EWM Pico 160 cel puls, Pico 160 cel puls VRD (RU), Pico 160 cel puls VRD (AUS) Operating Instructions Manual
Operating instructions
EN
Welding machine
Pico 160 cel puls
Pico 160 cel puls VRD (RU)
Pico 160 cel puls VRD (AUS)
099-002129-EW501
11.05.2017
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the location where the machine is operated.
• Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
• Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on +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-Straße 8
56271 Mündersbach
Germany
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.
Contents
Notes on the use of these operating instructions
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1 Contents
1 Contents .................................................................................................................................................. 3
2 For your safety ....................................................................................................................................... 5
2.1 Notes on the use of these operating instructions .......................................................................... 5
2.1.1 Complete documentation ............................................................................................... 5
2.2 Explanation of icons ....................................................................................................................... 6
2.3 General .......................................................................................................................................... 7
3 Intended use ........................................................................................................................................... 8
3.1 Documents which also apply ......................................................................................................... 8
3.1.1 Warranty ......................................................................................................................... 8
3.1.2 Declaration of Conformity ............................................................................................... 8
3.1.3 Welding in environments with increased electrical hazards ........................................... 8
3.1.4 Calibration/Validation ..................................................................................................... 8
4 Machine description – quick overview ................................................................................................ 9
4.1 Front view ...................................................................................................................................... 9
4.2 Rear view ..................................................................................................................................... 10
4.3 Machine control – Operating elements ........................................................................................ 10
5 Design and function ............................................................................................................................. 12
5.1 Transport and installation ............................................................................................................ 12
5.1.1 Machine cooling ............................................................................................................ 12
5.1.2 Workpiece lead, general ............................................................................................... 12
5.1.3 Ambient conditions ....................................................................................................... 13
5.1.3.1 In operation ................................................................................................... 13
5.1.3.2 Transport and storage ................................................................................... 13
5.1.4 Adjusting the length of the carrying strap ..................................................................... 13
5.1.5 Notes on the installation of welding current leads ........................................................ 13
5.1.5.1 Stray welding currents................................................................................... 14
5.1.6 Mains connection .......................................................................................................... 15
5.1.6.1 Mains configuration ....................................................................................... 15
5.2 Operating the machine control ..................................................................................................... 15
5.2.1 Machine display ............................................................................................................ 15
5.2.2 Welding power setting .................................................................................................. 15
5.2.3 Welding parameter setting in the operation sequence ................................................. 15
5.2.4 Setting advanced welding parameters (Expert menu) ................................................. 15
5.2.5 Changing basic settings (machine configuration menu) .............................................. 15
5.3 MMA welding ............................................................................................................................... 16
5.3.1 Connecting the electrode holder and workpiece lead .................................................. 16
5.3.2 Welding task selection .................................................................................................. 16
5.3.3 Arcforce ........................................................................................................................ 17
5.3.4 Hotstart ......................................................................................................................... 17
5.3.5 Antistick ........................................................................................................................ 17
5.3.6 Average value pulse welding ........................................................................................ 18
5.3.7 Expert menu (MMA) ..................................................................................................... 19
5.4 TIG welding .................................................................................................................................. 20
5.4.1 Connecting a TIG welding torch with rotating gas valve .............................................. 20
5.4.2 Shielding gas supply (shielding gas cylinder for welding machine) ............................. 20
5.4.3 Pressure regulator connection ..................................................................................... 21
5.4.4 Welding task selection .................................................................................................. 21
5.4.4.1 Gas test – setting the shielding gas volume ................................................. 21
5.4.5 Arc ignition .................................................................................................................... 22
5.4.5.1 Liftarc ............................................................................................................ 22
5.4.6 Average value pulse welding ........................................................................................ 22
5.4.7 Expert menu (TIG) ........................................................................................................ 23
5.5 Arc length restriction (USP) ......................................................................................................... 24
5.6 Power-saving mode (Standby) .................................................................................................... 24
5.7 Voltage reducing device .............................................................................................................. 24
5.8 Access control .............................................................................................................................. 25
Contents
Notes on the use of these operating instructions
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5.9 Machine configuration menu ........................................................................................................ 26
6 Maintenance, care and disposal ......................................................................................................... 28
6.1 General......................................................................................................................................... 28
6.2 Cleaning ....................................................................................................................................... 28
6.2.1 Dirt filter......................................................................................................................... 28
6.3 Maintenance work, intervals ........................................................................................................ 29
6.3.1 Daily maintenance tasks ............................................................................................... 29
6.3.2 Monthly maintenance tasks .......................................................................................... 29
6.3.3 Annual test (inspection and testing during operation) .................................................. 29
6.4 Disposing of equipment ................................................................................................................ 30
6.5 Meeting the requirements of RoHS .............................................................................................. 30
7 Rectifying faults.................................................................................................................................... 31
7.1 Error messages (power source) ................................................................................................... 31
7.2 Checklist for rectifying faults ........................................................................................................ 32
7.3 Display machine control software version .................................................................................... 32
7.4 Dynamic power adjustment .......................................................................................................... 32
7.5 Resetting welding parameters to the factory settings .................................................................. 33
8 Technical data....................................................................................................................................... 34
8.1 Pico 160 cel puls .......................................................................................................................... 34
9 Accessories .......................................................................................................................................... 35
9.1 Electrode holder / workpiece lead ................................................................................................ 35
9.2 Remote controls and accessories ................................................................................................ 35
9.3 TIG welding torch ......................................................................................................................... 35
9.4 General accessories .................................................................................................................... 35
9.5 Options ......................................................................................................................................... 35
10 Service documents .............................................................................................................................. 36
10.1 Spare and replacement parts ....................................................................................................... 36
10.2 Circuit diagram ............................................................................................................................. 38
11 Appendix A ............................................................................................................................................ 39
11.1 Parameter overview – setting information .................................................................................... 39
12 Appendix B ............................................................................................................................................ 40
12.1 Overview of EWM branches......................................................................................................... 40
For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of these operating instructions
