EWM Picomig 180 Synergic TKG User manual

Operating instructions
EN
Welding machine
Picomig 180 Synergic TKG
Picomig 180 puls TKG
099-005114-EW501 05.02.2016
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General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
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-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, 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
1Contents.................................................................................................................................................. 3
2Safety instructions.................................................................................................................................7
2.1Notes on the use of these operating instructions ..........................................................................7
2.2Explanation of icons.......................................................................................................................8
2.3General ..........................................................................................................................................9
2.4Transport and installation ............................................................................................................13
2.4.1Ambient conditions .......................................................................................................14
2.4.1.1In operation ...................................................................................................14
2.4.1.2Transport and storage...................................................................................14
3Intended use .........................................................................................................................................15
3.1Documents which also apply ....................................................................................................... 15
3.1.1Warranty .......................................................................................................................15
3.1.2Declaration of Conformity............................................................................................. 15
3.1.3Welding in environments with increased electrical hazards.........................................15
3.1.4Service documents (spare parts and circuit diagrams) ................................................15
3.1.5Calibration/Validation ...................................................................................................15
4Machine 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
5Design and function............................................................................................................................. 22
5.1General ........................................................................................................................................22
5.2Machine cooling ...........................................................................................................................23
5.3Workpiece lead, general ..............................................................................................................23
5.4Installation....................................................................................................................................23
5.5Notes on the installation of welding current leads .......................................................................24
5.6Mains connection ......................................................................................................................... 26
5.6.1Mains configuration ......................................................................................................26
5.7Shielding gas supply (shielding gas cylinder for welding machine)............................................. 27
5.7.1Connection ...................................................................................................................27
5.7.2Gas test, rinse hose package....................................................................................... 28
5.7.2.1Setting the shielding gas quantity .................................................................28
5.8Welding data display....................................................................................................................29
5.9Polarity setting .............................................................................................................................29
5.10MIG/MAG welding........................................................................................................................30
5.10.1Welding torch and workpiece line connection .............................................................. 30
5.10.2Wire feed ......................................................................................................................32
5.10.2.1Open the protective flap of the wire feeder................................................... 32
5.10.2.2Inserting the wire spool .................................................................................32
5.10.2.3Changing the wire feed rollers ......................................................................33
5.10.2.4Inching the wire electrode .............................................................................34
5.10.2.5Spool brake setting .......................................................................................36
5.10.3Definition of MIG/MAG welding tasks........................................................................... 37
5.10.4Welding task selection..................................................................................................37
5.10.4.1JOB selection ................................................................................................ 37
5.10.4.2Operating mode ............................................................................................37
5.10.4.3Welding type (MIG/MAG standard/pulse arc welding).................................. 38
5.10.4.4Choke effect / dynamics................................................................................ 38
5.10.4.5Gas post-flow time ........................................................................................38
5.10.4.6Spot time .......................................................................................................39
5.10.4.7Pause time (interval operation) ..................................................................... 39
5.10.5MIG/MAG operating point.............................................................................................40
5.10.5.1Selecting the welding parameter display mode ............................................ 40
5.10.5.2Operating point setting using material thickness .......................................... 40
5.10.5.3Arc length correction setting .........................................................................40

