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Operating instructions
EN
Welding machine
Picomig 180 Synergic TKG
Picomig 180 puls TKG
099-005114-EW501
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www.ewm-group.com
03.11.2015
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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 +49 2680 181-0.
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
1 Contents
Open the protective flap of the wire feeder ................................................... 32
Welding type (MIG/MAG standard/pulse arc welding) .................................. 38
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Contents
Notes on the use of these operating instructions
Selecting the welding parameter display mode ............................................ 40
Operating point setting using material thickness .......................................... 40
Conventional MIG/MAG Welding (GMAW non synergic) ............................................. 46
Setting the operating point (welding output).................................................. 46
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Contents
Notes on the use of these operating instructions
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Safety instructions
Notes on the use of these operating instructions
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.
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Safety instructions
Explanation of icons
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
4 s
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use
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Safety instructions
General
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 Maintenance, care and disposal 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!
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Safety instructions
General
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!
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Safety instructions
General
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.
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Safety instructions
General
CAUTION
EMC Machine Classification
In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic
compatibility classes - See 8 Technical data 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
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Safety instructions
Transport and installation
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!
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Safety instructions
Transport and installation
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
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Intended use
Applications
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!
3.1 Applications
3.1.1 MIG/MAG standard welding
Metal arc welding using a wire electrode, where the arc and the weld pool are shielded from the atmosphere with inert (MIG) or active (MAG) gasses or gas mixtures.
3.1.2 MIG/MAG pulse welding
For machine versions with pulsed arc welding procedures only.
Welding process for optimum welding results when joining unalloyed, low-allow and high-alloy steels and aluminium thanks to controlled droplet transfer and targeted, adapted heat input.
3.1.3 MIG/MAG cored wire welding
Welding with cored wire electrodes consisting of a metal casing and a powder core.
As with MIG/MAG standard welding, the arc is protected from the atmosphere by shielding gas. The gas is supplied either externally (gas shielded cored wires) or produced in the arc by means of the powder core (self-shielding cored wires).
3.1.4 TIG (Liftarc) welding
TIG welding procedure with arc striking by contact with the workpiece and subsequent removal of the electrode.
3.1.5 MMA welding
Manual arc welding or, for short, MMA welding. It is characterised by the fact that the arc burns between a melting electrode and the molten pool. There is no external protection; any protection against the atmosphere comes from the electrode.
3.1.6 Polarity setting
selection plug.
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Intended use
Documents which also apply
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 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.
3.2.3 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)
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.
3.2.5 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
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Machine description
– quick overview
Front view
4
Machine description – quick overview
4.1 Front view
16
Figure 4-1
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Machine description
– quick overview
Front view
Item Symbol Description 0
1 Carrying handle
2
3
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.
Wire spool inspection window
Check wire supply
4
5
Slide latch, lock for the protective cap
Machine control- See 4.4 Machine control – Operating elements chapter
6
7
8
9
10
Welding torch connection (Euro torch connector)
Welding current, shielding gas and torch trigger integrated
Connection socket, "+" welding current
• MIG/MAG cored wire welding: Workpiece connection
• TIG welding:
• MMA welding:
Workpiece connection
Workpiece connection
"-" welding current connection socket
• MIG/MAG welding:
• TIG welding:
• MMA welding:
Workpiece connection
Welding current connection for welding torch electrode holder connection
Park socket, polarity selection plug
Retainer for the polarity selection plug in MMA mode or for transport.
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
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Machine description
– quick overview
Rear view
4.2 Rear view
18
3
4
5
Figure 4-2
Item Symbol Description 0
1 Main switch, machine on/off
2 Connecting nipple G¼, shielding gas connection
Mains connection cable with connector plug
Cooling air outlet
Cooling air inlet
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4.3 Inside view
Machine description
– quick overview
Inside view
Figure 4-3
Item Symbol Description 0
1 Wire spool holder
2 Wheels
3 Machine feet
4 Wire feed unit
5
6
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.
Sticker, JOB List
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Machine description
– quick overview
Machine control – Operating elements
4.4 Machine control – Operating elements
20
Figure 4-4
Item Symbol Description 0
1 Welding data display (3-digit)
Displays the welding parameters and the corresponding values
2
3
4
Signal light, JOB-List
Illuminates upon display or selection of the JOB number
Key button JOB-List
Selection of the welding task (JOB) from the JOB list
“Collective interference” signal light
5
“Excess temperature” signal light
6 Signal light polarity setting
7 Signal light polarity setting
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Machine description
– quick overview
Machine control – Operating elements
Item Symbol Description 0
8 Welding parameter display mode/power-saving mode push-button
Welding current
Welding voltage
Material thickness
9
10
Wire feed speed
Press for 2 s to put the machine into power-saving mode.
To reactivate, activate one of the operating elements.
Gas test / rinse button
• Gas test:
• Rinse:
For setting the shielding gas quantity
For rinsing longer hose packages
- See 5.7 Shielding gas supply (shielding gas cylinder for welding machine) chapter
Welding type push-button (for machine versions with pulsed arc welding procedures only)
Standard arc welding
11
12
Pulsed arc welding
Operating mode button
Non-latched
Latched
Spots
Interval
Welding parameter setting dial
For setting the welding performance, for selecting the JOB (welding task) and for setting other welding parameters.
13 Arc length correction rotary dial
14 Runtime parameters button
For selecting the parameters to be set. Also for entering and exiting the menus for advanced settings.
Choke effect/dynamics
Gas post-flow time
Spot time
Pause time
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Design and function
General
5
Design and function
5.1 General
WARNING
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
• Follow safety instructions on the opening pages of the operating instructions.
• Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead, interfaces) may only be connected when the machine is switched off!
CAUTION
Insulate the arc welder from welding voltage!
Not all active parts of the welding current circuit can be shielded from direct contact. To avoid any associated risks it is vital for the welder to adhere to the relevant safety regulations. Even low voltages can cause a shock and lead to accidents.
• Wear dry and undamaged protective clothing (shoes with rubber soles/welder's gloves made from leather without any studs or braces)!
• Avoid direct contact with non-insulated connection sockets or connectors!
• Always place torches and electrode holders on an insulated surface!
Risk of burns on the welding current connection!
If the welding current connections are not locked, connections and leads heat up and can cause burns, if touched!
• Check the welding current connections every day and lock by turning in clockwise direction, if necessary.
Risk of injury due to moving parts!
