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Summary of Contents for EWM Picomig 355 Synergic TKM
- Page 1 Operating instructions Welding machine Picomig 355 Synergic TKM 099-005512-EW501 Observe additional system documents! 21.9.2022...
- 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
Contents Notes on using these operating instructions Contents 1 Contents........................3 2 For your safety......................7 Notes on using these operating instructions ............... 7 Explanation of icons ....................8 Saf ety instructions ....................9 Transport and installation ..................12 3 Intended use ........................14 Applications......................14 Software version ....................14 Documents which also apply ...................14... - Page 4 7.6.1 Resetting a single JOB ................70 7.6.2 Resetting all JOBs ...................70 Welding parameter calibration .................71 8 Technical data ......................72 Picomig 355 Synergic TKM..................72 9 Accessories.........................73 Welding torch cooling system..................73 9.1.1 Coolant - type blueCool ................73 9.1.2 Coolant - type KF..................73 Transport system ....................73...
- Page 5 Contents Notes on using these operating instructions General accessories ....................74 10 Replaceable parts ......................75 10.1 Wire f eed rollers....................75 10.1.1 Wire f eed rollers for steel wire..............75 10.1.2 Wire f eed rollers for aluminium wire ............75 10.1.3 Wire f eed rollers for cored wire ..............76 10.1.4 Wire guide ....................76 11 Appendix ........................77...
- Page 6 Contents Notes on using these operating instructions 099-005512-EW501 21.9.2022...
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Page 7: 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 8: 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 9: 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 10 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 11 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 12: 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 13 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 14: 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 decla- ration. -
Page 15: 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 16: Machine Description - Quick Overview
Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-005512-EW501 21.9.2022... - Page 17 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 f or the polarity selection plug in MMA mode or for transport.
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Page 18: Inside View
Machine description – quick overview Inside view Inside view Figure 4-2 099-005512-EW501 21.9.2022... - Page 19 Machine description – quick overview Inside view Item Symbol Description Slide latch, lock for the protective cap Wire spool inspection window Check wire supply 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.
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Page 20: 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 21 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 22: 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 23: 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 24: 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 25: 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 26: 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 27: 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 28: 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 29: 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 30: 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. 5.1.10 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 pores to form. -
Page 31: Gas Test
Design and function Transport and installation 5.1.10.1 Gas test Figure 5-10 5.1.10.2 Purge hose package 300s Figure 5-11 099-005512-EW501 21.9.2022... -
Page 32: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.2.1 Assemble the wire guide The Euro torch connector is factory-fitted with a guide tube for welding torches with steel liner. Conver- sion is necessary if a welding torch with a steel liner is used! •... -
Page 33: Welding Torch And Workpiece Line Connection
Design and function MIG/MAG welding 5.2.2 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 34: Mig/Mag Function Torch
Design and function MIG/MAG welding • Insert the polarity selection plug into the "+" welding current connection socket and lock in place by turning to the right. • Insert the central plug for the welding torch into the central connector and screw together with crown nut. -
Page 35: Inserting The Wire Spool
Design and function MIG/MAG welding 5.2.5.1 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 5.2.5.2 Changing the wire feed rollers Figure 5-18 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 37 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 38: Inching The Wire Electrode
Design and function MIG/MAG welding 5.2.5.3 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 39: 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 40: Welding Task Selection
Design and function MIG/MAG welding 5.2.7 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 5-22 The settings for spot time, pause time and wire feed speed apply to all JOBs. All other parameter values are stored separately in each JOB. -
Page 41: Arc Length
Design and function MIG/MAG welding 5.2.8.3 Arc length If required, the arc length (welding voltage) can be corrected from -5 V to +5 V for the individual welding task. Figure 5-25 The basic settings are now completed. Other welding parameters have already been set optimally in the f actory;... -
Page 42: Rootarc/Rootarc Puls
Design and function MIG/MAG welding 5.2.10 rootArc/rootArc puls Short arc with perfect weld modelling capabilities for effortless gap bridging, especially for root welding Figure 5-27 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion •... - Page 43 Design and function MIG/MAG welding Non-latched mode Figure 5-28 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire f eed 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 5-29 1. cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire f eed 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 5-30 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 46: Conventional Mig/Mag Welding (Gmaw Non Synergic)
