EWM Picomig 180 Synergic TKG Operating Instructions Manual
  1. Manuals
  2. Brands
  3. EWM Manuals
  4. Welding System
  5. Picomig 180 Synergic TKG
  6. Operating instructions manual

EWM Picomig 180 Synergic TKG Operating Instructions Manual

Hide thumbs Also See for Picomig 180 Synergic TKG:
Table of Contents

Advertisement

Quick Links

Download this manual
Operating instructions
Welding machine
EN
Picomig 180 Synergic TKG
099-005546-EW501
Observe additional system documents!
7.12.2020

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Picomig 180 Synergic TKG and is the answer not in the manual?

Questions and answers

Related Manuals for EWM Picomig 180 Synergic TKG

Summary of Contents for EWM Picomig 180 Synergic TKG

  • Page 1 Operating instructions Welding machine Picomig 180 Synergic TKG 099-005546-EW501 Observe additional system documents! 7.12.2020...
  • 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.

  • Page 3: Table Of Contents

    Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use ..........................
  • Page 4 Resetting welding parameters to the factory settings ............58 Display machine control software version ................58 Dynamic power adjustment ....................58 8 Technical data..........................59 Picomig 180 Synergic TKG ....................59 9 Accessories ..........................60 General accessories ......................60 Options ..........................60 Transport system .........................

  • Page 5: 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 6: 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 7: 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 8 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 9 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 10: Transport And Installation

    For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the introduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.
  • Page 11 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.

  • Page 12: Intended Use

    3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the declaration.

  • Page 13: Part Of The Complete Documentation

    Intended use Documents which also apply 3.3.6 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 14: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-005546-EW501 7.12.2020...
  • Page 15 Machine description – quick overview Front view Item Symbol Description Carrying handle Machine control > see 4.3 chapter Welding torch connection (Euro torch connector) Welding current, shielding gas and torch trigger integrated Connection socket, "+" welding current • ----------- MIG/MAG cored wire welding: Workpiece connection •...

  • Page 16: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-2 099-005546-EW501 7.12.2020...
  • Page 17 Machine description – quick overview Inside view Item Symbol Description Rotary closure Locking of 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 replacement 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 The setting ranges for the parameter values are summarised in the Parameter overview section > see 11.2 chapter. Figure 4-3 Item Symbol Description “Collective interference” signal light “Excess temperature”...
  • Page 19 Machine description – quick overview Machine control – Operating elements Item Symbol Description Welding parameter setting dial For setting the welding performance, for selecting the JOB (welding task) and for setting other welding parameters. Operating mode button ---------- Non-latched ------- Latched ----- Spots ----- Interval Runtime parameters button...

  • 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 Design and function Transport and installation • 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! • Always keep leads as short as possible! Lay any excess cable lengths in meanders.

  • Page 24: Stray Welding Currents

    Design and function Transport and installation 5.1.5 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 Connection

    Design and function Transport and installation 5.1.6 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • The connection (mains plug or cable), the repair or voltage adjustment of the device must be carried out by a qualified electrician in accordance with the respective local laws or national regulations! •...

  • Page 26: Pressure Regulator Connection

    Design and function Transport and installation 5.1.7.1 Pressure regulator connection Figure 5-6 Item Symbol Description Pressure regulator Output side of the pressure regulator Shielding gas cylinder Cylinder valve • Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out any dirt.

  • Page 27: Gas Test - Setting The Shielding Gas Volume

    Design and function Transport and installation 5.1.7.3 Gas test – setting the shielding gas volume If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to form. Adjust the shielding gas quantity to suit the welding task! •...

  • Page 28: Mig/Mag Welding

    Design and function MIG/MAG welding 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 29 Design and function MIG/MAG welding Choose welding current connection socket according to the signal light for the polarity setting! • Select JOB > see 5.2.4 chapter • Polarity selection “+” or polarity selection “-” signal lights show the polarity setting. Figure 5-8 Item Symbol Description...

  • Page 30: Wire Feed

    Design and function MIG/MAG welding 5.2.2 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 31: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding • Unlock and open protective flap. • Loosen knurled nut from spool holder. • Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore. • Fasten wire spool using knurled nut. Figure 5-10 Abspulrichtung der Schweißdrahtspule beachten.

  • Page 32: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.2.2.3 Inching the wire electrode CAUTION Risk of injury due to welding wire escaping from the welding torch! The welding wire can escape from the welding torch at high speed and cause bodily injury including injuries to the face and eyes! •...

  • Page 33: Spool Brake Setting

    Design and function MIG/MAG welding 5.2.2.4 Spool brake setting Figure 5-13 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! 5.2.3...

  • Page 34: Welding Task Selection

    Design and function MIG/MAG welding 5.2.4 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 5-14 Validity of the settings. Spot time, pause time and wire feed speed settings apply to all JOBs.

