Design and function

Design and function

Operating instructions

EN

Welding machine

Picomig 305 D3 puls TKG

Picomig 305 D3 Synergic TKG

099-005313-EW501

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www.ewm-group.com

02.09.2015

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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

1 Contents .................................................................................................................................................. 3

2 Safety instructions ................................................................................................................................. 6

2.1

Notes on the use of these operating instructions .......................................................................... 6

2.2

Explanation of icons ....................................................................................................................... 7

2.3

General .......................................................................................................................................... 8

2.4

Transport and installation ............................................................................................................ 12

2.4.1

Ambient conditions ....................................................................................................... 13

2.4.1.1

In operation ................................................................................................... 13

2.4.1.2

Transport and storage ................................................................................... 13

3 Intended use ......................................................................................................................................... 14

3.1

Applications .................................................................................................................................. 14

3.1.1

MIG/MAG standard welding ......................................................................................... 14

3.1.1.1

forceArc ......................................................................................................... 14

3.1.1.2

rootArc ........................................................................................................... 14

3.1.1.3

coldArc .......................................................................................................... 14

3.1.2

MIG/MAG pulse welding ............................................................................................... 14

3.1.2.1

forceArc puls ................................................................................................. 14

3.1.2.2

rootArc puls ................................................................................................... 14

3.1.3

MIG/MAG cored wire welding ....................................................................................... 14

3.1.4

MMA welding ................................................................................................................ 14

3.1.5

TIG (Liftarc) welding ..................................................................................................... 14

3.1.6

Polarity setting .............................................................................................................. 14

3.2

Documents which also apply ....................................................................................................... 15

3.2.1

Warranty ....................................................................................................................... 15

3.2.2

Declaration of Conformity ............................................................................................. 15

3.2.3

Welding in environments with increased electrical hazards ......................................... 15

3.2.4

Service documents (spare parts and circuit diagrams) ................................................ 15

3.2.5

Calibration/Validation ................................................................................................... 15

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

Installation .................................................................................................................................... 23

5.2

Machine cooling ........................................................................................................................... 23

5.3

Workpiece lead, general .............................................................................................................. 23

5.4

Notes on the installation of welding current leads ....................................................................... 24

5.5

Mains connection ......................................................................................................................... 26

5.5.1

Mains configuration ...................................................................................................... 26

5.6

Shielding gas supply (shielding gas cylinder for welding machine) ............................................. 27

5.6.1

Connection ................................................................................................................... 27

5.6.2

Gas test, rinse hose package ....................................................................................... 28

5.6.2.1

Setting the shielding gas quantity ................................................................. 28

5.7

MIG/MAG welding ........................................................................................................................ 29

5.7.1

Welding torch and workpiece line connection .............................................................. 29

5.7.2

MIG/MAG function torch ............................................................................................... 31

5.7.3

MIG/MAG Push/Pull welding torch ............................................................................... 31

5.7.3.1

Pin assignment .............................................................................................. 31

5.7.4

Wire feed ...................................................................................................................... 32

5.7.4.1

Open the protective flap of the wire feeder ................................................... 32

5.7.4.2

Inserting the wire spool ................................................................................. 32

5.7.4.3

Changing the wire feed rollers ...................................................................... 33

5.7.4.4

Inching the wire electrode ............................................................................. 35

5.7.4.5

Spool brake setting ....................................................................................... 37

5.7.5

Welding data display .................................................................................................... 37

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Contents

Notes on the use of these operating instructions

5.7.5.1

Setting the operating point (welding output).................................................. 38

5.7.6

Definition of MIG/MAG welding tasks ........................................................................... 39

5.7.7

Welding task selection .................................................................................................. 39

5.7.7.1

JOB selection ................................................................................................ 39

5.7.7.2

Operating mode ............................................................................................. 39

5.7.7.3

Welding type (MIG/MAG standard/pulse arc welding) .................................. 39

5.7.8

MIG/MAG operating point ............................................................................................. 40

5.7.8.1

Selecting the welding parameter display mode ............................................ 40

5.7.8.2

Operating point setting using material thickness .......................................... 40

5.7.8.3

Arc length correction setting .......................................................................... 40

5.7.9

Further welding parameters .......................................................................................... 41

5.7.9.1

Choke effect / dynamics ................................................................................ 41

5.7.9.2

Gas post-flow time ......................................................................................... 41

5.7.9.3

Spot time ....................................................................................................... 42

5.7.9.4

Pause time (interval operation) ..................................................................... 42

5.7.9.5

Burn-back ...................................................................................................... 43

5.7.9.6

gas pre-flow time ........................................................................................... 43

5.7.10

forceArc / forceArc puls ................................................................................................ 44

5.7.11

rootArc/rootArc puls ...................................................................................................... 45

5.7.12

MIG/MAG functional sequences / operating modes ..................................................... 46

5.7.12.1

Explanation of signs and functions ................................................................ 46

5.7.13

Conventional MIG/MAG Welding (GMAW non synergic) ............................................. 51

5.7.13.1

Operating mode ............................................................................................. 51

5.7.14

MIG/MAG automatic cut-out ......................................................................................... 51

5.8

MMA welding ................................................................................................................................ 52

5.8.1

Connecting the electrode holder and workpiece lead .................................................. 52

5.8.2

Welding task selection .................................................................................................. 53

5.8.3

Welding current setting ................................................................................................. 53

5.8.4

MMA welding data display ............................................................................................ 53

5.8.5

Arcforce......................................................................................................................... 54

5.8.6

Hotstart ......................................................................................................................... 54

5.8.6.1

Hotstart settings ............................................................................................ 55

5.8.7

Antistick......................................................................................................................... 55

