EWM PICO 230, PICO 260 CEL PWS, PICO 300, PICO 300 CEL Operating Instructions Manual

EWM

HIGHTEC WELDING GmbH

Dr. Günter - Henle - Straße 8 • D-56271 Mündersbach

Phone: [phone] • Fax: [phone]

www.ewm.de • [e-mail]

GB

Operating instructions

Welding machines for MMA welding

PICO 230
PICO 230 CEL
PICO 260
PICO 260 CEL
PICO 260 CEL PWS
PICO 300
PICO 300 CEL
PICO 300 CEL PWS

N. B. These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machines may only be operated by personnel who are familiar with the appropriate safety

regulations.

The machines bear the conformity mark and thus comply with the

• EC Low Voltage Directive (2006/95/ EG)

• EC EMC Directive (2004/108/ EG)

In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.

© 2007 Subject to alteration.

Item No.: 099-002032-EWM01

Revised: 28.03.2007

Dear customer,

Congratulations! You have chosen a quality product from EWM HIGHTEC WELDING GmbH.

EWM machines provide results of the highest perfection thanks to their PREMIUM quality. Therefore
we are happy to provide you with a full 3-year warranty according to our operating instructions.

We develop and produce quality! From individual components to the final product, we retain sole
responsibility for our machines.

In all their high-tech components, our welding machines embody future-oriented advanced technology
at the utmost level of quality. Each of our products is carefully checked; we guarantee that the material
and processing of our products is faultless.

These operating instructions contain everything about commissioning the machine, notes regarding
safety, maintenance and care, technical data as well as information regarding the warranty. Please
heed all these notes to ensure many years of safe operation of the machine.

Thank you for the trust that you have placed in us. We look forward to a long-term partnership with you
in the spirit of “ONCE EWM – ALWAYS EWM”.

Yours sincerely,

EWM HIGHTEC WELDING GmbH

Bernd Szczesny
Executive management

Machine and Company Data

Please enter the EWM machine data and your company’s data in the appropriate fields.

CE

EWM HIGHTEC WELDING GMBH
D-56271 MÜNDERSBACH

TYP:
ART:

SNR:
PROJ:

GEPRÜFT/CONTROL:

Name of Customer / company

Adress

Post code / Place

Country

Stamp / Signature of EWM-distibutor

Date of purchase

Name of Customer / company

Adress

Post code / Place

Country

Stamp / Signature of EWM-distibutor

Date of purchase

3

Contents

For your safety

4 Item No.: 099-002032-EWM01

1 Contents

1 Contents..................................................................................................................................................4

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

2.1 For your safety...............................................................................................................................6

2.2 Transport and installation...............................................................................................................8

2.2.1 Ambient conditions .........................................................................................................8

2.3 Notes on the use of these operating instructions...........................................................................9

3 Technical data.......................................................................................................................................10

3.1 PICO 230; 230 CEL .....................................................................................................................10

3.2 PICO 260; 260 CEL; 260 CEL PWS............................................................................................11

3.3 PICO 300; 300 CEL; 300 CEL PWS............................................................................................12

4 Machine description.............................................................................................................................13

4.1.1 PICO 230; 260; 300; PICO 230; 260; 300 CEL............................................................13

4.1.2 Front view.....................................................................................................................13

4.1.3 Rear view......................................................................................................................14

4.2 PICO 260; 300 CEL PWS............................................................................................................15

4.2.1 Front view.....................................................................................................................15

4.2.2 Rear view......................................................................................................................16

5 Functional characteristics...................................................................................................................17

5.1 Machine control – Operating elements........................................................................................17

5.2 Welding data display....................................................................................................................18

5.3 MMA welding................................................................................................................................18

5.3.1 Selecting MMA welding ................................................................................................18

5.3.2 Selecting the electrode type – Arcforce (welding characteristics)................................18

5.3.2.1 Electrode type allocation...............................................................................19

5.3.3 Selecting hotstart..........................................................................................................19

5.3.4 Antistick.........................................................................................................................20

5.4 TIG welding..................................................................................................................................20

5.4.1 TIG welding selection ...................................................................................................20

5.4.2 TIG arc ignition .............................................................................................................21

5.5 Remote control.............................................................................................................................21

5.5.1 Manual remote control RT 1.........................................................................................21

5.5.2 Foot-operated remote control RTF 1............................................................................21

5.5.3 Manual remote control RT PWS 1................................................................................21

5.6 Advanced settings (MMA welding)...............................................................................................22

5.6.1 Arcforce correction (welding characteristics)................................................................22

5.6.2 Arc length restriction (USP)..........................................................................................23

5.6.3 VRD open circuit voltage reduction (optional)..............................................................23

6 Commissioning.....................................................................................................................................24

6.1 General.........................................................................................................................................24

6.2 Area of application – proper usage..............................................................................................24

6.3 Installation....................................................................................................................................24

6.3.1 Dirt filter.........................................................................................................................25

6.4 Mains connection.........................................................................................................................25

6.5 Machine cooling...........................................................................................................................25

6.6 Workpiece lead, general ..............................................................................................................25

6.7 MMA welding................................................................................................................................26

6.7.1 PICO 230; 260; 300; PICO 230; 260; 300 CEL............................................................26

6.7.1.1 Electrode holder connection..........................................................................26

6.7.1.2 Connection for workpiece lead......................................................................26

6.8 PICO 260; 300 CEL PWS............................................................................................................27

6.8.1.1 Pole reversal changeover switch ..................................................................27

6.8.1.2 Electrode holder connection..........................................................................28

6.8.1.3 Connection for workpiece lead......................................................................28

Contents

For your safety

Item No.: 099-002032-EWM01 5

6.9

TIG welding..................................................................................................................................28

6.9.1 Connecting a TIG welding torch with rotating gas valve..............................................28

6.9.2 Shielding gas supply (shielding gas cylinder for welding machine).............................28

6.9.3 Connection for workpiece lead.....................................................................................29

7 Maintenance and care..........................................................................................................................30

7.1 General........................................................................................................................................30

7.2 Cleaning.......................................................................................................................................30

7.3 Repetition test..............................................................................................................................30

7.3.1 Test intervals and scope ..............................................................................................31

7.3.2 Documentation of the test ............................................................................................31

7.3.3 Visual inspection...........................................................................................................31

7.3.4 Measurement of protective conductor resistance ........................................................31

7.3.5 Measurement of insulation resistance..........................................................................32

7.3.6 Measuring the leakage current (protective conductor and contact current).................32

7.3.7 Measuring the open circuit voltage...............................................................................32

7.3.8 Function test of the welding machine...........................................................................32

7.4 Repair Work.................................................................................................................................33

7.5 Disposing of equipment...............................................................................................................34

7.5.1 Manufacturer's declaration to the end user..................................................................34

7.6 Meeting the requirements of RoHS .............................................................................................34

8 3-Year Warranty....................................................................................................................................35

8.1 General Validity............................................................................................................................35

8.2 Warranty Declaration...................................................................................................................36

9 Operating problems, causes and remedies ......................................................................................37

9.1 Error messages (power source) ..................................................................................................37

10 Spare parts list .....................................................................................................................................38

10.1 PICO 230; 230 CEL.....................................................................................................................38

10.1.1 Front view.....................................................................................................................38

10.1.2 Rear view......................................................................................................................39

10.1.3 Left-hand side...............................................................................................................40

10.1.4 Right-hand side ............................................................................................................41

10.2 PICO 260; 260 CEL; 260 CEL PWS............................................................................................42

11 Accessories, options...........................................................................................................................43

11.1 Remote control / connection cable ..............................................................................................43

11.2 Electrode holder / workpiece lead................................................................................................43

11.3 TIG welding torch.........................................................................................................................43

11.4 Options.........................................................................................................................................43

11.5 General accessories....................................................................................................................43

12 Circuit diagrams...................................................................................................................................44

12.1 PICO 230 .....................................................................................................................................44

12.2 PICO 230 CEL.............................................................................................................................45

12.3 PICO 260 .....................................................................................................................................46

12.4 PICO 260 CEL.............................................................................................................................47

12.5 PICO 260 CEL PWS....................................................................................................................48

12.6 PICO 300 .....................................................................................................................................49

12.7 PICO 300 CEL.............................................................................................................................50

12.8 PICO 300 CEL PWS....................................................................................................................51

13 Appendix A ...........................................................................................................................................52

13.1 Declaration of Conformity ............................................................................................................52

Safety instructions

For your safety

6 Item No.: 099-002032-EWM01

2 Safety instructions

2.1 For your safety

Observe accident prevention regulations!
Ignoring the following safety procedures can be fatal!

Proper usage

This machine has been manufactured according to the latest developments in technology and
current regulations and standards. It is to be operated only for the use for which it was designed
(see chapter Commissioning/Area of application).

Improper usage
However, this machine may be a hazard to persons, animals and property if it is

• not used as directed

• used by unskilled persons who have not been trained

• modified or converted improperly

Our operating instructions will provide you with an introduction into the safe use of the machine.
Therefore please read them carefully and only start work when you are familiar with them.

Any person involved in the operation, maintenance and repair of this machine must read and
follow these operating instructions, especially the safety precautions. Where appropriate, this
should be confirmed by signature.

Furthermore, the

• relevant accident prevention regulations,

• generally accepted safety regulations,

• local regulations, etc. must be observed.

Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves.

• Protect eyes and face with protective visor.

Electric shocks can be fatal!

• Do not touch any live parts in or on the machine!

• The machine may only be connected to correctly earthed sockets.

• Only operate with intact connection lead including protective conductor and safety plug.

• An improperly repaired plug or damaged mains cable insulation can cause electric shocks.

• The machine may only be opened by qualified and authorised specialist staff.

• Disconnect from the mains before opening. Switching off is not sufficient. Wait for 2 minutes until the
capacitors have discharged.

• Always put down welding torch, stick electrode holder in an insulated condition.

• The machine must not be used to defrost pipes!

Even touching low voltages can cause you to get a shock and lead to accidents, so:

• Protect yourself from falling before working on platforms or scaffolding.

• During welding ensure that you operate earth tongs, torch and workpiece correctly, and not in ways for
which they are not intended. Do not touch live parts with bare skin.

• Only replace electrodes when wearing dry gloves.

• Never use torches or earth cables with damaged insulation.

Smoke and gases can lead to breathing difficulties and poisoning.

• Do not breathe in smoke and gases.

• Ensure that there is sufficient fresh air.

• Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can be
converted into poisonous phosgene by ultraviolet radiation.

Safety instructions

For your safety

Item No.: 099-002032-EWM01 7

Workpiece, flying sparks and droplets are hot!

• Keep children and animals well away from the working area. Their behaviour is unpredictable.

• Move containers with inflammable or explosive liquids away from the working area. There is a danger
of fire and explosion.

• Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of
explosions when apparently harmless substances develop high pr essures in enclosed containers by
heating.

Take care to avoid fire hazards

• Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when parts
are glowing or hot slag is present.

• A constant check must be kept on whether fire hazards have arisen in the working area.

• Highly inflammable objects, such as matches and cigarette lighters for example, must not be carried in
trouser pockets.

• You must ensure that fire extinguishing equipment - appropriate for the welding process - is a vailable
close to the welding work area and that this equipment can be accessed easily.

• Containers in which fuels or lubricants have been present must be thoroughly cleaned before welding
begins. It is not sufficient simply for the receptacle to be empty.

• After a workpiece has been welded, it must only be touched or brought into contact with inflammable
material when it has cooled down sufficiently.

• Loose welding connections can comple t e ly destroy protective conductor systems of interior
installations and cause fires. Before beginning welding work, ensure that the earth tongs are properly
fixed to the workpiece or welding bench and that there is a direct electrical connection from the
workpiece to the power source.

Noise exceeding 70 dBA can cause permanent hearing damage!

• Wear suitable earmuffs or plugs.

• Ensure that other people who spend time in the working area are not inconvenienced by the noise.

Interference by electrical and electromagnetic fields is possible e.g. from the welding machine or
from the high-voltage pulses of the ignition unit.

• As laid down in Electromagnetic Compatibility Standard EN 50199, the machines are intended for use
in industrial areas; if they are operated in residential environments, for example, problems may occur
in ensuring electromagnetic compatibility.

• The functioning of heart pacemakers can be adversely affected when you are standing near the
welding machine.

• It is possible that electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the welding site
could malfunction.

• Other mains supply leads, control leads, signal and teleco mmunications leads above, under and near
the welding device may be subject to interference.

Electromagnetic interference must be reduced to a level that no longer constitutes interference.
Possible reduction measures:

• Welding machines must be serviced regularly. (see Chap. Maintenance and care)

• Welding leads should be as short as possible and run closely together on or near to the ground.

• Selective shielding of other leads and equipment in the environment can reduce radiation.

Repair and modifications may only carried out by authorised, trained, specialist staff.
The warranty becomes null and void in the event of unauthorised interference.

Safety instructions

Transport and installation

8 Item No.: 099-002032-EWM01

2.2 Transport and installation

The machines may only be transported and operated in an upright position.

Before carrying away or moving, pull out mains plug and place on the machine.

When setting up the machine, resistance to tilting is only guaranteed up to an angle of 10°
(as specified in EN 60974-1).

Secure the gas cylinder!

• Place shielding gas cylinders in the holders provided for them and secure with safety chains.

• Take care when handling cylinders; do not throw or heat, guard against them toppling over.

• When moving by crane, take off the gas cylinder from the welding machine.