The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons!
• Do not reach into rotating or moving parts or drive components!
• Keep casing covers or protective caps closed during operation!
Risk of injury due to welding wire escaping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may escape in an uncontrolled manner and injure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the welding torch!
• Remove the pressure rollers from the wire feeder if no welding torch is fitted!
• Check wire guide at regular intervals!
• Keep all casing covers or protective caps closed during operation!
Risk from electrical current!
If welding is carried out alternately using different methods and if a welding torch and an electrode holder remain connected to the machine, the open-circuit/welding voltage is applied simultaneously on all cables.
• The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks.
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Design and function
Machine cooling
CAUTION
Damage due to incorrect connection!
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.
Using protective dust caps!
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!
5.2 Machine cooling
To obtain an optimal duty cycle from the power components, the following precautions should be observed:
• Ensure that the working area is adequately ventilated.
• Do not obstruct the air inlets and outlets of the machine.
• Do not allow metal parts, dust or other objects to get into the machine.
5.3 Workpiece lead, general
CAUTION
Risk of burns due to incorrect connection of the workpiece lead!
Paint, rust and dirt on the connection restrict the power flow and may lead to stray welding currents.
Stray welding currents may cause fires and injuries!
• Clean the connections!
• Fix the workpiece lead securely!
• Do not use structural parts of the workpiece as a return lead for the welding current!
• Take care to ensure faultless power connections!
5.4 Installation
WARNING
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
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.
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Design and function
Notes on the installation of welding current leads
5.5 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.
Lay the workpiece lead and hose package of power sources with HF igniter (TIG) for as long as possible in parallel with a distance of 20 cm to avoid HF sparkover.
Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences
Always keep leads as short as possible! For optimum welding results max. 30 m (welding lead + intermediate hose package + torch lead).
24
Figure 5-1
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Design and function
Notes on the installation of welding current leads
Use an individual welding lead to the workpiece for each welding machine!
Figure 5-2
Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops!
Always keep leads as short as possible!
Lay any excess cable lengths in meanders.
Figure 5-3
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Design and function
Mains connection
5.6 Mains connection
DANGER
Hazard caused by improper mains connection!
An improper mains connection can cause injuries or damage property!
• Only use machine with a plug socket that has a correctly fitted protective conductor.
• If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations!
• Mains plug, socket and lead must be checked regularly by an electrician!
• When operating the generator always ensure it is earthed as stated in the operating instructions. The resulting network has to be suitable for operating devices according to protection class 1.
5.6.1 Mains configuration
The machine may only be connected to a one-phase system with two conductors and an earthed neutral conductor.
Figure 5-4
Legend
Item
L
N
PE
Designation
Outer conductor
Neutral conductor
Protective conductor
Colour code brown blue green-yellow
CAUTION
Operating voltage - mains voltage!
The operating voltage shown on the rating plate must be consistent with the mains voltage, in order to avoid damage to the machine!
• - See 8 Technical data chapter!
• Insert mains plug of the switched-off machine into the appropriate socket.
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Design and function
Shielding gas supply (shielding gas cylinder for welding machine)
5.7 Shielding gas supply (shielding gas cylinder for welding machine)
5.7.1 Connection
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!
CAUTION
Faults in the shielding gas supply.
An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results. In addition, a blocked shielding gas supply may result in the welding torch being destroyed.
• Always re-fit the yellow protective cap when not using the shielding gas connection.
• All shielding gas connections must be gas tight.
Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to expel any dirt.
Figure 5-5
Item Symbol Description 0
1 Pressure regulator
2 Shielding gas cylinder
3 Output side of the pressure regulator
4 Cylinder valve
• Place the shielding gas cylinder into the relevant cylinder bracket.
• Secure the shielding gas cylinder using a securing chain.
• Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.
• Tighten gas hose on pressure regulator to be gas tight.
• Fasten the gas hose to the shielding gas connecting nipple at the back of the machine using the crown nut.
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Shielding gas supply (shielding gas cylinder for welding machine)
5.7.2 Gas test, rinse hose package
• Slowly open the gas cylinder valve.
• Open the pressure reducer.
• Switch on the power source at the main switch.
• Trigger gas test function on the machine control by pressing the button briefly.
• Set the relevant gas quantity for the application on the pressure reducer.
Operating element
Action Result
Select gas test, rinse hose package.
Shielding gas flows for around 25 seconds or until the button is pressed again. Repeat rinsing process several times.
5.7.2.1 Setting the shielding gas quantity
Welding process Recommended shielding gas quantity
MAG welding
MIG brazing
MIG welding (aluminium)
TIG
Wire diameter x 11.5 = l/min
Wire diameter x 11.5 = l/min
Wire diameter x 13.5 = l/min (100 % argon)
Gas nozzle diameter in mm corresponds to l/min gas throughput
Helium-rich gas mixtures require a higher gas volume!
The table below can be used to correct the gas volume calculated where necessary:
Shielding gas
75% Ar/25% He
50% Ar/50% He
25% Ar/75% He
100% He
Factor
1.14
1.35
1.75
3.16
Incorrect shielding gas setting!
• If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to form.
• Adjust the shielding gas quantity to suit the welding task!
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Welding data display
5.8 Welding data display
Figure 5-6
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.
The display shows:
• Nominal values (before welding)
• Actual values (during welding)
• Hold values (after welding)
MIG/MAG
Parameter
Welding current
Material thickness
Wire feed speed
Welding voltage
Nominal values
/ [1]
Actual values
Hold values
[1] traditional MIG/MAG
TIG/MMA
Parameter
Welding current
Welding voltage
Nominal values
Actual values
Hold values
After the welding, the display switches form hold values to nominal values by
• pressing the push-buttons or turning the rotary knobs of the control
• waiting for about 5 seconds
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5.9 MIG/MAG welding
5.9.1 Welding torch and workpiece line connection
For connection, observe the operating instructions for the welding torch.
Depending on the wire electrode diameter or type, either a steel liner or liner with the correct inner diameter must be inserted in the torch!
Recommendation:
• Use a steel liner when welding hard, unalloyed wire electrodes (steel).
• Use a chrome nickel liner when welding hard, high-alloy wire electrodes (CrNi).
• Use a liner to weld or braze soft wire electrodes, high-alloy wire electrodes or aluminium materials.
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!
• Operate welding torches with a liner > with a guide tube.
