EWM Pico 350 cel puls pws MMA User manual

Operating instructions
EN
Welding machine
Pico 350 cel puls pws dgs
099-002127-EW501
Observe additional system documents!
27.9.2022

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 f orm 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: [e-mail]
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.
Data security
The user is responsible for backing up data of all changes from the factory setting. The user is liable for
erased personal settings. The manufacturer does not assume any liability for this.

Contents
Notes on using these operating instructions
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1 Contents
1Contents....................................................................................................................... 3
2For your safety.............................................................................................................. 6
2.1 Notes on using these operating instructions ............................................................... 6
2.2 Explanation of icons ............................................................................................... 7
2.3 Safety instructions .................................................................................................. 8
2.4 Transport and installation .......................................................................................11
3Intended use ................................................................................................................13
3.1 Applications..........................................................................................................13
3.1.1 Degaussing ............................................................................................13
3.1.2 MIG/MAG standard welding ......................................................................13
3.2 Software version ...................................................................................................13
3.3 Overview of device types........................................................................................13
3.3.1 Cellulose electrode types (cel) ...................................................................13
3.3.2 Pole reversing switch (pws) .......................................................................13
3.4 Voltage reducing device .........................................................................................13
3.5 Documents which also apply ...................................................................................13
3.5.1 Warranty ................................................................................................13
3.5.2 Declaration of Conformity..........................................................................14
3.5.3 Welding in environments with increased electrical hazards.............................14
3.5.4 Service documents (spare parts and circuit diagrams) ...................................14
3.5.5 Calibration/Validation ...............................................................................14
3.5.6 Part of the complete documentation............................................................14
4Machine description – quick overview ...........................................................................15
4.1 Front view / rear view.............................................................................................15
4.2 Machine control – Operating elements......................................................................17
4.2.1 Welding data display ................................................................................18
5Design and function .....................................................................................................19
5.1 Transport and installation .......................................................................................19
5.1.1 Ambient conditions ..................................................................................19
5.1.2 Machine cooling ......................................................................................19
5.1.3 Workpiece lead, general ...........................................................................20
5.1.4 Transport belt..........................................................................................20
5.1.4.1 Adjusting the length of the carrying strap........................................20
5.1.5 Cable strap .............................................................................................21
5.1.6 Cable holder ...........................................................................................22
5.1.7 Deinstallation/Installation ..........................................................................22
5.1.7.1 Application ................................................................................22
5.1.8 Protective flap, welding machine control ......................................................23
5.1.9 Deinstallation/Installation ..........................................................................23
5.1.10 Notes on the installation of welding current leads..........................................24
5.1.11 Stray welding currents ..............................................................................25
5.1.12 Mains connection.....................................................................................26
5.1.12.1 Mains configuration.....................................................................26
5.1.13 Shielding gas supply (shielding gas cylinder for welding machine)...................27
5.1.14 Pressure regulator connection ...................................................................27
5.2 MMA welding........................................................................................................28
5.2.1 Connecting the electrode holder and workpiece lead .....................................28
5.2.2 Welding task selection ..............................................................................28
5.2.2.1 Arcforce (welding characteristics)..................................................29
5.2.3 Hotstart ..................................................................................................29
5.2.3.1 Hotstart time ..............................................................................29
5.2.3.2 Hotstart current ..........................................................................29
5.2.4 Antistick .................................................................................................30
5.2.5 Average value pulse welding .....................................................................30
5.2.5.1 Average value pulsing in the vertical-up position (PF) ......................31
5.2.6 Expert menu (MMA) .................................................................................31
5.3 TIG welding..........................................................................................................32
5.3.1 Connecting a TIG welding torch with rotating gas valve .................................32

