EWM Picomig 180 puls TGE User manual

Operating instructions
EN
Welding machine
Picomig 180 puls TKG
099-005545-EW501
03.11.2016
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the location where the machine is operated.
•Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
•Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of
liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Straße 8
56271 Mündersbach
Germany
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2For your safety.......................................................................................................................................6
2.1 Notes on the use of these operating instructions ..........................................................................6
2.2 Explanation of icons.......................................................................................................................7
2.3 Part of the complete documentation..............................................................................................8
2.4 Safety instructions..........................................................................................................................9
2.5 Transport and installation ............................................................................................................13
3Intended use.........................................................................................................................................14
3.1 Applications..................................................................................................................................14
3.2 Documents which also apply.......................................................................................................15
3.2.1 Warranty.......................................................................................................................15
3.2.2 Declaration of Conformity.............................................................................................15
3.2.3 Welding in environments with increased electrical hazards.........................................15
3.2.4 Service documents (spare parts and circuit diagrams)................................................15
3.2.5 Calibration/Validation ...................................................................................................15
4Machine description –quick overview ..............................................................................................16
4.1 Front view ....................................................................................................................................16
4.2 Rear view.....................................................................................................................................18
4.3 Inside view...................................................................................................................................19
4.4 Machine control –Operating elements........................................................................................20
5Design and function.............................................................................................................................22
5.1 Transport and installation ............................................................................................................22
5.1.1 Ambient conditions.......................................................................................................22
5.1.1.1 In operation...................................................................................................22
5.1.1.2 Transport and storage...................................................................................22
5.1.2 Machine cooling............................................................................................................23
5.1.3 Workpiece lead, general...............................................................................................23
5.1.4 Notes on the installation of welding current leads........................................................24
5.1.4.1 Stray welding currents...................................................................................25
5.1.5 Mains connection..........................................................................................................26
5.1.5.1 Mains configuration.......................................................................................26
5.1.6 Shielding gas supply (shielding gas cylinder for welding machine).............................27
5.1.6.1 Pressure regulator connection......................................................................27
5.1.6.2 Shielding gas hose connection.....................................................................28
5.1.6.3 Gas test –setting the shielding gas volume.................................................29
5.2 Welding data display....................................................................................................................30
5.2.1 Polarity setting..............................................................................................................30
5.2.2 Setting the operating point (welding output).................................................................31
5.2.2.1 Operating point setting via welding current...................................................31
5.3 MIG/MAG welding........................................................................................................................32
5.3.1 Welding torch and workpiece line connection..............................................................32
5.3.2 Wire feed......................................................................................................................34
5.3.2.1 Open the protective flap of the wire feeder...................................................34
5.3.2.2 Inserting the wire spool.................................................................................35
5.3.2.3 Changing the wire feed rollers......................................................................36
5.3.2.4 Inching the wire electrode.............................................................................37
5.3.2.5 Spool brake setting .......................................................................................38
5.3.3 Definition of MIG/MAG welding tasks...........................................................................39
5.3.4 Welding task selection..................................................................................................40
5.3.5 Further welding parameters .........................................................................................41
5.3.6 MIG/MAG functional sequences / operating modes.....................................................42
5.3.6.1 Explanation of signs and functions ...............................................................42
5.3.7 Conventional MIG/MAG Welding (GMAW non synergic).............................................47
5.3.8 MIG/MAG automatic cut-out.........................................................................................47
5.4 MMA welding ...............................................................................................................................48
5.4.1 Connecting the electrode holder and workpiece lead..................................................48