• Operate welding torches with a steel liner > with a capillary tube.
Preparation for connecting welding torches with a liner:
• Push forward the capillary tube on the wire feed side in the direction of the Euro torch connector and remove it there.
• Insert the liner guide tube from the Euro torch connector side.
• Carefully insert the welding torch connector with as yet too long a liner into the Euro torch connector and secure with a crown nut.
• Cut off the liner with a liner cutter just before the wire feed roller.
• Loosen the welding torch connector and remove.
• Carefully chamfer the cut off end of the liner with a liner sharpener and sharpen.
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Choose welding current connection socket according to the signal light for the polarity setting!
• Select JOB- See 5.9.4 Welding task selection chapter
• Polarity selection “+” or polarity selection “-” signal lights show the polarity setting.
Figure 5-7
Item Symbol Description 0
1 Welding torch
2
3
4
5
Welding torch connection (Euro torch connector)
Welding current, shielding gas and torch trigger integrated
Workpiece
"-" welding current connection socket
• MIG/MAG welding: Workpiece connection
Polarity selector plug, welding current cable
Internal welding current cable for central connection/welding torch.
• Connection socket for “+” welding current
• Insert the central plug for the welding torch into the central connector and screw together with crown nut.
• Insert the plug of the workpiece lead in the respective welding current connection socket and lock in place by turning to the right.
• Insert the polarity selection plug in the respective welding current connection socket and lock in place by turning to the right.
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5.9.2 Wire feed
5.9.2.1 Open the protective flap of the wire feeder
CAUTION
To perform the following steps, the protective flap of the wire feeder needs to be opened. Make sure to close the protective flap again before starting to work.
• Unlock and open protective flap.
5.9.2.2 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 holder and fall to the ground, causing damage to the machine and injuries.
• Securely fasten the wire spool to the wire spool holder using the knurled nut.
• Before you start working, always check the wire spool is securely fastened.
Figure 5-8
Item Symbol Description 0
1 Carrier pin
For fixing the wire spool
2 Knurled nut
For fixing the wire spool
• Loosen knurled nut from spool holder.
• Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore.
• Fasten wire spool using knurled nut.
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5.9.2.3 Changing the wire feed rollers
Unsatisfactory welding results due to faulty wire feeding! Wire feed rollers must be suitable for the diameter of the wire and the material.
• Check the roller label to verify that the rollers are suitable for the wire diameter.
Turn or change if necessary!
• use V-groove rollers with for steel wires and other hard wires,
• use U-groove rollers for aluminium wires and other soft, alloyed wires.
• Slide new drive rollers into place so that the diameter of the wire used is visible on the drive roller.
• Screw the drive rollers in place with knurled screws.
Figure 5-9
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5.9.2.4 Inching the wire electrode
CAUTION
Risk of injury due to moving parts!
The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons!
• Do not reach into rotating or moving parts or drive components!
• Keep casing covers or protective caps closed during operation!
Risk of injury due to welding wire escaping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may escape in an uncontrolled manner and injure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the welding torch!
• Remove the pressure rollers from the wire feeder if no welding torch is fitted!
• Check wire guide at regular intervals!
• Keep all casing covers or protective caps closed during operation!
Risk of injury due to welding wire escaping from the welding torch!
The welding wire can escape from the welding torch at high speed and cause bodily injury including injuries to the face and eyes!
• Never direct the welding torch towards your own body or towards other persons!
CAUTION
Extensive wear due to incorrect contact pressure!
Incorrect contact pressure will cause extensive wear of the wire feed rollers!
• With the adjusting nuts of the pressure units set the contact pressure so that the wire electrode is conveyed but will still slip through if the wire spool jams.
• Set the contact pressure of the front rollers (in wire feed direction) to a higher value!
The inching speed is infinitely adjustable by simultaneously pressing the wire inching pushbutton and turning the wire speed rotary knob.
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Figure 5-10
Item Symbol Description 0
1 Adjusting nut
2
3
Feed roll tensioner
Fixing the clamping unit and setting the pressure.
Clamping unit
4 Knurled screw
5 Pressure roller
6 Drive roller
7 Wire feed nipple
8 Guide tube
• Extend and lay out the torch hose package.
• Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards).
• Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe.
• Press the clamping element with the pressure roller back downwards and fold the wire units back up again (wire electrode should be in the groove on the drive roller).
• Set the contact pressure with the adjusting nuts of the pressure unit.
• Press the wire inching button until the wire electrode projects out of the welding torch.
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5.9.2.5 Spool brake setting
Figure 5-11
Item Symbol Description 0
1 Allen screw
Securing the wire spool retainer and adjustment of the spool brake
• Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect.
Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation!
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5.9.3 Definition of MIG/MAG welding tasks
This machine range features simple operation with a very wide range of functions.
• JOBs (welding tasks consisting of welding process, type of material, wire diameter and type of shielding gas) are pre-defined for all common welding tasks.
• Simple JOB selection from a list of pre-defined JOBs (sticker on the machine).
• The required process parameters are calculated by the system depending on the operating point specified (single-dial operation via wire speed rotary dial).
• Conventional welding task definition using wire speed and welding voltage is also possible.
The welding task definition described below applies when defining MIG/MAG and cored wire welding tasks.
Pay attention to the signal light for the polarity setting!
It may be necessary to change the welding current polarity depending on the JOB selected or the welding process.
• Reconnect the polarity selction plug if necessary.
5.9.4 Welding task selection
The settings for the respective welding parameters are defined by the different JOBs. The right JOB can be determined quickly with the JOB list .
Validity of the settings.
Spot time, pause time and wire feed speed settings apply to all JOBs. Throttling effect/dynamics, gas post-flow time, gas pre-flow time and wire burn-back correction are stored for each JOB individually.
Changes are stored permanently in the JOB that is currently selected.
5.9.4.1 JOB selection
• Select JOB (welding task) by means of the JOB list.
The "JOB list" sticker is on the inside of the cover of the wire feed unit.
It is only possible to change the JOB number when no welding current is flowing.
Operating element
Action Result Display
Select JOB list
1 x
(LED is on)
Set JOB number.
Wait 3 s until the setting has been applied.
5.9.4.2 Operating mode
Operating element
Action Result n x
Selecting the operating mode
The LED indicates the selected operating mode.
Non-latched operation
Latched operation
Spots
Interval operation
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5.9.4.3 Welding type (MIG/MAG standard/pulse arc welding)
For machine versions with pulsed arc welding procedures only.
