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Summary of Contents for EWM Picomig 305 Synergic TKM
- Page 1 Operating instructions Welding machine Picomig 305 Synergic TKM 099-005640-EW501 Observe additional system documents! 04.06.2020...
- Page 2 +49 2680 181-0. A list of 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 form of liability, regardless of type, shall be accepted.
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Page 3: Table Of Contents
Contents Notes on using these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................6 Notes on using these operating instructions .................. 6 Explanation of icons ........................7 Part of the complete documentation ....................8 Safety instructions .......................... 9 Transport and installation ...................... - Page 4 Contents Notes on using these operating instructions 5.2.10 Operating modes (functional sequences) ..............39 5.2.10.1 Explanation of signs and functions ..............39 5.2.10.2 Automatic cut-out ..................39 5.2.11 Conventional MIG/MAG Welding (GMAW non synergic) ..........43 5.2.12 Expert menu (MIG/MAG) ....................44 MMA welding ..........................
- Page 5 Contents Notes on using these operating instructions General accessories ........................70 10 Replaceable parts ..........................71 10.1 Wire feed rollers ........................... 71 10.1.1 Wire feed rollers for steel wire ..................71 10.1.2 Wire feed rollers for aluminium wire ................71 10.1.3 Wire feed rollers for cored wire ..................
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Page 6: For Your Safety
For your safety Notes on using these operating instructions For your safety Notes on using these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
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 hold Switch Incorrect / Invalid Turn Correct / Valid Numerical value –... -
Page 8: Part Of The Complete Documentation
For your safety Part of the complete documentation Part of the complete 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 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 radiation or heat! Arc radiation can lead to skin and eye injuries. Contact with hot workpieces and sparks can lead to burns. • Use hand shield or welding helmet with the appropriate safety level (depends on the appli- cation).
- Page 11 For your safety Safety instructions CAUTION According to IEC 60974-10, welding machines are divided into two classes of electromagnetic compatibility (the EMC class can be found in the Technical da- ta) > see 8 chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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Page 12: Transport And Installation
For your safety Transport and installation The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode hold- ers, remote controls, spare parts and replacement parts, etc.) from our range of products! •... - Page 13 For your safety Transport and installation Accessory components and the power source itself can be damaged by incorrect connection! • Only insert 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 components.
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Page 14: Intended Use
3.2.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our 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 decla- ration. -
Page 15: Machine Description - Quick Overview
Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-005640-EW501 04.06.2020... - Page 16 Machine description – quick overview Front view / rear view Item Symbol Description Carrying handle Machine control > see 4.3 chapter 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Park socket, polarity selection plug Retainer for the polarity selection plug in MMA mode or for transport.
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Page 17: Inside View
Machine description – quick overview Inside view Inside view Figure 4-2 Item Symbol Description Slide latch, lock for the protective cap Wire spool inspection window Check wire supply Protective cap Cover for the wire feed mechanism and 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. -
Page 18: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 Item Symbol Description “Collective interference” signal light “Excess temperature” signal light Welding data display (3-digit) Displays the welding parameters and the corresponding values > see 4.3.1 chapter Welding parameter display mode/power-saving mode push-button --------- Welding current --------- Material thickness... - Page 19 Machine description – quick overview Machine control – Operating elements Item Symbol Description Operating mode button ---------- Non-latched ------- Latched ----- Spots ----- Interval Runtime parameters button For selecting the parameters to be set. Also for entering and exiting the menus for ad- vanced settings.