Contents
Notes on using these operating instructions
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5.3.2 Welding task selection ..............................................................................33
5.3.3 Arc ignition .............................................................................................33
5.3.3.1 Liftarc .......................................................................................33
5.3.4 Average value pulse welding .....................................................................34
5.3.5 Expert menu (TIG) ...................................................................................35
5.4 MIG/MAG welding .................................................................................................35
5.4.1 Connecting the intermediate hose package to the power source .....................35
5.4.2 Shielding gas supply (shielding gas cylinder for welding machine)...................37
5.4.3 Gas test – setting the shielding gas volume .................................................37
5.4.4 MIG/MAG welding with constant voltage characteristics (CV) .........................38
5.4.5 Welding task selection ..............................................................................38
5.4.6 Expert menu ...........................................................................................38
5.4.7 MIG/MAG welding with constant current characteristics (CC)..........................38
5.4.8 Welding task selection ..............................................................................38
5.4.9 Expert menu ...........................................................................................39
5.4.10 MIG/MAG welding – voltage-sensing ..........................................................39
5.5 Connection plan ....................................................................................................39
5.5.1 Legend ..................................................................................................40
5.5.2 Connecting the supply lines.......................................................................40
5.6 Degaussing ..........................................................................................................41
5.6.1 Description of procedure ...........................................................................41
5.6.2 Notes on laying power cables ....................................................................42
5.6.3 Degaussing the workpiece before welding (degauss) ....................................43
5.6.3.1 Automatic cut-out .......................................................................44
5.7 Arc length restriction (USP).....................................................................................44
5.7.1.1 Welding current polarity reversal (polarity reversal) ..........................44
5.8 Remote control .....................................................................................................44
5.8.1 RT1 19POL ............................................................................................44
5.8.2 RTF1 19POL ..........................................................................................44
5.8.3 RT PWS1 19POL ....................................................................................45
5.8.4 RTA PWS2 .............................................................................................45
5.9 Power-saving mode (Standby) ................................................................................45
5.10 Machine configuration menu ...................................................................................46
6Maintenance, care and disposal ....................................................................................47
6.1 General ...............................................................................................................47
6.1.1 Cleaning.................................................................................................47
6.1.2 Dirt filter .................................................................................................47
6.2 Maintenance work, intervals....................................................................................48
6.2.1 Daily maintenance tasks ...........................................................................48
6.2.2 Monthly maintenance tasks .......................................................................48
6.2.3 Annual test (inspection and testing during operation).....................................48
6.3 Disposing of equipment..........................................................................................49
7Rectifying faults ...........................................................................................................50
7.1 Checklist for rectifying faults ...................................................................................50
7.2 Error messages (power source)...............................................................................51
7.3 Software version of the machine control ...................................................................52
7.4 Resetting welding parameters to the factory settings ..................................................52
8Technical data .............................................................................................................53
8.1 Pico 350 cel puls pws dgs ......................................................................................53
9Accessories.................................................................................................................54
9.1 System components ..............................................................................................54
9.1.1 Wire feed unit..........................................................................................54
9.2 19-pole remote control ...........................................................................................54
9.2.1 Connection cables ...................................................................................54
9.2.2 Extension cable .......................................................................................54
9.3 Options................................................................................................................54
9.4 General accessories ..............................................................................................54
10 Appendix .....................................................................................................................55
10.1 Parameter overview – setting ranges .......................................................................55

Contents
Notes on using these operating instructions
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10.2 Magnetic flux density - adjustment aid ......................................................................56
10.3 Guide values of magnetic flux density, weldability ......................................................56
10.4 Searching for a dealer............................................................................................57

For your safety
Notes on using these operating instructions
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2 For your safety
2.1 Notes on using these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning sym-
bol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general warn-
ing symbol.
• The risk is explained using a symbol on the edge of the page.
Technical aspects which the user must observe to avoid material or equipment damage.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.

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 hold
Incorrect / Invalid
Switch
Correct / Valid
Turn
Input
Numerical value – adjustable
Navigation
Signal light lights up in green
Output
Signal light flashes green
Time representation (e.g.: wait 4 s / ac-
tuate)
Signal light lights up in red
Interruption in the menu display (other
setting options possible)
Signal light flashes red
Tool not required/do not use
Signal light lights up in blue
Tool required/use
Signal light flashes blue