2.1.1 Complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with the "Safety instructions”!
Read and observe the documents for all system components!
Figure 2-1
Item
Documentation
A.1
Safety instructions
A.2
Power source
A.3
Electrode holder/welding torch
A.4
Remote control
A
Complete documentation
For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/tip
Switch off machine
Release
Switch on machine
Press and keep pressed
Switch
Wrong
Turn
Correct
Numerical value – adjustable
Menu entry
Signal light lights up in green
Navigating the menu
Signal light flashes green
Exit menu
Signal light lights up in red
Time representation (e.g.: wait
4 s/activate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use
For your safety
General
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2.3 General
Obligations of the operator!
The respective national directives and laws must be complied with when operating the machine!
• Implementation of national legislation relating to framework directive 89/391/EEC on the
introduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
• In particular, directive 89/655/EEC concerning the minimum safety and health requirements for
the use of work equipment by workers at work.
• The regulations applicable to occupational safety and accident prevention in the country
concerned.
• Setting up and operating the machine as per IEC 60974.-9.
• Brief the user on safety-conscious work practices on a regular basis.
• Regularly inspect the machine as per IEC 60974.-4.
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of the
operator, where necessary in consultation with the mains network operator, to ensure that the
machine can be connected.
Intended use
Documents which also apply
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
• The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
Arc welding machine for MMA DC welding with TIG DC welding with lift arc (touch starting) as secondary
process.
3.1 Documents which also apply
3.1.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.1.2 Declaration of Conformity
The labelled machine complies with the following EC directives in terms of its design and
construction:
• Low Voltage Directive (LVD)
• Electromagnetic Compatibility Directive (EMC)
• Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which
have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the
specific declaration of conformity is included with every product.
3.1.3 Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
3.1.4 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months
Machine description – quick overview
Front view
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4 Machine description – quick overview
4.1 Front view
Figure 4-1
Item
Symbol
Description 0
1
Carrying strap > see 5.1.4 chapter
2
Machine control > see 4.3 chapter
3
Protective cap
4
Connection socket, "+" welding current
• MMA: Electrode holder or workpiece lead connection
• TIG: Connection for workpiece lead
5
Cooling air outlet
6
Connection socket, "-" welding current
• MMA welding: Electrode holder or workpiece lead connection
• TIG welding: Welding current lead connection for TIG welding torch
Machine description – quick overview
Rear view
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4.2 Rear view
Figure 4-2
Item
Symbol
Description 0
1
Main switch, machine on/off
2
Cooling air inlet
3
Mains connection cable > see 5.1.6 chapter
4.3 Machine control – Operating elements
The setting ranges for the parameter values are summarised in the Parameter overview
section > see 11.1 chapter.
Figure 4-3
Machine description – quick overview
Machine control – Operating elements
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Item
Symbol
Description 0
1
Excess temperature signal light
In case of excess temperature, temperature monitors de-activate the power unit, and
the excess temperature control lamp comes on. Once the machine has cooled down,
welding can continue without any further measures.
2
Collective interference signal light
For error messages, > see 7 chapter
3
VRD
Voltage reduction device (VRD) signal light
The VRD signal light is illuminated when the voltage reduction device is operating
without fault and the output voltage is reduced to a value specified in the relevant
standard (see technical data) > see 5.7 chapter. The voltage reduction device is only
active on VRD machine versions.
