-button (JOB) LIST Select the welding task from the welding task list (JOB-LIST).

  • Page 54: Further Welding Parameters

    Design and function TIG welding 5.5.5 Further welding parameters The setting ranges for the parameter values are summarised in the Parameter overview section > see 12.1 chapter. • Preselection: Select TIG JOB 127 > see 5.5.3 chapter. NAVIGATION EXIT ENTER Figure 5-31 Display Setting/selection...

  • Page 55: Tig Arc Ignition

    Design and function TIG welding 5.5.6 TIG arc ignition 5.5.6.1 Liftarc Figure 5-32 The arc is ignited on contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger (liftarc current flowing, regardless of the main current set).

  • Page 56: Function Sequences/Operating Modes

    Design and function TIG welding 5.5.7 Function sequences/operating modes 5.5.7.1 Legend Symbol Meaning Press torch trigger Release torch trigger Welding current Gas pre-flows Gas post-flows Non-latched Latched Time Upslope time Downslope time Down Ignition current start End-crater current 099-005545-EW501 03.11.2016...
  • Page 57 Design and function TIG welding Non-latched mode Figure 5-33 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). The arc is ignited using liftarc. • The welding current flows with the value set for the starting current I start •...

  • Page 58: Tig Automatic Cut-Out

    Design and function TIG welding Latched mode Figure 5-34 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). The arc is ignited using liftarc. • The welding current flows with the value set for the starting current I start 2nd cycle •...

  • Page 59: Machine Configuration Menu

    Design and function Machine configuration menu Machine configuration menu 5.6.1 Selecting, changing and saving parameters ENTER (Enter the menu) • Switch off the machine at the main switch. • Press and hold the "Sequence parameter" push-button and switch the machine on again at the same time.
  • Page 60 Design and function Machine configuration menu NAVIGATION ENTER EXIT Figure 5-35 Display Setting/selection Calibration The machine will be calibrated for approx 2 seconds each time it is switched on. Exit the menu Machine configuration Settings for machine functions and parameter display Dynamic power adjustment 20 A ----- Setting for 20 A mains fuse protection 16 A ----- Setting for 16 A mains fuse protection (factory setting)

  • Page 61: Power-Saving Mode (Standby)

    Design and function Machine configuration menu 5.6.2 Power-saving mode (Standby) You can activate the power-saving mode by either pressing the push-button > see 4.4 chapter for a prolonged time or by setting a parameter in the machine configuration menu (time-controlled power- saving mode When power-saving mode is activated, the machine displays show the horizontal digit in the centre of the display only.

  • Page 62: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal General DANGER Incorrect maintenance and testing! The machine may be cleaned, repaired and tested by skilled and qualified personnel only. A qualified person is one who, due to their training, knowledge and experience, can detect any hazards and possible consequential damage when checking the machine, and can take the necessary safety measures.

  • Page 63: Maintenance Work, Intervals

    Maintenance, care and disposal Maintenance work, intervals Maintenance work, intervals Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine.

  • Page 64: Annual Test (Inspection And Testing During Operation)

    In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives on the Declaration of Conformity on your machine).

  • Page 65: Rectifying Faults

    Rectifying faults Checklist for rectifying faults 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.

  • Page 66: Error Messages (Power Source)

    Rectifying faults Error messages (power source) Error messages (power source) A welding machine error is indicated by the collective fault signal lamp (A1) lighting up and an error code (see table) being displayed in the machine control display. In the event of a machine error, the power unit shuts down.

  • Page 67: Resetting Welding Parameters To The Factory Settings

    Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings RESET Figure 7-1 Display Setting/selection Calibration The machine will be calibrated for approx 2 seconds each time it is switched on. Initialising Keep the push-button pressed until "InI" is shown on the display. Display machine control software version The query of the software versions only serves to inform the authorised service staff.

  • Page 68: Technical Data

    Technical data Picomig 180 puls TKG Technical data Picomig 180 puls TKG Performance specifications and guarantee only in connection with original spare and replacement parts! Setting range MIG/MAG Welding current 5 A to 180 A 5 A to 180 A...

  • Page 69: Accessories

    Accessories Options Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Options Type Designation Item no. ON Filter Picomig 180 Retrofit option, dirt filter for air inlet 092-002553-00000 ON Trolly Picomig Trolly Picomig 180 with holder for 300 mm wire 092-000312-00000 spool...

  • Page 70: Replaceable Parts

    Replaceable parts Wire feed rollers Replaceable parts The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...

  • Page 71: 10.1.4 Conversion Kit

    Replaceable parts Wire feed rollers 10.1.4 Conversion kit Type Designation Item no. URUE VERZ>UNVERZ FE/AL Conversion kit, 37mm, 4-roller drive on non-toothed 092-000415-00000 4R SF rollers (steel/aluminium) URUE ROE 2DR4R Conversion kit, 37 mm, 4-roller drive for cored wire 092-000410-00000 0,8/0,9+0,8/0,9 SF URUE ROE 2DR4R Conversion kit, 37 mm, 4-roller drive for cored wire...

  • Page 72: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List We recommend using the characteristics for 1.0-mm solid wire electrodes also for the 0.9-mm solid wire electrodes. Figure 11-1 For machine versions with pulsed arc welding procedures only. MIG/MAG pulse arc welding can be selected with JOBs 6, 34, 42, 74, 75, 82, 83, 90, 91, 110, 111, 114 and 115.

  • Page 73: Parameter Overview - Setting Information

    Appendix B Parameter overview – setting information Appendix B Parameter overview – setting information 12.1 Parameters/function Setting range MIG/MAG Gas pre-flow time 20,0 Dynamic correction Gas post-flow time 20,0 Spot time 20,0 Pause time (interval) 20,0 Wire burn-back Gas pre-flow time Ignition current Up-slope time 20,0...

  • Page 74: Overview Of Ewm Branches

    Appendix C Overview of EWM branches Appendix C 13.1 Overview of EWM branches 099-005545-EW501 03.11.2016...

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