EWM Pico 350 cel puls Operating Instructions Manual
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- Page 1 Operating instructions Welding machine Pico 350 cel puls Pico 350 cel puls vrd (AUS) Pico 350 cel puls vrd (RU) Pico 350 cel puls 460V 099-002060-EW501 19.10.2015 Register now and benefit! Jetzt Registrieren und Profitieren! www.ewm-group.com...
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Page 2: General Instructions
+49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 General ............................8 Transport and installation ......................12 2.4.1 Ambient conditions ....................... - Page 4 Error messages (power source) ....................55 Resetting welding parameters to the factory settings ..............56 8 Technical data............................57 Pico 350 cel puls .......................... 57 Pico 350 cel puls 460V ......................... 58 9 Accessories ............................59 Remote controls and accessories ....................59 Options ............................59 General accessories ........................
- Page 5 Contents Notes on the use of these operating instructions 099-002060-EW501 19.10.2015...
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Page 6: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions Notes on the use of 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. •... -
Page 7: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Special technical points which users must observe. Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine enter the menu ENTER Navigating in the menu NAVIGATION Exit the menu EXIT... -
Page 8: General
Safety instructions General General DANGER 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. •... - Page 9 Safety instructions General WARNING 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! •...
- Page 10 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
- Page 11 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes - See 8 Technical data chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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Page 12: Transport And Installation
Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •... -
Page 13: Ambient Conditions
Safety instructions Transport and installation 2.4.1 Ambient conditions CAUTION Installation location The machine may only be placed and operated on a suitable, load-bearing and even surface (according 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. -
Page 14: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! 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 proper usage and by trained or expert staff! •... -
Page 15: 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 The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-002060-EW501 19.10.2015... - Page 17 Machine description – quick overview Front view Item Symbol Description Transport bar Protective cap Connection socket, “+” welding current How to connect the accessories depends on the welding procedure. Please observe the connection description for the corresponding welding procedure. Cooling air inlet Dirt filter can be retrofitted Machine feet Connection socket, “-”...
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Page 18: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 099-002060-EW501 19.10.2015... - Page 19 Machine description – quick overview Rear view Item Symbol Description Transport bar Cable holder Main switch, machine on/off Cooling air outlet Machine feet Mains connection cable - See 5.6 Mains connection chapter Key button, automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse Carrying handle 099-002060-EW501...
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Page 20: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 Item Symbol Description 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. - Page 21 Machine description – quick overview Machine control – Operating elements Item Symbol Description Welding procedure/MMA characteristics selection push-button Select MMA welding procedure and electrode type Electrode type rutile Electrode type rutile-basic B / RC Electrode type basic/rutile-cellulose Electrode type cellulose Display/Power-saving mode switching push-button Welding current display VOLT...
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Page 22: Design And Function
Design and function General Design and function General 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! •... -
Page 23: Machine Cooling
Design and function Machine cooling Machine cooling To obtain an optimal duty cycle from the power components, the following precautions should be observed: • Ensure that the working area is adequately ventilated. • Do not obstruct the air inlets and outlets of the machine. •... -
Page 24: Adjusting The Length Of The Carrying Strap
Design and function Transport and installation 5.4.1 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 5.4.2 Cable strap In the delivery state, the machine has a cable strap for easy and orderly transport of earth lead, welding torch, electrode holder etc. -
Page 25: Cable Holder
Design and function Transport and installation 5.4.3 Cable holder The machine is supplied with a cable holder with mounting material. This cable holder can be used to coil and conveniently transport the mains cable. Install the cable holder as shown in the figure. 5.4.3.1 Assembly Figure 5-3... -