Contents
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5.4.2 Welding task selection..................................................................................................49
5.4.2.1 Arcforce.........................................................................................................50
5.4.3 Hotstart .........................................................................................................................50
5.4.3.1 Hotstart settings ............................................................................................51
5.4.4 Antistick.........................................................................................................................51
5.5 TIG welding..................................................................................................................................52
5.5.1 Preparing the TIG welding torch...................................................................................52
5.5.2 Welding torch and workpiece line connection..............................................................52
5.5.3 Welding task selection..................................................................................................53
5.5.4 Adjusting the gas post-flow time...................................................................................53
5.5.5 Further welding parameters..........................................................................................54
5.5.6 TIG arc ignition .............................................................................................................55
5.5.6.1 Liftarc.............................................................................................................55
5.5.7 Function sequences/operating modes..........................................................................56
5.5.7.1 Legend...........................................................................................................56
5.5.8 TIG automatic cut-out...................................................................................................58
5.6 Machine configuration menu........................................................................................................59
5.6.1 Selecting, changing and saving parameters.................................................................59
5.6.2 Power-saving mode (Standby).....................................................................................61
6Maintenance, care and disposal.........................................................................................................62
6.1 General.........................................................................................................................................62
6.2 Cleaning.......................................................................................................................................62
6.3 Maintenance work, intervals ........................................................................................................63
6.3.1 Daily maintenance tasks...............................................................................................63
6.3.1.1 Visual inspection ...........................................................................................63
6.3.1.2 Functional test...............................................................................................63
6.3.2 Monthly maintenance tasks..........................................................................................63
6.3.2.1 Visual inspection ...........................................................................................63
6.3.2.2 Functional test...............................................................................................63
6.3.3 Annual test (inspection and testing during operation)..................................................64
6.4 Disposing of equipment................................................................................................................64
6.4.1 Manufacturer's declaration to the end user..................................................................64
6.5 Meeting the requirements of RoHS..............................................................................................64
7Rectifying faults....................................................................................................................................65
7.1 Checklist for rectifying faults........................................................................................................65
7.2 Error messages (power source)...................................................................................................66
7.3 Resetting welding parameters to the factory settings..................................................................67
7.4 Display machine control software version....................................................................................67
7.5 Dynamic power adjustment..........................................................................................................67
8Technical data.......................................................................................................................................68
8.1 Picomig 180 puls TKG .................................................................................................................68
9Accessories ..........................................................................................................................................69
9.1 Options.........................................................................................................................................69
9.2 Transport systems........................................................................................................................69
9.3 General accessories ....................................................................................................................69
10 Replaceable parts.................................................................................................................................70
10.1 Wire feed rollers...........................................................................................................................70
10.1.1 Wire feed rollers for steel wire......................................................................................70
10.1.2 Wire feed rollers for aluminium wire.............................................................................70
10.1.3 Wire feed rollers for cored wire.....................................................................................70
10.1.4 Conversion kit...............................................................................................................71
11 Appendix A............................................................................................................................................72
11.1 JOB-List........................................................................................................................................72
12 Appendix B............................................................................................................................................73
12.1 Parameter overview –setting information....................................................................................73
13 Appendix C............................................................................................................................................74
13.1 Overview of EWM branches.........................................................................................................74

Contents
Notes on the use of these operating instructions
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For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
•The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
•Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
•The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
•The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
•The risk is explained using a symbol on the edge of the page.
Special technical points which users must observe.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
•Insert the welding current lead socket into the relevant socket and lock.

For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/tip
Switch off machine
Release
Switch on machine
Press and keep pressed
Switch
Wrong
Turn
Correct
Numerical value –adjustable
Menu entry
Signal light lights up in green
Navigating the menu
Signal light flashes green
Exit menu
Signal light lights up in red
Time representation (e.g.: wait
4 s/activate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use

For your safety
Part of the complete documentation
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2.3 Part of the complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with all other parts of these instructions! Read and observe the operating
instructions for all system components, especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 2-1
Item
Documentation
A.1
Transport cart
A.2
Power source
A.3
Welding torch
A
Complete documentation