Contents
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5.10.6MIG/MAG functional sequences / operating modes.....................................................41
5.10.6.1Explanation of signs and functions................................................................41
5.10.6.2MIG/MAG automatic cut-out..........................................................................45
5.10.7Conventional MIG/MAG Welding (GMAW non synergic) .............................................46
5.10.7.1Operating mode.............................................................................................46
5.10.7.2Setting the operating point (welding output)..................................................46
5.10.8Expert menu (MIG/MAG)..............................................................................................47
5.11TIG welding ..................................................................................................................................48
5.11.1Preparing the TIG welding torch...................................................................................48
5.11.2Welding torch and workpiece line connection ..............................................................48
5.11.3Welding task selection ..................................................................................................49
5.11.4Welding current setting .................................................................................................49
5.11.5Adjusting the gas post-flow time...................................................................................49
5.11.6TIG arc ignition .............................................................................................................50
5.11.6.1Liftarc ignition ................................................................................................50
5.11.7Function sequences/operating modes..........................................................................50
5.11.7.1Legend...........................................................................................................50
5.11.7.2TIG automatic cut-out....................................................................................52
5.11.8Expert menu (TIG) ........................................................................................................53
5.12MMA welding................................................................................................................................54
5.12.1Connecting the electrode holder and workpiece lead ..................................................54
5.12.2Welding task selection ..................................................................................................55
5.12.3Welding current setting .................................................................................................55
5.12.4Arcforce.........................................................................................................................55
5.12.5Hotstart .........................................................................................................................55
5.12.6Antistick.........................................................................................................................56
5.12.7Expert menu (MMA)......................................................................................................57
5.13Power-saving mode (Standby).....................................................................................................57
5.14Machine configuration menu........................................................................................................57
5.14.1Selecting, changing and saving parameters.................................................................57
6Maintenance, care and disposal .........................................................................................................59
6.1General.........................................................................................................................................59
6.2Maintenance work, intervals ........................................................................................................59
6.2.1Daily maintenance tasks...............................................................................................59
6.2.1.1Visual inspection ...........................................................................................59
6.2.1.2Functional test ...............................................................................................59
6.2.2Monthly maintenance tasks ..........................................................................................59
6.2.2.1Visual inspection ...........................................................................................59
6.2.2.2Functional test ...............................................................................................59
6.2.3Annual test (inspection and testing during operation) ..................................................60
6.3Disposing of equipment................................................................................................................60
6.3.1Manufacturer's declaration to the end user ..................................................................60
6.4Meeting the requirements of RoHS..............................................................................................60
7Rectifying faults....................................................................................................................................61
7.1Checklist for rectifying faults ........................................................................................................61
7.2Error messages (power source)...................................................................................................62
7.3Resetting welding parameters to the factory settings ..................................................................63
7.4Display machine control software version....................................................................................63
7.5Dynamic power adjustment..........................................................................................................63
8Technical data.......................................................................................................................................64
8.1Picomig 180 .................................................................................................................................64
9Accessories ..........................................................................................................................................65
9.1Options.........................................................................................................................................65
9.2Transport systems........................................................................................................................65
9.3General accessories ....................................................................................................................65
10Replaceable parts.................................................................................................................................66
10.1Wire feed rollers ...........................................................................................................................66
10.1.1Wire feed rollers for steel wire ......................................................................................66
10.1.2Wire feed rollers for aluminium wire .............................................................................66

Contents
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10.1.3Wire feed rollers for cored wire ....................................................................................66
10.1.4Conversion sets............................................................................................................67
11Appendix A ...........................................................................................................................................68
11.1JOB-List .......................................................................................................................................68
12Appendix B ...........................................................................................................................................69
12.1Overview of EWM branches ........................................................................................................69

Contents
Notes on the use of these operating instructions
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Safety instructions
Notes on the use of these operating instructions
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2 Safety instructions
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.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at 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.

Safety instructions
Explanation of icons
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2.2 Explanation of icons
Symbol Description
Special technical points which users must observe.
Correct
Wrong
Press
Do not press
Press and keep pressed
Turn
Switch
Switch off machine
Switch on machine
ENTER enter the menu
NAVIGATION Navigating in the menu
EXIT Exit the menu
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use
l
0
l
0

Safety instructions
General
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2.3 General
DANGER
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 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).
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)!
Electric shock!
Welding machines use high voltages which can result in potentially fatal electric shocks
and burns on contact. Even low voltages can cause you to get a shock and lead to
accidents.
• Do not touch any live parts in or on the machine!
• Connection cables and leads must be free of faults!
• Switching off alone is not sufficient!
• Place welding torch and stick electrode holder on an insulated surface!
• The unit should only be opened by specialist staff after the mains plug has been
unplugged!
• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!
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!
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!

Safety instructions
General
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WARNING
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!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
• Check for fire hazards in the working area!
• Do not carry any easily flammable objects such as matches or lighters.
• Keep appropriate fire extinguishing equipment to hand in the working area!
• Thoroughly remove any residue of flammable substances from the workpiece before
starting welding.
• Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
• Connect welding leads correctly!
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!
Danger when coupling multiple power sources!
Coupling multiple power sources in parallel or in series has to be carried out by
qualified personnel and in accordance with the manufacturer's guidelines. Before
bringing the power sources into service for arc welding operations, a test has to verify
that they cannot exceed the maximum allowed open circuit voltage.
• Connection of the machine may be carried out by qualified personnel only!
• When decommissioning individual power sources, all mains and welding current leads have
to be safely disconnected from the welding system as a whole. (Danger due to inverse
voltages!)
• Do not couple welding machines with pole reversing switch (PWS series) or machines for
AC welding, as a minor error in operation can cause the welding voltages to be combined.
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!