2.2.1 Ambient conditions

This machine must not be operated in any area where any risk of explosion exists.
The following conditions must be observed during operation:

Temperature range of the ambient air

• During welding: -10°C to +40°C *),

• For transport and storage: -25°C to +55°C *)
*) Using the appropriate coolant.

Relative air humidity

• up to 50% at 40°C

• up to 90% at 20°C
The ambient air must be free of unusual amounts of dust, acids, corrosive gases or substance s, etc.,
assuming these are not produced by the welding process.
Examples of unusual operating conditions:

• unusual corrosive smoke,

• vapour,

• excessive oil vapour,

• unusual vibrations or jolts,

• excessive quantities of dust such a s gri nding dust etc.,

• severe weather conditions,

• unusual conditions near the coast or on board ship.
When setting up the machine, ensure a free inlet and outlet of air.
The machine is tested to protection class IP23, i.e.:

• Protection against penetration of solid foreign bodies ∅ > 12mm,

• Protection against water spray up to an angle of 60° to the vertical.

Safety instructions

Notes on the use of these operating instructions

Item No.: 099-002032-EWM01 9

2.3 Notes on the use of these operating instructions

These operating instructions are arranged into chapters.
To help you find your way around more quickly, in the margins you will occasio nally see symbols along

with the sub-headings. These symbols refer to particularly important passages of text which are graded
as follows depending on their importance:

Please note:
Technical features which users must observe.
Warning:
Working and operating procedures which must be followed precisely to avoid damaging or

destroying the machine.
Caution:
Working and operating procedures which must be followed precisely to avoid risk to persons and

includes the "Warning" symbol.

Instructions and lists detailing step-by-step actions in given situatio ns can be recognised by bullet points,
e.g.:

• Insert the welding current lead socket into the relevant socket and lock.

Symbol Description

Press

Do not press

Turn

Switch

Technical data

PICO 230; 230 CEL

10 Item No.: 099-002032-EWM01

3 Technical data

3.1 PICO 230; 230 CEL

PICO range 230 / 230 CEL
Setting range:
TIG

electrode

10 A / 10.4 V to 260 A / 20.4 V
10 A / 20.4 V to 230 A / 29.2 V

MMA operating time

20°C 40°C

40%
50%
55%
60%
100%

-

­230 A
220 A
180 A

230 A

-

­200 A
150 A

TIG operating time

20°C 40°C

40%
50%
60%
100%

­260 A
240 A
200 A

260 A

­210 A
160 A

Load alternation

10min (60% DC ∧ 6 min welding, 4min break)

MMA open circuit voltage

99 V

MMA open circuit voltage with VRD
option

12 V

TIG open circuit voltage

12 V

Mains voltage (tolerances)

3x400 V (+ 20 % to – 25 % )
3x415 V (+ 15 % to – 25 % )

Frequency

50/60 Hz

Mains fuse (safety fuse, slow-blow)

16 A

Mains connection lead

H07RN-F4G1.5

Max. connected power

10.1 kVA

Recommended generator rating

13.7 kVA

cosϕ at Imax / efficiency

0,99 / 88%

Insulation class / protection
classification

H / IP 23

Ambient temperature

-10 °-C to +40°C

Machine cooling / torch cooling

Fan / Gas

Workpiece lead

35 mm2

Dimensions L/W/H

490 x 186 x 350 mm

Weight

16.5 kg

Constructed to standards

EN 60974 / IEC 60974 / VDE 0544

EN 50199 / VDE 0544 Part 206

/

Technical data

PICO 260; 260 CEL; 260 CEL PWS

Item No.: 099-002032-EWM01 11

3.2 PICO 260; 260 CEL; 260 CEL PWS

PICO range 260; 260 CEL; 260CEL PWS
Setting range:
TIG

electrode

10 A / 10.4 V to 260 A / 20.4 V
10 A / 20.4 V to 260 A / 30.4 V

MMA operating time

20°C 40°C

40%
50%
60%
100%

­260 A
250 A
190 A

260 A

­220 A
170 A

TIG operating time

20°C 40°C

50%
60%
100%

­260 A
200 A

260 A
240 A
190 A

Load alternation

10min (60% DC ∧ 6 min welding, 4min break)

MMA open circuit voltage

99 V

MMA open circuit voltage with VRD
option

12 V

TIG open circuit voltage

12 V

Mains voltage (tolerances)

3x400 V (+ 20 % to – 25 % )
3x415 V (+ 15 % to – 25 % )

Frequency

50/60 Hz

Mains fuse (safety fuse, slow-blow)

16 A

Mains connection lead

H07RN-F4G1.5

Max. connected power

11.8 kVA

Recommended generator rating

16.0 kVA

cosϕ at Imax / efficiency

0,99 / 88%

Insulation class / protection
classification

H / IP 23

Ambient temperature

-10 °-C to +40 °C

Machine cooling / torch cooling

Fan / Gas

Workpiece lead

35 qmm

Dimensions L/W/H

490 x 186 x 350 mm;

490 x 186 x 445 mm (260CEL PWS)

Weight

16.5 kg;

23.5 kg (260CEL PWS)

Constructed to standards

EN 60974 / IEC 60974 / VDE 0544

EN 50199 / VDE 0544 Part 206

/

Technical data

PICO 300; 300 CEL; 300 CEL PWS

12 Item No.: 099-002032-EWM01

3.3 PICO 300; 300 CEL; 300 CEL PWS

PICO range 300; 300 CEL; 300 CEL PWS
Setting range:
TIG

electrode

10 A / 10.4 V to 260 A / 22 V
10 A / 20.4 V to 260 A / 32 V

MMA operating time

20°C 40°C

25%
30%
60%
100%

­300 A
250 A
190 A

300 A

­220 A
170 A

TIG operating time

20°C 40°C

30%
40%
60%
100%

­300 A
260 A
200 A

300 A

­240 A
190 A

Load alternation

10min (60% DC ∧ 6 min welding, 4 min break)

MMA open circuit voltage

99 V

MMA open circuit voltage with VRD
option

12 V

TIG open circuit voltage

12 V

Mains voltage (tolerances)

3x400 V (+ 20 % to – 25 % )
3x415 V (+ 15 % to – 25 % )

Frequency

50/60 Hz

Mains fuse (safety fuse, slow-blow)

16 A

Mains connection lead

H07RN-F4G1.5

Max. connected power

14.3 kVA

Recommended generator rating

19.3 kVA

cosϕ at Imax / efficiency

0,99 / 88%

Insulation class / protection
classification

H / IP 23

Ambient temperature

-10 °-C to +40 °C

Machine cooling / torch cooling

Fan / Gas

Workpiece lead

35 qmm

Dimensions L/W/H

490 x 186 x 350 mm;

490 x 186 x 445 mm (300 CEL PWS)

Weight

16.5 kg;

23.5 kg (300 CEL PWS)

Constructed to standards

EN 60974 / IEC 60974 / VDE 0544

EN 50199 / VDE 0544 Part 206

/

Machine description

PICO 300; 300 CEL; 300 CEL PWS

Item No.: 099-002032-EWM01 13

4 Machine description

4.1.1 PICO 230; 260; 300; PICO 230; 260; 300 CEL

4.1.2 Front view

1
2

3

4

6

5

7

8

9

Figure 4-1

Item Symbol Description 0
1 Carrying strap
2 Transport bar
3 Carrying handle
4 Control / Operating elements (see chapter Function specification)
5 Cooling air inlet
6

Connection socket, “+” welding current

Workpiece lead or electrode holder connection

7

Rubber feet

8

Connection socket, 19-pole

Remote control connection

9

Connection socket, “-” welding current

Electrode holder or workpiece lead connection

Machine description

PICO 300; 300 CEL; 300 CEL PWS

14 Item No.: 099-002032-EWM01

4.1.3 Rear view

1

2

3

Figure 4-2

Item Symbol Description 0
1

Main switch, machine on/off

2 Strain relief with mains connection cable
3 Cooling air outlet

Machine description

PICO 260; 300 CEL PWS

Item No.: 099-002032-EWM01 15

4.2 PICO 260; 300 CEL PWS

4.2.1 Front view

1
2

3

4

6

5

8

7

10

9

Figure 4-3

Item Symbol Description 0
1 Carrying strap
2 Transport bar
3 Carrying handle
4 Control / Operating elements (see chapter Function specification)
5 Cooling air inlet
6

Connection socket, 19-pole

Remote control connection

7

Connection socket, electrode holder

The welding current polarity (“+” or “-”) are based on the setting of the “Welding current
polarity changeover switch”.

8

Rubber feet

9

Welding current potential changeover switch

The changeover switch is used to switch over the welding current polarity (“+” or “-” ) of
the electrode holder and workpiece lead connection sockets.

= Welding current polarity “+” on connection socket .
= Welding current polarity “-” on connection socket .

10

Connection socket, workpiece lead

The welding current polarity (“+” or “-”) are based on the setting of the “Welding current
polarity changeover switch".

Machine description

PICO 260; 300 CEL PWS

16 Item No.: 099-002032-EWM01

4.2.2 Rear view

1

2

3

4

5

Figure 4-4

Item Symbol Description 0
1

Main switch, machine on/off

2 Strain relief with mains connection cable
3 Cooling air outlet
4

F4

Fuse

Solenoid switch pole reversal fuse

5

F5

Fuse

Solenoid switch pole reversal fuse

Functional characteristics

Machine control – Operating elements

Item No.: 099-002032-EWM01 17

5 Functional characteristics

5.1 Machine control – Operating elements

Figure 5-1

Item Symbol Description 0
1

Three-figure LED display

Display of welding current and voltage, welding parameters, error code

2

“Collective interference” signal light

Error messages, see chapter on troubleshooting, causes and remedies

3

“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.

4

sec

Hotstart time signal light (0.1 sec to 20 sec)

5

AMP%

Hotstart current signal light

50 % to 200 % of the main current

6

AMP

Current signal light

7

AMP

sec

“Welding parameter setting” rotary transducer

Setting of welding current and other welding parameter and their values

8

VRD open circuit voltage reduction (optional)

9

“Welding process” button

MMA welding

TIG welding

Functional characteristics

Welding data display

18 Item No.: 099-002032-EWM01

Item Symbol Description 0
10

AMP

VOLT

“Display switching” button

AMP

Welding current display

VOLT

Welding voltage display

11

“Arcforce” button (welding characteristics) according to electrode type

12

“Select welding parameters” button

This button is used to select the welding parameters depending on the welding process
and operating mode used.

5.2 Welding data display

The welding data display shows all relevant welding parameters and their values as selected. To the right
of the display on the control is an "arrow key" for selecting between welding current and welding voltage.

Further parameter displays are described later on in this chapter.

5.3 MMA welding

5.3.1 Selecting MMA welding

Control element Action Result Display

x x

MMA welding signal light
lights up

The last welding current set in this
procedure is displayed

AMP

sec

Main current setting

Welding current is displayed

5.3.2 Selecting the electrode type – Arcforce (welding characteristics)

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.
The electrode types used must be selected on the machine control to achieve the optimum
welding properties of the electrode types.

Control element Action Result Display

x x

The corresponding signal light
displays the selection.

-

Functional characteristics

MMA welding

Item No.: 099-002032-EWM01 19

5.3.2.1 Electrode type allocation
PICO 230; 260; 300
Item Electrode type

a)

rutile

b)

rutile basic

c)

basic

d)

rutile/cellulose

PICO 230; 260; 300 CEL
PICO 260; 300 CEL PWS

Item Electrode type

a)

rutile

b)

rutile basic

c)

basic and
rutile/cellulose

e)

cellulose

Figure 5-2

The selectable electrode characteristics on the machine control are guideline values. Every
characteristic can also be optimised for the relevant electrode types and their welding properties
(see chapter "Arcforce correction").

5.3.3 Selecting hotstart

Hotstart current

Control element Action Result Display

1 x

Signal light

AMP%

lights up.

Hotstart current is shown in
%

Hotstart current is set as a percentage of
the main current (50 % to 200 %).

Hotstart current is shown in
%

After a waiting time of approx 5 seconds, the display changes back to the main current set and
the signal light

AMP

comes on.

Hotstart time

Control element Action Result Display

2 x

Signal light

sec

lights up.

Hotstart time is displayed in
seconds

Hotstart time is set (0.1 sec to 20 secs) Hotstart time is displayed in

seconds

After a waiting time of approx 5 seconds, the display changes back to the main current set and
the signal light

AMP

comes on.

Functional characteristics

TIG welding

20 Item No.: 099-002032-EWM01

Functional sequence of hotstart device
The hotstart device uses an increased ignition current to improve arc ignition. The parameters for

the hotstart current and time can be adjusted individually.

When the stick electrode has been struck, the arc ignites at the adjusted hotsta rt current AMP (factory
setting: 120% of main current)

and welds at this current until the hotstart time in seconds has elapsed

(factory setting: 1 second). The hotstart current then reduces to the main current set.

Symbol Meaning

AMP Main current
AMP% Hotstart

current

sec Hotstart time

t

AMP%

AMP

I

sec

Figure 5-3

5.3.4 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 5-4

5.4 TIG welding

5.4.1 TIG welding selection

Control element Action Result Display

x x

TIG welding signal light

lights

up

The last welding current set in
this procedure is displayed

AMP

sec

Main current setting

Read welding current

Functional characteristics

Remote control

Item No.: 099-002032-EWM01 21

5.4.2 TIG arc ignition

a) b) c)

Figure 5-5

The arc is ignited on contact with the workpiece:

a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece (liftarc current

flowing, regardless of the main current set).

b) Incline the torch towards the torch gas nozzle until there is a gap of approx. 2-3mm between the tip of

the electrode and the workpiece (arc ignites, current increases to the main current set).

c) Lift off the torch and swivel to the normal position.