For your safety
Safety instructions
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2.3 Safety instructions
WARNING
Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
• Carefully read the safety instructions in this manual!
• Observe the accident prevention regulations and any regional regulations!
• Inform persons in the working area that they must comply with the regulations!
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low vol-
tages can cause a shock and lead to accidents.
• Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
• Always place torches and electrode holders on an insulated surface!
• Wear the full personal protective equipment (depending on the application)!
• The machine may only be opened by qualified personnel!
• The device must not be used to defrost pipes!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a techni-
cal specialist may interconnect the sources as per standard IEC 60974-9:2010: Installa-
tion and use and German Accident Prevention Regulation BVG D1 (formerly VBG 15) or
country-specific regulations.
Before commencing arc welding, a test must verify that the equipment cannot exceed
the maximum permitted open circuit voltage.
• Only qualified personnel may connect the machine.
• When taking individual power sources out of operation, all mains and welding current leads
must be safely disconnected from the welding system as a whole. (Hazard due to reverse
polarity voltage!)
• Do not interconnect welding machines with pole reversing switch (PWS series) or machines
for AC welding since a minor error in operation can cause the welding voltages to be com-
bined, which is not permitted.
Risk of injury due to radiation or heat!
Arc radiation can lead to skin and eye injuries.
Contact with hot workpieces and sparks can lead to burns.
• Use hand shield or welding helmet with the appropriate safety level (depends on the appli-
cation).
• Wear dry protective clothing (e.g. hand shield, gloves, etc.) in accordance with
the applicable regulations of your country.
• Persons who are not directly involved should be protected with a welding curtain or suitable
safety screen against radiation and the risk of blinding!

For your safety
Safety instructions
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WARNING
Risk of injury due to improper clothing!
During arc welding, radiation, heat and voltage are sources of risk that cannot be
avoided. The user has to be equipped with the complete personal protective equipment
at all times. The protective equipment has to include:
• Respiratory protection against hazardous substances and mixtures (fumes and vapours);
otherwise implement suitable measures such as extraction facilities.
• Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and
heat.
• Dry welding clothing (shoes, gloves and body protection) to protect against warm environ-
ments with conditions comparable to ambient temperatures of 100 °C or higher and arcing
and work on live components.
• Hearing protection against harming noise.
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during
welding, there is a risk of flames.
• Be watchful of potential sources of fire in the working area!
• Do not carry any easily inflammable objects, e.g. matches or lighters.
• Ensure suitable fire extinguishers are available in the working area!
• Thoroughly remove any residue of flammable materials from the workpiece prior to starting
to weld.
• Only f urther process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!

For your safety
Safety instructions
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CAUTION
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent
vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to
the ultraviolet radiation of the arc!
• Ensure that there is sufficient fresh air!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
According to IEC 60974-10, welding machines are divided into two classes of
electromagnetic compatibility (the EMC class can be found in the Technical
data) > see 8 chapter:
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas, inclu-
ding residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the
surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding system
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
• Observe the maintenance instructions > see 6.2 chapter!
• Unwind welding leads completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if nec-
essary).

For your safety
Transport and installation
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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.
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.
2.4 Transport and installation
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause seri-
ous injuries!
• Observe the instructions from the gas manufacturer and any relevant regulations concern-
ing the use of compressed air!
• Do not attach any element to the shielding gas cylinder valve!
• Prevent the shielding gas cylinder from heating up.

For your safety
Transport and installation
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CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
• Disconnect all supply lines before transport!
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10° (ac-
cording to IEC 60974-1).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Risk of accidents due to incorrectly installed leads!
Incorrectly installed leads (mains, control and welding leads or intermediate hose pack-
ages ) can present a tripping hazard.
• Lay the supply lines flat on the floor (avoid loops).
• Avoid laying the leads on passage ways.
Risk of injury from heated coolant and its connections!
The coolant used and its connection or connection points can heat up significantly
during operation (water-cooled version). When opening the coolant circuit, escaping
coolant may cause scalding.
• Open the coolant circuit only when the power source or cooling unit is switched off!
• Wear proper protective equipment (protective gloves)!
• Seal open connections of the hose leads with suitable plugs.
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 ac-
cessory components.
• Accessory components are detected automatically after the power source is switched on.
Protective dust caps protect the connection sockets and therefore the machine against dirt and
damage.
• The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
• The cap must be replaced if faulty or if lost!