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Page 20: Welding Data Display
Machine description – quick overview Machine control – Operating elements 4.3.1 Welding data display Figure 4-4 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 21: Design And Function
Design and function Transport and installation 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! •... -
Page 22: Workpiece Lead, General
Design and function Transport and installation 5.1.3 Workpiece lead, general CAUTION Risk of burning due to incorrect welding current connection! If the welding current plugs (machine connections) are not locked or if the workpiece connection is contaminated (paint, corrosion), these connections and leads can heat up and cause burns when touched! •... -
Page 23: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.5 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 24: Stray Welding Currents
Design and function Transport and installation 5.1.6 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. •... -
Page 25: Mains Configuration
Design and function Transport and installation 5.1.7.1 Mains configuration 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. -
Page 26: Welding Torch Holder
Design and function Transport and installation 5.1.8 Welding torch holder The item described in the following is part of the machine´s scope of delivery. Figure 5-7 Item Symbol Description Crossmember of the transport handle Torch holder Fixing screws (x 4) Fan-type lock washers •... -
Page 27: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Transport and installation 5.1.9 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 5.1.9.2 Shielding gas hose connection Figure 5-9 Item Symbol Description Shielding gas cylinder / pressure regulator Connection thread - G¼" Shielding gas connection (inlet) • Screw the gas hose connection to the shielding gas connection (inlet) on the machine gas-tight. 5.1.9.3 Shielding gas volume settings If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause... -
Page 29: Gas Test
Design and function MIG/MAG welding 5.1.9.4 Gas test Figure 5-10 5.1.9.5 Purge hose package 300s Figure 5-11 MIG/MAG welding 5.2.1 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 30 Design and function MIG/MAG welding Figure 5-12 Item Symbol Description Welding torch Polarity selector plug, welding current cable Internal welding current cable for central connection/welding torch. • ---------- Connection socket for “+” welding current Workpiece • Insert the polarity selection plug into the "+" welding current connection socket and lock in place by turning to the right.
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Page 31: Mig/Mag Function Torch
Design and function MIG/MAG welding 5.2.2 MIG/MAG function torch The torch trigger on the MIG welding torch is generally used to start and finish the welding process. Func- tion torches feature additional operating elements to set the wire feed speed and voltage correction. Welding torches with one rotary knob, one rocker or one pair of buttons only must be configured on the machine control appropriately. - Page 32 Design and function MIG/MAG welding Standard D300 wire spool holder can be used. Adapters are required when using standardised basket coils (DIN 8559) > see 9.5 chapter. Figure 5-14 Item Symbol Description Carrier pin For fixing the wire spool Knurled nut For fixing the wire spool •...
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Page 33: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.2.4.2 Changing the wire feed rollers Figure 5-16 Item Symbol Description Tommy The tommy is used to secure the closure brackets of the wire feed rollers. Closure bracket The closure brackets are used to secure the wire feed rollers. Feed roll tensioner Fixing the clamping unit and setting the pressure. -
Page 34: Inching The Wire Electrode
Design and function MIG/MAG welding Unsatisfactory welding results due to faulty wire feeding! The wire feed rolls must be suitable for the diameter of the wire and the material. The wire feed rolls are colour-coded to facilitate distinction (see the Wire feed roll overview table). When working with a wire diameter of >... - Page 35 Design and function MIG/MAG welding Incorrect contact pressure will cause extensive wear of the wire feed rollers! • With the adjusting nuts of the pressure units set the contact pressure so that the wire electro- de is conveyed but will still slip through if the wire spool jams. •...
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Page 36: Spool Brake Setting
Design and function MIG/MAG welding A prerequisite for the automatic inching process is the correct preparation of the wire guide, especially in the capillary and wire guide tube area > see 5.2.1 chapter. • The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll ten- sioner setting nuts depending on the welding consumable used. -
Page 37: Welding Task Selection
Design and function MIG/MAG welding 5.2.6 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 5-20 Validity of the settings. Spot time, pause time and wire feed speed settings apply to all JOBs. -
Page 38: Operating Point Setting Using Material Thickness
Design and function MIG/MAG welding 5.2.7.2 Operating point setting using material thickness 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. -
Page 39: Rootarc/Rootarc Puls
Design and function MIG/MAG welding 5.2.9 rootArc/rootArc puls Short arc with perfect weld modelling capabilities for effortless gap bridging, especially for root welding Figure 5-25 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion •... - Page 40 Design and function MIG/MAG welding Non-latched mode Figure 5-26 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 41 Design and function MIG/MAG welding Latched mode Figure 5-27 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 42 Design and function MIG/MAG welding 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. •...