5.9

TIG welding .................................................................................................................................. 56

5.9.1

Preparing the TIG welding torch ................................................................................... 56

5.9.2

Welding torch and workpiece line connection .............................................................. 56

5.9.3

Welding task selection .................................................................................................. 57

5.9.3.1

Welding current setting .................................................................................. 57

5.9.3.2

Adjusting the gas post-flow time ................................................................... 57

5.9.4

Further welding parameters .......................................................................................... 58

5.9.5

TIG welding data display .............................................................................................. 59

5.9.6

TIG arc ignition ............................................................................................................. 59

5.9.6.1

Liftarc ignition ................................................................................................ 59

5.9.7

Function sequences/operating modes .......................................................................... 60

5.9.7.1

Legend........................................................................................................... 60

5.9.8

TIG automatic cut-out ................................................................................................... 62

5.10

Welding torch holder .................................................................................................................... 63

5.11

Power-saving mode (Standby) ..................................................................................................... 63

5.12

Remote control ............................................................................................................................. 64

5.13

Special parameters (advanced settings) ...................................................................................... 64

5.13.1

Selecting, changing and saving parameters................................................................. 64

5.13.1.1

Special parameters in detail .......................................................................... 65

5.13.1.2

Reset to factory settings ................................................................................ 66

5.14

Machine configuration menu ........................................................................................................ 67

5.14.1

Selecting, changing and saving parameters................................................................. 67

5.14.2

Aligning the cable resistance ........................................................................................ 68

6 Maintenance, care and disposal ......................................................................................................... 70

6.1

General......................................................................................................................................... 70

6.2

Maintenance work, intervals ........................................................................................................ 70

6.2.1

Daily maintenance tasks ............................................................................................... 70

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Notes on the use of these operating instructions

6.2.1.1

Visual inspection ........................................................................................... 70

6.2.1.2

Functional test ............................................................................................... 70

6.2.2

Monthly maintenance tasks .......................................................................................... 70

6.2.2.1

Visual inspection ........................................................................................... 70

6.2.2.2

Functional test ............................................................................................... 70

6.2.3

Annual test (inspection and testing during operation) .................................................. 71

6.3

Disposing of equipment ............................................................................................................... 71

6.3.1

Manufacturer's declaration to the end user .................................................................. 71

6.4

Meeting the requirements of RoHS ............................................................................................. 71

7 Rectifying faults ................................................................................................................................... 72

7.1

Checklist for rectifying faults ........................................................................................................ 72

7.2

Error messages (power source) .................................................................................................. 73

7.3

Resetting welding parameters to the factory settings .................................................................. 75

7.4

Resetting JOBs (welding tasks) to the factory settings ............................................................... 76

7.4.1

Resetting a single JOB ................................................................................................. 76

7.4.2

Resetting all JOBs ........................................................................................................ 77

8 Technical data ...................................................................................................................................... 78

8.1

Picomig 305 TKG ......................................................................................................................... 78

9 Accessories .......................................................................................................................................... 79

9.1

General accessories .................................................................................................................... 79

9.2

Remote control/connecting and extension cable ......................................................................... 79

9.2.1

19-pole connection ....................................................................................................... 79

9.3

Options ......................................................................................................................................... 79

9.4

Transport systems ....................................................................................................................... 79

10 Replaceable parts ................................................................................................................................ 80

10.1

Wire feed rollers ........................................................................................................................... 80

10.1.1

Wire feed rollers for steel wire ...................................................................................... 80

10.1.2

Wire feed rollers for aluminium wire ............................................................................. 81

10.1.3

Wire feed rollers for cored wire .................................................................................... 81

10.1.4

Wire guide .................................................................................................................... 81

11 Appendix A ........................................................................................................................................... 82

11.1

JOB-List ....................................................................................................................................... 82

12 Appendix B ........................................................................................................................................... 83

12.1

Overview of EWM branches ........................................................................................................ 83

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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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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

NAVIGATION (Navigating in the menu)

Safety instructions

Explanation of icons

EXIT

4 s

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

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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 if these safety instructions are not observed!

Non-observance of these safety instructions is potentially fatal!

• Carefully read the safety information in this manual!

• Observe the accident prevention regulations in your country.

• Inform persons in the working area that they must observe 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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13

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.

3.1.1.1 forceArc

Low-heat, directionally stable and powerful high-performance arc with deep fusion penetration for the upper power range Unalloyed, low-alloy and high-alloy steels as well as high-tensile fine-grained steels.

3.1.1.2 rootArc

Short arc with perfect weld modelling capabilities for effortless gap bridging, especially for positional welding

3.1.1.3 coldArc

Heat-reduced, low-spatter short arc for high dimensional stability welding and brazing, plus root welding with excellent gap bridging capabilities.

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.

3.1.2.1 forceArc puls

Effective extension of the forceArc arc. Secure sidewall fusion, easy to model and control by the user.

Ideal for welding filler and final passes in all power ranges and positions.

3.1.2.2 rootArc puls

The perfect enhancement for focused heat input for the higher performance range

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

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.

3.1.5 TIG (Liftarc) welding

TIG welding procedure with arc striking by contact with the workpiece and subsequent removal of the electrode.

3.1.6 Polarity setting

The polarity setting displays the polarity required for the selected JOB

on the machine control- See 4.4

Machine control

– Operating elements chapter. The required polarity can then be set with the polarity

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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15

Machine description

– quick overview

Front view

4

Machine description – quick overview

4.1 Front view

Figure 4-1

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Machine description

– quick overview

Front view

Item Symbol Description 0

1

2

3

Transport bar

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

6

7

Slide latch, lock for the protective cap

Welding torch connection (Euro or Dinse torch connector)

Welding current, shielding gas and torch trigger integrated

Park socket, polarity selection plug

Retainer for the polarity selection plug in MMA mode or for transport.

