EWM Pico 160 cel puls User manual

Operating instructions
EN
Welding machine
Pico 160 cel puls
Pico 160 cel puls VRD (RU)
Pico 160 cel puls VRD (AUS)
099-002129-EW501
Observe additional system documents!
15.10.2020

General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read and observe the operating instructions for all system components, especially the sa-
fety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the location where the machine is operated.
• Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and re-
pair the machine.
• Technical changes due to further development in machine technology may lead to a dif-
fering welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers.
Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No
other form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed ac-
cepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and methods
are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this
reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect
installation, improper operation or incorrect usage and maintenance or any actions connected to this in
any way.
© EWM AG
Dr. Günter-Henle-Strasse 8
56271 Mündersbach Germany
Tel.: [phone], Fax: -244
Email: [email protected]
www.ewm-group.com
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.

Contents
Notes on using these operating instructions
099-002129-EW501
15.10.2020
3
1 Contents
1Contents .......................................................................................................................................... 3
2For your safety ............................................................................................................................... 5
2.1 Notes on using these operating instructions .......................................................................... 5
2.1.1 Explanation of icons ............................................................................................... 5
2.1.2 Complete documentation ....................................................................................... 6
2.2 General .................................................................................................................................. 6
3Intended use ................................................................................................................................... 8
3.1 Applications ............................................................................................................................ 8
3.1.1 Demagnetize function (degaussing) ....................................................................... 8
3.2 Documents which also apply ................................................................................................. 8
3.2.1 Warranty ................................................................................................................. 8
3.2.2 Declaration of Conformity ....................................................................................... 8
3.2.3 Welding in environments with increased electrical hazards ................................... 8
3.2.4 Calibration/Validation ............................................................................................. 8
4Machine description – quick overview ........................................................................................ 9
4.1 Front view .............................................................................................................................. 9
4.2 Rear view ............................................................................................................................. 10
4.3 Machine control – Operating elements ................................................................................ 11
5Design and function ..................................................................................................................... 12
5.1 Transport and installation .................................................................................................... 12
5.1.1 Machine cooling .................................................................................................... 12
5.1.2 Workpiece lead, general ....................................................................................... 12
5.1.3 Ambient conditions ............................................................................................... 13
5.1.3.1 In operation ........................................................................................... 13
5.1.3.2 Transport and storage ........................................................................... 13
5.1.4 Transport belt ....................................................................................................... 13
5.1.4.1 Adjusting the length of the carrying strap ............................................. 13
5.1.5 Notes on the installation of welding current leads ................................................ 14
5.1.6 Stray welding currents .......................................................................................... 15
5.1.7 Mains connection .................................................................................................. 16
5.1.7.1 Mains configuration ............................................................................... 16
5.2 Operating the machine control ............................................................................................. 16
5.3 Machine display ................................................................................................................... 16
5.3.1 Welding power setting .......................................................................................... 16
5.3.2 Welding parameter setting in the operation sequence ......................................... 16
5.3.3 Setting advanced welding parameters (Expert menu) ......................................... 16
5.3.4 Changing basic settings (machine configuration menu) ...................................... 16
5.4 MMA welding ....................................................................................................................... 17
5.4.1 Connecting the electrode holder and workpiece lead .......................................... 17
5.4.2 Welding task selection .......................................................................................... 18
5.4.3 Arcforce ................................................................................................................ 18
5.4.4 Hotstart ................................................................................................................. 18
5.4.5 Antistick ................................................................................................................ 19
5.4.6 Average value pulse welding ................................................................................ 19
5.4.7 Expert menu (MMA) ............................................................................................. 20
5.5 TIG welding .......................................................................................................................... 21
5.5.1 Connecting a TIG welding torch with rotating gas valve ...................................... 21
5.5.2 Shielding gas supply (shielding gas cylinder for welding machine) ..................... 21
5.5.3 Pressure regulator connection ............................................................................. 22
5.5.4 Welding task selection .......................................................................................... 22
5.5.5 Gas test – setting the shielding gas volume ......................................................... 22
5.5.6 Arc ignition ............................................................................................................ 23
5.5.6.1 Liftarc .................................................................................................... 23
5.5.7 Average value pulse welding ................................................................................ 23
5.5.8 Expert menu (TIG) ................................................................................................ 24
5.6 Degaussing .......................................................................................................................... 25
5.6.1 Description of procedure ...................................................................................... 25
5.6.2 Notes on laying power cables .............................................................................. 25