4
AMP%
Hotstart current signal light
5
sec
Hotstart time signal light
6
Pulsed welding/power-saving mode push-button
MMA ----- pulse welding > see 5.3.6 chapter
TIG ------- pulse welding > see 5.4.6 chapter
Press for 2 s to put the machine into power-saving mode. To reactivate, activate one of
the operating elements > see 5.6 chapter.
7
Control button
Central control button to be pressed or turned > see 5.2 chapter.
8
2-pole connection socket
Remote control control cable
9
Welding procedure push-button
------ MMA welding
------ MMA welding (Cel characteristics)
-------- TIG welding
10
AMP
Main current signal light
Imin to Imax (1 A increments)
11
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 5.2.1 chapter
12
A
“Welding current unit" signal light
Illuminates when welding currents are displayed.
13
Access control active signal light
Signal light is on when access control is active on the machine
control > see 5.8 chapter.
Design and function
Transport and installation
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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!
5.1 Transport and installation
WARNING
Risk of accident due to improper transport of machines that must not be lifted!
Do not lift or suspend the machine! The machine can drop and cause injuries! The
handles, straps or brackets are suitable for transport by hand only!
• The machine must not be suspended or lifted using a crane.
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant
accessory components.
• Accessory components are detected automatically after the power source is switched on.
5.1.1 Machine cooling
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!
5.1.2 Workpiece lead, general
CAUTION
Risk of burning due to incorrect welding current connection!
If the welding current plugs (machine connections) are not locked or if the workpiece
connection is contaminated (paint, corrosion), these connections and leads can heat up
and cause burns when touched!
• Check welding current connections on a daily basis and lock by turning to the right when
necessary.
• Clean workpiece connection thoroughly and secure properly. Do not use structural parts of
the workpiece as welding current return lead!
Design and function
Transport and installation
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5.1.3 Ambient conditions
T he 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.
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)!
5.1.3.1 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
5.1.3.2 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
5.1.4 Adjusting the length of the carrying strap
To demonstrate adjustment, lengthening the strap is shown in the figure. To shorten, the strap's
loops must be inched in the opposite direction.
Figure 5-1
5.1.5 Notes on the installation of welding current leads
Use an individual welding lead to the workpiece for each welding machine!
Figure 5-2
Design and function
Transport and installation
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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
5.1.5.1 Stray welding currents
WARNING
Risk of injury due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage machines and
electronic devices and cause overheating of components, leading to fire.
• Check that all welding current connections are firmly secured and electrical connections are
in perfect condition.
• Set up, attach or suspend all conductive power source components such as casing,
transport vehicles and crane frames so they are insulated.
• Do not place any other electronic devices such as drills or angle grinders 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.
Figure 5-4
Design and function
Operating the machine control
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5.1.6 Mains connection
DANGER
Hazards caused by improper mains connection!
An improper mains connection can cause injuries or damage property!
• Only operate machine using a socket that has correctly fitted protective earth.
• The mains voltage indicated on the rating plate must match the supply voltage.
• If a new mains plug must be fitted, only an electrician may do so as per the relevant
national legislation or regulations.
• Mains plug, socket and lead must be checked by an electrician on a regular basis.
• When operating the generator, always ensure it is earthed as stipulated in the operating
instructions. The network created must be suitable for operating machines according to
protection class I.
5.1.6.1 Mains configuration
The machine may only be connected to a one-phase system with two conductors and an earthed
neutral conductor.
Figure 5-5
Legend
Item
Designation
Colour code
L
Outer conductor
brown
N
Neutral conductor
blue
PE
Protective conductor
green-yellow
• Insert mains plug of the switched-off machine into the appropriate socket.
5.2 Operating the machine control
5.2.1 Machine display
The machine control switches to the main screen after it has been turned on or a setting has been
completed. This means that the previously selected settings (indicated by signal lights where applicable)
have been applied and the current nominal value (A) is displayed in the welding data display.
5.2.2 Welding power setting
The welding power is set using the control button. You can also adjust the parameters in the operation
sequence or settings in the different machine menus.
5.2.3 Welding parameter setting in the operation sequence
During the operation sequence you can set a welding parameter by briefly pressing the control button
(navigate the parameters) and then turning the button (set the parameter).
5.2.4 Setting advanced welding parameters (Expert menu)
The Expert menu contains functions and parameters which cannot be set directly in the machine control
or which do not need to be et on a regular basis. The number and display of these parameters depends
on the previously selected welding procedure or the functions.
5.2.5 Changing basic settings (machine configuration menu)
The basic welding system functions can be adjusted in the machine configuration menu. Only
experienced users should change the settings > see 5.9 chapter.
Design and function
MMA welding
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5.3 MMA welding
5.3.1 Connecting the electrode holder and workpiece lead
CAUTION
Risk of crushing and burns!
