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
11.05.2017
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the location where the machine is operated.
•Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
•Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of
liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Straße 8
56271 Mündersbach
Germany
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2For your safety.......................................................................................................................................5
2.1 Notes on the use of these operating instructions ..........................................................................5
2.1.1 Complete documentation ...............................................................................................5
2.2 Explanation of icons.......................................................................................................................6
2.3 General..........................................................................................................................................7
3Intended use...........................................................................................................................................8
3.1 Documents which also apply.........................................................................................................8
3.1.1 Warranty.........................................................................................................................8
3.1.2 Declaration of Conformity...............................................................................................8
3.1.3 Welding in environments with increased electrical hazards...........................................8
3.1.4 Calibration/Validation .....................................................................................................8
4Machine description –quick overview ................................................................................................9
4.1 Front view ......................................................................................................................................9
4.2 Rear view.....................................................................................................................................10
4.3 Machine control –Operating elements........................................................................................10
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 Adjusting the length of the carrying strap.....................................................................13
5.1.5 Notes on the installation of welding current leads........................................................13
5.1.5.1 Stray welding currents...................................................................................14
5.1.6 Mains connection..........................................................................................................15
5.1.6.1 Mains configuration.......................................................................................15
5.2 Operating the machine control.....................................................................................................15
5.2.1 Machine display............................................................................................................15
5.2.2 Welding power setting..................................................................................................15
5.2.3 Welding parameter setting in the operation sequence.................................................15
5.2.4 Setting advanced welding parameters (Expert menu).................................................15
5.2.5 Changing basic settings (machine configuration menu) ..............................................15
5.3 MMA welding ...............................................................................................................................16
5.3.1 Connecting the electrode holder and workpiece lead..................................................16
5.3.2 Welding task selection..................................................................................................16
5.3.3 Arcforce........................................................................................................................17
5.3.4 Hotstart.........................................................................................................................17
5.3.5 Antistick........................................................................................................................17
5.3.6 Average value pulse welding........................................................................................18
5.3.7 Expert menu (MMA) .....................................................................................................19
5.4 TIG welding..................................................................................................................................20
5.4.1 Connecting a TIG welding torch with rotating gas valve..............................................20
5.4.2 Shielding gas supply (shielding gas cylinder for welding machine).............................20
5.4.3 Pressure regulator connection .....................................................................................21
5.4.4 Welding task selection..................................................................................................21
5.4.4.1 Gas test –setting the shielding gas volume.................................................21
5.4.5 Arc ignition....................................................................................................................22
5.4.5.1 Liftarc ............................................................................................................22
5.4.6 Average value pulse welding........................................................................................22
5.4.7 Expert menu (TIG)........................................................................................................23
5.5 Arc length restriction (USP).........................................................................................................24
5.6 Power-saving mode (Standby) ....................................................................................................24
5.7 Voltage reducing device ..............................................................................................................24
5.8 Access control..............................................................................................................................25

Contents
Notes on the use of these operating instructions
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5.9 Machine configuration menu........................................................................................................26
6Maintenance, care and disposal.........................................................................................................28
6.1 General.........................................................................................................................................28
6.2 Cleaning.......................................................................................................................................28
6.2.1 Dirt filter.........................................................................................................................28
6.3 Maintenance work, intervals ........................................................................................................29
6.3.1 Daily maintenance tasks...............................................................................................29
6.3.2 Monthly maintenance tasks..........................................................................................29
6.3.3 Annual test (inspection and testing during operation)..................................................29
6.4 Disposing of equipment................................................................................................................30
6.5 Meeting the requirements of RoHS..............................................................................................30
7Rectifying faults....................................................................................................................................31
7.1 Error messages (power source)...................................................................................................31
7.2 Checklist for rectifying faults........................................................................................................32
7.3 Display machine control software version....................................................................................32
7.4 Dynamic power adjustment..........................................................................................................32
7.5 Resetting welding parameters to the factory settings..................................................................33
8Technical data.......................................................................................................................................34
8.1 Pico 160 cel puls..........................................................................................................................34
9Accessories ..........................................................................................................................................35
9.1 Electrode holder / workpiece lead................................................................................................35
9.2 Remote controls and accessories................................................................................................35
9.3 TIG welding torch.........................................................................................................................35
9.4 General accessories ....................................................................................................................35
9.5 Options.........................................................................................................................................35
10 Service documents ..............................................................................................................................36
10.1 Spare and replacement parts.......................................................................................................36
10.2 Circuit diagram.............................................................................................................................38
11 Appendix A............................................................................................................................................39
11.1 Parameter overview –setting information....................................................................................39
12 Appendix B............................................................................................................................................40
12.1 Overview of EWM branches.........................................................................................................40