Intended use
Applications
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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 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 system for MMA DC welding with pole reversing switch for quick polarity switching and, as
secondary process, TIG DC welding with lift arc (touch starting) or MIG/MAG welding with constant vol-
tage (CV) or constant current (CC).
3.1.1 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.
3.1.2 MIG/MAG standard welding
A suitable wire feed unit (system component) is required in order to operate the welding machine!
Pico drive 4L
Pico drive 200C
Pico 350, -400

3.2 Software version
The software version of the machine control can be displayed in the machine configuration menu
(menu Srv) > see 5.10 chapter.
3.3 Overview of device types
3.3.1 Cellulose electrode types (cel)
CEL device types are equipped with special Arcforce characteristics.
These device types facilitate welding with cellulose electrode types which is safe for vertical-down
welding, especially in the lower output range.
3.3.2 Pole reversing switch (pws)
With PWS device types, the polarity of the welding current connections (pole reversal) can be changed
using a changeover switch on the machine or on the remote control.
Useful function with frequently changing electrode types without time-consuming reconnection of the
welding current connections (also directly at the operating point, in combination with a PWS remote con-
trol).
3.4 Voltage reducing device
Only machine variants with the (VRD/SVRD/AUS/RU) code are equipped with a voltage reduction device
(VRD). The VRD is used for increased safety, especially in hazardous environments such as shipbuilding,
pipe construction or mining.
A VRD is mandatory in some countries and required by many on-site safety instructions for power
sources.
The VRD 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).
3.5 Documents which also apply
3.5.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information regarding
warranty, maintenance and testing at www.ewm-group.com!

Intended use
Documents which also apply
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3.5.2 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.
3.5.3 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!
3.5.4 Service documents (spare parts and circuit diagrams)
WARNING
No improper repairs and modifications!
To prevent injuries and damage to the machine, only competent personnel (authorised
service personnel) are allowed to repair or modify the machine.
Unauthorised manipulations will invalidate the warranty!
• Instruct competent personnel (authorised service personnel) to repair the machine.
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.5.5 Calibration/Validation
An original certificate is enclosed with the product. The manufacturer recommends calibration / validation
at intervals of 12 months.
3.5.6 Part of the complete documentation
This document is part of the complete documentation and valid only in combination with all other
parts of these instructions! Read and observe the operating instructions for all system
components, especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 3-1
Item
Documentation
A.1
Wire feeder
A.2
Power source
A.3
Welding torch
A
Complete documentation

Machine description – quick overview
Front view / rear view
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4 Machine description – quick overview
4.1 Front view / rear view
Figure 4-1

Machine description – quick overview
Front view / rear view
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Item
Symbol
Description 0
1
Transport elements
Transport handle and transport belt > see 5.1.4 chapter
2
Operating elements
Device control > see 4.2 chapter and protective cap > see 5.1.8 chapter
3
Connection socket, welding current (electrode holder)
The welding current polarity (+/-) can be reversed by pressing the welding current pola-
rity push-button (except with TIG welding) and is indicated by a signal light above the
relevant welding current socket.
How to connect the accessories depends on the welding procedure. Please observe
the connection description for the corresponding welding procedure > see 5 chapter.
4
Connection socket, welding current (workpiece)
The welding current polarity (+/-) can be reversed by pressing the welding current pola-
rity push-button (except with TIG welding) and is indicated by a signal light above the
relevant welding current socket.
How to connect the accessories depends on the welding procedure. Please observe
the connection description for the corresponding welding procedure > see 5 chapter.
5
19-pole connection socket
Control cable for remote control and/or wire feeder
6
Cooling air inlet
Dirt filter optional > see 6.1.2 chapter
7
Machine feet
8
Carrying strap > see 5.1.4.1 chapter
9
Main Switch
Switching the machine on or off.
10
Key button, automatic cutout
Wire feed motor supply voltage fuse
press to reset a triggered fuse
11
Mains connection cable > see 5.1.12 chapter
12
Cooling air outlet