Machine feet

8

9

10

11

12

13

Welding current cable, polarity selection

Welding current to Euro torch connector/torch, for polarity selection

• MIG/MAG: Connection socket for “+” welding current

• Self-shielding flux cored wire/TIG: Connection socket, “-” welding current

• MMA: Park socket

19-pole connection socket (analogue)

For connecting analogue accessory components (remote control, welding torch control lead, etc.)

"-" welding current connection socket

• MIG/MAG welding:

• TIG welding:

• MMA welding:

Workpiece connection

Welding current connection for welding torch electrode holder connection

Connection socket, "+" welding current

• MIG/MAG cored wire welding:

• TIG welding:

• MMA welding:

Workpiece connection

Workpiece connection

Workpiece connection

Cooling air inlet

Machine control- See 4.4 Machine control

– Operating elements chapter

14

Carrying handle

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Machine description

– quick overview

Rear view

4.2 Rear view

18

Item Symbol Description 0

1

Main switch, machine on/off

Figure 4-2

2

Connecting nipple G¼, shielding gas connection

3

4

Cooling air outlet

External wire feed inlet

Pre-cut casing inlet for external wire feed.

5

Mains connection cable

- See 5.5 Mains connection chapter

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4.3 Inside view

Machine description

– quick overview

Inside view

Figure 4-3

Item Symbol Description 0

1

2

3

Key button, Automatic cutout

Wire feed motor supply voltage fuse

(press to reset a triggered fuse)

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.

Wire spool holder

4

Wire feed unit

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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

Push-button welding parameter display mode

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:

For setting the shielding gas quantity

• Rinse:

For rinsing longer hose packages

- See 5.6 Shielding gas supply (shielding gas cylinder for welding machine) chapter

"Welding type" push-button (for machine versions with pulsed arc welding procedures only)

standard MIG/MAG welding

11

12

pulsed MIG/MAG 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

Machine control

– Operating elements

5

Design and function

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

Installation

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!

5.1

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.

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!

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Design and function

Notes on the installation of welding current leads

5.4 Notes on the installation of welding current leads

Incorrectly installed welding current leads can cause faults in the arc (flickering).

Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel.

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

5.5

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.

5.5.1 Mains configuration

The machine may be connected to:

• a three-phase system with four conductors and an earthed neutral conductor

• a three-phase system with three conductors of which any one can be earthed, e.g. the outer conductor

Figure 5-4

Legend

Item

L1

L2

L3

N

PE

Designation

Outer conductor 1

Outer conductor 2

Outer conductor 3

Neutral conductor

Protective conductor

Colour code

brown black grey 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)

5.6 Shielding gas supply (shielding gas cylinder for welding machine)

5.6.1 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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Design and function

Shielding gas supply (shielding gas cylinder for welding machine)

5.6.2 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.

5.6.2.1 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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MIG/MAG welding

5.7 MIG/MAG welding

5.7.1 Welding torch and workpiece line connection

On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used!

• Operate welding torches with a liner > with a guide tube.

• Operate welding torches with a steel liner > with a capillary tube.

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.

Preparation for connecting welding torches with a spiral guide:

• Check that the capillary tube is correctly positioned in relation to the central connector!

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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MIG/MAG welding

Choose welding current connection socket according to the signal light for the polarity setting!

• Select JOB- See 5.7.7 Welding task selection chapter

• Polarity selection “+” or polarity selection “-” signal lights show the polarity setting.

Figure 5-6

Item Symbol Description 0

1

Welding torch

2

3

4

5

6

Welding torch connection (Euro or Dinse torch connector)

Welding current, shielding gas and torch trigger integrated

19-pole connection socket (analogue)

For connecting analogue accessory components (remote control, welding torch control lead, etc.)

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.

• Insert the welding torch control cable into the 19-pole connection socket and lock (MIG/MAG torches with additional control cables only).

Some wire electrodes (e.g. self-shielding flux cored wire) are welded using negative polarity. Use the welding current polarity push-button (pole reversal) to reverse the welding current polarity

(+/-) without having to change the welding current leads. This reversal can also be effected using a suitable remote control (PWS). Signal lights above the welding current sockets show the welding current polarity (+/-) selected.

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5.7.2 MIG/MAG function torch

The torch trigger on the MIG welding torch is generally used to start and finish the welding process.

Function torches feature additional operating elements to set the wire feed speed and voltage correction.

Welding torches with one rotary knob, one rocker or one pair of buttons only must be configured on the machine control appropriately. For this purpose, set the FRC special parameter to the corresponding accessory component.

- See 5.13 Special parameters (advanced settings) chapter

5.7.3 MIG/MAG Push/Pull welding torch

5.7.3.1 Pin assignment

No potentiometers

With potentiometer for wire feeding speed

Figure 5-7

With potentiometers for wire feeding speed and arc length correction

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MIG/MAG welding

5.7.4 Wire feed

5.7.4.1 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.

5.7.4.2 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.

Standard D300 wire spool holder can be used. Adapters - See 9 Accessories chapter are required

when using standardised basket coils (DIN 8559).

Figure 5-8

Item Symbol Description 0

1

2

Carrier pin

For fixing the wire spool

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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5.7.4.3 Changing the wire feed rollers

Design and function

MIG/MAG welding

Figure 5-9

Item Symbol Description 0

1

2

Tommy

The tommy is used to secure the closure brackets of the wire feed rollers.

Closure bracket

The closure brackets are used to secure the wire feed rollers.