Safety instructions
General
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CAUTION
Obligations of the operator!
The respective national directives and laws must be observed for operation of the
machine!
• National implementation of the framework directive (89/391/EWG), as well as the
associated individual directives.
• In particular, directive (89/655/EWG), on the minimum regulations for safety and health
protection when staff members use equipment during work.
• The regulations regarding work safety and accident prevention for the respective country.
• Setting up and operating the machine according to IEC 60974-9.
• Check at regular intervals that users are working in a safety-conscious way.
• Regular checks of the machine according to IEC 60974-4.
Damage due to the use of non-genuine 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!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Damage to the machine due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage equipment and
electronic devices and cause overheating of components leading to fire.
• Make sure all welding leads are securely connected and check regularly.
• Always ensure a proper and secure electrical connection to the workpiece!
• Set up, attach or suspend all conductive power source components like casing, transport
vehicle and crane frames so they are insulated!
• Do not place any other electronic devices such as drillers or angle grinders, etc., on the
power source, transport vehicle or crane frames unless they are insulated!
• Always put welding torches and electrode holders on an insulated surface when they are
not in use!
Mains connection
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.

Safety instructions
General
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CAUTION
EMC Machine Classification
In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic
compatibility classes > 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 equipment
• 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

Safety instructions
Transport and installation
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2.4 Transport and installation
WARNING
Incorrect handling of shielding gas cylinders!
Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.
• Observe the instructions from the gas manufacturer and in any relevant regulations
concerning the use of compressed air!
• Place shielding gas cylinders in the holders provided for them and secure with fixing
devices.
• Avoid heating the shielding gas cylinder!
Risk of accident due to improper transport of machines that may not be lifted!
Do not lift or suspend the machine! The machine can fall down and cause injuries! The
handles and brackets are suitable for transport by hand only!
• The machine may not be lifted by crane or suspended!
CAUTION
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.
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
• Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
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!

Safety instructions
Transport and installation
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2.4.1 Ambient conditions
CAUTION
Installation site!
The machine must not be operated in the open air and must only be set up and
operated on a suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient
lighting for the place of work.
• Safe operation of the machine must be guaranteed at all times.
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
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!
2.4.1.1 In operation
Temperature range of the ambient air:
• -25 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.4.1.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -30 °C to +70 °C
Relative air humidity
• Up to 90% at 20 °C

Intended use
Documents which also apply
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3 Intended use
WARNING
Hazards due to improper usage!
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 proper usage and by trained or expert staff!
• Do not modify or convert the equipment improperly!
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).
3.1 Documents which also apply
3.1.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.1.2 Declaration of Conformity
The designated machine conforms to EC Directives and standards in terms of its design
and construction:
• EC Low Voltage Directive (2006/95/EC),
• EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly
conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted
conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
3.1.3 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.
3.1.4 Service documents (spare parts and circuit diagrams)
DANGER
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.
3.1.5 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 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.
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
Button, Wire inching
For inching the wire electrode when changing the wire spool.
The welding wire is inched into the tube package with the current off and without the
gas being expelled.
6 Sticker, JOB List

Machine description – quick overview
Machine control – Operating elements
20 099-005114-EW501
05.02.2016
4.4 Machine control – Operating elements
t2
t1
Hard
Soft
AMP
m/min
01
1
22
3
3
44
55
V
Test
VOLT
AMP
Wire
Gas
Material
JOB-
LIST
Pulse
M 1.81-A
000
6 7
4
3
2
1
10
5
9
14
11
12
8
13
Figure 4-4
Item Symbol Description 0
1
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 5.8 chapter
2
Signal light, JOB-List
Illuminates upon display or selection of the JOB number
3
Key button JOB-List
Selection of the welding task (JOB) from the JOB list
4
“Collective interference” signal light
5

“Excess temperature” signal light
6 Signal light polarity setting
7 Signal light polarity setting
Wire
Gas
Material
JOB-
LIST