Ending the welding process: Remove the torch from the workpiece until the arc goes out.

5.5 Remote control

Only the remote controls described in these operating instructions may be connected. Only plug
the remote control into the remote control socket and lock when the machine is switched off.
The remote control is detected automatically when the welding machine is switched on.

5.5.1 Manual remote control RT 1

Functions

• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.

• The remote control is connected to the 19-pole remote control connection socket
on the welding machine via a 19-pole extension cable.

5.5.2 Foot-operated remote control RTF 1

Functions

• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.

• It is connected to the 19-pole remote control connection socket

5.5.3 Manual remote control RT PWS 1

Functions

• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.

• Changeover switch for pole reversal, suitable for welding machines with PWS ­function.

• The remote control is connected to the 19-pole remote control connection socket on
the welding machine via a 19-pole extension cable.

Functional characteristics

Advanced settings (MMA welding)

22 Item No.: 099-002032-EWM01

5.6 Advanced settings (MMA welding)

To enable the greatest possible breadth of applications, the following parameters can be adjusted
or optimised for the welding task.

5.6.1 Arcforce correction (welding characteristics)

Note for "PICO CEL machines":
The arcforce characteristic for cellulose electrodes "

" has been optimised at the factory
for the "Thyssen Cell70 electrode" which requires relatively strong arcforcing. The experienc e has
now demonstrated numerous times that the factory-set arcforcing is too strong for a "light"
electrode, such as those from Böhler, and therefore had to be adjusted downwards to between -3
and -4.

Every 4 arcforce characteristics can also be optimised individually for the relevant electrode type s
and their welding properties, in addition to the selecting the electrode type.

Control element Action Result Display

X x

The corresponding signal light displays the
selection.

No change

3 sec

Select “Advanced settings”:
The last parameter selected is displayed

Parameter and
value flash
alternately

X x

Select “Electrode type correction”

Set correction value
Increase value (up to +5) =

more arcforce – harder arc
Reduce value (up to -5) =

less arcforce – softer arc

3sec.

Deselect “Advanced settings”:
Press for 3 seconds and hold until the welding

current or welding voltage is shown on the
display

Welding current or
voltage is displayed

Example:
You are using a rutile/basic electrode type and set "

" accordingly on the machine
control. When welding the electrode type, you specify a hard or aggressive arc. You should now
change the arcforce setting in the direction of "less arcforce – softer arc" until the required result
is achieved.

Functional characteristics

Advanced settings (MMA welding)

Item No.: 099-002032-EWM01 23

5.6.2 Arc length restriction (USP)

In spot or tack welding it can be useful to restrict the length of the arc to prevent the undesirable
“lengthening” of the arc.

The arc length restriction is switch on and off separately for each electrode characteristic.

Control element Action Result Display

3 sec

Select “Advanced settings”:
The last parameter selected is displayed

Parameter and value flash
alternately

X x

Select “Arc length restriction”

Switch the function on or off
Switch on USP = on
Switch off USP = off

3 secs.

Deselect “Advanced settings”:
Press for 3 seconds and hold until the

welding current or welding voltage is
shown on the display

Welding current or voltage
is displayed

5.6.3 VRD open circuit voltage reduction (optional)

Item Description

1 VRD open circuit voltage

reduction signal light

AMP

AMP%

sec

T 1.22

AMP

VOLT

RB

Rutilbas

RutilR

RC

Rutilcel

BasB

sec

Arcforce

PICO 230 CEL

S

CelC

1

VRD

Figure 5-6

Welding machines with the “VRD” option is equipped with a voltage reduction device which meets the
requirements set down in the Australian standard AS 1674.2-2003 in a category C environment, in
accordance with table 3.2.6:

Operating conditions Maximum permissible open circuit voltage

Category C environment DC 35V peak value, or

AC 35V peak value and 25V r.m.s. value

The signal light (VRD open circuit voltage reduction) indicates when the voltage reduction device has
been activated. This then ensures that the open circuit voltage between the electrode holder and the
workpiece is reduced to the permissible values.

Commissioning

General

24 Item No.: 099-002032-EWM01

6 Commissioning

6.1 General

Warning – Risk from electrical current!
Follow the safety instructions on the opening pages entitled “For your safety”.
Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead, interfaces)

may only be connected when the machine is switched off.

6.2 Area of application – proper usage

These welding machines are suitable only for MMA and TIG welding with Liftarc.

PICO 230; 260; 300

• MMA direct current welding for rutile, rutile/basic and rutile/cellulose electrode types.

PICO 230; 260 CEL; PICO 260; 300 CEL PWS

• MMA direct current welding for rutile, rutile/basic, basic, rutile/cellulose and cellulose electrode types.
Any other use is regarded as “improper” and no liability is assumed for any damage arisin g therefrom.

We can only guarantee smooth and trouble-free operation of the machines when used in conjunction with
the welding torches and accessories from our range!

6.3 Installation

Ensure that the machine is set up in a stable position and is appropriately secured.
With modular systems (power source, transport vehicle, cooling module), observe the operating

instructions for the relevant machine.
Set up the machine so that there is sufficient room to adjust the operating elements.

Commissioning

Mains connection

Item No.: 099-002032-EWM01 25

6.3.1 Dirt filter

The dirt filter can be used in places with unusually high levels of dirt and dust in the ambient air.

The filter reduces the duty cycle of the welding machine via the reduced flow of cooling air. The
filter must be disassembled and cleaned regularly depending on the level of dirt (blow out with
compressed air).

1

2

3

Figure 6-1

Item Symbol Description 0
1 4 fixing screws for dirt filter
2 Dirt filter with fixing plate
3 Cooling air inlet

• Fix dirt filter with 4 fixing screws on the front of the casing (cooling air inlet) of the welding machine.

6.4 Mains connection

The operating voltage shown on the rating plate must match the mains voltage.
For mains fuse protection, please refer to the “Technical Data” chapter.

The correct mains plug must be attached to the mains supply lead on the machine.
The connection must be made by a qualified electrician in compliance with the relevant local laws

and regulations.
The phase sequence for three-phase machines is optional and has no effect on the fans direction

of rotation.

• Insert mains plug of the switched-off machine into the appropriate socket.

6.5 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.

6.6 Workpiece lead, general

Remove paint, rust and dirt from clamping and welding areas with a wire brush. The workpiece
clamp must be mounted near the welding point and must be fixed in such a way that it cannot
come loose of its own accord.

Structural parts, pipes, rails etc. may not be used as return leads for the welding current unless
they are part of the actual workpiece.
Correct current connection must be ensured when using welding benches and appliances.

Commissioning

MMA welding

26 Item No.: 099-002032-EWM01

6.7 MMA welding

6.7.1 PICO 230; 260; 300; PICO 230; 260; 300 CEL

Item Description

1 Connection socket "+"
2 Connection socket "-"
3 Connection socket, 19-pole

1

2

3

Figure 6-2

Item Symbol Description 0
1

Connection socket, “+” welding current

Workpiece lead or electrode holder connection

2

Connection socket, “-” welding current

Electrode holder or workpiece lead connection

3

Connection socket, 19-pole

Remote control connection

6.7.1.1 Electrode holder connection
Caution: Risk of injury from crushing!
Suitable protective gloves should be worn when changing spent stick electrodes.
When pausing work, always place the electrode holder on an insulated surface.

• Insert cable plug of the electrode holder 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.

6.7.1.2 Connection for workpiece lead

• 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.

Commissioning

PICO 260; 300 CEL PWS

Item No.: 099-002032-EWM01 27

6.8 PICO 260; 300 CEL PWS

1
2

3
4

Figure 6-3

Item Symbol Description 0
1

Connection socket, 19-pole

Remote control connection

2

Connection socket, electrode holder

The welding current polarity (“+” or “-”) are based on the setting of the “Welding current
polarity changeover switch”.

3

Welding current potential changeover switch

The changeover switch is used to switch over the welding current polarity (“+” or “-” ) of
the electrode holder and workpiece lead connection sockets.

= Welding current polarity “+” on connection socket .
= Welding current polarity “-” on connection socket .

4

Connection socket, workpiece lead

The welding current polarity (“+” or “-”) are based on the setting of the “Welding current
polarity changeover switch".

6.8.1.1 Pole reversal changeover switch

This allows the welding current polarity (+/-) to be changed without unplugging the electrode holder or
workpiece leads.

The polarity cannot be changed during welding!
The polarity can also be changed over to an appropriate remote control with pole reversal switch.

Commissioning

TIG welding

28 Item No.: 099-002032-EWM01

6.8.1.2 Electrode holder connection
Caution: Risk of injury from crushing!
Suitable protective gloves should be worn when changing spent stick electrodes.
When pausing work, always place the electrode holder on an insulated surface.

• Insert cable plug on the electrode holder into the welding current socket “

” and lock by turning to

the right.

Polarity depends on the instructions from the electrode manufacturer given on the electrode
packaging.

6.8.1.3 Connection for workpiece lead

• Insert cable plug on the workpiece lead into the welding current socket “

” and lock by turning

to the right.

Polarity depends on the instructions from the electrode manufacturer given on the electrode
packaging.

6.9 TIG welding

6.9.1 Connecting a TIG welding torch with rotating gas valve

When pausing work, always place the welding torch on an insulated surface.
Prepare the welding torch according to the welding task in hand (see torch operating

instructions).
The welding torch shielding gas is supplied directly from the shielding gas cylinder.

• Fit the tungsten electrode and gas nozzle onto the welding torch (observe current load, see torch

operating instructions).

• Insert the welding current plug in the “-” welding current connection socket “

” and lock by turning to

the right.

For machines with pole reversal switch (PWS), the welding current polarity is changed as follows
after selecting “TIG welding process”:

• Electrode holder connection socket = welding current polarity “-” ,

• Workpiece lead connection socket = welding current polarity “+”.

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

No dirt must be allowed to enter the shielding gas supply, as this would cause blockages in the
shielding gas supply. All shielding gas connections must be gastight.

• Place shielding gas cylinder in the retainer provided for it and secure with chains.

• Before connecting the pressure reducer to the gas cylinder, open the cylinde r valve briefly to blow out

any dirt.

• Mount the pressure reducer onto the gas cylinder valve.

• Screw the gas hose of the welding torch tightly to the pressure regulator.

• Slowly open the gas cylinder valve.

• Open the rotating valve on the welding torch

• Set the required amount of shielding gas on the pressure reducer, about 4 - 15 l/min depending on the

current strength and the material.

Rule of thumb for gas flow rate:
Diameter of gas nozzle in mm corresponds to gas flow in l/min.

Example: 7 mm gas nozzle corresponds to 7 l/min gas flow
Before each welding process, the rotating valve must be opened; after the welding process, it

must be closed.

Commissioning

TIG welding

Item No.: 099-002032-EWM01 29

6.9.3 Connection for workpiece lead

• Insert cable plug of the workpiece lead into the “+” or “ ” welding current con nection socket and
lock by turning to the right.

For machines with pole reversal switch (PWS), the welding current polarity is changed as follows
after selecting “TIG welding process”:

• Electrode holder connection socket = welding current polarity “-” ,

• Workpiece lead connection socket = welding current polarity “+”.

Maintenance and care

General

30 Item No.: 099-002032-EWM01

7 Maintenance and care

7.1 General

Under the indicated environmental conditions and normal operating conditions, this machine is largely
maintenance-free and requires minimum care. However, a number of points 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 level of contamination in the environment and the usage time of
the welding machine.

Cleaning, testing and repairing of the welding machines may only be carried out by competent,
capable personnel. A capable person is one who, due to training, knowledge and experience, is
able to recognise the dangers that can occur during testing of welding power sources as well as
possible subsequent damage and who is able to implement the required safety procedures.

In the event of failure to comply with any one of the following tests, the machine must not be
operated again until it has been repaired and a new test has been carried out.

7.2 Cleaning

Before cleaning, carefully disconnect the machine from the mains. PULL OUT THE MAINS PLUG.
(Switching off or pulling out the fuse does not provide adequate insulation protection)
Wait 2 minutes until the capacitors are discharged. Remove the casing cover.

The individual components should be handled as follows:
Power source: Depending on the amount of dust, blow out power source using oil- and moisture-free

compressed air.
Electronics: Do not blast electronic components or circuit boards with compressed air but instead use

suction from a vacuum cleaner for cleaning purposes.

7.3 Repetition test

The repetition test described below must be conducted correctly and on a regular basis in order
to claim under the EWM warranty.

The repetition test must be conducted in accordance with E VDE 0544-207 "Repetition test on arc
welding equipment", according to the German Ordinance on Operational Safety. This draft standard
covers all the required test points specifically for welding machines, as mentioned in VDE 0702
"Repetition test on electrical equipment", in addition to special instructions for usage and specific limit
values.

In addition to the regulations on the repetition test given here, the relevant local laws and
regulations must also be observed.

Unfortunately, many test devices are not suitable for VDE 0702 in all respects due to the special
conditions in inverter arc welding machines!

EWM as a manufacturer offers all appropriately trained and authorised EWM sales partners the
appropriate test equipment and measuring devices conforming to VDE 0404-2, which eval uate the
frequency response conforming to DIN EN 61010-1 Appendix A – Measuring Circuit A1. You as the user
are tasked with ensuring that your EWM machines conform to the standard E VDE 0544-207 and are
tested with the relevant test equipment and measuring devices given above.

The following description of the repetition test is only a brief overview of the points to be tested.
For details on the test points or in the event of any queries, please refer to E VDE 0544-207.