When changing stick electrodes there is a risk of crushing and burns!
• Wear appropriate and dry protective gloves.
• Use an insulated pair of tongs to remove the used stick electrode or to move welded
workpieces.
Figure 5-6
Item
Symbol
Description 0
1
Workpiece
2
Connection socket for "+" welding current
Electrode holder or workpiece lead connection
3
Electrode holder
4
Connection socket, “-” welding current
Workpiece lead or electrode holder connection
Polarity depends on the instructions from the electrode manufacturer given on the electrode
packaging.
• 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.
5.3.2 Welding task selection
?
R
RB
B
RC
C
Figure 5-7
Design and function
MMA welding
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Type
Electrode type
R
Rutile
RB
Rutile-basic
B
Basic
RC
Rutile cellulose
C
Cellulose
5.3.3 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.
For parameter setting, > see 5.3.7 chapter.
5.3.4 Hotstart
The hot start function improves the arc striking.
After striking the stick electrode, the arc ignites at the increased hot start current and decreases to the set
main current once the hot start time has elapsed.
A = Hot start current
B = Hot start time
C = Main current
I = Current
t = Time
Setting
EXIT EXIT
Figure 5-8
5.3.5 Antistick
Anti-stick prevents the electrode from annealing.
If the electrode sticks in spite of the Arcforce device, the machine
automatically switches over to the minimum current within about 1
second to prevent the electrode from overheating. Check the welding
current setting and correct according to the welding task!
Figure 5-9
Design and function
MMA welding
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5.3.6 Average value pulse welding
Average value pulse welding means that two currents are switched periodically, a current average value
(AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The
predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the
parameter as a percentage of the current average value (AMP). The pulse pause current (IPP) requires
no setting. This value is calculated by the machine control, so that the welding current average value
(AMP) is maintained at all times.
Figure 5-10
AMP = Main current; e.g. 100 A
IPL = Pulse current = IP1 x AMP; e.g. 170% x 100 A = 170 A
IPP = Pulse pause current
Tpuls = Duration of one pulse cycle = 1/FrE; e.g. 1/1 Hz = 1 s
bAL = Balance
Selection
Figure 5-11
For parameter setting, > see 5.3.7 chapter.
Design and function
MMA welding
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5.3.7 Expert menu (MMA)
The Expert menu has adjustable parameters stored that don’t require regular setting. The number of
parameters shown may be limited, e.g. if a function is deactivated.
The setting ranges for the parameter values are summarised in the Parameter overview
section > see 11.1 chapter.
NAVIGATION
EXIT
2s
ENTER
2s
Figure 5-12
Display
Setting/selection
Arcforce correction
• Increase value > harder arc
• Decrease value > softer arc
Pulse frequency
Pulse balance
Pulse current > see 5.3.6 chapter
Arc length restriction > see 5.5 chapter
------- Function switched on
------- Function switched off
Design and function
TIG welding
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5.4 TIG welding
5.4.1 Connecting a TIG welding torch with rotating gas valve
Prepare welding torch according to the welding task in hand (see operating instructions for the torch).
Figure 5-13
Item
Symbol
Description 0
1
Workpiece
2
Connection socket for "+" welding current
Workpiece lead connection
3
Output side of the pressure regulator
4
Welding torch
5
Connection socket, "-" welding current
Welding current lead connection for TIG welding torch
• Insert the welding current plug on the welding torch into the welding current connection socket and
lock by turning to the right.
• Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by
turning to the right.
• Screw the shielding gas hose of the welding torch to the pressure regulator outlet.
5.4.2 Shielding gas supply (shielding gas cylinder for welding machine)
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders
can cause serious injuries!
• Place shielding gas cylinder into the designated holder and secure with
fastening elements (chain/belt)!
• Attach the fastening elements within the upper half of the shielding gas
cylinder!
• The fastening elements must tightly enclose the shielding gas cylinder!
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.
• All shielding gas connections must be gas tight.
Design and function
TIG welding
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5.4.3 Pressure regulator connection
Figure 5-14
Item
Symbol
Description 0
1
Pressure regulator
2
Shielding gas cylinder
3
Output side of the pressure regulator
4
Cylinder valve
• Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow
out any dirt.
• Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.
5.4.4 Welding task selection
Figure 5-15
5.4.4.1 Gas test – setting the shielding gas volume
If the rotary gas valve is open, the shielding gas flows permanently from the welding torch (no
adjustment with a separate gas valve). The rotary valve must be opened before each welding
procedure and closed after each welding procedure.
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!
Rule of thumb for the gas flow rate:
Diameter of gas nozzle in mm corresponds to gas flow in l/min.
Example: 7mm gas nozzle corresponds to 7l/min gas flow.
• Slowly open the gas cylinder valve.