Operating element
Action Result n x
Select welding type
The signal light indicates the selection.
Standard MIG/MAG welding
Pulse arc MIG/MAG welding
Display
No change
MIG/MAG pulse arc welding can be selected with JOBs 6, 34, 42, 74, 75, 82, 83, 90, 91, 110, 111,
114 and 115. 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 standard.
5.9.4.4 Choke effect / dynamics
Operating element
Action Result Display
Selecting the parameter to be set
The LED indicates the parameter selected.
Parameter value set n x
Choke effect/dynamics
Gas post-flow time
Spot time
Pause time (interval operation)
Set choke effect/dynamics.
Setting range:
40:
-40:
Arc hard and narrow, deeper fusion penetration.
Arc soft and wide.
5.9.4.5 Gas post-flow time
Operating element
Action Result Display
Selecting the parameter to be set
The LED indicates the parameter selected.
Parameter value set n x
Choke effect/dynamics
Gas post-flow time
Spot time
Pause time (interval operation)
Adjusting the gas post-flow time.
Setting range:
0.0 s to 20.0 s in increments of 0.1 s
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5.9.4.6 Spot time
Select the respective operating mode before setting the spot or pause time.
Operating element
Action Result
Selecting the parameter to be set
The LED indicates the parameter selected. n x
Choke effect/dynamics
Display
Parameter value set
Gas post-flow time
Spot time
Pause time (interval operation)
Setting the stop time.
Setting range:
0.1 s to 20.0 s in increments of 0.1 s
5.9.4.7 Pause time (interval operation)
Operating element
Action Result
Selecting the parameter to be set
The LED indicates the parameter selected. n x
Choke effect/dynamics
Gas post-flow time
Spot time
Pause time (interval operation)
Setting the pause time.
Setting range:
0.1 s to 20.0 s in increments of 0.1 s
Display
Parameter value set
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5.9.5 MIG/MAG operating point
5.9.5.1 Selecting the welding parameter display mode
The operating point (welding performance) can be displayed or set as the welding current, material thickness or wire speed.
Operating element
Action Result
Switching the display between:
Operating element n x
Welding current
Welding voltage (correction)
Material thickness
Wire speed
5.9.5.2 Operating point setting using material thickness
The process of setting the operating point by means of the panel thickness parameter is described as an example below.
Action Result Display
5.9.5.3 Arc length correction setting
Operating element
Action
Increase or reduce welding performance via the panel thickness parameter.
Display example: 2.0 mm
Result
“Arc length correction” setting
Setting range:
-5 V to +5 V
The basic settings are now completed. Other welding parameters have already been set optimally in the factory; they can, however, be modified to suit individual requirements.
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5.9.6 MIG/MAG functional sequences / operating modes
5.9.6.1 Explanation of signs and functions
Symbol Meaning
Press torch trigger
Release torch trigger
Shielding gas flowing
I Welding output
Wire electrode is being conveyed
Wire creep
Wire burn-back
Gas pre-flows
Gas post-flows t t
1 t
2
Non-latched
Latched
Time
Spot time
Pause time
Design and function
MIG/MAG welding
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Non-latched mode
Figure 5-12
Step 1
• Press and hold torch trigger.
• Shielding gas is expelled (gas pre-flows).
• Wire feed motor runs at “creep speed”.
• Arc ignites after the wire electrode makes contact with the workpiece; welding current flows.
• Change over to pre-selected wire speed.
Step 2
• Release torch trigger.
• WF motor stops.
• Arc is extinguished after the preselected wire burn-back time expires.
• Gas post-flow time elapses.
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Latched mode
Figure 5-13
1. cycle
• Press and hold torch trigger
• Shielding gas is expelled (gas pre-flows)
• Wire feed motor runs at “creep speed”
• Arc ignites when the wire electrode makes contact with the workpiece
Welding current flows
• Wire feed speed increases to the set nominal value
2. cycle
• Release torch trigger (no effect)
3. cycle
• Press torch trigger (no effect)
4. cycle
• Release torch trigger
• Wire feed motor stops
• Arc is extinguished after the pre-selected wire burn-back time elapses
• Gas post-flow time elapses
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Spot welding
Figure 5-14
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.
• Wire feed speed increases to the set nominal value.
• The wire feed stop welding after the spot time elapses.
• Arc is extinguished after the wire burn-back time elapses.
• Gas post-flow time elapses.
Premature termination
• Release torch trigger.
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Interval
Figure 5-15
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.
• Wire feed speed increases to the set nominal value.
• The wire feed stops after the spot time elapses.
• Arc is extinguished after the wire burn-back time elapses.
• The process is repeated when the pause time is over.
End
• Release torch trigger, wire feed stops, arc is extinguished, gas post-flow time elapses.
If the pause time is less than 3 s, wire creep only takes place in the first spot phase.
When the torch trigger is released, the welding process is also ended even before the spot time elapses.
5.9.6.2 MIG/MAG automatic cut-out
The welding machine ends the ignition process or the welding process with an
• Ignition fault (no welding current flows within 5 s after the start signal).
• Arc interruption (arc is intrerupted for longer than 3 s).
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5.9.7 Conventional MIG/MAG Welding (GMAW non synergic)
• Select JOB 188
It is only possible to change the JOB number when no welding current is flowing.
Operating element
Action Result
Select JOB list
1 x
(LED is on)
Set JOB number.
Wait 3 s until the setting has been applied.
Display
5.9.7.1 Operating mode
Operating element
Action Result n x
Selecting the operating mode
The LED indicates the selected operating mode.
Non-latched operation
Latched operation
Spots
Interval operation
5.9.7.2 Setting the operating point (welding output)
The operating point (welding performance) is set with the wire speed and the welding voltage.
Operating element
Action Result
Switch the display between:
Operating element n x
Welding current (only actual and hold values are displayed)
Welding voltage
Material thickness (will be skipped)
Wire speed
Settings are made using the "welding parameter setting" and "arc length correction" rotary dials, which are used here to set the wire speed and the welding voltage.
Action Result
Increase or reduce welding performance via the wire speed parameter.
Operating element
Action Result
Set the welding voltage
Setting range:
10 V to 30 V
Automatic display mode switching:
If the wire speed or the voltage is changed, the display will switch briefly to show the respective parameter. This means that you don't have to change the display mode before setting the parameter.