Contents
Notes on using these operating instructions
4
099-002129-EW501
15.10.2020
5.6.3 Generating an opposing magnetic field during welding (activgauss) ................... 26
5.6.3.1 Automatic cut-out .................................................................................. 28
5.6.4 Decommissioning ................................................................................................. 28
5.7 Remote control ..................................................................................................................... 28
5.8 Arc length restriction (USP).................................................................................................. 28
5.9 Power-saving mode (Standby) ............................................................................................. 29
5.10 Voltage reducing device ....................................................................................................... 29
5.11 Access control ...................................................................................................................... 29
5.12 Machine configuration menu ................................................................................................ 30
6Maintenance, care and disposal ................................................................................................. 32
6.1 General................................................................................................................................. 32
6.1.1 Cleaning ................................................................................................................ 32
6.1.2 Dirt filter................................................................................................................. 32
6.2 Maintenance work, intervals ................................................................................................ 33
6.2.1 Daily maintenance tasks ....................................................................................... 33
6.2.2 Monthly maintenance tasks .................................................................................. 33
6.2.3 Annual test (inspection and testing during operation) .......................................... 33
6.3 Disposing of equipment ........................................................................................................ 34
7Rectifying faults............................................................................................................................ 35
7.1 Error messages (power source) ........................................................................................... 35
7.2 Checklist for rectifying faults ................................................................................................ 36
7.3 Display machine control software version ............................................................................ 36
7.4 Dynamic power adjustment .................................................................................................. 36
7.5 Resetting welding parameters to the factory settings .......................................................... 37
8Technical data............................................................................................................................... 38
8.1 Pico 160 cel puls .................................................................................................................. 38
9Accessories .................................................................................................................................. 39
9.1 Electrode holder / workpiece lead ........................................................................................ 39
9.2 Remote controls and accessories ........................................................................................ 39
9.3 TIG welding torch ................................................................................................................. 39
9.4 General accessories ............................................................................................................ 39
9.5 Options ................................................................................................................................. 39
9.6 Degaussing .......................................................................................................................... 39
10 Service documents ...................................................................................................................... 40
10.1 Spare and replacement parts ............................................................................................... 40
10.2 Circuit diagram ..................................................................................................................... 42
11 Appendix ....................................................................................................................................... 43
11.1 Parameter overview – setting ranges .................................................................................. 43
11.2 Guide values of magnetic flux density, weldability ............................................................... 44
11.3 Searching for a dealer .......................................................................................................... 45

For your safety
Notes on using these operating instructions
099-002129-EW501
15.10.2020
5
2 For your safety
2.1 Notes on using these operating instructions
2.1.1 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the u-
ser must observe.
Activate and release / Tap / Tip
Switch off machine
Release
Switch on machine
Press and hold
Switch
Incorrect / Invalid
Turn
Correct / Valid
Numerical value – adjustable
Input
Signal light lights up in green
Navigation
Signal light flashes green
Output
Signal light lights up in red
Time representation (e.g.: wait 4 s / ac-
tuate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use

For your safety
General
6
099-002129-EW501
15.10.2020
2.1.2 Complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with the "Safety instructions”!
Read and observe the documents for all system components!
Figure 2-1
Item
Documentation
A.1
Safety instructions
A.2
Power source
A.3
Electrode holder/welding torch
A.4
Remote control
A
Complete documentation
2.2 General
CAUTION
Obligations of the operator!
The respective national directives and laws must be complied with when operating the
machine!
• Implementation of national legislation relating to framework directive 89/391/EEC on the int-
roduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
• In particular, directive 89/655/EEC concerning the minimum safety and health requirements
for the use of work equipment by workers at work.
• The regulations applicable to occupational safety and accident prevention in the country
concerned.
• Setting up and operating the machine as per IEC 60974.-9.
• Brief the user on safety-conscious work practices on a regular basis.
• Regularly inspect the machine as per IEC 60974.-4.
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode hold-
ers, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the ma-
chine is switched off.