3

4

Feed roll tensioner

Fixing the clamping unit and setting the pressure.

Clamping unit

5

Wire feed roller

see the Wire feed roller overview table

• Rotate the tommy by 90° clockwise or anti-clockwise (tommy locks into place).

• Fold the closure brackets outwards by 90°.

• Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards).

• Remove the wire feed rollers from the roller support.

• Select new wire feed rollers accoridng to the Wire feed roller overview table and reassemble the wire feed mechanism in reverse order.

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MIG/MAG welding

Unsatisfactory welding results due to faulty wire feeding!

The wire feed rollers must be suitable for the diameter of the wire and the material. The wire feed rollers are colour-coded to facilitate distinction (see the Wire feed roller overview table).

Wire feed roller overview table

Material Diameter

mm

inch

Colour code Groove form

Steel

Stainless steel

Brazing

Aluminium

Flux cored wire

3.2

0.8

0.9

1.0

1.2

1.4

1.6

2.0

2.4

3.2

0.8

0.9/1.0

1.2

1.6

2.0

2.4

2.8

0.6

0.8

0.9/1.0

1.2

1.4

1.6

2.0

2.4

2.8

.125

.030

.035

.040

.045

.052

.060

.080

.095

.023

.030

.035/.040

045

052

060

.080

.095

.110

.125

.030

.035/.040

.045

.060

.080

.095

.110 monochrome bichrome bichrome black grey brown

Light green purple white blue light pink white blue red green black grey brown

Light green purple white blue red red green black grey brown

- yellow orange

V-groove

U-groove

V-groove, knurled

- See 10 Replaceable parts chapter

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5.7.4.4 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. The left display shows the wire feed speed selected, the right display shows the current motor current of the wire feed mechanism.

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MIG/MAG welding

Figure 5-10

Item Symbol Description 0

1

Welding wire

2

Wire feed nipple

3

Guide tube

4

Adjusting nut

• Extend and lay out the torch hose package.

• Carefully unwind the welding wire from the wire spool and insert through the wire feed nipples up to the wire feed rollers.

• Press the inching push-button (the drive catches the welding wire and automatically guides it to the welding torch outlet).

A prerequisite for the automatic inching process is the correct preparation of the wire guide, especially in the capillary and wire guide tube area .

• The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll tensioner setting nuts depending on the welding consumable used. A table with the setting values can be found on a sticker near the wire drive.

Version 1: left hand mounting Version 2: right hand mounting

Automatic inching stop

Touch the welding torch against the workpiece during inching. Inching of the welding wire will stop as soon it touches the workpiece.

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MIG/MAG welding

5.7.4.5 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!

5.7.5 Welding data display

Diagram 5-12

The button for the welding parameter display mode is next to the display.

Each time the 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)

Parameter

Welding current

Material thickness

Wire speed

Welding voltage

Nominal values

Actual values

Hold values

After welding you can change back to the nominal values

• by pressing the buttons or using the dials on the controls

• or by briefly pressing the torch trigger.

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MIG/MAG welding

5.7.5.1 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: 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.

Operating element

Action Result

Increase or reduce welding performance via the wire speed parameter.

Operating element

Action Result

Set the welding voltage

Setting range:

5 V to 35 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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5.7.6 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.

5.7.7 Welding task selection

The settings for the respective welding parameters are defined by the different JOBs. The right JOB can be determined quickly with the JOB list .

5.7.7.1 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.

• Set the operating point by means of the panel thickness- See 5.7.8 MIG/MAG operating point chapter.

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.

5.7.7.2 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

5.7.7.3 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

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5.7.8 MIG/MAG operating point

5.7.8.1 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

5.7.8.2 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

5.7.8.3 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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5.7.9 Further welding parameters

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.

If required, these parameter values can be reset to the factory settings- See 7.3 Resetting welding parameters to the factory settings chapter.

5.7.9.1 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.

5.7.9.2 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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5.7.9.3 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

5.7.9.4 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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5.7.9.5 Burn-back

• Preselection: Select a MIG/MAG JOB- See 5.7.7 Welding task selection chapter.

ENTER NAVIGATION EXIT

3 s

3 s m/min

AMP

Figure 5-13

Display Setting/selection

Burn-back correction

0 to 499 of the burn back time specified in the JOB

5.7.9.6 gas pre-flow time

• Preselection: Select a MIG/MAG JOB- See 5.7.7 Welding task selection chapter.

ENTER NAVIGATION EXIT

3 s

3 s m/min

AMP

Display

Figure 5-14

Setting/selection

Gas pre-flow time

0.0 s to 20.0 s (0.1 s increments)

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5.7.10 forceArc / forceArc puls

Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range.

Figure 5-15

• Smaller included angle due to deep penetration and directionally stable arc

• Excellent root and sidewall fusion

• Secure welding also with very long stick-outs

• Reduced undercuts

• Un-, low- and high-alloyed steels as well as high-tensile fine-grained building steels

• Manual and automated applications

forceArc welding from: Wire Ø (mm)

0.8 1 1.2 1.6

Material

Steel

Gas

Ar 91

–99%

Ar 80

–90%

Ar 91

–99%

JOB

189 17.0

JOB

179 12.0

JOB

190 17.0 254 12.0 255

180

9.5

9.5

JOB

256

181

CrNi

- - 251 12.0 252 12.0 253

You can make use of these properties after selecting the forceArc process- See 5.7.7 Welding task selection chapter.

7.0

6.0

6.0

As with pulse arc welding, it is important to make sure of a good welding current connection.

• Keep welding current cables as short as possible and ensure that cable cross-sections are adequate!