For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of these operating instructions
2.1.1 Complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with the "Safety instructions”!
Read and observe the documents for all system components!
Figure 2-1
Item
Documentation
A.1
Safety instructions
A.2
Power source
A.3
Electrode holder/welding torch
A.4
Remote control
A
Complete documentation

For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/tip
Switch off machine
Release
Switch on machine
Press and keep pressed
Switch
Wrong
Turn
Correct
Numerical value –adjustable
Menu entry
Signal light lights up in green
Navigating the menu
Signal light flashes green
Exit menu
Signal light lights up in red
Time representation (e.g.: wait
4 s/activate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use

For your safety
General
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2.3 General
Obligations of the operator!
The respective national directives and laws must be complied with when operating the machine!
•Implementation of national legislation relating to framework directive 89/391/EEC on the
introduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
•In particular, directive 89/655/EEC concerning the minimum safety and health requirements for
the use of work equipment by workers at work.
•The regulations applicable to occupational safety and accident prevention in the country
concerned.
•Setting up and operating the machine as per IEC 60974.-9.
•Brief the user on safety-conscious work practices on a regular basis.
•Regularly inspect the machine as per IEC 60974.-4.
The manufacturer's warranty becomes void if non-genuine parts are used!
•Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of products!
•Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of the
operator, where necessary in consultation with the mains network operator, to ensure that the
machine can be connected.

Intended use
Documents which also apply
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
•The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
•Do not improperly modify or convert the equipment!
Arc welding machine for MMA DC welding with TIG DC welding with lift arc (touch starting) as secondary
process.
3.1 Documents which also apply
3.1.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.1.2 Declaration of Conformity
The labelled machine complies with the following EC directives in terms of its design and
construction:
•Low Voltage Directive (LVD)
•Electromagnetic Compatibility Directive (EMC)
•Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment –Inspection and Testing during Operation", and/or prohibited modifications which
have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the
specific declaration of conformity is included with every product.
3.1.3 Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
3.1.4 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months

Machine description –quick overview
Front view
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4 Machine description – quick overview
4.1 Front view
Figure 4-1
Item
Symbol
Description 0
1
Carrying strap > see 5.1.4 chapter
2
Machine control > see 4.3 chapter
3
Protective cap
4
Connection socket, "+" welding current
•MMA: Electrode holder or workpiece lead connection
•TIG: Connection for workpiece lead
5
Cooling air outlet
6
Connection socket, "-" welding current
•MMA welding: Electrode holder or workpiece lead connection
•TIG welding: Welding current lead connection for TIG welding torch

Machine description –quick overview
Rear view
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4.2 Rear view
Figure 4-2
Item
Symbol
Description 0
1
Main switch, machine on/off
2
Cooling air inlet
3
Mains connection cable > see 5.1.6 chapter
4.3 Machine control –Operating elements
The setting ranges for the parameter values are summarised in the Parameter overview
section > see 11.1 chapter.
Figure 4-3

Machine description –quick overview
Machine control –Operating elements
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Item
Symbol
Description 0
1
Excess temperature signal light
In case of excess temperature, temperature monitors de-activate the power unit, and
the excess temperature control lamp comes on. Once the machine has cooled down,
welding can continue without any further measures.
2
Collective interference signal light
For error messages, > see 7 chapter
3
VRD
Voltage reduction device (VRD) signal light
The VRD signal light is illuminated when the voltage reduction device is operating
without fault and the output voltage is reduced to a value specified in the relevant
standard (see technical data) > see 5.7 chapter. The voltage reduction device is only
active on VRD machine versions.
4
AMP%
Hotstart current signal light
5
sec
Hotstart time signal light
6
Pulsed welding/power-saving mode push-button
MMA-----pulse welding > see 5.3.6 chapter
TIG-------pulse welding > see 5.4.6 chapter
Press for 2 s to put the machine into power-saving mode. To reactivate, activate one of
the operating elements > see 5.6 chapter.
7
Control button
Central control button to be pressed or turned > see 5.2 chapter.
8
2-pole connection socket
Remote control control cable
9
Welding procedure push-button
------MMA welding
------MMA welding (Cel characteristics)
--------TIG welding
10
AMP
Main current signal light
Imin to Imax (1 A increments)
11
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 5.2.1 chapter
12
A
“Welding current unit" signal light
Illuminates when welding currents are displayed.
13
Access control active signal light
Signal light is on when access control is active on the machine
control > see 5.8 chapter.