Maintenance and care

Repetition test

Item No.: 099-002032-EWM01 31

7.3.1 Test intervals and scope

A quarterly partial test and an annual extensive test are to be carried out. The extensive test must also be
carried out each time that repairs are made; in the case of heavy use, the period can be reduced (e.g. to
6 months when used at construction sites). In the extensive test, the machine must be opened and
cleaned according to the section entitled “Cleaning”. Only exterior cleaning i s re quired for the partial test.

Partial test Full test

a) Visual check a) Visual check
b) Electrical test: measurement of

• Protective conductor resistance

b) Electrical test: measurement of

• Protective conductor resistance

• Insulation resistance

• Leakage currents

• Open circuit voltage

c) Functional test c) Functional test

7.3.2 Documentation of the test

The result of the test must be documented to show the following clearly:

• Identify the tested machines,

• The date of the test

• The time of the next test and

• The results

for later reference. The machine must be marked if the test is successful (e.g. with a test plate). This plate
must include the date of the next repetition test.

7.3.3 Visual inspection

Given below are the main points in the full test. The points to be tested with the machine open are not
required for the partial test.

1. Torch/stick electrode holder, welding current return lead clamp

2. Leads including plugs and couplings

3. Open plugs and couplings

4. Casing

5. Open casing

6. Special features of the welding power sources for plasma cutting

7. Operating, message, safety and adjustment devices

8. Other, general condition

7.3.4 Measurement of protective conductor resistance

Measure between the plug earthed contact and accessible metal parts, e.g. casing screws. During the
measurement, the connection lead must be moved across the entire length, but especially close to the
casing and plug inputs. This should uncover any interruptions in the protective conductor. All conductive
parts of the casing accessible from outside should also be tested to ensure a correct PE connection fo r
safety class I.

The resistance must not exceed a mains connection lead 0.3 Ω up to 5m in length. For longer lead s, the
permissible value increases by 0.1 Ω per 7.5m of lead.

Maintenance and care

Repetition test

32 Item No.: 099-002032-EWM01

7.3.5 Measurement of insulation resistance

The mains switch must be on before the insulation in the interior of the machine through to the
transformer can be checked. If a mains contactor is fitted, this should be bridged or the measurement
must be carried out on both sides.

The insulation resistance must not be less than:

Input power circuit
(mains)

against Welding current circuit and

electronics

5 MΩ at test voltage 1000V=

Input power circuit
(mains)

against Casing (PE)

2.5 MΩ at test voltage 500V =

Welding current
circuit and
electronics

against Casing (PE)

2.5 MΩ at test voltage 500V =

7.3.6 Measuring the leakage current (protective conductor and contact current)

These measurements cannot be carried out with a normal multimeter. Even test devices for VDE 0702
(especially older devices) are generally only intended for 50/60Hz. With inverter welding machines,
however, significantly higher frequencies occur, which can interfere with some measuring devices, and
results in others measuring the frequency incorrectly.

Test devices must meet the requirements of VDE 0404-2. For the frequency response measurement,
please refer to DIN EN 61010-1 Appendix A – Measuring Circuit A1.

For these measurements the welding machine must be switched on and supplying open circuit
voltage.

1. Protective conductor current: <3.5mA

2. Contact current from welding sockets separately to PE: <10mA

3. Contact current of accessible, conductive parts not connected to PE, to PE: <0.5mA

7.3.7 Measuring the open circuit voltage

6u8F

10nF

0...5k

0k2

1k0

1N 4007

Measuring circuit according to DIN EN

60974-1

Connect the measuring circuit to the welding current
sockets. The voltmeter must display mean values and
have an internal resistance ≥ 1 MΩ. In the case of step
switch controlled devices, set the maximum output voltage
(step switch). Adjust the potentiometer from 0 kΩ to 5 kΩ
during the measurement. The measured voltage should
not deviate from that specified on the rating plate by more
than +/- 5% and may be no greater than 113 V (for devices
with VRD: 35 V).

7.3.8 Function test of the welding machine

Safety devices, selector switches and command units (if fitted) and the entire machine or the entire
system for arc welding, must be functioning perfectly.

1. Main switch

2. Emergency stop devices

3. Danger reduction devices

4. Gas solenoid valve

5. Message and control lamps

6. Command devices and selector switches (including remote controls)

7. Locks

Maintenance and care

Repair Work

Item No.: 099-002032-EWM01 33

7.4 Repair Work

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, please contact your EMW sales partner.
Returns of defective equipment subject to warranty may only be made through your EWM sal es partner.
In the event of problems or queries, please contact the EWM Service Department directly (+49 (0) 2680
181 0). Use only original spare parts and replacement parts when servicing. When placing an order,
please quote the type designation and item number, as well as the type, serial number and item number
of the relevant equipment.

We hereby confirm that the servicing and maintenance instructions given above and the repetition test described
above have been completed correctly.

Date / Stamp / Signature of EWM sales partner

Date / Stamp / Signature of EWM sales partner

Date of next repetition test

Date of next repetition test

Date / Stamp / Signature of EWM sales partner

Date / Stamp / Signature of EWM sales partner

Date of next repetition test

Date of next repetition test

Date / Stamp / Signature of EWM sales partner

Date / Stamp / Signature of EWM sales partner

Date of next repetition test

Date of next repetition test

Maintenance and care

Disposing of equipment

34 Item No.: 099-002032-EWM01

7.5 Disposing of equipment

This machine does not belong in household waste, in accordance with the German Law on
Electrical Equipment Waste.

In Germany, waste equipment from private households can be disposed of free of charge at local
community collection points. Your administrative office will be pleased to inform you of the options.
EWM participates in an approved waste disposal and recycling system and is registe red in th e Used
Electrical Equipment Register (EAR) under number WEEE DE 57686922.

In addition, within Europe the machine can also be returned to your EWM sales partner.

7.5.1 Manufacturer's declaration to the end user

• In accordance with European guidelines (Directive 2002/96/EC from the European Parliament and the
Council of 27.01.03), it is no longer permissible to dispose of used electrical and electronic equipment
in unsorted household waste collections. It must be kept separate from other waste. The symbol on
the wheeled bins indicates the requirement to separate this waste.
Help to protect the environment and ensure that this equipment, when you no longer want to use it, is
disposed of in the relevant system of separated waste disposal.

• In Germany, (German Law on the Distribution, Return and Environmentally-Friendly Dispo sal of
Electrical and Electronic Equipment (ElektroG) of 16.03.05) you are required to take old equipment to
a waste collection point separated from household waste. The public waste disposal contractor (local
authorities) have set up collection points for this purpose where old equipment from private
households in your area can be collected for you free of charge.
It is also possible that the legally responsible waste disposal company will collect old equipment from
private households.

• Please obtain the relevant information from your local waste calendar or from your town council or
local authority on the options available in your area for returning or collecting old equipment.

7.6 Meeting the requirements of RoHS

We, EWM HIGHTEC Welding GmbH Mündersbach, hereby confirm that all products supplied by us which
are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).

3-Year Warranty

General Validity

Item No.: 099-002032-EWM01 35

8 3-Y ear Warranty

8.1 General Validity

3-year warranty on all new EWM machines:

• Power sources

• Wire feeds

• Cooling units

• Trolleys

1-year warranty on:

• Used EWM machines

• Automation and mechanisation components

• Remote controls

• Inverters

• Intermediate tube packages

6-month warranty on:

• spare parts supplied separately (such as circuit boards, ignition units)

Manufacturer/supplier warranty on:

• all additional parts used by EWM, but manufactured by other companies (e.g. motors, pumps, fans,
torches, etc.)

Non-reproducible software errors and parts subject to mechanical aging are excluded from the warranty
(e.g. WF rollers, wheels, solenoid valves, workpiece leads, electrode holders, connection tubes,
replacement torches and spare torch parts, mains and control leads, etc.).

These terms shall apply without affecting the customer’s legal righ ts to a warranty and subject to our
General Terms and Conditions of Business and our terms on the warranty de claration. Agreements to the
contrary must be confirmed by EWM in writing.

Our General Terms and Conditions of Business are available for access anytim e online at

www.ewm.de

.

3-Year Warranty

Warranty Declaration

36 Item No.: 099-002032-EWM01

8.2 Warranty Declaration

Your 3-year warranty

Regardless of statutory warranty rights and based o n our General Terms and Conditions, EWM
HIGHTEC WELDING GmbH provides a 3-year warranty for its welding products starting on the date of
purchase. Different warranty periods apply for accessories and spare parts; plea se see the “General
Validity” section for these periods. Wearing parts are of course exempt from the warranty.

EWM guarantees the error-free condition of our products in terms of materials and processing. If the
product proves to be defective in terms of materials or processing within the warranty period, you have
the right to free repair or to replacement by an appropriate product, at our discretion. In this case, the
returned product becomes the property of EWM when it reaches Mündersbach or our premise s.

Conditions

The prerequisite for receiving the full 3-year warranty is simply to operate the products in accordance with
the EWM operating instructions observing the relevant legal recommend ations and guidelines and
regularly having the repetition test conducted by an EWM sales partner (see "Maintenance and care"
chapter). This is because only machines that are maintained regularly function correctly in the long term.

Making a claim

When making a claim under the warranty, please only contact your authorised EWM sales partner.

Exclusion of warranty

The warranty does not apply to products that are damaged due to accidents, misuse, imp roper operation,
incorrect installation, use of force, disregard of the specifications and operating instructions, inadequate
maintenance (see chapter "Maintenance and care"), damage due to exterior influences, acts of God or
personal misfortunes. Furthermore, it is not valid in the case of unauthorised changes, repairs or
modifications. In addition, a claim for warranty does not exist in the case of partially or completely
dismantled products and interventions by persons who are not authori sed by EWM, as well as in the case
of normal wear.

Limitation

All claims regarding fulfilment or non-fulfilment on the part of EWM from this declaration in connection
with this product are limited to the replacement of the actual damages, as outlined below. EWM’s liability
stemming from this declaration in connection with this product is strictly limited to the amount that the
purchaser originally paid for the original purchase. This limitation does not apply to personal injuries or
damage to property caused by negligent behaviour on the part of EWM. In no way will EWM be
responsible for lost profits, indirect or consequential damage. EWM accepts no liability for damages
based on the claims of third parties.

Place of jurisdiction

If the person making the claim is a business person, the sole place of jurisdiction for all disputes resulting
directly or indirectly from the contractual relationship shall be the headquarters or the branch office of the
supplier, at the discretion of the supplier. The purchaser gains ownership of the products supplied as
replacements at the time of replacement within the framework of the warranty provided.

Operating problems, causes and remedies

Error messages (power source)

Item No.: 099-002032-EWM01 37

9 Operating problems, causes and remedies

9.1 Error messages (power source)

Item Description

1 Collective interference signal light
2 Three-figure LED display

AMP

AMP%

sec

T 1.22

AMP

VOLT

RB

Rutilbas

RutilR

RC

Rutilcel

BasB

sec

Arcforce

PICO 230 CEL

S

CelC

1
2

VRD

Figure 9-1

A welding machine error is indicated by the collective fault signal light (A1) lighting up and an
error code (see table) being displayed in the three-digit LED display of the machine controller
(B1).

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

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

• Document machine errors and inform service staff as necessary.

Error message Possible cause Remedy
"E 1" Electronics error Switch the machine off and back on again. If the

error persists, inform the service dept.

"E 2" Temperature error Allow machine to cool down.
"E 3" Electronics error See “E 1”.
"E 4" Electronics error See “E 1”.
"E 5" Electronics error See “E 1”.
"E 6" Balancing error in voltage

recording

"E 7" Balancing 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, inform the service
dept.

"E 8"

Error in one of the electronics
supply voltages

Switch the machine off and back on again. If the
error persists, inform the service dept.

"E 9" Mains undervoltage Switch off the machine and check the mains

voltage.

"E10" Secondary excess voltage Switch the machine off and back on again. If the

error persists, inform the service dept.

"E11" Mains excess voltage Switch off the machine and check the mains

voltage.

"E12" Voltage reduction error (VRD) Switch the machine off and back on again. If the

error persists, inform the service dept.