• Fully unroll welding current cables, torche hose packages and, if applicable, intermediate hose packages. Avoid loops!

• Use welding torches, preferably water-cooled, that are suitable for the higher power range.

• Use welding wire with adequate copper coating when welding steel. The wire spool should have layer spooling.

Unstable arc!

Welding current cables that are not fully unrolled can cause faults in the arc (flickering).

Fully unroll welding current cables, torch hose packages and, if applicable, intermediate hose

packages. Avoid loops!

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5.7.11 rootArc/rootArc puls

Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding.

Figure 5-16

• Reduced spatter compared to standard short arc

• Good root formation and secure sidewall fusion

• Un-alloyed and low-alloy steels

• Manual and automated applications

rootArc welding up to:

0.6 0.8

Material

Steel

Gas

CO2

Ar 80

–90%

JOB

-

-

-

-

JOB JOB

-

-

-

-

-

-

Wire Ø (mm)

0.9 1

JOB

1.2

JOB

1.6

JOB

- 204 7.0 205 5.0 -

- 206 8.0 207 6.0 -

-

-

Unstable arc!

Welding current cables that are not fully unrolled can cause faults in the arc (flickering).

Fully unroll welding current cables, torch hose packages and, if applicable, intermediate hose

packages. Avoid loops!

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5.7.12 MIG/MAG functional sequences / operating modes

5.7.12.1 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

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Non-latched mode

Figure 5-17

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 5-18

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 5-19

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 5-20

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.

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5.7.13 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

5.7.13.1 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

5.7.14 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 intrerrupted for longer than 5 s)

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MMA welding

5.8

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.

5.8.1 Connecting the electrode holder and workpiece lead

Figure 5-21

Item Symbol Description 0

1

Electrode holder

2

Workpiece

3

4

5

Connection socket for "+" welding current

Electrode holder or workpiece lead connection

Connection socket, “-” welding current

Electrode holder or workpiece lead connection

Polarity selector plug, welding current cable

• Connect to the park socket.

• 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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5.8.2 Welding task selection

• Select MMA JOB 128- See 11.1 JOB-List chapter.

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

5.8.3 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

5.8.4 MMA welding data display

Diagram 5-22

The button for the welding parameter display mode is next to the display.

Each time the button is pressed it switches between welding current and welding voltage.

The display shows:

• Nominal values (before welding)

• Actual values (during welding)

• Hold values (after welding)

Parameter

Welding current

Welding voltage

Nominal values

Actual values

Hold values

The display switches back from hold values to actual values for approximately 5 s after welding is finished.

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5.8.5 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 DYN setting

(LED is on)

Parameter value setting

1 x

Arc force setting for electrode types:

Setting range -40 to 40

Negative values: Rutile

Values around zero: Basic

Positive values: Rutilecellulose

5.8.6 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 5-23

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5.8.6.1 Hotstart settings

• Select MMA JOB 128- See 5.8.2 Welding task selection chapter.

ENTER

DY N

NAVIGATION

DY N

3 s t1 t2 t1 t2 m/min

AMP

Design and function

MMA welding

EXIT

3 s

Display

5.8.7

Antistick

Figure 5-24

Setting/selection

Hotstart current

0% to 200% of the welding current (1% increments)

Hotstart time

0.0 s to 20.0 s (0.1 s increments)

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

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TIG welding

5.9

TIG welding

5.9.1 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!

5.9.2 Welding torch and workpiece line connection

Figure 5-26

Item Symbol Description 0

1

Welding torch

2

3

4

5

Welding torch connection (Euro or Dinse 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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5.9.3 Welding task selection

• Select TIG JOB 127- See 11.1 JOB-List chapter.

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

5.9.3.1 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

5.9.3.2 Adjusting the gas post-flow time

Operating element

Action Result

Select setting for gas post-flow time

1 x

(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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5.9.4 Further welding parameters

• Preselection: Select TIG JOB 127- See 5.9.3 Welding task selection chapter.

ENTER

DY N

NAVIGATION EXIT

DY N

3 s

3 s t1 t2 t1 t2 m/min

AMP

Display

Figure 5-27

Setting/selection

Gas pre-flow time

0.0 s to 20.0 s (0.1 s increments)

Ignition current

0% to 200% of the welding current (1% increments)

Upslope time

0.0 s to 20.0 s (0.1 s increments)

Downslope time

0.0 s to 20.0 s (0.1 s increments)

End current

0% to 200% of the welding current (1% increments)

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5.9.5 TIG welding data display

Diagram 5-28

The button for the welding parameter display mode is next to the display.

Each time the button is pressed it switches between welding current and welding voltage.

The display shows:

• Nominal values (before welding)

• Actual values (during welding)

• Hold values (after welding)

Parameter

Welding current

Nominal values

Actual values

Hold values

Welding voltage

The display switches back from hold values to actual values for approximately 5 s after welding is finished.

5.9.6 TIG arc ignition

5.9.6.1 Liftarc ignition

Figure 5-29

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.

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5.9.7 Function sequences/operating modes

5.9.7.1 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 5-30

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 5-31

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.

5.9.8 TIG 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 intrerrupted for longer than 5 s)

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Welding torch holder

5.10 Welding torch holder

The item described in the following is part of the machine´s scope of delivery.

Figure 5-32

Item Symbol Description 0

1

Crossmember of the transport handle

2

Torch holder

3

Fan-type lock washers

4

Fixing screws (x 4)

• Use the mounting screws to screw the torch holder onto the crossmember of the transport handle.

• Insert the welding torch into the welding torch holder as shown.

5.11 Power-saving mode (Standby)

The power-saving function can be activated either by pressing the button for a longer time - See 4.4

Machine control

– Operating elements chapter or by setting a parameter in the configuration menu (time-

based power-saving mode).