For your safety
Safety instructions
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2.4 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!
•Inform persons in the working area that they must comply with the regulations!
WARNING
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low
voltages can cause a shock and lead to accidents.
•Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
•Always place torches and electrode holders on an insulated surface!
•Wear the full personal protective equipment (depending on the application)!
•The machine may only be opened by qualified personnel!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a
technical specialist may interconnect the sources as per standard IEC 60974-9:2010:
Installation and use and German Accident Prevention Regulation BVG D1 (formerly VBG
15) or country-specific regulations.
Before commencing arc welding, a test must verify that the equipment cannot exceed
the maximum permitted open circuit voltage.
•Only qualified personnel may connect the machine.
•When taking individual power sources out of operation, all mains and welding current leads
must be safely disconnected from the welding system as a whole. (Hazard due to reverse
polarity voltage!)
•Do not interconnect welding machines with pole reversing switch (PWS series) or machines
for AC welding since a minor error in operation can cause the welding voltages to be
combined, which is not permitted.

For your safety
Safety instructions
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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. The protective equipment has to include:
•Respiratory protection against hazardous substances and mixtures (fumes and vapours);
otherwise implement suitable measures such as extraction facilities.
•Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and
heat.
•Dry welding clothing (shoes, gloves and body protection) to protect against warm
environments with conditions comparable to ambient temperatures of 100 °C or higher and
arcing and work on live components.
•Hearing protection against harming noise.
WARNING
Risk of injury due to radiation or heat!
Arc radiation results in injury to skin and eyes.
Contact with hot workpieces and sparks results in burns.
•Use welding shield or welding helmet with the appropriate safety level (depending on the
application)!
•Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
•Protect persons not involved in the work against arc beams and the risk of glare using
safety curtains!
WARNING
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
•Move containers with inflammable or explosive liquids away from the working area!
•Never heat explosive liquids, dusts or gases by welding or cutting!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during
welding, there is a risk of flames.
•Be watchful of potential sources of fire in the working area!
•Do not carry any easily inflammable objects, e.g. matches or lighters.
•Ensure suitable fire extinguishers are available in the working area!
•Thoroughly remove any residue of flammable materials from the workpiece prior to starting
to weld.
•Only further process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!

For your safety
Safety instructions
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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!
•Keep solvent vapour away from the arc beam field!
•Wear suitable breathing apparatus if appropriate!
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
•Wear suitable ear protection!
•Persons located within the working area must wear suitable ear protection!
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.
•In particular, directive 89/655/EEC concerning the minimum safety and health requirements for
the use of work equipment by workers at work.
•The regulations applicable to occupational safety and accident prevention in the country
concerned.
•Setting up and operating the machine as per IEC 60974.-9.
•Brief the user on safety-conscious work practices on a regular basis.
•Regularly inspect the machine as per IEC 60974.-4.
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!
•Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of the
operator, where necessary in consultation with the mains network operator, to ensure that the
machine can be connected.

For your safety
Safety instructions
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CAUTION
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
•Observe the maintenance instructions > see 6.3 chapter!
•Unwind welding leads completely!
•Shield devices or equipment sensitive to radiation accordingly!
•The correct functioning of pacemakers may be affected (obtain advice from a doctor if
necessary).
According to IEC 60974-10, welding machines are divided into two classes of
electromagnetic compatibility (the EMC class can be found in the Technical
data) > 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. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas,
including residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the
surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
•Mains, control, signal and telecommunication lines
•Radios and televisions
•Computers and other control systems
•Safety equipment
•The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
•Calibration and measuring equipment
•The immunity to interference of other equipment in the surrounding area
•The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
•Mains connection, e.g. additional mains filter or shielding with a metal tube
•Maintenance of the arc welding system
•Welding leads should be as short as possible and run closely together along the ground
•Potential equalization
•Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
•Shielding from other equipment in the surrounding area or the entire welding system

For your safety
Transport and installation
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2.5 Transport and installation
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause
serious injuries!
•Observe the instructions from the gas manufacturer and any relevant regulations
concerning the use of compressed air!
•Do not attach any element to the shielding gas cylinder valve!
•Prevent the shielding gas cylinder from heating up.
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. Tilt resistance is guaranteed up to an angle of 10°
(according to IEC 60974-1).
•Set up and transport the machine on level, solid ground.
•Secure add-on parts using suitable equipment.
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
•Only transport and operate in an upright position!
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
machine is switched off.
•Comprehensive descriptions can be found in the operating instructions for the relevant
accessory components.
•Accessory components are detected automatically after the power source is switched on.
Protective dust caps protect the connection sockets and therefore the machine against dirt and
damage.
•The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
•The cap must be replaced if faulty or if lost!