Design and function MIG/MAG welding Interval Figure 5-31 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: Expert Menu (Mig/Mag)
Design and function MIG/MAG welding 5.2.13 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 f unction is deactivated. Figure 5-33 Display Setting/selection Gas pre-flow time Burn-back correction... -
Page 48: 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 49: 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 5-35 5.3.3 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current. -
Page 50: Antistick
Design and function MMA welding 5.3.5 Antistick The Antistick feature prevents the electrode from annealing. Should the electrode stick despite the Arcforce feature, the machine au- tomatically switches to the minimum current within approx. one second. This prevents the electrode from annealing. Check the welding current setting and correct for the welding task in hand. -
Page 51: 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 5-40... -
Page 52: 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 5-41 5.4.4 Adjusting the gas post-flow time Figure 5-42 Display Setting/selection Gas post-flow time 099-005512-EW501 21.9.2022... -
Page 53: 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 f unction is deactivated. Figure 5-43 Display Setting/selection Gas pre-flow time Start current (as percentage, dependent on main current) -
Page 54: Arc Ignition
Design and function TIG welding 5.4.6 Arc ignition 5.4.6.1 Liftarc Figure 5-44 The arc ignites through contact with the workpiece: a) Caref ully place the torch gas nozzle and tungsten electrode tip against the workpiece (lift arc current f lows 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 55 Design and function TIG welding Non-latched mode Figure 5-45 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 56: Remote Control
Design and function Remote control Latched mode Figure 5-46 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 57: Selecting, Changing And Saving Parameters
Design and function Special parameters (advanced settings) 5.6.1 Selecting, changing and saving parameters Figure 5-47 Display Setting/selection Wire inching / wire return ramp time 0 = -------- normal inching (10 s ramp time) 1 = -------- f ast inching (3 s ramp time) (ex works) Lat. -
Page 58: 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 5-48 099-005512-EW501 21.9.2022... -
Page 59: Machine Configuration Menu
Design and function Machine configuration menu Machine configuration menu 5.7.1 Selecting, changing and saving parameters Figure 5-49 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 5.8 chapter Time to activation of the power-saving mode in case of inactivity. -
Page 60: 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 f actory 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 61: Power-Saving Mode (Standby)
Design and function Power-saving mode (Standby) 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle f rom 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 62: 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 63: 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 64 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 65: 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 66: 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 67: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) The possible error numbers displayed depend on the machine series and version! Depending on the options of the machine display, a fault is shown as follows: Display type - machine control Display Graphic display two 7-segment displays... -
Page 68: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Category Possible cause Remedy Overcurrent detection on wire Check ease of wire feeding f eeder Error in tachometer generator Check the connection and particularly the ta- chometer generator of the second wire fee- signal der (slave drive). Mains phase failure Check mains voltages Check welding circuit for short circuit;... -
Page 69: Software Version Of The Machine Control
Rectifying faults Sof tware version of the machine control Figure 7-2 • Position a suitable collection container for collecting the escaping coolant at the quick-connect coup- ling and switch on the machine for approx. 5s. • Lock the quick-connect coupling by pushing back the locking ring. Software version of the machine control The query of the software versions only serves to inform the authorised service staff. -
Page 70: Resetting Jobs (Welding Tasks) To The Factory Settings
Rectifying faults Resetting JOBs (welding tasks) to the factory settings Display Setting/selection Initialisation complete All customised welding parameters haven been overwritten by the factory settings. Resetting JOBs (welding tasks) to the factory settings 7.6.1 Resetting a single JOB Figure 7-4 Display Setting/selection RESET to factory settings... -
Page 71: 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 7-6 099-005512-EW501 21.9.2022... -
Page 72: Technical Data
Technical data Picomig 355 Synergic TKM Technical data Picomig 355 Synergic TKM Performance specifications and guarantee only in connection with original spare and replacement parts! MIG/MAG Welding current (I 5 A to 350 A Welding voltage according to stan- 14,3 V to 31,5 V... -
Page 73: Accessories
Accessories Welding torch cooling system Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Welding torch cooling system Type Designation Item no. cool50 U40 Cooling module 090-008598-00502 cool50-2 U42 Cooling unit with reinforced pump 090-008797-00502 HOSE BRIDGE UNI Tube bridge... -
Page 74: Options
Accessories Options Options Type Designation Item no. ON D Barrel TG.0003 Wire guide Rolliner for drum feed 092-007929-00000 Tool box for mounting to trolly Trolly 55-5 / Trolly ON Case 092-002899-00000 55-6 ON CS Crane suspension for Picomig 180 / 185 D3 / 305 092-002549-00000 T.005/TG.0003/D.0002 D3, Phoenix and Taurus 355 compact, drive 4... -
Page 75: 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 76: 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 77: 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 78: Parameter Overview - Setting Ranges
Appendix Parameter overview – setting ranges 11.2 Parameter overview – setting ranges Parameters/function Setting range MIG/MAG Gas pre-f low 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-f low time 20,0 Start current 20,0... -
Page 79: 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" 099-005512-EW501 21.9.2022...
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