When power-saving mode is activated, both 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.

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Remote control

5.12 Remote control

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.

The remote controls are operated on the 19-pole remote control connection socket (analogue).

Please note the relevant documentation of the accessory components.

5.13 Special parameters (advanced settings)

Special parameters (P1 to Pn) are applied for customer-specific configuration of machine functions. This allows the user maximum flexibility in optimising their requirements.

These settings are not configured directly on the machine control since a regular setting of the parameters is generally not required. The number of selectable special parameters can deviate between the machine controls used in the welding system (also see the relevant standard operating instructions).

If required, the special parameters can be reset to the factory settings- See 5.13.1.2 Reset to factory settings chapter.

5.13.1 Selecting, changing and saving parameters

ENTER (Enter the menu)

• Switch off the machine at the main switch.

• Press and hold the "operating mode" push-button and switch the machine on again at the same time.

NAVIGATION (Navigate the menu)

• Select parameters by turning the "welding parameter setting" rotary knob.

• Set or change the parameters by turning the "welding voltage" rotary knob.

EXIT (Exit the menu)

• Press the "gas test" push-button (switch machine off and on again).

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ENTER

0 l

+

Design and function

Special parameters (advanced settings)

EXIT

Figure 5-33

Display Setting/selection

Ramp time for wire inching

0 = normal inching (10s ramp time)

1 = fast inching (3s ramp time) (Ex works)

Lat. and sp. lat. tapping start

0 = no latched tapping start (Ex works)

1 = latched tapping start possible

Remote control encoding (FRC)

0 Automatic remote control detection (factory setting)

2 Remote control encoding for accessory components with a single rotary knob only

9 Remote control encoding for accessory components with a single pair of buttons or a rocker only

5.13.1.1 Special parameters in detail

Ramp time for wire inching (P1)

The wire inching starts with a speed 1.0 m/min for 2 secs. It is subsequently increased to a ramp function to 6.0 m/min. The ramp time can be set between two ranges.

During wire inching, the speed can be changed by means of the welding parameter setting rotary dial.

Changing the speed has no effect on the ramp time.

Latched/special-latched tap start (P9)

In latched

– tap start – operating mode it is possible to switch straight to the second step by tapping the torch trigger; it is not necessary for current to be flowing.

The welding can be halted by pressing the torch trigger for a second time.

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Special parameters (advanced settings)

5.13.1.2 Reset to factory settings

All special parameters saved by the user will be overwritten by the factory settings!

Operating element

Action Result left

Display right

Switch off welding machine

Press and hold push-button

Switch on welding machine

Release push-button

Wait for about 3 s

Switch off the welding machine and restart in order to implement the changes.

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Machine configuration menu

5.14 Machine configuration menu

5.14.1 Selecting, changing and saving parameters

ENTER (Enter the menu)

• Switch off the machine at the main switch.

• Press and hold the "sequence parameter" push-button and switch the machine on again at the same time.

NAVIGATION (Navigate the menu)

• Select parameters by pressing the "sequence parameter" push-button.

• Set or change the parameters by turning the "welding parameter setting" rotary knob.

EXIT (Exit the menu)

• Press the "gas test/flushing" push-button (switch machine off and on again).

ENTER

EXIT

D YN

0 l t1 t2

+

NAVIGATION

D YN t1 t2 m/min

AMP

Display

Figure 5-34

Setting/selection

Lead resistance 1

Lead resistance for the first welding circuit 0 mΩ–60 mΩ (8 mΩ ex works).

Only qualified service personnel may change the parameters!

Time-based power-saving mode

• 5 min.–60 min. = Time to activation of power-saving mode in case of inactivity.

• off = inactivated

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Machine configuration menu

5.14.2 Aligning the cable resistance

The resistance value of cables can either be set directly or it can be aligned using the power source. The factory setting of the power sources is 8 m-ohm. This value correponds to a 5 m earth cable, a 1.5 m intermediate hose package and a 3 m water-cooled welding torch. With other hose package lengths, it is necessary to carry out a +/- voltage correction to optimise welding properties. The voltage correction value can be set close to zero by means of realigning the cable resistance. It is recommended to align the electric cable resistance after replacing accessories such as torches or intermediate hose packages.

In case a second wire feeder is used the (rL2) parameter has to be aligned. For all other configurations it is sufficient to align the (rL1) parameter.

1

0

50mm

l

2

D YN t1 t2

+

3

B

A

4

0 l

Figure 5-35

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Machine configuration menu

1 Preparation

• Switch off the welding machine.

• Unscrew the gas nozzle of the welding torch.

• Cut off the welding wire to be flush with the contact tip.

• Retract the welding wire a bit (approx. 50 mm) on the wire feeder. Now there should be no more welding wire in the contact tip.

2 Configuration

• Press the "sequence parameter" push-button while simultaneously switching on the welding machine.

Release the "sequence parameter" push-button.

• The desired parameter can now be selected using the "sequence parameter" push-button. Parameter rL1 must be aligned for all machine combinations. In case of welding systems with a second power circuit

– if two wire feeders are to be operated from a single power source, for example – a second alignment with parameter rL2 must be performed.

3 Alignment/measurement

• Applying slight pressure, put the welding torch in place with the contact tip on a clean, purged location on the workpiece and then press the torch trigger for approx. 2 seconds. Short-circuit current flows briefly, which is used to determine and display the cable resistance. The value can be between 0 mΩ and 40 mΩ. The new value is immediately saved without requiring any further confirmation. If no value is shown in the right display, then the measurement failed. The measurement must be repeated.