  • Page 35: Arc Length

    Design and function MIG/MAG welding 5.2.5.3 Arc length Setting range: -5 V to +5 V Figure 5-17 The basic settings are now completed. Other welding parameters have already been set optimally in the factory; they can, however, be modified to suit individual requirements. 5.2.6 Further welding parameters •...

  • Page 36: Operating Modes (Functional Sequences)

    Design and function MIG/MAG welding 5.2.7 Operating modes (functional sequences) 5.2.7.1 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 Latched...
  • Page 37 Design and function MIG/MAG welding Non-latched mode Figure 5-19 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 38 Design and function MIG/MAG welding Latched mode Figure 5-20 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 39 Design and function MIG/MAG welding Spot welding Figure 5-21 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 40: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Design and function MIG/MAG welding Interval Figure 5-22 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 41: Mma Welding

    Design and function MMA welding MMA welding CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. • Use an insulated pair of tongs to remove the used stick electrode or to move welded workpieces.

  • Page 42: Welding Task Selection

    Design and function MMA welding 5.3.2 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 5-25 5.3.3 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current.

  • Page 43: Hotstart Settings

    Design and function TIG welding 5.3.4.1 Hotstart settings The setting ranges for the parameter values are summarised in the Parameter overview section > see 11.2 chapter. • Select MMA JOB 128 > see 5.3.2 chapter. Figure 5-28 Display Setting/selection Hotstart current Hotstart time 5.3.5 Antistick...

  • Page 44: Welding Torch And Workpiece Line Connection

    Design and function TIG welding 5.4.2 Welding torch and workpiece line connection Figure 5-30 Item Symbol Description Welding torch Welding torch connection (Euro torch connector) Welding current, shielding gas and torch trigger integrated Workpiece Connection socket, "+" welding current • TIG welding: Workpiece connection Polarity selector plug, welding current cable...

  • Page 45: 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 5-31 5.4.4 Adjusting the gas post-flow time • Preselection: Select TIG JOB 127 > see 5.4.3 chapter. Figure 5-32 Display Setting/selection...

  • Page 46: Further Welding Parameters

    Design and function TIG welding 5.4.5 Further welding parameters The setting ranges for the parameter values are summarised in the Parameter overview section > see 11.2 chapter. • Preselection: Select TIG JOB 127 > see 5.4.3 chapter. Figure 5-33 Display Setting/selection Gas pre-flow time Ignition current...

  • Page 47: Operating Modes (Functional Sequences)

    Design and function TIG welding 5.4.6 Operating modes (functional sequences) 5.4.6.1 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 5.4.6.2 Automatic cut-out Once the fault periods have elapsed, the automatic cut-out stops the welding process when it has been triggered by one of two states:...

  • Page 48: Gas Post-Flow Time

    Design and function TIG welding Non-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 •...
  • Page 49 Design and function TIG welding Latched mode Figure 5-35 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 50: Arc Ignition

    Design and function Machine configuration menu 5.4.7 Arc ignition 5.4.7.1 Liftarc Figure 5-36 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: Power-Saving Mode (Standby)

    Design and function Power-saving mode (Standby) Display Setting/selection Dynamic power adjustment > see 7.5 chapter Time-based power-saving mode > see 5.6 chapter Time to activation of the power-saving mode in case of inactivity. Setting = disabled or numerical value 5-60 min.. Arc detection for welding helmets (TIG) Modulated waviness for better arc detection ------ Function enabled...

  • Page 52: 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 53: 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! 099-005546-EW501 7.12.2020...

  • Page 54: 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. 099-005546-EW501 7.12.2020...

  • Page 55: 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 56 Rectifying faults Checklist for rectifying faults Wire feed problems  Contact tip blocked Clean, spray with anti-spatter spray and replace if necessary   Setting the spool brake > see 5.2.2.4 chapter Check settings and correct if necessary   Setting pressure units > see 5.2.2.3 chapter Check settings and correct if necessary ...

  • Page 57: 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 58: 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 is shown on the display.

  • Page 59: Technical Data

    Technical data Picomig 180 Synergic TKG Technical data Picomig 180 Synergic TKG Performance specifications and guarantee only in connection with original spare and replacement parts! MIG/MAG Welding current (I 5 A to 180 A 5 A to 150 A Welding voltage according to...

  • Page 60: Accessories

    Accessories General accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. ADAP CEE16/SCHUKO Earth contact coupling/CEE16A plug 092-000812-00000 DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 G1 G1/4 R 3M...

  • Page 61: 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 62: 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 63: Appendix

    Appendix JOB-List Appendix 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 MIG/MAG pulse arc welding can be selected with JOBs 6, 34, 42, 74, 75, 76, 82, 83, 84, 90, 91, 110, 111, 114 and 115.
  • Page 64 Appendix Parameter overview – setting ranges 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 Down-slope time 20,0 End current Gas post-flow time 20,0 Arcforce correction Hot start current...

  • Page 65: 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" 099-005546-EW501 7.12.2020...

Table of Contents