For your safety
General
099-002129-EW501
15.10.2020
7
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of the
operator, where necessary in consultation with the mains network operator, to ensure that the
machine can be connected.

Intended use
Applications
8
099-002129-EW501
15.10.2020
3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and stand-
ards applicable for use in industry and trade. It may only be used for the welding proce-
dures indicated at the rating plate. Hazards may arise for persons, animals and material
objects if the equipment is not used correctly. No liability is accepted for any damages
arising from improper usage!
• The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
3.1 Applications
Arc welding machine for MMA DC welding with TIG DC welding with lift arc (touch starting) as secondary
process.
3.1.1 Demagnetize function (degaussing)
The degaussing of ferromagnetic workpieces in welding technology is intended to reduce arc deflection,
arc instability, uneven droplet detachment, spatter and irregular flank connections.
3.2 Documents which also apply
3.2.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information regarding
warranty, maintenance and testing at www.ewm-group.com!
3.2.2 Declaration of Conformity
This product corresponds in its design and construction to the EU directives listed in the decla-
ration. The product comes with a relevant declaration of conformity in the original.
The manufacturer recommends carrying out the safety inspection according to national and in-
ternational standards and guidelines every 12 months.
3.2.3 Welding in environments with increased electrical hazards
Power sources with this marking can be used for welding in an environment with increased
electrical hazard (e.g. boilers). For this purpose, appropriate national or international regulations
must be followed. The power source must not be placed in the danger zone!
3.2.4 Calibration/Validation
An original certificate is enclosed with the product. The manufacturer recommends calibration / validation
at intervals of 12 months.

Machine description – quick overview
Front view
099-002129-EW501
15.10.2020
9
4 Machine description – quick overview
4.1 Front view
Figure 4-1
Item
Symbol
Description 0
1
Carrying strap > see 5.1.4.1 chapter
2
Machine control > see 4.3 chapter
3
Protective cap
4
Connection socket, "+" welding current
• MMA: Electrode holder or workpiece lead connection
• TIG: Connection for workpiece lead
5
Cooling air outlet
6
Connection socket, “-” welding current
• MMA: Connection of electrode holder or workpiece lead
• TIG: Connection of TIG welding torch

Machine description – quick overview
Rear view
10
099-002129-EW501
15.10.2020
4.2 Rear view
Figure 4-2
Item
Symbol
Description 0
1
Main Switch
Switching the machine on or off.
2
Cooling air inlet
3
Mains connection cable > see 5.1.7 chapter

Machine description – quick overview
Machine control – Operating elements
099-002129-EW501
15.10.2020
11
4.3 Machine control – Operating elements
Figure 4-3
Item
Symbol
Description 0
1
Excess temperature signal light
In case of excess temperature, temperature monitors de-activate the power unit, and
the excess temperature control lamp comes on. Once the machine has cooled down,
welding can continue without any further measures.
2
Collective interference signal light
For error messages, > see 7 chapter
3
VRD
Voltage reduction device (VRD) signal light > see 5.10 chapter
4
AMP%
Hotstart current signal light
5
sec
Hotstart time signal light
6
Pulsed welding/power-saving mode push-button
MMA ----- pulse welding > see 5.4.6 chapter
TIG ------- pulse welding > see 5.5.7 chapter
Press for 2 s to put the machine into power-saving mode. To reactivate, activate one of
the operating elements > see 5.9 chapter.
7
Control button
Central control button to be pressed or turned > see 5.2 chapter.
8
3-pole connection socket
Remote control control cable
9
Pushbutton welding process / degaussing (activgauss) > see 5.6 chapter
-- MMA welding > see 5.4 chapter
-------- MMA welding (Cel characteristics)
------ TIG welding > see 5.5 chapter
10
AMP
Main current signal light
Imin to Imax (1 A increments)
11
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 5.3 chapter
12
A
“Welding current unit" signal light
Illuminates when welding currents are displayed.
13
Access control active signal light
Signal light is on when access control is active on the machine con-
trol > see 5.11 chapter.