• Set the relevant gas quantity for the application on the pressure regulator.
Design and function
TIG welding
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5.4.5 Arc ignition
5.4.5.1 Liftarc
Figure 5-16
The arc ignites through contact with the workpiece:
a) Carefully place the torch gas nozzle and tungsten electrode tip against the workpiece (lift arc current
flows independent of the set main current)
b) Angle the torch above the torch gas nozzle until the distance between electrode tip and workpiece is
approx. 2–3 mm (arc ignites, current increases to the set main current).
c) Lift the torch off and bring into normal position.
Complete the welding task: Remove the torch from the workpiece so that the arc extinguishes.
5.4.6 Average value pulse welding
Average value pulse welding means that two currents are switched periodically, a current average value
(AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The
predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the
parameter as a percentage of the current average value (AMP). The pulse pause current (IPP) requires
no setting. This value is calculated by the machine control, so that the welding current average value
(AMP) is maintained at all times.
Figure 5-17
AMP = Main current; e.g. 100 A
IPL = Pulse current = IP1 x AMP; e.g. 170% x 100 A = 170 A
IPP = Pulse pause current
Tpuls = Duration of one pulse cycle = 1/FrE; e.g. 1/1 Hz = 1 s
bAL = Balance
For parameter setting, > see 5.4.7 chapter.
Selection
Figure 5-18
Design and function
TIG welding
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23
5.4.7 Expert menu (TIG)
The Expert menu has adjustable parameters stored that don’t require regular setting. The number of
parameters shown may be limited, e.g. if a function is deactivated.
The setting ranges for the parameter values are summarised in the Parameter overview
section > see 11.1 chapter.
NAVIGATION
EXIT
2s
ENTER
2s
Figure 5-19
Display
Setting/selection
Ignition current (as percentage, dependent on main current)
Upslope time to main current
Pulse frequency
Pulse balance
Pulse current > see 5.4.6 chapter
Arc length restriction > see 5.5 chapter
------- Function switched on
------- Function switched off
Design and function
Arc length restriction (USP)
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5.5 Arc length restriction (USP)
The arc length restriction function stops the welding process when an excessive arc voltage is
detected (unusually high gap between electrode and workpiece). This function can be adjusted in the
corresponding Expert menu, depending on the process:
MMA welding > see 5.3.7 chapter
TIG welding > see 5.4.7 chapter
The arc length restriction cannot be used for cel characteristics (if available).
5.6 Power-saving mode (Standby)
You can activate the power-saving mode by either pressing the push-button > see 4.3 chapter for a
prolonged time or by setting a parameter in the machine configuration menu (time-controlled powersaving mode ) > see 5.9 chapter.
When power-saving mode is activated, the machine displays show the horizontal digit in the
centre of the display only.
Pressing any operating element (e.g. turning a rotary knob) deactivates power-saving mode and the
machine is ready for welding again.
5.7 Voltage reducing device
Only machine variants with the (VRD/AUS/RU) code are equipped with a voltage reduction device (VRD).
The VRD is used for increased safety, especially in hazardous environments such as shipbuilding, pipe
construction or mining.
A VRD is mandatory in some countries and required by many on-site safety instructions for power
sources.
The VRD > see 4.3 chapter signal light is illuminated when the voltage reduction device is operating
without fault and the output voltage is reduced to a value specified in the relevant standard (see technical
data > see 8 chapter).
Design and function
Access control
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5.8 Access control
The control can be locked to secure some basic parameters against unauthorised or unintentional
adjustment of machine settings. The access block operates as follows:
• The parameters and their settings in the machine configuration menu, Expert menu and operation
sequence can only be viewed but not changed.
• Welding procedure cannot be changed.
The parameters for the access block are configured in the machine configuration menu > see 5.9 chapter.
Enabling the access block
• Assign the access code for the access block: Select parameter and select a number code (000–
999).
• Enable the access block: Set parameter to access block enabled .
The access block activation is indicated by the "Access block active" signal light > see 4.3 chapter.
Disabling the access block
• Enter the access code for the access block: Select parameter and enter the previously selected
number code (000–999).
• Disable the access block: Set parameter to access block disabled . The only way to disable
the access block is to enter the previously selected number code.
Design and function
Machine configuration menu
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5.9 Machine configuration menu
Basic machine settings are defined in the machine configuration menu.
ENTER NAVIGATION
A
B
EXIT
+
B
B
A A
A
A
B
B B
l0l
0
A
B B
B
A A
Figure 5-20
Design and function
Machine configuration menu
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27
Display
Setting/selection
Calibration
The machine will be calibrated for approx 2 seconds each time it is switched on.