If the display mode is set to display the welding current, it will always show "0" before welding begins. Actual values are shown during welding; these can be changed as necessary using the
"welding parameter setting" rotary dial.
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5.9.8 Expert menu (MIG/MAG)
To enable the greatest possible breadth of applications, the following parameters can be adjusted or optimised for the welding task.
ENTER NAVIGATION EXIT
5s 5s
Display
Figure 5-16
Setting/selection
Burn-back correction
-50 % to +50 % of the burn back time specified in the JOB (1 % increments)
Gas pre-flow time
0.0 s to 20.0 s (0.1 s increments)
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TIG welding
5.10 TIG welding
5.10.1 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!
5.10.2 Welding torch and workpiece line connection
Figure 5-17
Item Symbol Description 0
1 Welding torch
2
3
4
5
Welding torch connection (Euro torch connector)
Welding current, shielding gas and torch trigger integrated
Workpiece
Connection socket, "+" welding current
• TIG welding: Workpiece connection
Polarity selector plug, welding current cable
Internal welding current cable for central connection/welding torch.
• Connection socket for “-” welding current
• Insert the central plug for the welding torch into the central connector and screw together with crown nut.
• Insert the polarity selection plug into the "-" welding current connection socket and lock in place by turning to the right.
• Insert the plug of the workpiece lead into the "+" welding current connection socket and lock in place by turning to the right.
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5.10.3 Welding task selection
• Select TIG JOB 127.
You can only change the JOB number when no welding current is flowing.
Operating element
Action Result
JOB list selection
1 x
(LED illuminated)
Set JOB number.
Wait 3 s until the setting has been applied.
Display x x
Welding type selection
• Standard arc welding
• Pulsed arc welding
- See 5.10.4.2 TIG pulsed welding chapter
5.10.4 Welding current setting
Set the welding current with the rotary dial for the welding parameter settings.
Operating element
Action Result
Set welding current.
Display current nominal value
5.10.4.1 Adjusting the gas post-flow time
Operating Action Result element
1 x
Select setting for gas post-flow time
(LED is on
Display parameter value setting
Setting the gas post-flow time
Setting range:
0.0 s to 20.0 s
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5.10.4.2 TIG pulsed welding
For machine versions with pulsed arc welding procedures only.
Operating element
Action Result
Press the push-button until the illuminates.
signal light (pulse arc welding)
Figure 5-18
AMP = Main current; e.g. 100 A
IPL = Pulse current = IP1 x AMP; e.g. 170% x 100 A = 170 A
I2 = Pulse pause current
Tpuls = Duration of one pulse cycle = 1/FrE; e.g. 1/1 Hz = 1 s bAL = Balance = bAL x Tpuls; e.g. 30% x 1 s = 0.3 s
For parameter setting, - See 5.10.7 Expert menu (TIG) chapter.
The pulse pause current (I2) requires no setting. This value is calculated by the machine control, so that the welding current average value always corresponds to the main current selected.
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5.10.5 TIG arc ignition
5.10.5.1 Liftarc ignition
Figure 5-19
The arc is ignited on contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger (liftarc current flowing, regardless of the main current set). b) Incline the torch over the torch gas nozzle to produce a gap of approx. 2-3 mm between the electrode tip and the workpiece. The arc ignites and the welding current is increased, depending on the operating mode set, to the ignition or main current set. c) Lift off the torch and swivel to the normal position.
Ending the welding process: Release or press the torch trigger depending on the operating mode selected.
5.10.6 Function sequences/operating modes
5.10.6.1 Legend
Symbol Meaning
Press torch trigger
Release torch trigger
I Welding current
Gas pre-flows
Gas post-flows
Non-latched
Latched t Time t
Up
Upslope time t
Down
Downslope time
I start
Ignition current
I end
End-crater current
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Non-latched mode
Figure 5-20
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
.
• Welding current increases to the main current in the set upslope time.
2nd cycle
• Release torch trigger.
• The main current falls in the set downslope time to the end-crater current I end
.
If the torch trigger is pressed again during the downslope time, the welding current returns to the set main current!
• The main current reaches the end-crater current I end
, the arc extinguishes.
• Gas post-flow time elapses.
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Latched mode
Figure 5-21
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
• Release torch trigger.
• Welding current increases to the main current in the set upslope time.
3rd cycle
• Press and hold torch trigger.
• The main current falls in the set downslope time to the end-crater current I end
.
4th cycle
• Release torch trigger, arc is extinguished.
• Gas post-flow time elapses.
The welding process is terminated immediately if the torch trigger is released during the downslope time.
The welding current drops to zero and the gas post-flow time begins.
5.10.6.2 TIG automatic cut-out
The welding machine ends the ignition process or the welding process with an
• Ignition fault (no welding current flows within 3 s after the start signal).
• Arc interruption (arc is intrerupted for longer than 3 s).
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5.10.7 Expert menu (TIG)
To enable the greatest possible breadth of applications, the following parameters can be adjusted or optimised for the welding task.
ENTER NAVIGATION EXIT
5s 5s
54
Display
Figure 5-22
Setting/selection
Gas pre-flow time
Setting range: 0.0 s to 5.0 s (0.1 s increments)
Ignition current
Setting: 1% to 200% of main current AMP (depending on main current)
Upslope time to main current
Setting: 0.0 sec. to 20.0 sec. (factory setting 1.0 sec.)
Downslope time
0.00 s to 20.0 s (0.1 s increments). The downslope time can be set separately for latched and non-latched operation.
End-crater current
Setting range in percent: 1 % to 200 % depending on main current
Pulsed TIG welding frequency
Setting range: 0.2 Hz –2.0 kHz
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Display Setting/selection
Balance
Percentage of time from pulse cycle Tpuls for pulse current IP1
Setting range 1% –99%
Pulse current
Setting range 1% –200%
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MMA welding
5.11 MMA welding
CAUTION
Risk of being crushed or burnt.
When replacing spent or new stick electrodes
• Switch off machine at the main switch
• Wear appropriate safety gloves
• Use insulated tongs to remove spent stick electrodes or to move welded workpieces and
• Always put the electrode holder down on an insulated surface.
5.11.1 Connecting the electrode holder and workpiece lead
Figure 5-23
Item Symbol Description 0
1 Electrode holder
2 Connection socket for "+" welding current
Electrode holder or workpiece lead connection
3
4
Polarity selector plug, welding current cable
• Connect to the park socket.