Design and function
Transport and installation
12
099-002129-EW501
15.10.2020
5 Design and function
WARNING
Risk of injury from electrical voltage!
Contact with live parts, e.g. power connections, can be fatal!
• Observe the safety information on the first pages of the operating instructions!
• Commissioning must be carried out by persons who are specifically trained in handling
power sources!
• Connect connection or power cables while the machine is switched off!
Read and observe the documentation to all system and accessory components!
5.1 Transport and installation
WARNING
Risk of accident due to improper transport of machines that must not be lifted!
Do not lift or suspend the machine! The machine can drop and cause injuries! The
handles, straps or brackets are suitable for transport by hand only!
• The machine must not be suspended or lifted using a crane.
5.1.1 Machine cooling
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!
5.1.2 Workpiece lead, general
CAUTION
Risk of burning due to incorrect welding current connection!
If the welding current plugs (machine connections) are not locked or if the workpiece
connection is contaminated (paint, corrosion), these connections and leads can heat up
and cause burns when touched!
• Check welding current connections on a daily basis and lock by turning to the right when
necessary.
• Clean workpiece connection thoroughly and secure properly. Do not use structural parts of
the workpiece as welding current return lead!

Design and function
Transport and installation
099-002129-EW501
15.10.2020
13
5.1.3 Ambient conditions
T he machine must not be operated in the open air and must only be set up and operated on a
suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient lighting
for the place of work.
• Safe operation of the machine must be guaranteed at all times.
Equipment damage due to contamination!
Unusually high amounts of dust, acids, corrosive gases or substances can damage the machine
(observe maintenance intervals > see 6.2 chapter).
• Avoid large amounts of smoke, steam, oily fumes, grinding dust and corrosive ambient air!
5.1.3.1 In operation
Temperature range of the ambient air:
• -25 °C to +40 °C (-13 °F to 104 °F)
Relative humidity:
• up to 50 % at 40 °C (104 °F)
• up to 90 % at 20 °C (68 °F)
5.1.3.2 Transport and storage
Storage in a closed room, temperature range of the ambient air:
• -30 °C to +70 °C (-22 °F to 158 °F)
Relative humidity
• up to 90 % at 20 °C (68 °F)
5.1.4 Transport belt
5.1.4.1 Adjusting the length of the carrying strap
To demonstrate adjustment, lengthening the strap is shown in the figure. To shorten, the strap's
loops must be inched in the opposite direction.
Figure 5-1

Design and function
Transport and installation
14
099-002129-EW501
15.10.2020
5.1.5 Notes on the installation of welding current leads
• Use an individual welding lead to the workpiece for each welding machine!
Figure 5-2
• Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops!
• Always keep leads as short as possible!
Lay any excess cable lengths in meanders.
Figure 5-3

Design and function
Transport and installation
099-002129-EW501
15.10.2020
15
5.1.6 Stray welding currents
WARNING
Risk of injury due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage machines and
electronic devices and cause overheating of components, leading to fire.
• Check that all welding current connections are firmly secured and electrical connections are
in perfect condition.
• Set up, attach or suspend all conductive power source components such as casing, trans-
port vehicles and crane frames so they are insulated.
• Do not place any other electronic devices such as drills or angle grinders on the power
source, transport vehicle or crane frames unless they are insulated.
• Always put welding torches and electrode holders on an insulated surface when they are
not in use.
Figure 5-4

Design and function
Operating the machine control
16
099-002129-EW501
15.10.2020
5.1.7 Mains connection
DANGER
Hazards caused by improper mains connection!
An improper mains connection can cause injuries or damage property!
• The connection (mains plug or cable), the repair or voltage adjustment of the device must
be carried out by a qualified electrician in accordance with the respective local laws or nati-
onal regulations!
• The mains voltage indicated on the rating plate must match the supply voltage.
• Only operate machine using a socket that has correctly fitted protective earth.
• Mains plug, socket and lead must be checked by a qualified electrician on a regular basis!
• When operating the generator, always ensure it is earthed as stipulated in the operating in-
structions. The network created must be suitable for operating machines according to pro-
tection class I.
5.1.7.1 Mains configuration
The machine may only be connected to a one-phase system with two conductors and an earthed
neutral conductor.
Figure 5-5
Legend
Item
Designation
Colour code
L
Outer conductor
brown
N
Neutral conductor
blue
PE
Protective conductor
green-yellow
• Insert mains plug of the switched-off machine into the appropriate socket.
5.2 Operating the machine control
5.3 Machine display
The machine control switches to the main screen after it has been turned on or a setting has been com-
pleted. This means that the previously selected settings (indicated by signal lights where applicable) have
been applied and the current nominal value (A) is displayed in the welding data display.
5.3.1 Welding power setting
The welding power is set using the control button. You can also adjust the parameters in the operation
sequence or settings in the different machine menus.
5.3.2 Welding parameter setting in the operation sequence
During the operation sequence you can set a welding parameter by briefly pressing the control button
(navigate the parameters) and then turning the button (set the parameter).
5.3.3 Setting advanced welding parameters (Expert menu)
The Expert menu contains functions and parameters which cannot be set directly in the machine control
or which do not need to be et on a regular basis. The number and display of these parameters depends
on the previously selected welding procedure or the functions.
5.3.4 Changing basic settings (machine configuration menu)
The basic welding system functions can be adjusted in the machine configuration menu. Only experi-
enced users should change the settings > see 5.12 chapter.