Exit the menu
Exit
Machine configuration
Settings for machine functions and parameter display
Dynamic power adjustment > see 7.4 chapter
Time-based power-saving mode > see 5.6 chapter
5 min.–60 min. = Time to activation of power-saving mode in case of inactivity.
------- inactivated
Expert menu
Access control – access code
Setting: 000 to 999 (000 ex works)
Access control > see 5.8 chapter
------- Function enabled
------- Function disabled (ex works)
Service menu
Any changes to the service menu should be agreed with the authorised service
personnel.
Software version of the machine control
Version display
Maintenance, care and disposal
General
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6 Maintenance, care and disposal
6.1 General
DANGER
Risk of injury due to electrical voltage after switching off!
Working on an open machine can lead to fatal injuries!
Capacitors are loaded with electrical voltage during operation. Voltage remains present
for up to four minutes after the mains plug is removed.
1. Switch off machine.
2. Remove the mains plug.
3. Wait for at last 4 minutes until the capacitors have discharged!
WARNING
Incorrect maintenance, testing and repair!
Maintenance, testing and repair of the machine may only be carried out by skilled and
qualified personnel. A qualified person is one who, because of his or her 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.
Observe the maintenance instructions > see 6.3 chapter.
• In the event that the provisions of one of the below-stated tests are not met, the machine
must not be operated again until it has been repaired and a new test has been carried out!
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.
Under the specified ambient conditions and normal working conditions this machine is essentially
maintenance-free and requires just a minimum of care.
Contamination of the machine may impair service life and duty cycle. The cleaning intervals depend on
the ambient conditions and the resulting contamination of the machine. The minimum interval is every six
months.
6.2 Cleaning
• Clean the outer surfaces with a moist cloth (no aggressive cleaning agents).
• Purge the machine venting channel and cooling fins (if present) with oil- and water-free compressed
air. Compressed air may overspeed and destroy the machine fans. Never direct the compressed air
directly at the machine fans. Mechanically block the fans, if required.
• Check the coolant for contaminants and replace, if necessary.
6.2.1 Dirt filter
The duty cycle of the welding machine decreases as an effect of the reduced cooling air volume.
Depending on the amount of dirt building up (at least every two months), the dirt filter has to be
uninstalled and cleaned regularly (e.g. by purging with compressed air).
Maintenance, care and disposal
Maintenance work, intervals
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6.3 Maintenance work, intervals
6.3.1 Daily maintenance tasks
Visual inspection
• Mains supply lead and its strain relief
• Gas cylinder securing elements
• Check hose package and power connections for exterior damage and replace or have repaired by
specialist staff as necessary!
• Gas tubes and their switching equipment (solenoid valve)
• Check that all connections and wearing parts are hand-tight and tighten if necessary.
• Check correct mounting of the wire spool.
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
• Other, general condition
Functional test
• Operating, message, safety and adjustment devices (Functional test)
• Welding current cables (check that they are fitted correctly and secured)
• Gas tubes and their switching equipment (solenoid valve)
• Gas cylinder securing elements
• Check correct mounting of the wire spool.
• Check that all screw and plug connections and replaceable parts are secured correctly, tighten if
necessary.
• Remove any spatter.
• Clean the wire feed rollers on a regular basis (depending on the degree of soiling).
6.3.2 Monthly maintenance tasks
Visual inspection
• Casing damage (front, rear and side walls)
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
• Check coolant tubes and their connections for impurities
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.
• Check coolant tubes and their connections for impurities
• Check and clean the welding torch. Deposits in the torch can cause short circuits and have a negative
impact on the welding result, ultimately causing damage to the torch.
6.3.3 Annual test (inspection and testing during operation)
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.
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
Maintenance, care and disposal
Disposing of equipment
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6.4 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!
• According to European provisions (guideline 2012/19/EU of the European Parliament and the Council
of Juli, 4th 2021), 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.
6.5 Meeting the requirements of RoHS
We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and
that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives
on the Declaration of Conformity on your machine).
Rectifying faults
Error messages (power source)
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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 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 message
Possible cause
Remedy
E 0
Start signal set in the event of
errors
Do not press the torch trigger or the foot-
operated remote control
E 4
Temperature error
Allow the machine to cool down
E 5
Mains overvoltage
Switch off the machine and check the mains
voltage
E 6
Mains undervoltage
E 7
Electronics error
Switch the machine on and off again.
If the error persists, notify service department
E 9
Secondary overvoltage
E12
Voltage reduction error (VRD)
E13
Electronics error
E14
Adjustment error in current
recording
Switch off the machine, place the electrode
holder in an insulated position and switch the
machine back on. If the error persists, notify
service department
E15
Error in on of the electronics
supply voltages
Switch the machine off and on again.
If the error persists, notify service department
E23
Temperature error
Allow the machine to cool down
E32
Electronics error
Switch the machine on and off again.