Design and function
Transport and installation
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5 Design and function
WARNING
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
•Follow safety instructions on the opening pages of the operating instructions.
•Commissioning may only be carried out by persons who have the relevant expertise of
working with arc welding machines!
•Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
5.1 Transport and installation
WARNING
Risk of accident due to improper transport of machines that must not be lifted!
Do not lift or suspend the machine! The machine can drop and cause injuries! The
handles, straps or brackets are suitable for transport by hand only!
•The machine must not be suspended or lifted using a crane.
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
•Only transport and operate in an upright position!
Accessory components and the power source itself can be damaged by incorrect connection!
•Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
•Comprehensive descriptions can be found in the operating instructions for the relevant
accessory components.
•Accessory components are detected automatically after the power source is switched on.
5.1.1 Machine cooling
Insufficient ventilation results in a reduction in performance and equipment damage.
•Observe the ambient conditions!
•Keep the cooling air inlet and outlet clear!
•Observe the minimum distance of 0.5 m from obstacles!
5.1.2 Workpiece lead, general
CAUTION
Risk of burning due to incorrect welding current connection!
If the welding current plugs (machine connections) are not locked or if the workpiece
connection is contaminated (paint, corrosion), these connections and leads can heat up
and cause burns when touched!
•Check welding current connections on a daily basis and lock by turning to the right when
necessary.
•Clean workpiece connection thoroughly and secure properly. Do not use structural parts of
the workpiece as welding current return lead!

Design and function
Transport and installation
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5.1.3 Ambient conditions
T he machine must not be operated in the open air and must only be set up and operated on a
suitable, stable and level base!
•The operator must ensure that the ground is non-slip and level, and provide sufficient lighting
for the place of work.
•Safe operation of the machine must be guaranteed at all times.
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
•Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
•Avoid ambient air containing salt (sea air)!
5.1.3.1 In operation
Temperature range of the ambient air:
•-25 °C to +40 °C
Relative air humidity:
•Up to 50% at 40 °C
•Up to 90% at 20 °C
5.1.3.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
•-30 °C to +70 °C
Relative air humidity
•Up to 90% at 20 °C
5.1.4 Adjusting the length of the carrying strap
To demonstrate adjustment, lengthening the strap is shown in the figure. To shorten, the strap's
loops must be inched in the opposite direction.
Figure 5-1
5.1.5 Notes on the installation of welding current leads
Use an individual welding lead to the workpiece for each welding machine!
Figure 5-2

Design and function
Transport and installation
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Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid
loops!
Always keep leads as short as possible!
Lay any excess cable lengths in meanders.
Figure 5-3
5.1.5.1 Stray welding currents
WARNING
Risk of injury due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage machines and
electronic devices and cause overheating of components, leading to fire.
•Check that all welding current connections are firmly secured and electrical connections are
in perfect condition.
•Set up, attach or suspend all conductive power source components such as casing,
transport vehicles and crane frames so they are insulated.
•Do not place any other electronic devices such as drills or angle grinders on the power
source, transport vehicle or crane frames unless they are insulated.
•Always put welding torches and electrode holders on an insulated surface when they are
not in use.
Figure 5-4

Design and function
Operating the machine control
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5.1.6 Mains connection
DANGER
Hazards caused by improper mains connection!
An improper mains connection can cause injuries or damage property!
•Only operate machine using a socket that has correctly fitted protective earth.
•The mains voltage indicated on the rating plate must match the supply voltage.
•If a new mains plug must be fitted, only an electrician may do so as per the relevant
national legislation or regulations.
•Mains plug, socket and lead must be checked by an electrician on a regular basis.
•When operating the generator, always ensure it is earthed as stipulated in the operating
instructions. The network created must be suitable for operating machines according to
protection class I.
5.1.6.1 Mains configuration
The machine may only be connected to a one-phase system with two conductors and an earthed
neutral conductor.
Figure 5-5
Legend
Item
Designation
Colour code
L
Outer conductor
brown
N
Neutral conductor
blue
PE
Protective conductor
green-yellow
•Insert mains plug of the switched-off machine into the appropriate socket.
5.2 Operating the machine control
5.2.1 Machine display
The machine control switches to the main screen after it has been turned on or a setting has been
completed. This means that the previously selected settings (indicated by signal lights where applicable)
have been applied and the current nominal value (A) is displayed in the welding data display.
5.2.2 Welding power setting
The welding power is set using the control button. You can also adjust the parameters in the operation
sequence or settings in the different machine menus.
5.2.3 Welding parameter setting in the operation sequence
During the operation sequence you can set a welding parameter by briefly pressing the control button
(navigate the parameters) and then turning the button (set the parameter).
5.2.4 Setting advanced welding parameters (Expert menu)
The Expert menu contains functions and parameters which cannot be set directly in the machine control
or which do not need to be et on a regular basis. The number and display of these parameters depends
on the previously selected welding procedure or the functions.
5.2.5 Changing basic settings (machine configuration menu)
The basic welding system functions can be adjusted in the machine configuration menu. Only
experienced users should change the settings > see 5.9 chapter.