4 Restoring welding standby mode

• Switch off the welding machine.

• Screw the gas nozzle onto the welding torch.

• Switch on the welding machine

• Insert the welding wire.

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Maintenance, care and disposal

General

6

Maintenance, care and disposal

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)!

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 5.7.4.5 Spool brake setting chapter

Check settings and correct if necessary

 Setting pressure units - See 5.7.4.4 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 an error code being displayed (see table) on the display on the machine control.

In the event of a machine error, the power unit is shut down.

The display of possible error numbers depends on the machine version (interfaces/functions).

• Document machine errors and inform service staff as necessary.

• If multiple errors occur, these are displayed in succession.

Error Category Possible cause a) b) c)

- - x Mains overvoltage

Remedy

Error 1

(Ov.Vol)

Error 2

(Un.Vol)

Error 3

(Temp)

Error 4

(Water)

- - x Mains undervoltage x - - Welding machine excess temperature x x - Low coolant level

Check the mains voltages and compare with the connection voltages of the welding machine

Error 5

(Wi.Spe)

Error 6

(gas)

Error 7

(Se.Vol)

Error 8

(no PE)

Error 9

(fast stop) x - - Wire feeder/speedometer error x - - Shielding gas error

- - x Secondary excess voltage

Allow the machine to cool down (mains switch to "1")

Top off the coolant

Leak in the coolant circuit > rectify the leak and top off the coolant

Coolant pump is not working > check excess current trigger on air cooling unit

Check the wire feeder speedometer is not issuing a signal,

M3.51 defective > inform Service

Check shielding gas supply (for machines with shielding gas monitoring)

Inverter error > inform Service

Separate the connection between the welding wire and casing or an earthed object

Rectify error on robot

Error 10

(no arc)

Error 11

(no ign)

Error 14

(no DV)

Error 15

(DV2?)

Error 16

(VRD)

Error 18

(Wf.Sl.)

Error 17

(WF. Ov.)

- - x Earth fault between welding wire and earth line x - - Fast cut-out triggered by BUSINT X11 or

RINT X12

- x - Arc break triggered by BUSINT X11 or

RINT X12

- x - Ignition fault after 5 s triggered by BUSINT X11 or

RINT X12

- x - Wire feeder not detected.

Control cable not connected.

Incorrect ID numbers assigned during operation with multiple wire feeders.

- x - Wire feeder 2 not detected.

Control cable not connected.

- - x VRD (open circuit voltage reduction error) x - - Auxiliary drive/ speedometer error

- x x Wire feed mechanism overcurrent detection

Check wire feeding

Check wire feeding

Check cable connection

Check assignment of ID numbers

Check cable connection

Inform Service

Check auxiliary drive tachogenerator not issuing signals.

M3.51 defective > inform Service

Check the wire feeding

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Rectifying faults

Error messages (power source)

Error

Error 18

(WF. Sl.)

Error 56

(no Pha)

Category Possible cause a) b) c)

- x x No speedometer signal from second wire feeder (slave drive)

- - x Mains phase failure

Remedy

Check the connection and particularly the speedometer of the second wire feeder

(slave drive).

Check mains voltages

Legend for categories (error reset)

a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a key button:

Welding machine control

RC1 / RC2

Key button

Expert

CarExpert / Progress (M3.11) alpha Q / Concept / Basic / Basic S / Synergic /

Synergic S / Progress (M3.71) / Picomig 305 not possible c) The error message can only be reset by switching the machine off and on again.

The shielding gas error (Err 6) can be reset by pressing the "Welding parameters" key button.

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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

AMP

VOLT

+

D YN t1 t2

+

AMP

VOLT

+

D YN t1 t2

0 l

Display

Figure 7-1

Setting/selection

Code of machine control

Initialisation complete

All customised welding parameters haven been overwritten by the factory settings.

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Rectifying faults

Resetting JOBs (welding tasks) to the factory settings

7.4 Resetting JOBs (welding tasks) to the factory settings

7.4.1 Resetting a single JOB

ENTER

RESET

3 s

JOB-

LIST

3 s

JOB-

LIST

EXIT

3 s

Display

Figure 7-2

Setting/selection

Reset to factory settings

The RESET will be done after pressing the button.

The menu will be ended when no changes are done after 3 sec.

JOB-number (example)

The shown JOB will be set to ex works.

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Rectifying faults

Resetting JOBs (welding tasks) to the factory settings

7.4.2 Resetting all JOBs

All customised welding parameters that are stored will be replaced by the factory settings.

ENTER

RESET

3 s

JOB-

LIST

3 s

JOB-

LIST

EXIT

3 s

Display

Figure 7-3

Setting/selection

Reset to factory settings

The RESET will be done after pressing the button.

The menu will be ended when no changes are done after 3 sec.

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Technical data

Picomig 305 TKG

8

Technical data

8.1 Picomig 305 TKG

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

45%

60%

100%

Load cycle

MIG/MAG

14.3 V to 29 V

TIG

5 A to 300 A

10.2 V to 22 V

MMA

20.2 V to 32 V

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

Welding torch connection

Wire feed speed

Standard roller installation

Drive

Wire spool diameter

Workpiece lead

Dimensions L x W x H in mm

Weight (without mains cable)

EMC class

Constructed to standard

300 A

260 A

200 A

10 min (60% DC

6 min welding, 4 min pause)

93 V

11.0 kVA

3 x 400 V (-25% to +20%)

50/60 Hz

3 x 16 A

H07RN-F4G2,5

8.3 kVA

16.3 kVA

0.99/88%

H/IP 23

-25 °C to +40 °C

Fan/gas

Euro torch connector

1 m/min. to 20 m/min.