Spare parts list

PICO 230; 230 CEL

38 Item No.: 099-002032-EWM01

10 Spare parts list

10.1 PICO 230; 230 CEL

10.1.1 Front view

4

3
2

1

7

8

5
6

Figure 10-1

Item Designation Type Item number

1

BH490X259X186-DRUCK Casing angle 094-008896-00002

2

CARRYING HANDLE Hand grip mount 094-007383-00003

3

D25X1.5X548MM TUBE Hand grip 094-007501-00003

4

40x1500MM Carrying strap 094-007543-00000
T1.22 PCB control 040-000662-E0000

5

T1.2

PCB control

040-000645-E0000

6

2523060 Rotary dial 074-000315-00000

7

CX 58/35-50QMM Built-in socket 074-000232-00000

8

KB PICO 230 Socket with cable harness 094-008936-00001

9

30X25/M8/AG 8MM Rubber / metal buffer 094-001718-00001

10

BBG440X183X60 Floor plate casing 094-008834-00002

11

BFG257.5X185X44 Front plate casing 094-008835-00002

Spare parts list

PICO 230; 230 CEL

Item No.: 099-002032-EWM01 39

10.1.2 Rear view

3

1

4

2

Figure 10-2

Item Designation Type Item number

1

Cable assembly MAINS CABLE 4X1.5QMM/5.5M 092-001844-00000

2

Cap nut M20X1.5 SIZE THREADED JOI NT METR. 094-007871-00000

3

Mains switch MAINS SWITCH 25A/3PHASE 074-000279-00003

4

Rear panel casing BRG257.5X185X44 094-008836-0000 2

Spare parts list

PICO 230; 230 CEL

40 Item No.: 099-002032-EWM01

10.1.3 Left-hand side

5

4

3

1

2

Figure 10-3

Item Description Type Item number

1

Mains switch MAINS SWITCH 25A/3PHASE 074-000279-00003

2

Lock nut M20X1.5 7035 COUNTERNUT METR. 094-007878-00000

3

PCB primary circuit board DC 231 040-000643-00000

4

Cable harness KB "PICO 230" 094-008936-00001

5

MULTIDUL IGBT INV20/1000 080-000306-00000

Spare parts list

PICO 230; 230 CEL

Item No.: 099-002032-EWM01 41

10.1.4 Right-hand side

1

4
5

3

2

11

7
9

6

8

10

Figure 10-4

Item Designation Type Item number

1 Mains switch MAINS SWITCH 25A/3PHASE 074-000279-00003
2 Flat band cable PKS-LC/26POLIG/340MM 094-007715-00000
3 Fan / 120x120x38mm NMB4715KL-05W-B40-P00 094-007861-00000
4 MINI-FIT pin housing 5559-02P 044-002252-00000
5 MINI-FIT contact pin 5558-TL/AWG 16 044-002251-00000
6 Bridge rectifier 074-002908-00000
7 IND choke PICO 230 SECONDARY AIR CHOKE 032-000201-00000
8 PCB current transformer SW1 042-000787-00000
9 DIO MODULE BYT200PIV-400/ISOTOP 044-002601-00000
10 Cable harness KB " PICO 230 CEL ADD-ON" 094-008937-00000
11 PCB SEC. connections CELL 1 (PICO 230 CELL) 042-000786-00000
12 PCB SEC. connections KON 2 (PICO 230) 042-000785-00000

Spare parts list

PICO 260; 260 CEL; 260 CEL PWS

42 Item No.: 099-002032-EWM01

10.2 PICO 260; 260 CEL; 260 CEL PWS

This chapter is currently in preparation!

Accessories, options

Remote control / connection cable

Item No.: 099-002032-EWM01 43

11 Accessories, options

11.1 Remote control / connection cable

Type Description / Name Item number

RT1 Remote control current 090-008097-00000
RT PWS 1 Vertical down current remote control, pole reversal 090-008199-00000
RA5 19POLE 5M Connection cable, e.g. for remote cont rol 092-00 1470-00005
RA10 19POLE 10M Connection cable, e.g. for remote control 092-001470-00010
RA20 19POL 20M Connection cable, e.g. for remote control 092-001470-00020
RTF1 19POLE 5M Foot-operated remote control current with

connection cable

094-006680-00000

RV5M19 19POLE 5M Extension cable 092-000857-00000

11.2 Electrode holder / workpiece lead

Type Description / Name Item number

EH35QMM 4M Electrode holder 092-000052-00000
WK35QMM 4M KL Workpiece lead, clamp 092-000008-00000

11.3 TIG welding torch

Type Description / Name Item number

TIG MISTRAL VT 4M G TIG welding torch 094-007819-00000

11.4 Options

Type Description / Name Item number

ON FILTER Retrofit option, dirt filter for air inlet 092-001856-00000
OW VRD Factory-fit option for open circuit voltage reduction 092-001875-00000

11.5 General accessories

Type Description / Name Item number

5POLE/CEE/16A/M Machine plug 094-000712-00000
DM1 32L/MIN Manometer pressure reducer 094-000009-00000

Circuit diagrams

PICO 230

44 Item No.: 099-002032-EWM01

12 Circuit diagrams

Original format circuit diagrams are located inside the machine.

12.1 PICO 230

Figure 12-1

Circuit diagrams

PICO 230 CEL

Item No.: 099-002032-EWM01 45

12.2 PICO 230 CEL

Figure 12-2

Circuit diagrams

PICO 260

46 Item No.: 099-002032-EWM01

12.3 PICO 260

L1L2L3

PE

Netzfilter

PE2

GRL1

GRL2

GRL3

U1

GR+

GR-

+

+

X5/1

X5/5

X5/4

X5/8

SPW TRI

Spg.Versorg.

Brücke A-B

Netzfreigabe

Signal

Spg. Versorg.

X2

X1

X4/2

X4/1

R2B2US2

A2

X3/2

X3/1

R1B1US1

A1

TM

TP

-Ud

+Ud

NC

NC

0V/24

0V/24

NC

-15V

NC

UZWK

0V/15

0V/15

0V/15

0V/15

+24V

+24V

+15V

+15V

+8V

+8V

NC

Relais

IPrim-

IPrim+

NC

NC

TDW1-

TDW1+

X6/26

X6/25

X6/24

X6/23

X6/22

X6/21

X6/20

X6/19

X6/18

X6/17

X6/16

X6/15

X6/14

X6/13

X6/12

X6/11

X6/10

X6/9

X6/8

X6/7

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

+24V

+15V

0V/24

0V

-15V
+8V

UZWK

D C 2 3 1

A1-

Gleichrichter auf Kühlkörper

Ringkern

F1

6.3AT

Überspannungsableiter

PE

L1L2L3

Q1-

T1T3T2

L1L2L3

A1-L1

A1-L2

A1-L3

PE-

T?

1

A1-PE

PE1-

T?

1

A1-PE2

PE2-

1

Ringkern

n=5Wdg.

Ringkern

n=2Wdg.

Ringkern

T?

PE1-

ABCDEFGHJKLMNPRSTUV

PE

NC

Poti IH

NC

Polwendung PWS

Uref.10V

NC

NC0VNC

NC

FR-Typ1

FR-Typ2

NCNCNCNCNC

NC

X2-

1

Uref. 10V

2

Poti IH

3

FR-Typ2

4

0V

5

PWS

6

FR-Typ1

1

?T2

1

Schalter PWS

3

IGR0-

40V5

Relais+

6

IGRO+

2

Relais-

1 2

?T

L1-

X1/1
X1/2
X1/3
X1/4

1:2000

S W 1

A2-

1

+15V

2

M

3

-15V

1

+15V

2

M

3

-15V

T1?T1.1?

21

T2?T2.1?

F1-

80°C

Temp Pri.-Kühler

T1?T1.1?

21

T2?T2.1?

F2-

Temp Trafo

140°C

T1?T1.1?

21

T2?T2.1?

F3-

85°C

Temp Sek.-Kühler

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26NC

NC

+15V

+15V

+5V

+5V

0V

0V

NC

NC

0V

0V

OE

NC

NC

NC

Drehg.-A

NC

Drehg.-A

NC

CLK

CLK

CS2

CS1

RD

WR1

X2/26

X2/25

X2/24

X2/23

X2/22

X2/21

X2/20

X2/19

X2/18

X2/17

X2/16

X2/15

X2/14

X2/13

X2/12

X2/11

X2/10

X2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

TDW1-
TDW2+
TDW2-

TDW1+

Iprim+

Iprim-

Relais

NC
+8V
+8V

+15V
+15V
+24V

+24V
0V/15
0V/15
0V/15
0V/15

UZWK

NC

-15V
NC

0V/24
0V/24

NC
NC

X5

Inverter+Stromversorgung

X2

Bedienfeld

X3/1

X3/2

X3/3

X3/4

X3/5

X3/6

X3/7

X3/8

X3/9

X3/10

X3/11

X3/12

X3

Peripherie

X7/1

X7/2

X7/3

X7/4

X7/5

X7/6

X7

PWS

X4/1
X4/2
X4/3
X4/4

X4

Mess-Stromwandler

X5/6

X5/5

X5/4

X5/3

X5/2

X5/1

X5

Fernsteller

T R D C 5

A4-

X6/1

1

Temp. Pri.2Temp. Sek.3Lüfter+4Temp. Trafo

6

U2-7Temp. Pri.8Temp. Sek.9Lüfter-10Temp. Trafo

12

U2+

rt

T1?

1

X4-

2 sw

T2?

+24V

Lüfter

M1-

+

-

1

U2-

2

U2+

T1-

A1

E1

A2

E3

4

0V

Ringkern

X1-

?T

EA

sw

br

2n2F

PE

-

-

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26

RD
CS1
CS2

WR1

CLK
CLK

NC

Drehg.-A

NC

Drehg.-A

NC
NC
NC
OE

0V

0V
NC
NC

0V

0V

+5V

+5V
+15V
+15V

NC
NC

T 2 0 1 / 2

X1

Bedienfeld

PE

A5-

+

+

X1/2

X1/1

PE

A3-

K O N 2

V1

L1L2L3

PE

Netzfilter

PE2

GRL1

GRL2

GRL3

U1

GR+

GR-

+

+

X5/1

X5/5

X5/4

X5/8

SPW TRI

Spg.Versorg.

Brücke A-B

Netzfreigabe

Signal

Spg. Versorg.

X2

X1

X4/2

X4/1

R2B2US2

A2

X3/2

X3/1

R1B1US1

A1

TM

TP

-Ud

+Ud

NC

NC

0V/24

0V/24

NC

-15V

NC

UZWK

0V/15

0V/15

0V/15

0V/15

+24V

+24V

+15V

+15V

+8V

+8V

NC

Relais

IPrim-

IPrim+

NC

NC

TDW1-

TDW1+

X6/26

X6/25

X6/24

X6/23

X6/22

X6/21

X6/20

X6/19

X6/18

X6/17

X6/16

X6/15

X6/14

X6/13

X6/12

X6/11

X6/10

X6/9

X6/8

X6/7

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

+24V

+15V

0V/24

0V

-15V
+8V

UZWK

D C 2 3 1

A1-

Gleichrichter auf Kühlkörper

Ringkern

F1

6.3AT

Überspannungsableiter

PE

L1L2L3

Q1-

T1T3T2

L1L2L3

A1-L1

A1-L2

A1-L3

PE-

T?

1

A1-PE

PE1-

T?

1

A1-PE2

PE2-

1

Ringkern

n=5Wdg.

Ringkern

n=2Wdg.

Ringkern

T?

PE1-

ABCDEFGHJKLMNPRSTUV

PE

NC

Poti IH

NC

Polwendung PWS

Uref.10V

NC

NC0VNC

NC

FR-Typ1

FR-Typ2

NCNCNCNCNC

NC

X2-

1

Uref. 10V

2

Poti IH

3

FR-Typ2

4

0V

5

PWS

6

FR-Typ1

1

?T2

1

Schalter PWS

3

IGR0-

40V5

Relais+

6

IGRO+

2

Relais-

1 2

?T

L1-

X1/1
X1/2
X1/3
X1/4

1:2000

S W 1

A2-

1

+15V

2

M

3

-15V

1

+15V

2

M

3

-15V

T1?T1.1?

21

T2?T2.1?

F1-

80°C

Temp Pri.-Kühler

T1?T1.1?

21

T2?T2.1?

F2-

Temp Trafo

140°C

T1?T1.1?

21

T2?T2.1?

F3-

85°C

Temp Sek.-Kühler

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26NC

NC

+15V

+15V

+5V

+5V

0V

0V

NC

NC

0V

0V

OE

NC

NC

NC

Drehg.-A

NC

Drehg.-A

NC

CLK

CLK

CS2

CS1

RD

WR1

X2/26

X2/25

X2/24

X2/23

X2/22

X2/21

X2/20

X2/19

X2/18

X2/17

X2/16

X2/15

X2/14

X2/13

X2/12

X2/11

X2/10

X2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

TDW1­TDW2+
TDW2-

TDW1+

Iprim+

Iprim-

Relais

NC
+8V
+8V

+15V
+15V
+24V

+24V
0V/15
0V/15
0V/15
0V/15

UZWK

NC

-15V
NC

0V/24
0V/24

NC
NC

X5

Inverter+Stromversorgung

X2

Bedienfeld

X3/1

X3/2

X3/3

X3/4

X3/5

X3/6

X3/7

X3/8

X3/9

X3/10

X3/11

X3/12

X3

Peripherie

X7/1

X7/2

X7/3

X7/4

X7/5

X7/6

X7

PWS

X4/1
X4/2
X4/3
X4/4

X4

Mess-Stromwandler

X5/6

X5/5

X5/4

X5/3

X5/2

X5/1

X5

Fernsteller

T R D C 5

A4-

X6/1

1

Temp. Pri.2Temp. Sek.3Lüfter+4Temp. Trafo

6

U2-7Temp. Pri.8Temp. Sek.9Lüfter-10Temp. Trafo

12

U2+

rt

T1?

1

X4-

2 sw

T2?

+24V

Lüfter

M1-

+

-

1

U2-

2

U2+

T1-

A1

E1

A2

E3

4

0V

Ringkern

X1-

?T

EA

sw

br

2n2F

PE

-

-

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26

RD
CS1
CS2

WR1

CLK
CLK

NC

Drehg.-A

NC

Drehg.-A

NC
NC
NC
OE

0V

0V
NC
NC

0V

0V

+5V

+5V
+15V
+15V

NC
NC

T 2 0 1 / 2

X1

Bedienfeld

PE

A5-

+

+

X1/2

X1/1

PE

A3-

K O N 2

V1

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

Änderung-4:

Änderung-3:

Änderung-2:

Änderung-1:

29.04.2004 NIEDENTHAL

Blatt: /1

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

1

PICO 260

Z02066-00

Zeichnungsnummer:

ELEK-GERAET, 3X400V

Figure 12-3

Circuit diagrams

PICO 260 CEL

Item No.: 099-002032-EWM01 47

12.4 PICO 260 CEL

L1L2L3

PE

Netzfilter

PE2

GRL1

GRL2

GRL3

U1

GR+

GR-

+

+

X5/1

X5/5

X5/4

X5/8

SPW TRI

Spg.Versorg.