Design and function
MMA welding
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5.3 MMA welding
5.3.1 Connecting the electrode holder and workpiece lead
CAUTION
Risk of crushing and burns!
When changing stick electrodes there is a risk of crushing and burns!
•Wear appropriate and dry protective gloves.
•Use an insulated pair of tongs to remove the used stick electrode or to move welded
workpieces.
Figure 5-6
Item
Symbol
Description 0
1
Workpiece
2
Connection socket for "+" welding current
Electrode holder or workpiece lead connection
3
Electrode holder
4
Connection socket, “-” welding current
Workpiece lead or electrode holder connection
Polarity depends on the instructions from the electrode manufacturer given on the electrode
packaging.
•Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and
lock by turning to the right.
•Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and
lock by turning to the right.
5.3.2 Welding task selection
?
R
RB
B
RC
C
Figure 5-7

Design and function
MMA welding
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Type
Electrode type
R
Rutile
RB
Rutile-basic
B
Basic
RC
Rutile cellulose
C
Cellulose
5.3.3 Arcforce
During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in
current. This makes it easier to weld large-drop melting electrode types at low current strengths with a
short arc in particular.
For parameter setting, > see 5.3.7 chapter.
5.3.4 Hotstart
The hot start function improves the arc striking.
After striking the stick electrode, the arc ignites at the increased hot start current and decreases to the set
main current once the hot start time has elapsed.
A = Hot start current
B = Hot start time
C = Main current
I = Current
t = Time
Setting
EXIT EXIT
Figure 5-8
5.3.5 Antistick
Anti-stick prevents the electrode from annealing.
If the electrode sticks in spite of the Arcforce device, the machine
automatically switches over to the minimum current within about 1
second to prevent the electrode from overheating. Check the welding
current setting and correct according to the welding task!
Figure 5-9

Design and function
MMA welding
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5.3.6 Average value pulse welding
Average value pulse welding means that two currents are switched periodically, a current average value
(AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The
predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the
parameter as a percentage of the current average value (AMP). The pulse pause current (IPP) requires
no setting. This value is calculated by the machine control, so that the welding current average value
(AMP) is maintained at all times.
Figure 5-10
AMP = Main current; e.g. 100 A
IPL = Pulse current = IP1 x AMP; e.g. 170% x 100 A = 170 A
IPP = Pulse pause current
Tpuls = Duration of one pulse cycle = 1/FrE; e.g. 1/1 Hz = 1 s
bAL = Balance
Selection
Figure 5-11
For parameter setting, > see 5.3.7 chapter.

Design and function
MMA welding
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5.3.7 Expert menu (MMA)
The Expert menu has adjustable parameters stored that don’t require regular setting. The number of
parameters shown may be limited, e.g. if a function is deactivated.
The setting ranges for the parameter values are summarised in the Parameter overview
section > see 11.1 chapter.
NAVIGATION
EXIT
2s
ENTER
2s
Figure 5-12
Display
Setting/selection
Arcforce correction
•Increase value > harder arc
•Decrease value > softer arc
Pulse frequency
Pulse balance
Pulse current > see 5.3.6 chapter
Arc length restriction > see 5.5 chapter
-------Function switched on
-------Function switched off

Design and function
TIG welding
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5.4 TIG welding
5.4.1 Connecting a TIG welding torch with rotating gas valve
Prepare welding torch according to the welding task in hand (see operating instructions for the torch).
Figure 5-13
Item
Symbol
Description 0
1
Workpiece
2
Connection socket for "+" welding current
Workpiece lead connection
3
Output side of the pressure regulator
4
Welding torch
5
Connection socket, "-" welding current
Welding current lead connection for TIG welding torch
•Insert the welding current plug on the welding torch into the welding current connection socket and
lock by turning to the right.
•Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by
turning to the right.
•Screw the shielding gas hose of the welding torch to the pressure regulator outlet.
5.4.2 Shielding gas supply (shielding gas cylinder for welding machine)
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders
can cause serious injuries!
•Place shielding gas cylinder into the designated holder and secure with
fastening elements (chain/belt)!
•Attach the fastening elements within the upper half of the shielding gas
cylinder!
•The fastening elements must tightly enclose the shielding gas cylinder!
An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a
fundamental requirement for optimum welding results. In addition, a blocked shielding gas
supply may result in the welding torch being destroyed.
•All shielding gas connections must be gas tight.