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Page 43: Conventional Mig/Mag Welding (Gmaw Non Synergic)
Design and function MIG/MAG welding Interval Figure 5-29 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 44: Expert Menu (Mig/Mag)
Design and function MMA welding 5.2.12 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. Figure 5-31 Display Setting/selection Gas pre-flow time Burn-back correction MMA welding... -
Page 45: Welding Task Selection
Design and function MMA welding Item Symbol Description Electrode holder Workpiece • Insert the polarity selection plug in the park socket and lock in place by turning to the right. • Insert the electrode holder plug and workpiece lead into the welding current socket depending on ap- plication and lock in place by turning to the right. -
Page 46: Hotstart
Design and function MMA welding 5.3.4 Hotstart The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent metal at the beginning of the welding process. The ignition takes place here with increased current (hot start current) over a certain time (hot start time). -
Page 47: Tig Welding
Design and function TIG welding TIG welding 5.4.1 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! 5.4.2 Welding torch and workpiece line connection... -
Page 48: Welding Task Selection
Design and function TIG welding 5.4.3 Welding task selection • Select TIG JOB 127. You can only change the JOB number when no welding current is flowing. Figure 5-39 5.4.4 Adjusting the gas post-flow time Figure 5-40 Display Setting/selection Gas post-flow time 099-005640-EW501 04.06.2020... -
Page 49: Expert Menu (Tig)
Design and function TIG welding 5.4.5 Expert menu (TIG) 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. Figure 5-41 Display Setting/selection Gas pre-flow time Ignition current (as percentage, dependent on main current) Upslope time to main current... -
Page 50: Arc Ignition
Design and function TIG welding 5.4.6 Arc ignition 5.4.6.1 Liftarc Figure 5-42 The arc ignites through contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip against the workpiece (lift arc current flows independent of the set main current) b) Angle the torch above the torch gas nozzle until the distance between electrode tip and workpiece is approx. - Page 51 Design and function TIG welding Non-latched mode Figure 5-43 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 •...
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Page 52: Remote Control
Design and function Remote control Latched mode Figure 5-44 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 53: Selecting, Changing And Saving Parameters
Design and function Special parameters (advanced settings) 5.6.1 Selecting, changing and saving parameters Figure 5-45 Display Setting/selection Wire inching / wire return ramp time 0 = -------- normal inching (10 s ramp time) 1 = -------- fast inching (3 s ramp time) (ex works) Lat. -
Page 54: Reset To Factory Settings
Design and function Special parameters (advanced settings) 5.6.3 Reset to factory settings All special parameters saved by the user will be overwritten by the factory settings! Figure 5-46 099-005640-EW501 04.06.2020... -
Page 55: Machine Configuration Menu
Design and function Machine configuration menu Machine configuration menu 5.7.1 Selecting, changing and saving parameters Figure 5-47 Display Setting/selection Lead resistance 1 Lead resistance for the first welding circuit 0 mΩ–60 mΩ (8 mΩ ex works). Time-based power-saving mode > see 5.7.3 chapter Time to activation of the power-saving mode in case of inactivity. -
Page 56: Aligning The Cable Resistance
Design and function Machine configuration menu 5.7.2 Aligning the cable resistance The resistance value of cables can either be set directly or it can be aligned using the power source. The factory setting of the power sources is 8 mΩ. This value correponds to a 5 m earth cable, a 1.5 m inter- mediate hose package and a 3 m water-cooled welding torch. -
Page 57: Power-Saving Mode (Standby)
Design and function Machine configuration menu 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Trim the welding wire so that it is flush with the contact tip. • Retract the welding wire a little (approx. 50 mm) on the wire feeder. There should now be no more welding wire in the contact tip. -
Page 58: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed. -
Page 59: Maintenance Work, Intervals
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. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-005640-EW501 04.06.2020... -
Page 60: Disposing Of Equipment
• Information about returning used equipment or about collections can be obtained from the respective municipal administration office. • In addition to this, returns are also possible throughout Europe via EWM sales partners. 099-005640-EW501 04.06.2020... -
Page 61: 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 dea- ler. -
Page 62: Error Messages (Power Source)
Rectifying faults Error messages (power source) Mains fuse triggers Mains fuse triggers - unsuitable mains fuse Set up recommended mains fuse > see 8 chapter. Error messages (power source) Depending on the options of the machine display, a fault is shown as follows: Display type - machine control Display Graphic display... - Page 63 Rectifying faults Error messages (power source) Category Possible cause Remedy Detection of wire feeder 2 Check cable connections Error in open circuit voltage Inform Service. reduction (VRD) Overcurrent detection on wire Check ease of wire feeding feeder Error in tachometer generator Check the connection and particularly the signal tachometer generator of the second wire...