If the error persists, notify service department
E33
Adjustment error in voltage
recording
Switch off the machine, place the electrode
holder in an insulated position and switch the
machine back on. If the error persists, notify
service department
E34
Electronics error
Switch the machine on and off again.
If the error persists, notify service department
E37
Temperature error
Allow the machine to cool down
E40
Motor fault
Check wire feed unit,
switch the machine off and on again, inform the
service department if the fault persists.
E55
Failure of a mains phase
Switch off the machine and check the mains
voltage
E58
Short circuit in welding circuit
Switch off machine and check welding current
leads for correct installation, e.g., put down
electrode holder in an electrically insulated
manner, disconnect degausser current lead.
Rectifying faults
Checklist for rectifying faults
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7.2 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
Excess temperature signal light illuminates
Excess temperature, welding machine
Allow the machine to cool down whilst still switched on
Functional errors
All machine control signal lights are illuminated after switching on
No machine control signal light is illuminated after switching on
No welding power
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
7.3 Display machine control software version
The query of the software versions only serves to inform the authorised service staff. It is available in the
machine configuration menu > see 5.9 chapter.
7.4 Dynamic power adjustment
This requires use of the appropriate mains fuse.
Observe mains fuse specification > see 8 chapter!
This function enables aligning the machine to the mains connection fusing to avoid continuous tripping of
the mains fuse. The maximum power input of the machine is limited by an exemplary value for the
existing mains fuse (several levels available).
You can predefine this value in the machine configuration menu > see 5.9 chapter using parameter .
The selected value will be shown on the machine display for two seconds after the machine has been
switched on.
The function automatically adjusts the welding power to an uncritical level for the mains fuse.
When using a 20-A mains fuse, a suitable mains plug has to be installed by a qualified electrician.
Rectifying faults
Resetting welding parameters to the factory settings
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7.5 Resetting welding parameters to the factory settings
All customised welding parameters that are stored will be replaced by the factory settings.
RESET
+
l
0
+
Figure 7-1
Display
Setting/selection
Calibration
The machine will be calibrated for approx 2 seconds each time it is switched on.
Initialising
Keep the push-button pressed until "InI" is shown on the display.
Technical data
Pico 160 cel puls
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8 Technical data
Performance specifications and guarantee only in connection with original spare and
replacement parts!
8.1 Pico 160 cel puls
MMA
TIG
Current setting range
5 A–150 A
5 A–160 A
Voltage setting range
20.2 V–26.0 V
10.2 V–16.4 V
Duty cycle 40 °C
30%
150 A
160 A
60%
120 A
100%
110 A
Load cycle
10 min. (60% DC 6 min. welding, 4 min. pause)
Open circuit voltage
94 V
Reduced open circuit voltage (VRD AUS)
33 V
Reduced open circuit voltage (VRD RU)
12 V
12 V
Mains voltage (tolerances)
1 x 230 V (+15% to –40%)
Maximum mains impedance (@PCC)
Zmax XXX mΩ 1
Frequency
50/60 Hz
Mains fuse (safety fuse, slow-blow)
16 A 2
Continuous primary current (100%)
20 A
13 A
Mains connection lead
H07RN-F3G2,5
Maximum connected load
7.3 kVA
4.9 kVA
Recommended generator rating
9.9 kVA
cos/efficiency
0.99/83%
Ambient temperature
–25 C to +40 C
Machine cooling/torch cooling
Fan (AF)/gas
Noise level
< 70 dB(A)
Workpiece lead (minimum)
16 mm2
Insulation class/protection classification
H/IP 23
EMC class
A
Safety identification
/ /
Harmonised standards used
see declaration of conformity (machine documentation)
Dimensions L/W/H
370 x 129 x 236 mm
14.6 x 5.1 x 9.3 inch
Weight
4.9 kg
10.8 lb
1
This welding direction does not conform to IEC 61000-3-12. When connecting a welding machine to a
public low-voltage supply system, the manufacturer or operator has to consult the electricity utilities to
make sure the welding machine may be connected.
2
DIAZED xxA gG safety fuses are recommended. When using automatic cutouts, the "C" trigger
characteristic must be used.
Accessories
Electrode holder / workpiece lead
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9 Accessories
9.1 Electrode holder / workpiece lead
Type
Designation
Item no.
EH25 QMM 4M
Electrode holder
094-005800-00000
WK16mm² 170A/60% 4m/K
Workpiece lead
094-005801-00000
9.2 Remote controls and accessories
Type
Designation
Item no.
RG13
Remote control
090-008113-00000
9.3 TIG welding torch
Type
Designation
Item no.