Page 26: Protective Flap, Welding Machine Control
Design and function Transport and installation 5.4.4 Protective flap, welding machine control 5.4.4.1 Deinstallation/Installation Figure 5-5 Item Symbol Description Seating hole for mounting nipple Mounting nipple, protective cap Protective cap • Remove the protective cap by gently pressing from the side while simultaneously pulling. To attach, insert and snap into place. -
Page 27: Welding Data Display
Design and function Welding data display 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 manner. -
Page 28: Mains Connection
Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations! •... -
Page 29: Mma Welding
Design and function MMA welding MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •... -
Page 30: Welding Procedure And Parameter Selection
Design and function MMA welding 5.7.2 Welding procedure and parameter selection Operating Action Result element Select MMA welding procedure and electrode type Electrode type rutile Electrode type rutile-basic B / RC Electrode type basic/rutile-cellulose Electrode type cellulose Set welding current 5.7.2.1 Arcforce (welding characteristics) During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in... -
Page 31: Hotstart Current And Hotstart Time
Design and function MMA welding 5.7.2.2 Hotstart current and Hotstart time The hotstart device uses an increased ignition current to improve arc ignition. The parameters for the hotstart current and time can be adjusted individually. When the stick electrode has been struck, the arc ignites at the adjusted hotstart current AMP% (factory setting: 120 % of main current) and welds at this current until the hotstart time in seconds has elapsed (factory setting: 1 second). -
Page 32: Mma Pulse Welding In The Vertical Up Position (Pf)
Design and function MMA welding 5.7.3 MMA pulse welding in the vertical up position (PF) Welding characteristics: • Especially suitable for root welding • Fine-flaked weld surface with a TIG look for final passes • Less finishing work thanks to less spatter •... -
Page 33: Mma Pulsed Welding
Design and function MMA welding 5.7.4 MMA pulsed welding Operating Action Result element Press the push-button until the Pulse (pulse arc welding) signal light illuminates. Figure 5-12 AMP = Main current; e.g. 100 A IPL = Pulse current = IP1 x AMP; e.g. 170% x 100 A = 170 A I2 = Pulse pause current Tpuls = Duration of one pulse cycle = 1/FrE;... -
Page 34: Expert Menu (Mma)
Design and function MMA welding 5.7.5 Expert menu (MMA) To enable the greatest possible breadth of applications, the following parameters can be adjusted or optimised for the welding task. To change the advanced setting parameters, hold down the "Welding parameters" button for 2 seconds after selecting the welding process. -
Page 35: Tig Welding
Design and function TIG welding TIG welding 5.8.1 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! •... -
Page 36: Connection
Design and function TIG welding 5.8.1.1 Connection • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. Figure 5-14 Item Symbol Description Pressure regulator Output side of the pressure regulator Cylinder valve Shielding gas cylinder •... -
Page 37: Connecting A Tig Welding Torch With Rotating Gas Valve
Design and function TIG welding 5.8.2 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 5-15 Item Symbol Description Workpiece Connection socket for "+" welding current Workpiece lead connection Output side of the pressure regulator Welding torch... -
Page 38: Welding Procedure And Parameter Selection
Design and function TIG welding 5.8.3 Welding procedure and parameter selection Operating Action Result element Press the welding procedure selection push-button until the TIG signal light illuminates. Set main current 5.8.4 TIG arc ignition 5.8.4.1 Liftarc ignition Figure 5-16 The arc is ignited on contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece (liftarc current flowing, regardless of the main current set). -
Page 39: Tig Pulsed Welding
Design and function TIG welding 5.8.4.2 TIG pulsed welding Operating Action Result element Press the push-button until the Pulse (pulse arc welding) signal light illuminates. Figure 5-17 AMP = Main current; e.g. 100 A IPL = Pulse current = IP1 x AMP; e.g. 170% x 100 A = 170 A I2 = Pulse pause current Tpuls = Duration of one pulse cycle = 1/FrE;... -
Page 40: Advanced Settings
Design and function TIG welding 5.8.5 Advanced settings ENTER EXIT NAVIGATION PF Pulse Pulse Figure 5-18 Display Setting/selection Ignition current Setting: 1% to 200% (20% ex works, dependent on main current) Up-slope time 0.0 s to 20.0 s (1.0 s ex works, 0.1 s increments) Pulsed TIG welding frequency Setting range: 0.2 Hz–2.0 kHz Balance... -
Page 41: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.9.1 Connecting the intermediate hose package to the power source Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity. In this case, the welding current lead should be connected to the "-" welding current socket, and the workpiece lead should be connected to the "+"... -
Page 42: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function MIG/MAG welding 5.9.2 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! •... -
Page 43: Setting The Shielding Gas Quantity
