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Summary of Contents for EWM Picomig 225 puls TKG
- Page 1 Operating instructions Welding machine Picomig 225 puls TKG Picomig 225 Synergic TKG 099-005682-EW501 Observe additional system documents! 7.9.2022...
- 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 f orm of liability, regardless of type, shall be accepted.
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Page 3: Table Of Contents
Explanation of icons ....................6 Saf ety instructions ....................7 Transport and installation ..................10 3 Intended use ........................12 Applications......................12 3.1.1 Picomig 225 puls TKG ................12 3.1.2 Picomig 225 Synergic TKG ...............12 Documents which also apply ...................12 3.2.1 Warranty ....................12 3.2.2 Declaration of Conformity................12... - Page 4 Contents Notes on using these operating instructions Error messages (power source)................38 Checklist for rectifying faults ...................39 Dynamic power adjustment..................40 Resetting welding parameters to the factory settings ..........41 8 Technical data ......................42 Picomig 225 ......................42 9 Accessories.........................43 Transport system ....................43 Options........................43 General accessories ....................43 10 Replaceable parts ......................44 10.1 Wire f eed rollers....................44...
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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. • Saf ety 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 Incorrect / Invalid Switch Correct / Valid Turn... -
Page 7: Safety Instructions
For your safety Saf ety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Caref ully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 8 For your safety Saf ety 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 Saf ety 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! •...
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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 int- roduction 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.
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Page 12: 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 13: Part Of The Complete Documentation
Intended use Documents which also apply 3.2.6 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 / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-005682-EW501 7.9.2022... - Page 15 Machine description – quick overview Front view / rear view Item Symbol Description Carrying handle Machine control (see the relevant control operating instructions) Welding torch connection (Euro torch connector) Welding current, shielding gas and torch trigger integrated Park socket, polarity selection plug Retainer f or the polarity selection plug in MMA mode or for transport.
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Page 16: Inside View
Machine description – quick overview Inside view Inside view Figure 4-2 Item Symbol Description Protective cap Cover f or the wire f eed 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 17: 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 18: Machine Cooling
Design and function Transport and installation In operation Temperature range of the ambient air: • -25 °C to +40 °C (-13 °F to 104 °F) Relative humidity: • up to 50 % at 40 °C (104 °F) • up to 90 % at 20 °C (68 °F) Transport and storage Storage in a closed room, temperature range of the ambient air: •... -
Page 19: 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 20: 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 21: Welding Torch Holder
Design and function Transport and installation 5.1.6 Welding torch holder The item described in the following is part of the machine´s scope of delivery. Figure 5-5 Item Symbol Description Crossmember of the transport handle Torch holder Fixing screws (x 4) Fan-type lock washers •... -
Page 22: Mains Connection
Design and function Transport and installation 5.1.7 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 nati- onal regulations! •... -
Page 23: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Transport and installation 5.1.8 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 24: Shielding Gas Hose Connection
Design and function Transport and installation 5.1.8.2 Shielding gas hose connection Figure 5-8 Item Symbol Description Connection thread - G¼" Shielding gas connection (inlet) • Screw the gas hose connection to the shielding gas connection (inlet) on the machine gas-tight. 5.1.8.3 Gas test –... -
Page 25: 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 26: Wire Feed
Design and function MIG/MAG welding • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the plug of the workpiece lead in the respective welding current connection socket and lock in place by turning to the right. -
Page 27: 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 5-11 Observe the unwinding direction of the wire spool. - Page 28 Design and function MIG/MAG welding Item Symbol Description Clamping unit Wire feed roller see the Wire f eed roller overview table • Rotate the tommy by 90° clockwise or anti-clockwise (tommy locks into place). • Fold the closure brackets outwards by 90°. •...
- Page 29 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 >...
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Page 30: 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 in- jury including injuries to the face and eyes! •... -
Page 31: Spool Brake Setting
Design and function MIG/MAG welding • 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. A table with the setting values can be f ound on a sticker near the wire drive. -
Page 32: Mma Welding
Design and function MMA welding MMA welding 5.3.1 Connecting the electrode holder and workpiece lead CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. •... -
Page 33: 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 Figure 5-17... -
Page 34: 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 35: Explanation Of Icons
Maintenance, care and disposal Explanation of icons Explanation of icons Personnel Welder / operator Qualif ied person (authorised service personnel) Tests Visual inspection Functional test Period, interval One-shif t operation Multi-shift operation Every 8 hours Daily Weekly Monthly Every 6 months Annually Maintenance schedule Maintenance step... - Page 36 Maintenance, care and disposal Maintenance schedule Maintenance step Only personnel designated as inspectors or repairers due to their trai- ning are allowed to carry out the relevant work step! Non-applicable in- spection points are omitted. • Transport elements (strap, lifting eyes, handle, wheels, parking brake) corresponding safety elements (if necessary fuse caps) are present and f lawless? •...
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Page 37: Disposing Of Equipment
Inf ormation on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further inf ormation on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html. -
Page 38: Rectifying Faults
Rectifying faults Sof tware version of the machine control 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 39: Checklist For Rectifying Faults
Rectifying faults Checklist for rectifying faults Error message Possible cause Remedy Switch the machine off and on again. Electronics error If the error persists, notify service department Temperature error Allow the machine to cool down Motor fault Check wire f eed mechanism, switch the machine off and on again, inform the service department if the fault persists. -
Page 40: Dynamic Power Adjustment
Rectifying faults Dynamic power adjustment Functional errors Mains f use triggers - unsuitable mains fuse Set up recommended mains fuse > see 8 chapter. Machine does not start up after switching on (device fan and possibly coolant pump have no function). Connect the control cable of the wire feeder. -
Page 41: Resetting Welding Parameters To The Factory Settings
Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by 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 42: Technical Data
Technical data Picomig 225 Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Picomig 225 MIG/MAG Welding current (I 5 A to 220 A 5 A to 230 A 5 A to 180 A Welding voltage according to stan- 14,3 V to 25 V 10,2 V to 19,2 V... -
Page 43: Accessories
Cross arm and holder for wire f eeder 092-002700-00000 Options Type Designation Item no. Retrof it 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... -
Page 44: Replaceable Parts
Replaceable parts Wire f eed 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 45: 10.1.3 Wire Feed Rollers For Cored Wire
Replaceable parts Wire f eed 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 f lux 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 46: Appendix
Appendix Searching for a dealer Appendix 11.1 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005682-EW501 7.9.2022...
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