Workpiece
5 Connection socket, “-” welding current
Electrode holder or workpiece lead connection
• Insert the polarity selection plug in the park socket and lock in place by turning to the right.
• Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right.
• Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and lock by turning to the right.
Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.
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5.11.2 Welding task selection
• Select MMA JOB 128.
You can only change the JOB number when no welding current is flowing.
Operating element
Action Result
JOB list selection
1 x
(LED illuminated)
Set JOB number.
Wait 3 s until the setting has been applied.
Display x x
Welding type selection
• Standard arc welding
• Pulsed arc welding
5.11.3 Welding current setting
Set the welding current with the rotary dial for the welding parameter settings.
Operating element
Action Result
Set welding current.
Display current nominal value
5.11.3.1 Arcforce
During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current. This makes it easier to weld large-drop melting electrode types at low current strengths with a short arc in particular.
Operating element
Action Result Display
Select setting
(LED is on)
Parameter value setting 1 x
Arc force setting for electrode types:
Setting range -10 to 10
Negative values: Rutile
Values around zero: Basic
Positive values: Rutilecellulose
5.11.3.2 Hotstart
The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current
I = Welding current t = Time
Figure 5-24
The hotstart device uses an increased ignition current to improve arc ignition. There are presets for the optimum hotstart current and hotstart time parameters on the machine.
After striking the stick electrode, the arc will ignite with the hotstart current and will then drop to the main current setting.
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Design and function
MMA welding
5.11.3.3 Antistick
Anti-stick prevents the electrode from annealing.
If the electrode sticks in spite of the Arcforce device, the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating. Check the welding current setting and correct according to the welding task!
Figure 5-25
5.11.4 MMA pulsed welding
For machine versions with pulsed arc welding procedures only.
Operating element
Action Result
Press the push-button until the illuminates.
signal light (pulse arc welding)
Figure 5-26
AMP = Main current; e.g. 100 A
IPL = Pulse current = IP1 x AMP; e.g. 170% x 100 A = 170 A
I2 = Pulse pause current
Tpuls = Duration of one pulse cycle = 1/FrE; e.g. 1/1 Hz = 1 s bAL = Balance = bAL x Tpuls; e.g. 30% x 1 s = 0.3 s
The pulse pause current (I2) requires no setting. This value is calculated by the machine control, so that the welding current average value always corresponds to the main current selected.
For parameter setting, - See 5.11.5 Expert menu (MMA) chapter.
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Design and function
MMA welding
5.11.5 Expert menu (MMA)
To enable the greatest possible breadth of applications, the following parameters can be adjusted or optimised for the welding task.
ENTER NAVIGATION EXIT
5s 5s
Display
Figure 5-27
Setting/selection
Hotstart current
Hotstart current setting (50 % to 200 %)
Hotstart time
Hotstart time setting (0,1 s to 20,0 s)
Frequency, MMA pulsed welding
Setting range 0.2 Hz to 500 Hz, 1.2 Hz ex works.
Balance
Percentage of time from pulse cycle Tpuls for pulse current IP1
Setting range 1% –99%
Pulse current
Setting range 1% –200%
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Design and function
Power-saving mode (Standby)
5.12 Power-saving mode (Standby)
You can activate the power-saving mode by either pressing the push-button for a prolonged time or by setting a parameter in the machine configuration menu (time-controlled power-saving mode).
When power-saving mode is activated, the machine displays show the horizontal digit in the centre of the display only.
Pressing any operating element (e.g. tapping the torch trigger) deactivates power-saving mode and the machine is ready for welding again.
- See 4.4 Machine control – Operating elements chapter
- See 5.13 Machine configuration menu chapter
5.13 Machine configuration menu
5.13.1 Selecting, changing and saving parameters
ENTER (Enter the menu)
• Switch off machine at the main switch.
• Hold down the "welding parameter display mode" button and simultaneously switch the machine on again. Wait until the "Elt" menu item is shown and release the button.
EXIT (Exit the menu)
• Select the "EIt" menu item.
• Press the " welding parameter display mode " button (settings will be applied, machine changes to the ready-to-operate status).
ENTER EXIT NAVIGATION
0 l
+
60
Display
Figure 5-28
Setting/selection
Calibration
The machine will be calibrated for approx 2 seconds each time it is switched on.
Exit the menu
Exit
Machine configuration
Settings for machine functions and parameter display
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Design and function
Machine configuration menu
Display Setting/selection
Dynamic power adjustment
20 A Setting for 20 A mains fuse protection
16 A Setting for 16 A mains fuse protection (factory setting)
Time-based power-saving mode
• 5 min.–60 min. = Time to activation of power-saving mode in case of inactivity.
• off = inactivated (ex works 20 min.)
Service menu
Modifications to the service menu may only be carried out by authorised maintenance staff!
Software version of the machine control
Version display
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Maintenance, care and disposal
General
6
Maintenance, care and disposal
DANGER
Improper maintenance and testing
The equipment may only be cleaned, repaired or tested by specialist, skilled persons! A skilled person is one who, due to training, knowledge and experience, is able to recognise the dangers that can occur during testing of this equipment as well as possible subsequent damage and who is able to implement the required safety procedures.
• Complete all tests given in the chapter below!
• Only put the equipment back into operation following a successful test.
Risk of injury from electric shock!
Cleaning machines that are not disconnected from the mains can lead to serious injuries!
• Disconnect the machine completely from the mains.
• Remove the mains plug!
• Wait for 4 minutes until the capacitors have discharged!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine. Return deliveries of defective equipment subject to warranty may only be made through your dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the machine type, serial number and item number of the machine, as well as the type designation and item number of the spare part.
6.1 General
When used in the specified environmental conditions and under normal operating conditions, this machine is largely maintenance-free and requires a minimum of care.
There are some points, which should be observed, to guarantee fault-free operation of your welding machine. Among these are regular cleaning and checking as described below, depending on the pollution level of the environment and the length of time the unit is in use.
6.2 Maintenance work, intervals
6.2.1 Daily maintenance tasks
• Clean the wire feed rollers on a regular basis (depending on the degree of soiling).
6.2.1.1 Visual inspection
• Mains supply lead and its strain relief
• Gas tubes and their switching equipment (solenoid valve)
• Other, general condition
6.2.1.2 Functional test
• Check correct mounting of the wire spool.