TIG 26 GDV 4m
TIG welding torch, rotary gas valve, gas-cooled,
decentral
094-511621-00100
TIG 26 GDV 8m
TIG welding torch, rotary gas valve, gas-cooled,
decentral
094-511621-00108
DM 842 Ar/CO2 230bar 30l D
Pressure regulator with manometer
394-002910-00030
GH 2X1/4'' 2M
Gas hose
094-000010-00001
9.4 General accessories
Type
Designation
Item no.
SKGS 16A 250V CEE7/7, DIN
49440/441
Safety plug
094-001756-00000
ADAP CEE16/SCHUKO
Earth contact coupling/CEE16A plug
092-000812-00000
9.5 Options
Type
Designation
Item no.
ON Filter Pico160
Air inlet dirt filter, retrofit option
092-003206-00000
ON Handle Pico 160
Grip, retrofit option
092-003205-00000
Service documents
Spare and replacement parts
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10 Service documents
WARNING
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
10.1 Spare and replacement parts
Spare parts can be obtained from the relevant authorised dealer.
Figure 10-1
Service documents
Spare and replacement parts
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Item
Order number
Item
Type
1
094-015236-E0501
Carrying strap
TG3-E
2
094-021818-E0501
Casing panel
BH276,5X201,5X124,2
3
094-021826-00000
Insulating foil
IP
4
040-001090-E0000
Operating panel assembly with
rotary transducer
E160
5
044-004185-10015
Rotary transducer
30POS/1,5NCM
6
094-019308-00000
Plastic insulation for rotary
transducer
KID/D23X7,3
7
094-021994-00000
Fibre optics
LL8X6
8
094-021794-00502
Adhesive film
KLF-E 1.05
9
074-000315-00000
Rotary knob
KNOB 23MM
10
094-015043-00001
Rotary knob cover
KNOB COVER 23MM
11
094-021514-00000
Cover cap
KKS
12
094-021511-00000
Socket
EB/35-50QMM
13
094-021795-00502
Adhesive film
LOGO/PLUS/MINUS
14
094-021477-00000
Casing, front section
KFG
15
094-022172-00001
Spacer
AHD35X22X4
16
092-003193-00001
Choke
WD
17
094-021509-00000
Casing, lower section
KBG
18
094-014311-00000
Plate nut
M5/21X15X6
19
094-021508-00000
Air duct
IPL
20
094-015248-00000
Foam, fan support
S95X48X23
21
092-019418-00000
Fan
92X92X32
22
094-008045-10000
Mains switch
WS 250V/20A 2POLE
23
092-003003-00001
Mains cable
3X2.5QMM/3.5M SCHUKO
24
094-021478-00000
Casing, back panel
KRG
25
094-019537-00000
Nut
M20x1,5
26
094-021796-00500
Adhesive film
processes PICO CEL PULS
27
040-001084-E0000
PCB inverter circuit board
HB160
28
094-012942-00000
Screw
M5X14/DELTA-PT-SCHRAUBE
29
094-010089-00000
Screw, Torx
M3X8-DG-SCHRAUBE
30
094-015135-00000
Screw
M5X16/KOMBITORX PLUS T25
31
094-021833-00000
Screw
M5X10/DIN6900-5 Z9/8.8/VERZ.
32
094-022122-00000
Clamping screw
M5X16/DIN6900-5 Z9/8.8/VERZ.
Service documents
Circuit diagram
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10.2 Circuit diagram
Figure 10-2
Appendix A
Parameter overview – setting information
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11 Appendix A
11.1 Parameter overview – setting information
Welding data display
(3-digit)
Parameters/function
Setting range
Standard
(ex works)
Min. Max.
Unit
MMA (MMA)
Main current (AMP)
5 - 150
A
Hot start current (AMP%)
120
50 - 200
%
Hot start time (sec)
0,5
0,1 - 20,0
s
Arcforce correction
0
-10 - 10
Pulse frequency
1,2
0,2 - 500
Hz
Pulse balance
30
1 - 99
%
Pulse current
142
1 - 200
%
Arc length restriction
off
off - on
TIG (TIG)
Main current AMP
5 - 160
A
Ignition current
20
1 - 200
%
Up-slope time
1,0
0,0 - 20,0
s
Pulse frequency
2,8
0,2 - 2000
Hz
Pulse balance
50
1 - 99
%
Pulse current
140
1 - 200
%
Arc length restriction
on
off - on
Basic parameters (independent of procedure)
Calibration
Exit menu
Machine configuration
Dynamic power adjustment
16
10 - 20
A Time-based power-saving mode
off
5 - 60
min.
Expert menu
Access control – access code
000
000 - 999
Access control
off
off - on
Service menu
Power-saving mode active
Appendix B
Overview of EWM branches
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12 Appendix B
12.1 Overview of EWM branches
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