Brücke A-B

Netzfreigabe

Signal

Spg. Versorg.

X2

X1

X4/2

X4/1

R2B2US2

A2

X3/2

X3/1

R1B1US1

A1

TM

TP

-Ud

+Ud

NC

NC

0V/24

0V/24

NC

-15V

NC

UZWK

0V/15

0V/15

0V/15

0V/15

+24V

+24V

+15V

+15V

+8V

+8V

NC

Relais

IPrim-

IPrim+

NC

NC

TDW1-

TDW1+

X6/26

X6/25

X6/24

X6/23

X6/22

X6/21

X6/20

X6/19

X6/18

X6/17

X6/16

X6/15

X6/14

X6/13

X6/12

X6/11

X6/10

X6/9

X6/8

X6/7

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

+24V

+15V

0V/24

0V

-15V
+8V

UZWK

D C 2 3 1

A1-

Gleichrichter auf Kühlkörper

Ringkern

F1

6.3AT

Überspannungsableiter

PE

L1L2L3

Q1-

T1T3T2

L1L2L3

A1-L1

A1-L2

A1-L3

PE-

T?

1

A1-PE

PE1-

T?

1

A1-PE2

PE2-

1

Ringkern

n=5Wdg.

Ringkern

n=2Wdg.

Ringkern

T?

PE1-

ABCDEFGHJKLMNPRSTUV

PE

NC

Poti IH

NC

Polwendung PWS

Uref.10V

NC

NC0VNC

NC

FR-Typ1

FR-Typ2

NCNCNCNCNC

NC

X2-

1

Uref. 10V

2

Poti IH

3

FR-Typ2

4

0V

5

PWS

6

FR-Typ1

1

?T2

1

Schalter PWS

3

IGR0-

40V5

Relais+

6

IGRO+

2

Relais-

1 2

?T

L1-

A3-X2/1

X1/1
X1/2
X1/3
X1/4

1:2000

S W 1

A2-

1

+15V

2

M

3

-15V

1

+15V

2

M

3

-15V

T1?T1.1?

21

T2?T2.1?

F1-

80°C

Temp Pri.-Kühler

T1?T1.1?

21

T2?T2.1?

F2-

Temp Trafo

140°C

T1?T1.1?

21

T2?T2.1?

F3-

85°C

Temp Sek.-Kühler

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26NC

NC

+15V

+15V

+5V

+5V

0V

0V

NC

NC

0V

0V

OE

NC

NC

NC

Drehg.-A

NC

Drehg.-A

NC

CLK

CLK

CS2

CS1

RD

WR1

X2/26

X2/25

X2/24

X2/23

X2/22

X2/21

X2/20

X2/19

X2/18

X2/17

X2/16

X2/15

X2/14

X2/13

X2/12

X2/11

X2/10

X2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

TDW1-
TDW2+
TDW2-

TDW1+

Iprim+

Iprim-

Relais

NC
+8V

+8V
+15V
+15V
+24V
+24V

0V/15
0V/15
0V/15
0V/15

UZWK

NC

-15V
NC

0V/24
0V/24

NC
NC

X5

Inverter+Stromversorgung

X2

Bedienfeld

X3/1

X3/2

X3/3

X3/4

X3/5

X3/6

X3/7

X3/8

X3/9

X3/10

X3/11

X3/12

X3

Peripherie

X7/1

X7/2

X7/3

X7/4

X7/5

X7/6

X7

PWS

X4/1
X4/2
X4/3
X4/4

X4

Mess-Stromwandler

X5/6

X5/5

X5/4

X5/3

X5/2

X5/1

X5

Fernsteller

T R D C 5

A4-

X6/1

1

Temp. Pri.2Temp. Sek.3Lüfter+4Temp. Trafo

6

U2-7Temp. Pri.8Temp. Sek.9Lüfter-10Temp. Trafo

12

U2+

rt

T1?

1

X4-

2 sw

T2?

+24V

Lüfter

M1-

+

-

1

U2-

2

U2+

1

L1-

X3/1

X2/1

X1/2

X1/1

C E L L 1

A3-

-

PE

DW+

T+

DW-

T1

A1

E1

A2

E3

V1An=je 2Wdg.

4

0V

Ringkern

X1-

?T

EA

sw

br

2n2F

PE

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26

RD
CS1
CS2

WR1

CLK
CLK

NC

Drehg.-A

NC

Drehg.-A

NC
NC
NC
OE
0V
0V
NC
NC
0V

0V
+5V
+5V

+15V
+15V

NC

NC

T 2 0 1 / 2

X1

Bedienfeld

PE

A5-

+

+

-

-

L1L2L3

PE

Netzfilter

PE2

GRL1

GRL2

GRL3

U1

GR+

GR-

+

+

X5/1

X5/5

X5/4

X5/8

SPW TRI

Spg.Versorg.

Brücke A-B

Netzfreigabe

Signal

Spg. Versorg.

X2

X1

X4/2

X4/1

R2B2US2

A2

X3/2

X3/1

R1B1US1

A1

TM

TP

-Ud

+Ud

NC

NC

0V/24

0V/24

NC

-15V

NC

UZWK

0V/15

0V/15

0V/15

0V/15

+24V

+24V

+15V

+15V

+8V

+8V

NC

Relais

IPrim-

IPrim+

NC

NC

TDW1-

TDW1+

X6/26

X6/25

X6/24

X6/23

X6/22

X6/21

X6/20

X6/19

X6/18

X6/17

X6/16

X6/15

X6/14

X6/13

X6/12

X6/11

X6/10

X6/9

X6/8

X6/7

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

+24V

+15V

0V/24

0V

-15V
+8V

UZWK

D C 2 3 1

A1-

Gleichrichter auf Kühlkörper

Ringkern

F1

6.3AT

Überspannungsableiter

PE

L1L2L3

Q1-

T1T3T2

L1L2L3

A1-L1

A1-L2

A1-L3

PE-

T?

1

A1-PE

PE1-

T?

1

A1-PE2

PE2-

1

Ringkern

n=5Wdg.

Ringkern

n=2Wdg.

Ringkern

T?

PE1-

ABCDEFGHJKLMNPRSTUV

PE

NC

Poti IH

NC

Polwendung PWS

Uref.10V

NC

NC0VNC

NC

FR-Typ1

FR-Typ2

NCNCNCNCNC

NC

X2-

1

Uref. 10V

2

Poti IH

3

FR-Typ2

4

0V

5

PWS

6

FR-Typ1

1

?T2

1

Schalter PWS

3

IGR0-

40V5

Relais+

6

IGRO+

2

Relais-

1 2

?T

L1-

A3-X2/1

X1/1
X1/2
X1/3
X1/4

1:2000

S W 1

A2-

1

+15V

2

M

3

-15V

1

+15V

2

M

3

-15V

T1?T1.1?

21

T2?T2.1?

F1-

80°C

Temp Pri.-Kühler

T1?T1.1?

21

T2?T2.1?

F2-

Temp Trafo

140°C

T1?T1.1?

21

T2?T2.1?

F3-

85°C

Temp Sek.-Kühler

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26NC

NC

+15V

+15V

+5V

+5V

0V

0V

NC

NC

0V

0V

OE

NC

NC

NC

Drehg.-A

NC

Drehg.-A

NC

CLK

CLK

CS2

CS1

RD

WR1

X2/26

X2/25

X2/24

X2/23

X2/22

X2/21

X2/20

X2/19

X2/18

X2/17

X2/16

X2/15

X2/14

X2/13

X2/12

X2/11

X2/10

X2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

TDW1­TDW2+
TDW2-

TDW1+

Iprim+

Iprim-

Relais

NC
+8V

+8V
+15V
+15V
+24V
+24V

0V/15
0V/15
0V/15
0V/15

UZWK

NC

-15V
NC

0V/24
0V/24

NC
NC

X5

Inverter+Stromversorgung

X2

Bedienfeld

X3/1

X3/2

X3/3

X3/4

X3/5

X3/6

X3/7

X3/8

X3/9

X3/10

X3/11

X3/12

X3

Peripherie

X7/1

X7/2

X7/3

X7/4

X7/5

X7/6

X7

PWS

X4/1
X4/2
X4/3
X4/4

X4

Mess-Stromwandler

X5/6

X5/5

X5/4

X5/3

X5/2

X5/1

X5

Fernsteller

T R D C 5

A4-

X6/1

1

Temp. Pri.2Temp. Sek.3Lüfter+4Temp. Trafo

6

U2-7Temp. Pri.8Temp. Sek.9Lüfter-10Temp. Trafo

12

U2+

rt

T1?

1

X4-

2 sw

T2?

+24V

Lüfter

M1-

+

-

1

U2-

2

U2+

1

L1-

X3/1

X2/1

X1/2

X1/1

C E L L 1

A3-

-

PE

DW+

T+

DW-

T1

A1

E1

A2

E3

V1An=je 2Wdg.

4

0V

Ringkern

X1-

?T

EA

sw

br

2n2F

PE

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26

RD
CS1
CS2

WR1

CLK
CLK

NC

Drehg.-A

NC

Drehg.-A

NC
NC
NC
OE
0V
0V
NC
NC
0V

0V
+5V
+5V

+15V
+15V

NC

NC

T 2 0 1 / 2

X1

Bedienfeld

PE

A5-

+

+

-

-

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

Änderung-4:

Änderung-3:

Änderung-2:

Änderung-1:

28.04.2004 NIEDENTHAL

Blatt: /1

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

1

PICO 260 CEL

Z02065-00

Zeichnungsnummer:

ELEK-GERAET, 3X400V

Figure 12-4

Circuit diagrams

PICO 260 CEL PWS

48 Item No.: 099-002032-EWM01

12.5 PICO 260 CEL PWS

L1L2L3

PE

Netzfilter

PE2

GRL1

GRL2

GRL3

U1

GR+

GR-

+

+

X5/1

X5/5

X5/4

X5/8

SPW TRI

Spg.Versorg.

Brücke A-B

Netzfreigabe

Signal

Spg. Versorg.

X2

X1

X4/2

X4/1

R2B2US2

A2

X3/2

X3/1

R1B1US1

A1

TM

TP

-Ud

+Ud

NC

NC

0V/24

0V/24

NC

-15V

NC

UZWK

0V/15

0V/15

0V/15

0V/15

+24V

+24V

+15V

+15V

+8V

+8V

NC

Relais

IPrim-

IPrim+

NC

NC

TDW1-

TDW1+

X6/26

X6/25

X6/24

X6/23

X6/22

X6/21

X6/20

X6/19

X6/18

X6/17

X6/16

X6/15

X6/14

X6/13

X6/12

X6/11

X6/10

X6/9

X6/8

X6/7

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

+24V

+15V

0V/24

0V

-15V
+8V

UZWK

D C 2 3 1

A1-

Gleichrichter auf Kühlkörper

Ringkern

F1

6.3AT

Überspannungsableiter

PE

L1L2L3

Q1-

T1T3T2

L1L2L3

A1-L1

A1-L2

A1-

L3

PE-

T?

1

A1-PE

PE1-

T?

1

A1-PE2

PE2-

1

Ringkern

n=5Wdg.

Ringkern

n=2Wdg.

Ringkern

T?

PE1-

ABCDEFGHJKLMNPRSTUV

PE

NC

Poti IH

NC

Polwendung PWS

Uref.10V

NC

NC0VNC

NC

FR-Typ1

FR-Typ2

NCNCNCNCNC

NC

X2-

1

Uref. 10V

2

Poti IH

3

FR-Typ2

4

0V

5

PWS

6

FR-Typ1

1

?T2

T1-

42V

0V

415V

400V

0V

551

1

799

7

1

2

F5-

1

2

F4-

1

F4-

2

F4-

1

F5-

2

F5-

1

Schalter PWS

3

IGR0-

40V5

Relais+

6

IGRO+

2

Relais-

1 2

?T

L1-

A3-X2/1

X1/1
X1/2
X1/3
X1/4

1:2000

S W 1

A2-

1

+15V

2

M

3

-15V

1

+15V

2

M

3

-15V

T1?T1.1?

21

T2?T2.1?

F1-

80°C

Temp Pri.-Kühler

T1?T1.1?

21

T2?T2.1?

F2-

Temp Trafo

140°C

T1?T1.1?

21

T2?T2.1?

F3-

85°C

Temp Sek.-Kühler

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26NC

NC

+15V

+15V

+5V

+5V

0V

0V

NC

NC

0V

0V

OE

NC

NC

NC

Drehg.-A

NC

Drehg.-A

NC

CLK

CLK

CS2

CS1

RD

WR1

X2/26

X2/25

X2/24

X2/23

X2/22

X2/21

X2/20

X2/19

X2/18

X2/17

X2/16

X2/15

X2/14

X2/13

X2/12

X2/11

X2/10

X2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

TDW1-

TDW2+

TDW2-

TDW1+

Iprim+

Iprim-

Relais

NC
+8V
+8V

+15V
+15V
+24V

+24V
0V/15
0V/15
0V/15
0V/15

UZWK

NC

-15V
NC

0V/24
0V/24

NC
NC

X5

Inverter+Stromversorgung

X2

Bedienfeld

X3/1

X3/2

X3/3

X3/4

X3/5

X3/6

X3/7

X3/8

X3/9

X3/10

X3/11

X3/12

X3

Peripherie

X7/1

X7/2

X7/3

X7/4

X7/5

X7/6

X7

PWS

X4/1
X4/2
X4/3
X4/4

X4

Mess-Stromwandler

X5/6

X5/5

X5/4

X5/3

X5/2

X5/1

X5

Fernsteller

T R D C 5

A4-

X6/1

1

Temp. Pri.2Temp. Sek.3Lüfter+4Temp. Trafo

6

U2-7Temp. Pri.8Temp. Sek.9Lüfter-10Temp. Trafo

12

U2+

rt

T1?