Design and function
MMA welding
099-002129-EW501
15.10.2020
17
5.4 MMA welding
5.4.1 Connecting the electrode holder and workpiece lead
CAUTION
Risk of crushing and burns!
When changing stick electrodes there is a risk of crushing and burns!
• Wear appropriate and dry protective gloves.
• Use an insulated pair of tongs to remove the used stick electrode or to move welded work-
pieces.
Figure 5-6
Item
Symbol
Description 0
1
Workpiece
2
Connection socket for "+" welding current
Electrode holder or workpiece lead connection
3
Electrode holder
4
Connection socket, “-” welding current
Workpiece lead or electrode holder connection
• Insert the electrode holder plug and workpiece lead into the welding current socket depending on ap-
plication and lock in place by turning to the right. The corresponding polarity will be based on the infor-
mation of the electrode manufacturer on the electrode packaging.

Design and function
MMA welding
18
099-002129-EW501
15.10.2020
5.4.2 Welding task selection
?
R
RB
B
RC
C
Figure 5-7
Type
Electrode type
R
Rutile
RB
Rutile-basic
B
Basic
RC
Rutile cellulose
C
Cellulose
5.4.3 Arcforce
During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in
current. This makes it easier to weld large-drop melting electrode types at low current strengths with a
short arc in particular.
For parameter setting, > see 5.4.7 chapter.
5.4.4 Hotstart
The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent
metal at the beginning of the welding process. The ignition takes place here with increased current (hot
start current) over a certain time (hot start time).
A = Hot start current
B = Hot start time
C = Main current
I = Current
t = Time
Figure 5-8
Setting
EXIT EXIT
Figure 5-9

Design and function
MMA welding
099-002129-EW501
15.10.2020
19
5.4.5 Antistick
The Antistick feature prevents the electrode from annealing.
Should the electrode stick despite the Arcforce feature, the machine au-
tomatically switches to the minimum current within approx. one second.
This prevents the electrode from annealing. Check the welding current
setting and correct for the welding task in hand.
Figure 5-10
5.4.6 Average value pulse welding
Average value pulse welding means that two currents are switched periodically, a current average value
(AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The
predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the para-
meter as a percentage of the current average value (AMP). The pulse pause current (IPP) requires no
setting. This value is calculated by the machine control, so that the welding current average value (AMP)
is maintained at all times.
Figure 5-11
AMP = Main current; e.g. 100 A
Ipuls = Pulse current = x AMP; e.g. 140% x 100 A = 140 A
IPP = Pulse pause current
Tpuls = Duration of one pulse cycle = 1/ ; e.g. 1/1 Hz = 1 s
= Balance
Selection
Figure 5-12
For parameter setting, > see 5.4.7 chapter.

Design and function
MMA welding
20
099-002129-EW501
15.10.2020
5.4.7 Expert menu (MMA)
The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa-
rameters shown may be limited, e.g. if a function is deactivated.
The setting ranges for the parameter values are summarised in the Parameter overview sec-
tion > see 11.1 chapter.
NAVIGATION
EXIT
2s
ENTER
2s
Figure 5-13
Display
Setting/selection
Arcforce correction
• Increase value > harder arc
• Decrease value > softer arc
Pulse frequency
Pulse balance
Pulse current > see 5.4.6 chapter
Arc length restriction > see 5.8 chapter
------- Function switched on
------- Function switched off