1.2 mm for steel wire

4 rolls (37 mm)

300 mm

50 mm

2

636 x 297 x 482

32 kg

A

IEC 60974-1, -5, -10

/

12.1 kVA

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Accessories

General accessories

9

Accessories

Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer.

9.1

General accessories

Type Designation

AK300

5POLE/CEE/16A/M

Wire spool adapter K300

Machine plug

DMDIN TN 200B AR/MIX 35L Manometer pressure regulator

G1 G1/4 R 3M Gas hose

SPL Sharpener for plastic liners

HC PL Hose cutter

9.2 Remote control/connecting and extension cable

9.2.1 19-pole connection

Type Designation

R10 19POL Remote control

RG10 19POL 5M

RA5 19POL 5M

RA10 19POL 10M

RA20 19POL 20M

RV5M19 19POLE 5M

RV5M19 19POLE 10M

RV5M19 19POLE 15M

RV5M19 19POLE 20M

Remote control to set the wire speed and welding voltage correction

Remote control e.g. connection cable

Remote control e.g. connection cable

Remote control e.g. connection cable

Extension cable

Extension cable

Extension cable

Extension cable

9.3 Options

Type

ON MF XX5

9.4 Transport systems

Type

Trolly 35.2-2

Designation

Dirt filter

Designation

Transport vehicle

Item no.

094-001803-00001

094-000712-00000

094-000009-00000

094-000010-00003

094-010427-00000

094-016585-00000

Item no.

090-008087-00000

090-008108-00000

092-001470-00005

092-001470-00010

092-001470-00020

092-000857-00000

092-000857-00010

092-000857-00015

092-000857-00020

Item no.

092-002662-00000

Item no.

090-008296-00000

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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 4R 0.6 MM/0.023 INCH

LIGHT PINK

FE 4R 0.8 MM/0.03 INCH

WHITE

FE 4R 1,0 MM/0.04 INCH

BLUE

FE 4R 1.2 MM/0.045 INCH

RED

FE 4R 1.4 MM/0.052 INCH

GREEN

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Item no.

092-002770-00006

092-002770-00008

092-002770-00010

092-002770-00012

092-002770-00014

FE 4R 1.6 MM/0.06 INCH

BLACK

FE 4R 2.0 MM/0.08 INCH

GREY

FE 4R 2.4 MM/0.095 INCH

BROWN

FE 4R 2.8 MM/0.11 INCH

LIGHT GREEN

FE 4R 3.2 MM/0.12 INCH

VIOLET

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

092-002770-00016

092-002770-00020

092-002770-00024

092-002770-00028

092-002770-00032

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Replaceable parts

Wire feed rollers

10.1.2 Wire feed rollers for aluminium wire

Type Designation

Drive roll set, 37 mm, for aluminium AL 4R 0.8 MM/0.03 INCH

WHITE

AL 4R 1.0 MM/0.04 INCH

BLUE

AL 4R 1.2 MM/0.045 INCH

RED

AL 4R 1.6 MM/0.06 INCH

BLACK

AL 4R 2.0 MM/0.08 INCH

GREY/YELLOW

AL 4R 2.4 MM/0.095 INCH

BROWN/YELLOW

Drive roll set, 37 mm, for aluminium

Drive roll set, 37 mm, for aluminium

Drive roll set, 37 mm, for aluminium

Drive roll set, 37 mm, for aluminium

Drive roll set, 37 mm, for aluminium

AL 4R 2.8 MM/0.110 INCH

LIGHT GREEN/YELLOW

AL 4R 3.2 MM/0.125 INCH

VIOLET/YELLOW

Drive roll set, 37 mm, for aluminium

Drive roll set, 37 mm, for aluminium

10.1.3 Wire feed rollers for cored wire

Type Designation

FUEL 4R 0.8 MM/0.03 INCH

WHITE/ORANGE

FUEL 4R 1.0 MM/0.04 INCH

BLUE/ORANGE

FUEL 4R 1.2 MM/0.045 INCH

RED/ORANGE

FUEL 4R 1.4 MM/0.052 INCH

GREEN/ORANGE

FUEL 4R 1.6 MM/0.06 INCH

BLACK/ORANGE

FUEL 4R 2.0 MM/0.08 INCH

GREY/ORANGE

FUEL 4R 2.4 MM/0.095 INCH

BROWN/ORANGE

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Item no.

092-002771-00008

092-002771-00010

092-002771-00012

092-002771-00016

092-002771-00020

092-002771-00024

092-002771-00028

092-002771-00032

Item no.

092-002848-00008

092-002848-00010

092-002848-00012

092-002848-00014

092-002848-00016

092-002848-00020

092-002848-00024

10.1.4 Wire guide

Type Designation

SET DRAHTFUERUNG Wire guide set

ON WF 2,0-3,2MM EFEED Retrofitting option, wire guide for 2.0

–3.2 mm wires, eFeed drive

Item no.

092-002774-00000

092-019404-00000

SET IG 4x4 1.6mm BL

GUIDE TUBE L105

Inlet guide set

Guide tube

092-002780-00000

094-006051-00000

CAPTUB L108 D1,6

CAPTUB L105 D2,0/2,4

Capillary tube

Capillary tube

094-006634-00000

094-021470-00000

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Appendix A

JOB-List

11

Appendix A

11.1 JOB-List

82

MIG/MAG pulse arc welding can be selected with JOBs 6-9, 34-36, 42-44, 74-76, 78-80, 82-84, 86-

88, 90-92, 94-96, 110, 111, 114, 115, 118, 119, 122, 123, 206 and 207.

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

12.1 Overview of EWM branches

Appendix B

Overview of EWM branches

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