• Welding current cables (check that they are fitted correctly and secured)
• Gas cylinder securing elements
• Operating, message, safety and adjustment devices (Functional test)
6.2.2 Monthly maintenance tasks
6.2.2.1 Visual inspection
• Casing damage (front, rear and side walls)
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
6.2.2.2 Functional test
• Selector switches, command devices, emergency stop devices, voltage reducing devices, message and control lamps
• Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
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Maintenance, care and disposal
Disposing of equipment
6.2.3 Annual test (inspection and testing during operation)
The welding machine may only be tested by competent, capable personsl. A capable person is one who, because of his training, knowledge and experience, is able to recognise the dangers that can occur while testing welding power sources as well as possible subsequent damage and who is able to implement the required safety procedures.
For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com
!
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed.
6.3 Disposing of equipment
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and electronic components, which must be disposed of.
• Do not dispose of in household waste!
• Observe the local regulations regarding disposal!
6.3.1 Manufacturer's declaration to the end user
• According to European provisions (guideline 2002/96/EG of the European Parliament and the Council of January, 27th 2003), used electric and electronic equipment may no longer be placed in unsorted municipal waste. It must be collected separately. The symbol depicting a waste container on wheels indicates that the equipment must be collected separately.
This machine is to be placed for disposal or recycling in the waste separation systems provided for this purpose.
• According to German law (law governing the distribution, taking back and environmentally correct disposal of electric and electronic equipment (ElektroG) from 16.03.2005), used machines are to be placed in a collection system separate from unsorted municipal waste. The public waste management utilities (communities) have created collection points at which used equipment from private households can be disposed of free of charge.
• Information about giving back used equipment or about collections can be obtained from the respective municipal administration office.
• EWM participates in an approved waste disposal and recycling system and is registered in the Used
Electrical Equipment Register (EAR) under number WEEE DE 57686922.
• In addition to this, returns are also possible throughout Europe via EWM sales partners.
6.4 Meeting the requirements of RoHS
We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the
RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU).
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Rectifying faults
Checklist for rectifying faults
7
Rectifying faults
All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer.
7.1 Checklist for rectifying faults
The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation!
Legend Symbol
Description
Fault/Cause
Remedy
Wire feed problems
Contact tip blocked
Clean, spray with anti-spatter spray and replace if necessary
Setting the spool brake - See 5.9.2.5 Spool brake setting chapter
Check settings and correct if necessary
Setting pressure units - See 5.9.2.4 Inching the wire electrode chapter
Check settings and correct if necessary
Worn wire rolls
Check and replace if necessary
Wire feed motor without supply voltage (automatic cutout triggered by overloading)
Reset triggered fuse (rear of the power source) by pressing the key button
Kinked hose packages
Extend and lay out the torch hose package
Wire guide core or spiral is dirty or worn
Clean core or spiral; replace kinked or worn cores
Functional errors
Machine control without displaying the signal lights after switching on
Phase failure > check mains connection (fuses)
No welding performance
Phase failure > check mains connection (fuses)
Connection problems
Make control lead connections and check that they are fitted correctly.
Loose welding current connections
Tighten power connections on the torch and/or on the workpiece
Tighten contact tip correctly
Mains fuse triggers
Unsuitable mains fuse
Set up recommended mains fuse.
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Rectifying faults
Error messages (power source)
7.2 Error messages (power source)
A welding machine error is indicated by the collective fault signal lamp (A1) lighting up and an error code (see table) being displayed in the machine control display. In the event of a machine error, the power unit shuts down.
• If multiple errors occur, these are displayed in succession.
• Document machine errors and inform service staff as necessary.
Error message Possible cause
E 0 Start signal set in the event of errors
E 4
E 5
Temperature error
Mains overvoltage
E 6
E 7
E 9
E12
E13
E14
Mains undervoltage
Electronics error
Secondary overvoltage
Voltage reduction error (VRD)
Electronics error
Adjustment error in current recording
Remedy
Do not press the torch trigger or the footoperated remote control
Allow the machine to cool down
Switch off the machine and check the mains voltage
Switch the machine on and off again.
If the error persists, notify service department
E15
E23
E32
E33
E34
E37
E40
E55
E58
Error in on of the electronics supply voltages
Temperature error
Electronics error
Adjustment error in voltage recording
Electronics error
Temperature error
Motor fault
Failure of a mains phase
Short circuit in welding circuit
Switch off the machine, place the electrode holder in an insulated position and switch the machine back on. If the error persists, notify service department
Switch the machine off and on again.
If the error persists, notify service department
Allow the machine to cool down
Switch the machine on and off again.
If the error persists, notify service department
Switch off the machine, place the electrode holder in an insulated position and switch the machine back on. If the error persists, notify service department
Switch the machine on and off again.
If the error persists, notify service department
Allow the machine to cool down
Check wire feed unit, switch the machine off and on again, inform the service department if the fault persists.
Switch off the machine and check the mains voltage
Switch off machine and check welding current leads for correct installation, e.g., put down electrode holder in an electrically insulated manner, disconnect degausser current lead.
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Rectifying faults
Resetting welding parameters to the factory settings
7.3 Resetting welding parameters to the factory settings
RESET
0 l
+ +
Figure 7-1
Display Setting/selection
Calibration
The machine will be calibrated for approx 2 seconds each time it is switched on.
Initialising
Keep the push-button pressed until "InI" is shown on the display.
7.4 Display machine control software version
The query of the software versions only serves to inform the authorised service staff. It is available in the machine configuration menu.
7.5 Dynamic power adjustment
This requires use of the appropriate mains fuse.
Observe mains fuse specification- See 8 Technical data chapter!
The dynamic power adjustment automatically adjusts the welding performance to an uncritical level for the fuse.
The dynamic power adjustment can be set in two increments in the machine configuration menu using parameter "FUS": 20 A, 16 A.
The currently selected value will be shown on the "cal" section of the display for three seconds after the machine has been switched on.
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Technical data
Picomig 180
8
Technical data
8.1 Picomig 180
Performance specifications and guarantee only in connection with original spare and replacement parts!