1

X4-

2 sw

T2?

+24V

Lüfter

M1-

+

-

1

U2-

2

U2+

K1

K2-

+

+

+

-

1

A
1

1B 1

1

L1-

X3/1

X2/1

X1/2

X1/1

C E L L 1

A3-

-

PE

DW+

T+

DW-

T2

A1

E1

A2

E3

V1An=je 2Wdg.

4

0V

Ringkern

L1

Q
1

-

L2

Q
1

-

2x0.316A

1

C
1

X3/2

X3/1

X3/3

X2/3

X2/2

X2/1

X2/4

F1

0.5AT

X4/2

X4/1

X4/3

X1/2

X1/1

R E L A I S 2 / 1 5

A6-

A6-X3/1

A6-X3/2

A6-X2/1

A6-X2/2

A6-X2/3

2

Relais-

1

Relais+

11

A
1

11

B
1

11

C
1

X1-

?T

EA

sw

br

2n2F

PE

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26

RD
CS1
CS2

WR1

CLK
CLK

NC

Drehg.-A

NC

Drehg.-A

NC
NC
NC
OE

0V

0V
NC
NC

0V

0V

+5V

+5V
+15V
+15V

NC
NC

T 2 0 1 / 2

X1

Bedienfeld

PE

A5-

1

2

PWS

S1-

1

PWS20V

L1L2L3

PE

Netzfilter

PE2

GRL1

GRL2

GRL3

U1

GR+

GR-

+

+

X5/1

X5/5

X5/4

X5/8

SPW TRI

Spg.Versorg.

Brücke A-B

Netzfreigabe

Signal

Spg. Versorg.

X2

X1

X4/2

X4/1

R2B2US2

A2

X3/2

X3/1

R1B1US1

A1

TM

TP

-Ud

+Ud

NC

NC

0V/24

0V/24

NC

-15V

NC

UZWK

0V/15

0V/15

0V/15

0V/15

+24V

+24V

+15V

+15V

+8V

+8V

NC

Relais

IPrim-

IPrim+

NC

NC

TDW1-

TDW1+

X6/26

X6/25

X6/24

X6/23

X6/22

X6/21

X6/20

X6/19

X6/18

X6/17

X6/16

X6/15

X6/14

X6/13

X6/12

X6/11

X6/10

X6/9

X6/8

X6/7

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

+24V

+15V

0V/24

0V

-15V
+8V

UZWK

D C 2 3 1

A1-

Gleichrichter auf Kühlkörper

Ringkern

F1

6.3AT

Überspannungsableiter

PE

L1L2L3

Q1-

T1T3T2

L1L2L3

A1-L1

A1-L2

A1-

L3

PE-

T?

1

A1-PE

PE1-

T?

1

A1-PE2

PE2-

1

Ringkern

n=5Wdg.

Ringkern

n=2Wdg.

Ringkern

T?

PE1-

ABCDEFGHJKLMNPRSTUV

PE

NC

Poti IH

NC

Polwendung PWS

Uref.10V

NC

NC0VNC

NC

FR-Typ1

FR-Typ2

NCNCNCNCNC

NC

X2-

1

Uref. 10V

2

Poti IH

3

FR-Typ2

4

0V

5

PWS

6

FR-Typ1

1

?T2

T1-

42V

0V

415V

400V

0V

551

1

799

7

1

2

F5-

1

2

F4-

1

F4-

2

F4-

1

F5-

2

F5-

1

Schalter PWS

3

IGR0-

40V5

Relais+

6

IGRO+

2

Relais-

1 2

?T

L1-

A3-X2/1

X1/1
X1/2
X1/3
X1/4

1:2000

S W 1

A2-

1

+15V

2

M

3

-15V

1

+15V

2

M

3

-15V

T1?T1.1?

21

T2?T2.1?

F1-

80°C

Temp Pri.-Kühler

T1?T1.1?

21

T2?T2.1?

F2-

Temp Trafo

140°C

T1?T1.1?

21

T2?T2.1?

F3-

85°C

Temp Sek.-Kühler

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26NC

NC

+15V

+15V

+5V

+5V

0V

0V

NC

NC

0V

0V

OE

NC

NC

NC

Drehg.-A

NC

Drehg.-A

NC

CLK

CLK

CS2

CS1

RD

WR1

X2/26

X2/25

X2/24

X2/23

X2/22

X2/21

X2/20

X2/19

X2/18

X2/17

X2/16

X2/15

X2/14

X2/13

X2/12

X2/11

X2/10

X2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

TDW1-

TDW2+

TDW2-

TDW1+

Iprim+

Iprim-

Relais

NC
+8V
+8V

+15V
+15V
+24V

+24V
0V/15
0V/15
0V/15
0V/15

UZWK

NC

-15V
NC

0V/24
0V/24

NC
NC

X5

Inverter+Stromversorgung

X2

Bedienfeld

X3/1

X3/2

X3/3

X3/4

X3/5

X3/6

X3/7

X3/8

X3/9

X3/10

X3/11

X3/12

X3

Peripherie

X7/1

X7/2

X7/3

X7/4

X7/5

X7/6

X7

PWS

X4/1
X4/2
X4/3
X4/4

X4

Mess-Stromwandler

X5/6

X5/5

X5/4

X5/3

X5/2

X5/1

X5

Fernsteller

T R D C 5

A4-

X6/1

1

Temp. Pri.2Temp. Sek.3Lüfter+4Temp. Trafo

6

U2-7Temp. Pri.8Temp. Sek.9Lüfter-10Temp. Trafo

12

U2+

rt

T1?

1

X4-

2 sw

T2?

+24V

Lüfter

M1-

+

-

1

U2-

2

U2+

K1

K2-

+

+

+

-

1

A
1

1B 1

1

L1-

X3/1

X2/1

X1/2

X1/1

C E L L 1

A3-

-

PE

DW+

T+

DW-

T2

A1

E1

A2

E3

V1An=je 2Wdg.

4

0V

Ringkern

L1

Q
1

-

L2

Q
1

-

2x0.316A

1

C
1

X3/2

X3/1

X3/3

X2/3

X2/2

X2/1

X2/4

F1

0.5AT

X4/2

X4/1

X4/3

X1/2

X1/1

R E L A I S 2 / 1 5

A6-

A6-X3/1

A6-X3/2

A6-X2/1

A6-X2/2

A6-X2/3

2

Relais-

1

Relais+

11

A
1

11

B
1

11

C
1

X1-

?T

EA

sw

br

2n2F

PE

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26

RD
CS1
CS2

WR1

CLK
CLK

NC

Drehg.-A

NC

Drehg.-A

NC
NC
NC
OE

0V

0V
NC
NC

0V

0V

+5V

+5V
+15V
+15V

NC
NC

T 2 0 1 / 2

X1

Bedienfeld

PE

A5-

1

2

PWS

S1-

1

PWS20V

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

Änderung-4:

Änderung-3:

Änderung-2:

Änderung-1:

28.04.2004 NIEDENTHAL

Blatt: /1

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

1

PICO 260 CEL-PWS

Z02064-00

Zeichnungsnummer:

ELEK-GERAET

Figure 12-5

Circuit diagrams

PICO 300

Item No.: 099-002032-EWM01 49

12.6 PICO 300

L1L2L3

PE

Netzfilter

PE2

GRL1

GRL2

GRL3

U1

GR+

GR-

+

+

X5/1

X5/5

X5/4

X5/8

SPW TRI

Spg.Versorg.

Brücke A-B

Netzfreigabe

Signal

Spg. Versorg.

X2

X1

X4/2

X4/1

R2B2US2

A2

X3/2

X3/1

R1B1US1

A1

TM

TP

-Ud

+Ud

NC

NC

0V/24

0V/24

NC

-15V

NC

UZWK

0V/15

0V/15

0V/15

0V/15

+24V

+24V

+15V

+15V

+8V

+8V

NC

Relais

IPrim-

IPrim+

NC

NC

TDW1-

TDW1+

X6/26

X6/25

X6/24

X6/23

X6/22

X6/21

X6/20

X6/19

X6/18

X6/17

X6/16

X6/15

X6/14

X6/13

X6/12

X6/11

X6/10

X6/9

X6/8

X6/7

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

+24V

+15V

0V/24

0V

-15V
+8V

UZWK

D C 2 3 1

A1-

Gleichrichter auf Kühlkörper

Ringkern

F1

6.3AT

Überspa nnungsable iter

PE

L1L2L3

A1-L1

A1-L2

A1-L3

PE-

T?

1

A1-PE

PE1-

T?

1

A1-PE2

PE2-

1

Ringkern

n=5Wdg.

Ringkern

n=2Wdg.

Ringkern

T?

PE1-

ABCDEFGHJKLMNPRSTUV

PE

NC

Poti IH

NC

Polwendung PWS

Uref.10V

NC

NC0VNC

NC

FR-Typ1

FR-Typ2

NCNCNCNCNC

NC

X2-

1

Uref. 10V

2

Poti IH

3

FR-Typ2

4

0V

5

PWS

6

FR-Typ1

1

?T2

1

Schalter PWS

3

IGR0-

40V5

Relais+

6

IGRO+

2

Relais-

1 2

?T

L1-

X1/1
X1/2
X1/3
X1/4

1:2000

S W 1

A2-

1

+15V

2

M

3

-15V

1

+15V

2

M

3

-15V

T1?T1.1?

21

T2?T2.1?

F1-

80°C

Temp Pri.-Kühler

T1?T1.1?

21

T2?T2.1?

F2-

Temp Tra fo

140°C

T1?T1.1?

21

T2?T2.1?

F3-

85°C

Temp Sek.-Kühler

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26NC

NC

+15V

+15V

+5V

+5V

0V

0V

NC

NC

0V

0V

OE

NC

NC

NC

Drehg.-A

NC

Drehg.-A

NC

CLK

CLK

CS2

CS1

RD

WR1

X2/26

X2/25

X2/24

X2/23

X2/22

X2/21

X2/20

X2/19

X2/18

X2/17

X2/16

X2/15

X2/14

X2/13

X2/12

X2/11

X2/10

X2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

TDW1-

TDW2+

TDW2-

TDW1+

Iprim+
Iprim­Relais

NC
+8V
+8V

+15V
+15V
+24V

+24V
0V/15
0V/15
0V/15
0V/15

UZWK

NC

-15V
NC

0V/24
0V/24

NC
NC

X5

Inverter+Stromversorgung

X2

Bedienfeld

X3/1

X3/2

X3/3

X3/4

X3/5

X3/6

X3/7

X3/8

X3/9

X3/10

X3/11

X3/12

X3

Peripherie

X7/1

X7/2

X7/3

X7/4

X7/5

X7/6

X7

PWS

X4/1
X4/2
X4/3
X4/4

X4

Mess-Stromwandler

X5/6

X5/5

X5/4

X5/3

X5/2

X5/1

X5

Fernsteller

T R D C 5

A4-

X6/1

1

Temp. Pri.2Temp. Sek.3Lüfter+4Temp. Trafo6U2-7Temp. Pri.8Temp. Sek.9Lüfter-10Temp. Trafo12U2+

rt

T1?

1

X4-

2 sw

T2?

+24V

Lüfter

M1-

+

-

1

U2-

2

U2+

T1-

A1

E1

A2

E3

4

0V

Ringkern

X1-

?T

EA

sw

br

2n2F

PE

-

-

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26

RD
CS1
CS2

WR1

CLK
CLK

NC

Drehg.-A

NC

Drehg.-A

NC
NC
NC
OE
0V
0V
NC
NC
0V

0V
+5V
+5V

+15V
+15V

NC

NC

T 2 0 1 / 2

X1

Bedienfeld

PE

A5-

+

+

X1/2

X1/1

PE

A3-

K O N 2

V1

Q1-

L2L3L1 T1

T2

T3

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

28.09.2006 NIEDENTHAL

Blatt: / 1

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

1

PICO 300

4441-00

Zeichnungsnummer:

ELEK-GERAET, 3X400V

Änderung-

Änderung-

Änderung-

Änderung-

Figure 12-6

Circuit diagrams

PICO 300 CEL

50 Item No.: 099-002032-EWM01

12.7 PICO 300 CEL

L1L2L3

PE

Netzfilter

PE2

GRL1

GRL2

GRL3

U1

GR+

GR-

+

+

X5/1

X5/5

X5/4

X5/8

SPW TRI

Spg.Versorg.

Brücke A-B

Netzfreigabe

Signal

Spg. Versorg.

X2

X1

X4/2

X4/1

R2B2US2

A2

X3/2

X3/1

R1B1US1

A1

TM

TP

-Ud

+Ud

NC

NC

0V/24

0V/24

NC

-15V

NC

UZWK

0V/15

0V/15

0V/15

0V/15

+24V

+24V

+15V

+15V

+8V

+8V

NC

Relais

IPrim-

IPrim+

NC

NC

TDW1-

TDW1+

X6/26

X6/25

X6/24

X6/23

X6/22

X6/21

X6/20

X6/19

X6/18

X6/17

X6/16

X6/15

X6/14

X6/13

X6/12

X6/11

X6/10

X6/9

X6/8

X6/7

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

+24V

+15V

0V/24

0V

-15V
+8V

UZWK

D C 2 3 1

A1-

Gleichrichter auf Kühlkörper

Ringkern

F1

6.3AT

Überspa nnungsable iter

PE

L1L2L3

A1-L1

A1-L2

A1-L3

PE-

T?