Intended use
Applications
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
•The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
•Do not improperly modify or convert the equipment!
3.1 Applications
Arc welding machine for standard and pulsed gas-shielded metal-arc welding with TIG welding and lift arc
(touch starting) or MMA welding as secondary process. It may be possible to expand the functionality by
using accessories (see the documentation in the relevant chapter).

Intended use
Documents which also apply
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3.2 Documents which also apply
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
The labelled machine complies with the following EC directives in terms of its design and
construction:
•Low Voltage Directive (LVD)
•Electromagnetic Compatibility Directive (EMC)
•Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment –Inspection and Testing during Operation", and/or prohibited modifications which
have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the
specific declaration of conformity is included with every product.
3.2.3 Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
3.2.4 Service documents (spare parts and circuit diagrams)
WARNING
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
•Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.2.5 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months

Machine description –quick overview
Front view
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4 Machine description – quick overview
4.1 Front view
Figure 4-1

Machine description –quick overview
Front view
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Item
Symbol
Description 0
1
Carrying handle
2
Protective cap
Cover for the wire feed mechanismand 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.
3
Wire spool inspection window
Check wire supply
4
Slide latch, lock for the protective cap
5
Machine control > see 4.4 chapter
6
Welding torch connection (Euro torch connector)
Welding current, shielding gas and torch trigger integrated
7
Connection socket, "+" welding current
•-----------MIG/MAG cored wire welding: Workpiece connection
•-----------TIG welding: Workpiece connection
•-----------MMA welding: Workpiece connection
8
"-" welding current connection socket
•-----------MIG/MAG welding: Workpiece connection
•-----------TIG welding: Welding current connection for welding torch
•-----------MMA welding: electrode holder connection
9
Park socket, polarity selection plug
Retainer for the polarity selection plug in MMA mode or for transport.
10
Polarity selector plug, welding current cable
Internal welding current cable for central connection/welding torch.
Connections with:
MIG/MAG Connection socket for “+” or "-" welding current
TIG Connection socket for “-” welding current
MMA Park socket

Machine description –quick overview
Rear view
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4.2 Rear view
Figure 4-2
Item
Symbol
Description 0
1
Main switch, machine on/off
2
Connecting nipple G¼, shielding gas connection
3
Mains connection cable with connector plug
4
Cooling air outlet
5
Cooling air inlet

Machine description –quick overview
Inside view
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4.3 Inside view
Figure 4-3
Item
Symbol
Description 0
1
Wire spool holder
2
Wheels
3
Machine feet
4
Wire feed unit
5
Push-button, wire inching
Potential- and gas-free inching of the wire electrode through the hose package to the
welding torch > see 5.3.2.4 chapter.
6
Sticker, JOB List

Machine description –quick overview
Machine control –Operating elements
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4.4 Machine control –Operating elements
The setting ranges for the parameter values are summarised in the Parameter overview
section > see 12.1 chapter.
Figure 4-4
Item
Symbol
Description 0
1
“Collective interference” signal light
2
“Excess temperature” signal light
3
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 5.2 chapter
4
Welding parameter display mode/power-saving mode push-button
--------- Welding current
-------- Material thickness
-------- Wire feed speed
Press for 2 s to put the machine into power-saving mode.
Activate one of the operating elements to reactivate > see 0 chapter.
5
Display, JOB
Shows the currently selected welding task (JOB number).