Setting range
Welding current
Welding voltage
Duty cycle (DC) at 40 °C
25%
30%
35%
60 %
100 %
Load alternation
MIG/MAG
5 A to 180 A
TIG
5 A to 180 A
MMA
5 A to 150 A
14.3 V to 23 V 10.2 V to 17.2 V 20.2 V to 26 V
180 A
-
-
120 A
-
180 A
-
140 A
-
-
150 A
110 A
100 A 120 A 100 A
10 min. (60% DC
6 min. welding, 4 min. pause)
Open circuit voltage
Mains voltage (tolerances)
Frequency
Mains fuse (safety fuse, slow-blow)
Mains connection lead
Max. connected load recommended generator rating cos
/ Efficiency
Insulation class/protection classification
Ambient temperature
Machine/torch cooling
Torch connection
Wire feed speed
Standard roller fitting
Drive
Workpiece lead
Dimensions L x W x H in mm
Weight
EMC class constructed to standards
5.9 kVA
80 V
1 x 230 V (-40% to +15%)
50/60 Hz
16 A*
H07RN-F3G2.5
4.4 kVA
8.0 kVA
0.99 / 86 %
5.5 kVA
H/IP 23
-25 °C to +40 °C
Fan/gas
Central connection for welding torch (Euro)
1 m/min to 15 m/min
0.8/1.0 mm for steel wire
4-roller (37 mm)
25 mm
2
685 x 280 x 360
15 kg
A
IEC 60974-1, -5, -10
/
* DIAZED XXA gG safety fuses are recommended
* When using automatic cutouts, the "C" trigger characteristic must be used.
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Accessories
Options
9
Accessories
Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer.
9.1 Options
Type
ON Filter Picomig 180
ON Trolly Picomig
ON CS K
Designation
Retrofit option, dirt filter for air inlet
Trolly Picomig 180 with holder for 300 mm wire spool
Crane suspension for Picomig 180 / 185 D3 / 305
D3, Phoenix and Taurus 355 compact, drive 4
Item no.
092-002553-00000
092-000312-00000
092-002549-00000
9.2 Transport systems
Type
Trolly 35-1
Designation
Transport vehicle
Item no.
090-008629-00000
9.3 General accessories
Type Designation
5POLE/CEE/16A/M
ADAP CEE16/SCHUKO
Machine plug
Earth contact coupling/CEE16A plug
DMDIN TN 200B AR/MIX 35L Manometer pressure regulator
G1 G1/4 R 3M Gas hose
ADAPTER EZA --> DINSE-ZA Adapter for welding torches with Dinse connector to
Euro central connector, on the machine
Item no.
094-000712-00000
092-000812-00000
094-000009-00000
094-000010-00003
094-016765-00000
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Replaceable parts
Wire feed rollers
10
Replaceable parts
CAUTION
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.
10.1 Wire feed rollers
10.1.1 Wire feed rollers for steel wire
Type Designation
FE 2DR4R 0,6+0,8
FE 2DR4R 0,8+1,0
FE 2DR4R 0,9+1,2
FE 2DR4R 1,0+1,2
FE 2DR4R 1,2+1,6
Drive rollers, 37 mm, steel
Drive rollers, 37 mm, steel
Drive rollers, 37 mm, steel
Drive rollers, 37 mm, steel
Drive rollers, 37 mm, steel
Item no.
092-000839-00000
092-000840-00000
092-000841-00000
092-000842-00000
092-000843-00000
092-000414-00000 FE/AL 2GR4R SF Pressure rollers, smooth, 37 mm
10.1.2 Wire feed rollers for aluminium wire
Type Designation
AL 4ZR4R 0,8+1,0 Twin rollers, 37 mm, for aluminium
AL 4ZR4R 1,0+1,2
AL 4ZR4R 1,2+1,6
AL 4ZR4R 2,4+3,2
Twin rollers, 37 mm, for aluminium
Twin rollers, 37 mm, for aluminium
Twin rollers, 37 mm, for aluminium
10.1.3 Wire feed rollers for cored wire
Type Designation
ROE 2DR4R 0,8/0,9+0,8/0,9 Drive rollers, 37 mm, cored wire
ROE 2DR4R 1,0/1,2+1,4/1,6 Drive rollers, 37 mm, cored wire
ROE 2DR4R 1,4/1,6+2,0/2,4 Drive rollers, 37 mm, cored wire
ROE 2DR4R 2,8+3,2 Drive rollers, 37 mm, cored wire
ROE 2GR4R Pressure rollers, knurled, 37mm
Item no.
092-000869-00000
092-000848-00000
092-000849-00000
092-000870-00000
Item no.
092-000834-00000
092-000835-00000
092-000836-00000
092-000837-00000
092-000838-00000
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Replaceable parts
Wire feed rollers
10.1.4 Conversion sets
Type
URUE VERZ>UNVERZ FE/AL
4R SF
Conversion kit, 37mm, 4-roller drive on non-toothed rollers (steel/aluminium)
URUE ROE 2DR4R
0,8/0,9+0,8/0,9 SF
URUE ROE 2DR4R
1,0/1,2+1,4/1,6 SF
Designation
Conversion kit, 37 mm, 4-roller drive for cored wire 092-000410-00000
Conversion kit, 37 mm, 4-roller drive for cored wire
Item no.
092-000415-00000
092-000411-00000
URUE ROE 2DR4R
1,4/1,6+2,0/2,4 SF
URUE ROE 2DR4R 2,8+3,2
SF
Conversion kit, 37 mm, 4-roller drive for cored wire
Conversion kit, 37 mm, 4-roller drive for cored wire
092-000412-00000
092-000413-00000
URUE AL 4ZR4R 0,8+1,0 SF Conversion kit, 37 mm, 4-roller drive for aluminium 092-002268-00000
URUE AL 4ZR4R 1,0+1,2 SF Conversion kit, 37 mm, 4-roller drive for aluminium 092-002266-00000
URUE AL 4ZR4R 1,2+1,6 SF Conversion kit, 37 mm, 4-roller drive for aluminium 092-002269-00000
URUE AL 4ZR4R 2,4+3,2 SF Conversion kit, 37 mm, 4-roller drive for aluminium 092-002270-00000
70
Figure 10-1
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Appendix A
JOB-List
11
Appendix A
11.1 JOB-List
We recommend using the characteristics for 1.0-mm solid wire electrodes also for the 0.9-mm solid wire electrodes.
For machine versions with pulsed arc welding procedures only.
MIG/MAG pulse arc welding can be selected with JOBs 6, 34, 42, 74, 75, 82, 83, 90, 91, 110, 111,
114 and 115. 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 standard.
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Appendix B
Overview of EWM branches
12
Appendix B
12.1 Overview of EWM branches
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