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Page 64: Welding Parameter Calibration
Rectifying faults Welding parameter calibration 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 allows for easy alignment. Figure 7-1 099-005640-EW501 04.06.2020... -
Page 65: 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 7-2 Display Setting/selection Code of machine control Initialisation complete All customised welding parameters haven been overwritten by the factory settings. 099-005640-EW501 04.06.2020... -
Page 66: Resetting Jobs (Welding Tasks) To The Factory Settings
Rectifying faults Resetting JOBs (welding tasks) to the factory settings Resetting JOBs (welding tasks) to the factory settings 7.5.1 Resetting a single JOB 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. -
Page 67: Technical Data
Technical data Picomig 305 TKM Technical data Picomig 305 TKM Performance specifications and guarantee only in connection with original spare and replacement parts! MIG/MAG Welding current (I 5 A to 300 A 5 A to 300 A 5 A to 300 A Welding voltage according to stan- 14,3 V to 29 V 10,2 V to 22 V... - Page 68 Technical data Picomig 305 TKM Ambient temperature dependent on coolant! Observe coolant temperature range! 099-005640-EW501 04.06.2020...
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Page 69: Accessories
RV5M19 19POL 20M Extension cable 092-000857-00020 Options Type Designation Item no. Retrofit option for connection to EWM Xnet over ON XNET PICOMIG 3XX 092-004004-00000 Xnet LAN/Wi-Fi gateway ON D Barrel TG.0003 Wire guide Rolliner for drum feed 092-007929-00000 Tool box for mounting to trolly Trolly 55-5 / Trolly... -
Page 70: General Accessories
Accessories General accessories General accessories Type Designation Item no. AK300 Wire spool adapter K300 094-001803-00001 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 hose 094-000010-00003 Sharpener for liner... -
Page 71: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts Performance specifications and guarantee only in connection with original spare and replacement parts! 10.1 Wire feed rollers 10.1.1 Wire feed rollers for steel wire Type Designation Item no. FE 4R 0.6 MM/0.023 INCH Drive roll set, 37 mm, 4 rolls, V-groove for steel, 092-002770-00006 LIGHT PINK... -
Page 72: 10.1.3 Wire Feed Rollers For Cored Wire
Replaceable parts Wire feed rollers 10.1.3 Wire feed rollers for cored wire Type Designation Item no. FUEL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00008 WHITE/ORANGE flux cored wire FUEL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00010 BLUE/ORANGE... -
Page 73: Appendix
Appendix JOB-List Appendix 11.1 JOB-List Figure 11-1 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, 110–112, 114–116, 118–120, 122–124, 179, 206, 207, 235–238 and 254. 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 default. -
Page 74: Parameter Overview - Setting Ranges
Appendix Parameter overview – setting ranges 11.2 Parameter overview – setting ranges 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 20,0 Ignition current 20,0 Up-slope time 20,0... -
Page 75: Searching For A Dealer
Appendix Searching for a dealer 11.3 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005640-EW501 04.06.2020...
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