1

A1-PE

PE1-

T?

1

A1-PE2

PE2-

1

Ringkern

n=5Wdg.

Ringkern

n=2Wdg.

Ringkern

T?

PE1-

ABCDEFGHJKLMNPRSTUV

PE

NC

Poti IH

NC

Polwendung PWS

Uref.10V

NC

NC0VNC

NC

FR-Typ1

FR-Typ2

NCNCNCNCNC

NC

X2-

1

Uref. 10V

2

Poti IH

3

FR-Typ2

4

0V

5

PWS

6

FR-Typ1

1

?T2

1

Schalter PWS

3

IGR0-

40V5

Relais+

6

IGRO+

2

Relais-

1 2

?T

L1-

A3-X2/1

X1/1
X1/2
X1/3
X1/4

1:2000

S W 1

A2-

1

+15V

2

M

3

-15V

1

+15V

2

M

3

-15V

T1?T1.1?

21

T2?T2.1?

F1-

80°C

Temp Pri.-Kühler

T1?T1.1?

21

T2?T2.1?

F2-

Temp Tra fo

140°C

T1?T1.1?

21

T2?T2.1?

F3-

85°C

Temp Sek.-Kühler

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26NC

NC

+15V

+15V

+5V

+5V

0V

0V

NC

NC

0V

0V

OE

NC

NC

NC

Drehg.-A

NC

Drehg.-A

NC

CLK

CLK

CS2

CS1

RD

WR1

X2/26

X2/25

X2/24

X2/23

X2/22

X2/21

X2/20

X2/19

X2/18

X2/17

X2/16

X2/15

X2/14

X2/13

X2/12

X2/11

X2/10

X2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

TDW1­TDW2+
TDW2-

TDW1+

Iprim+

Iprim­Relais

NC
+8V
+8V

+15V
+15V
+24V

+24V
0V/15
0V/15
0V/15
0V/15

UZWK

NC

-15V
NC

0V/24
0V/24

NC
NC

X5

Inverter+Stromversorgung

X2

Bedienfeld

X3/1

X3/2

X3/3

X3/4

X3/5

X3/6

X3/7

X3/8

X3/9

X3/10

X3/11

X3/12

X3

Peripherie

X7/1

X7/2

X7/3

X7/4

X7/5

X7/6

X7

PWS

X4/1
X4/2
X4/3
X4/4

X4

Mess-Stromwandler

X5/6

X5/5

X5/4

X5/3

X5/2

X5/1

X5

Fernsteller

T R D C 5

A4-

X6/1

1

Temp. Pri.2Temp. Sek.3Lüfter+4Temp. Trafo6U2-7Temp. Pri.8Temp. Sek.9Lüfter-10Temp. Trafo12U2+

rt

T1?

1

X4-

2 sw

T2?

+24V

Lüfter

M1-

+

-

1

U2-

2

U2+

1

L1-

X3/1

X2/1

X1/2

X1/1

C E L L 1

A3-

-

PE

DW+

T+

DW-

T1-

A1

E1

A2

E3

V1An=je 2Wdg.

4

0V

Ringkern

X1-

?T

EA

sw

br

2n2F

PE

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26

RD
CS1
CS2

WR1

CLK
CLK

NC

Drehg.-A

NC

Drehg.-A

NC
NC
NC
OE

0V

0V
NC
NC

0V

0V

+5V

+5V
+15V
+15V

NC
NC

T 2 0 1 / 2

X1

Bedienfeld

PE

A5-

+

-

Q1-

L2L3L1 T1

T2

T3

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

28.09.2006 NIEDENTHAL

Blatt: / 1

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

1

PICO 300 CEL

4439-00

Zeichnungsnummer:

ELEK-GERAET, 3X400V

Änderung-

Änderung-

Änderung-

Änderung-

Figure 12-7

Circuit diagrams

PICO 300 CEL PWS

Item No.: 099-002032-EWM01 51

12.8 PICO 300 CEL PWS

L1L2L3

PE

Netzfilter

PE2

GRL1

GRL2

GRL3

U1

GR+

GR-

+

+

X5/1

X5/5

X5/4

X5/8

SPW TRI

Spg.Versorg.

Brücke A-B

Netzfreigabe

Signal

Spg. Versorg.

X2

X1

X4/2

X4/1

R2B2US2

A2

X3/2

X3/1

R1B1US1

A1

TM

TP

-Ud

+Ud

NC

NC

0V/24

0V/24

NC

-15V

NC

UZWK

0V/15

0V/15

0V/15

0V/15

+24V

+24V

+15V

+15V

+8V

+8V

NC

Relais

IPrim-

IPrim+

NC

NC

TDW1-

TDW1+

X6/26

X6/25

X6/24

X6/23

X6/22

X6/21

X6/20

X6/19

X6/18

X6/17

X6/16

X6/15

X6/14

X6/13

X6/12

X6/11

X6/10

X6/9

X6/8

X6/7

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

+24V

+15V

0V/24

0V

-15V
+8V

UZWK

D C 2 3 1

A1-

Gleichrichter auf Kühlkörper

Ringkern

F1

6.3AT

Überspa nnungsable iter

PE

L1L2L3

A1-L1

A1-L2

A1-L3

PE-

T?

1

A1-PE

PE1-

T?

1

A1-PE2

PE2-

1

Ringkern

n=5Wdg.

Ringkern

n=2Wdg.

Ringkern

T?

PE1-

ABCDEFGHJKLMNPRSTUV

PE

NC

Poti IH

NC

Polwendung PWS

Uref.10V

NC

NC0VNC

NC

FR-Typ1

FR-Typ2

NCNCNCNCNC

NC

X2-

1

Uref. 10V

2

Poti IH

3

FR-Typ2

4

0V

5

PWS

6

FR-Typ1

1

?T2

T1-

42V

0V

415V

400V

0V

551

1

799

7

1

2

F1-

1

2

F2-

1

F4-

2

F4-

1

F5-

2

F5-

1

Schalter PWS

3

IGR0-

40V5

Relais+

6

IGRO+

2

Relais-

1 2

?T

L1-

A3-X2/1

X1/1
X1/2
X1/3
X1/4

1:2000

S W 1

A2-

1

+15V

2

M

3

-15V

1

+15V

2

M

3

-15V

T1?T1.1?

21

T2?T2.1?

F1-

80°C

Temp Pri.-Kühler

T1?T1.1?

21

T2?T2.1?

F2-

Temp Tra fo

140°C

T1?T1.1?

21

T2?T2.1?

F3-

85°C

Temp Sek.-Kühler

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26NC

NC

+15V

+15V

+5V

+5V

0V

0V

NC

NC

0V

0V

OE

NC

NC

NC

Drehg.-A

NC

Drehg.-A

NC

CLK

CLK

CS2

CS1

RD

WR1

X2/26

X2/25

X2/24

X2/23

X2/22

X2/21

X2/20

X2/19

X2/18

X2/17

X2/16

X2/15

X2/14

X2/13

X2/12

X2/11

X2/10

X2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

TDW1-

TDW2+

TDW2-

TDW1+

Iprim+
Iprim­Relais

NC
+8V
+8V

+15V
+15V
+24V

+24V
0V/15
0V/15
0V/15
0V/15

UZWK

NC

-15V
NC

0V/24
0V/24

NC
NC

X5

Inverter+Stromversorgung

X2

Bedienfeld

X3/1

X3/2

X3/3

X3/4

X3/5

X3/6

X3/7

X3/8

X3/9

X3/10

X3/11

X3/12

X3

Peripherie

X7/1

X7/2

X7/3

X7/4

X7/5

X7/6

X7

PWS

X4/1
X4/2
X4/3
X4/4

X4

Mess-Stromwandler

X5/6

X5/5

X5/4

X5/3

X5/2

X5/1

X5

Fernsteller

T R D C 5

A4-

X6/1

1

Temp. Pri.2Temp. Sek.3Lüfter+4Temp. Trafo6U2-7Temp. Pri.8Temp. Sek.9Lüfter-10Temp. Trafo12U2+

rt

T1?

1

X4-

2 sw

T2?

+24V

Lüfter

M1-

+

-

1

U2-

2

U2+

K1-

K2-

+

-

1A 1

1

B
1

1

L1-

X3/1

X2/1

X1/2

X1/1

C E L L 1

A3-

-

PE

DW+

T+

DW-

T2-

A1

E1

A2

E3

V1An=je 2Wdg.

4

0V

Ringkern

T1

Q1-T2

Q1-

2x0.316A

1C 1

X3/2

X3/1

X3/3

X2/3

X2/2

X2/1

X2/4

F1

0.5AT

X4/2

X4/1

X4/3

X1/2

X1/1

R E L A I S 2 / 1 5

A6-

A6-X3/1

A6-X3/2

A6-X2/1

A6-X2/2

A6-X2/3

2

Relais-1Relais+

11A 1

11B 1

11

C
1

X1-

?T

EA

sw

br

2n2F

PE

X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8

X1/9
X1/10
X1/11
X1/12
X1/13
X1/14
X1/15
X1/16
X1/17
X1/18
X1/19
X1/20
X1/21
X1/22
X1/23
X1/24
X1/25
X1/26

RD
CS1
CS2

WR1

CLK
CLK

NC

Drehg.-A

NC

Drehg.-A

NC
NC
NC
OE

0V

0V
NC
NC
0V

0V

+5V

+5V
+15V
+15V

NC
NC

T 2 0 1 / 2

X1

Bedienfeld

PE

A5-

1

2

PWS

S1-

1

PWS20V

Q1-

L2L3L1 T1

T2

T3

Datum: Name:

gezeichnet:

geprüft:

Freigabe:

28.09.2006 NIEDENTHAL

Blatt: / 1

This drawing is protected by copyright.

It may not be reproduced or utilised in any way

or communicated or forwarded to third parties

without our express permission!

1

PICO 300 CEL-PWS

4440-00

Zeichnungsnummer:

ELEK-GERAET, 3X400V

Änderung-

Änderung-

Änderung-

Änderung-

Figure 12-8

Appendix A

Declaration of Conformity

52 Item No.: 099-002032-EWM01

13 Appendix A

13.1 Declaration of Conformity

Originaldokument

liegt jedem Gerät bei!

Original document

is enclosed with each machine!

Document original

est joint à toute machine!

EG - Konformitätserklärung

EC – Declaration of Conformity

Déclaration de Conformité CE

Name des Herstellers:

Name of manufacturer:
Nom du fabricant:

EWM HIGHTEC WELDING GmbH

(nachfolgend EWM genannt)
(In the following called EWM)
(nommé par la suite EWM)

Anschrift des Herstellers:

Address of manufacturer:
Adresse du fabricant:

Dr.- Günter - Henle - Straße 8
D - 56271 Mündersbach – Germany
[e-mail]

Hiermit erklären wir, daß das bezeichne­te Gerät in seiner Konzeption und Bau­art sowie in der von uns in Verkehr
gebrachten Ausführung den grundle­genden Sicherheits-anforderungen der
unten genannten EG- Richtlinien ent­spricht. Im Falle von unbefugten Verän­derungen, unsachgemäßen Reparaturen
Nichteinhaltung der Fristen zur Wieder­holungsprüfung und / oder unerlaubten
Umbauten, die nicht ausdrücklich von
EWM autorisiert sind, verliert diese
Erklärung ihre Gültigkeit.

We hereby declare that the machine below
conforms to the basic safety requirements
of the EC Directives cited both in its design
and construction, and in the version re­leased by us. 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 non­permitted conversion work not specifically
authorised by EWM.

Par la présente, nous déclarons que le
poste, dans sa conception et sa construc­tion, ainsi que dans le modèle mis sur le
marché par nos services ci-dessous, cor­respondent aux directives fondamentales
de sécurité énoncées par l´CE et mention­nées ci-dessous. En cas de changements
non autorisés, de réparations inadéquates,
de non-respect des délais de contrôle en
exploitation et/ou de modifications prohi­bées n’ayant pas été autorisés expressé­ment par EWM, cette déclaration devient
caduque.

Gerätebezeichnung:

Description of the machine:
Déscription de la machine:

Gerätetyp:

Type of machine:
Type de machine:

Artikelnummer EWM:

Article number:
Numéro d´article

Seriennummer:

Serial number:
Numéro de série:

Optionen:

Options:
Options:

keine

none
aucune

Zutreffende EG - Richtlinien:

Applicable EU - guidelines:
Directives de la CE applicables:

EG - Niederspannungsrichtlinie (2006/95/EG)

EC – Low Voltage Directive (2006/95/EG)
Directive CE pour basses tensions (2006/95/EG)

EG- EMV- Richtlinie (2004/108/EG)

EC – EMC Directive (2004/108/ EG)
Directive CE EMV (2004/108/EG)

Angewandte harmonisierte Normen:

Used co-ordinated norms:
Normes harmonisées appliquées:

EN 60974 / IEC 60974 / VDE 0544
EN 50199 / VDE 0544 part 206
GOST-R

Hersteller - Unterschrift:

Manufacturer's signature:

Signature du fabricant:

Michael Szczesny , Geschäftsführer

managing director
gérant

01.2007