Design and function MIG/MAG welding 5.9.2.1 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11.5 = l/min MIG brazing Wire diameter x 11.5 = l/min MIG welding (aluminium) Wire diameter x 13.5 = l/min (100 % argon) Helium-rich gas mixtures require a higher gas volume! The table below can be used to correct the gas volume calculated where necessary: Shielding gas... -
Page 44: Mig/Mag Welding With Constant Voltage Characteristics (Cv)
Design and function MIG/MAG welding 5.9.3 MIG/MAG welding with constant voltage characteristics (CV) Default characteristics "CV constant voltage" for nearly all MIG/MAG processes 5.9.3.1 Selection Operating Action Result element Select welding procedure Press the push-button until the CV (constant voltage) signal light illuminates. -
Page 45: Mig/Mag Welding With Constant Current Characteristics (Cc)
Design and function MIG/MAG welding 5.9.4 MIG/MAG welding with constant current characteristics (CC) Used for special wires (flux cored wires), which, according to the manufacturer, are to be welded using "CC constant current" 5.9.4.1 Selection Operating Action Result element Select welding procedure Press the push-button until the CC (constant current) signal light illuminates. -
Page 46: Mig/Mag Welding - Voltage-Sensing
Design and function MIG/MAG welding – voltage-sensing MIG/MAG welding – voltage-sensing 5.10 5.10.1 General This welding machine supports wire feeders with voltage detection (voltage-sensing). Voltage is supplied to these wire feeders solely by the welding voltage. The wire feeder has a lead to connect to the workpiece, to ensure voltage detection and supply. -
Page 47: 5.10.3 Connecting The Supply Lines
Design and function MIG/MAG welding – voltage-sensing 5.10.3 Connecting the supply lines Figure 5-24 Item Symbol Description Workpiece "-" welding current connection socket • MIG/MAG welding: Workpiece connection Wire feed unit Connection socket, "+" welding current • MIG/MAG cored wire welding: Workpiece connection •... -
Page 48: Remote Control
Design and function Remote control 5.11 Remote control Insert the remote control control cable into the 19-pole connection socket for remote control connection and lock. 5.11.1 Foot-operated remote control RTF1 19POL Features • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. -
Page 49: Dirt Filter
Design and function Dirt filter 5.13 Dirt filter These accessory components can be retrofitted as an option - See 9 Accessories chapter. The dirt filter can be used in places with unusually high levels of dirt and dust in the ambient air. The filter reduces the duty cycle of the welding machine via the reduced flow of cooling air. -
Page 50: Machine Configuration Menu
Design and function Machine configuration menu 5.14 Machine configuration menu ENTER (Enter the menu) • Switch off machine at the main switch. • Hold down the "Welding process" button and simultaneously switch the machine on again. Wait until the "Elt" menu item is shown and release the button. NAVIGATION (navigating in the menu) •... - Page 51 Design and function Machine configuration menu Display Setting/selection Calibration The machine will be calibrated for approx 2 seconds each time it is switched on. Exit the menu Exit Machine configuration Settings for machine functions and parameter display Time-based power-saving mode •...
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Page 52: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Improper maintenance and testing The equipment may only be cleaned, repaired or tested by specialist, skilled persons! A skilled person is one who, due to training, knowledge and experience, is able to recognise the dangers that can occur during testing of this equipment as well as possible subsequent damage and who is able to implement the required safety procedures. -
Page 53: Annual Test (Inspection And Testing During Operation)
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU). -
Page 54: Rectifying Faults
Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer. -
Page 55: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) A welding machine error is indicated by an error code being displayed (see table) on the display on the machine control. In the event of a machine error, the power unit is shut down. The display of possible error numbers depends on the machine version (interfaces/functions). -
Page 56: Resetting Welding Parameters To The Factory Settings
Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. RESET R-Rutil RB-Rutilbas B-Bas RC-Rutilcel C-Cel Figure 7-1 Display Setting/selection Calibration The machine will be calibrated for approx 2 seconds each time it is switched on. -
Page 57: Technical Data
Technical data Pico 350 cel puls Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Pico 350 cel puls MIG/MAG Current setting range 10–350 A Voltage setting range 20.4 V–34.0 V 10.4 V–24.0 V 14.0 V–31.5 V... -
Page 58: Pico 350 Cel Puls 460V
Technical data Pico 350 cel puls 460V Pico 350 cel puls 460V MIG/MAG Current setting range 10–350 A Voltage setting range 20.4 V–34.0 V 10.4 V–24.0 V 14.0 V–31.5 V Duty cycle 25 °C 350 A 310 A 100% 260 A Duty cycle 40 °C... -
Page 59: Accessories
Accessories Remote controls and accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Remote controls and accessories Type Designation Item no. RT1 19POL Remote control current 090-008097-00000 RA5 19POL 5M Remote control e.g. -
Page 60: Overview Of Ewm Branches
Appendix A Overview of EWM branches Appendix A 10.1 Overview of EWM branches 099-002060-EW501 19.10.2015...
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