Machine description – quick overview
Machine control – Operating elements
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4.2 Machine control – Operating elements
Figure 4-2
Item
Symbol
Description 0
1
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 4.2.1 chapter
2
Collective interference signal light
For error messages, >see 7.2 chapter
3
VRD
Signal light of voltage reduction device (VRD)
Not used in this system!
4
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.
5
Push-button for welding current polarity (pole reversal) / degaussing
• ----------- changing the welding current polarity of the welding current so-
ckets > see 5.7.1.1 chapter
• ----------- degaussing the workpiece > see 5.6 chapter
6
Pulsing push-button
------ PF pulsing (MMA)
-------- Pulsing (MMA/TIG)
7
Welding parameter setting rotary transducer
Setting of welding current and other welding parameter and their values
8
Welding current polarity signal light
The signal light shows the selected polarity at the welding current socket below.
Use the welding current polarity push-button to reverse the welding current polarity of
the welding current sockets.
9
Welding procedure selection push-button
TIG ------- TIG welding
CV -------- MIG/MAG welding with constant voltage characteristics
Default characteristics "CV constant voltage" for nearly all MIG/MAG proces-
ses
CC -------- MIG/MAG welding with constant current characteristics
Used for special wires (flux cored wires), which, according to the manufactu-
rer, are to be welded using "CC constant current"

Machine description – quick overview
Machine control – Operating elements
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Item
Symbol
Description 0
10
Welding procedure/MMA characteristics selection push-button
Select MMA welding procedure and electrode type
R ---------- Electrode type rutile
RB-------- Electrode type rutile-basic
B / RC --- Electrode type basic/rutile-cellulose
C ---------- Electrode type cellulose
11
Select welding parameters button
This button is used to select the welding parameters depending on the welding process
and operating mode used.
12
Display/Power-saving mode switching push-button
AMP ----- Welding current display
VOLT ---- Welding voltage display
kW ------- Welding performance display (both signal lights are illuminated)
STBY---- Press for 2 s to put machine into power-saving mode. To reactivate, activate
one of the operating elements.
4.2.1 Welding data display
All relevant welding parameters with their values are shown depending on the welding procedure selected
and the associated functions. Machine parameters and error codes are shown as well in a unique man-
ner. The meaning of the parameters and values shown is explained in the relevant chapter f or the func-
tion.
Next to the display is the Display/Power-saving mode switching push-button. Each time the push-button is
pressed the display switches between the desired parameters.
Depending on the process, the parameters are shown as nominal values (before welding), actual values
(during welding) or hold values (after welding):
MMA welding, TIG welding and MIG/MAG welding with constant current (CC):
Nominal values
Actual values
Hold values (5 s)
Welding current (AMP)

/ [*]
/ [*]
Welding voltage (VOLT)



Welding performance (kW)



Open circuit voltage



By turning the rotary transducer for the welding parameter settings the display automatically switches to
the welding current display.
MIG/MAG welding with constant voltage (CV):
Nominal values
Actual values
Hold values (5 s)
Welding current (AMP)



Welding voltage (VOLT)



Welding performance (kW)



By turning the rotary transducer for the welding parameter settings the display automatically switches to
the welding voltage display.
[*] optionally adjustable – > see 5.10 chapter

Design and function
Transport and installation
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19
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 Ambient conditions
The machine may only be placed and operated on a suitable, load-bearing and even surface (ac-
cording to IP 34s in case of outside operation as well)!
• Ensure the machine is operated on an even, anti-slip floor and provide sufficient lighting of the
work area.
• 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!
In operation
Temperature range of the ambient air:
• -25 °C to +40 °C (-13 °F to 104 °F) [1]
Relative humidity:
• up to 50 % at 40 °C (104 °F)
• up to 90 % at 20 °C (68 °F)
Transport and storage
Storage in a closed room, temperature range of the ambient air:
• -30 °C to +70 °C (-22 °F to 158 °F) [1]
Relative humidity
• up to 90 % at 20 °C (68 °F)
[1] Ambient temperature dependent on coolant! Observe the coolant temperature range of the torch coo-
ling
5.1.2 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!

Design and function
Transport and installation
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5.1.3 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!
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