EWM Pico 350 cel puls vrd Operating Instructions Manual
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Summary of Contents for EWM Pico 350 cel puls vrd
- Page 1 Operating instructions Welding machine Pico 350 cel puls Pico 350 cel puls vrd (AUS) Pico 350 cel puls vrd (RU) 099-002060-EW501 Observe additional system documents! 24.03.2017...
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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 Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................5 Notes on the use of these operating instructions ................5 2.1.1 Explanation of icons ....................... 6 Part of the complete documentation ....................7 Safety instructions ..........................
- Page 4 General accessories ........................48 System components ........................48 9.4.1 Wire feed unit ........................ 48 10 Appendix A ............................49 10.1 Parameter overview – setting information ..................49 11 Appendix B ............................50 11.1 Overview of EWM branches......................50 099-002060-EW501 24.03.2017...
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Page 5: For Your Safety
For your safety Notes on the use of these operating instructions For your safety 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. •... -
Page 6: Explanation Of Icons
For your safety Notes on the use of these operating instructions 2.1.1 Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release/tap/tip user must observe. Switch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn... -
Page 7: Part Of The Complete Documentation
For your safety Part of the complete documentation Part of the complete documentation These operating instructions are 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. - Page 8 For your safety Safety instructions WARNING Hazard when interconnecting multiple power sources! If a number of power sources are to be connected in parallel or in series, only a technical specialist may interconnect the sources as per standard IEC 60974-9:2010: Installation and use and German Accident Prevention Regulation BVG D1 (formerly VBG 15) or country-specific regulations.
- Page 9 For your safety Safety instructions 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! •...
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Page 10: Transport And Installation
For your safety Transport and installation CAUTION 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. - Page 11 For your safety Transport and installation 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! •...
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Page 12: Intended Use
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. -
Page 13: Calibration/Validation
Intended use Documents which also apply 3.2.5 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 099-002060-EW501 24.03.2017... -
Page 14: Machine Description – Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Transport bar Carrying strap > see 5.1.4 chapter 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 >... -
Page 15: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Cable holder Main switch, machine on/off Cooling air outlet Key button, automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse Mains connection cable > see 5.1.9 chapter 099-002060-EW501 24.03.2017... -
Page 16: 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 17 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 R ---------- Rutile electrode type RB / RC - Rutile-basic/rutile-cellulose electrode type B ---------- Basic electrode type C ---------- Cellulose electrode type Display/Power-saving mode switching push-button AMP ----- Welding current display...
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Page 18: Design And Function
Design and function Transport and installation 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! •... -
Page 19: Workpiece Lead, General
Design and function Transport and installation 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! •... -
Page 20: Cable Strap
Design and function Transport and installation 5.1.5 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. The following figure shows the fastened strap and how the components can be secured. -
Page 21: Cable Holder
Design and function Transport and installation 5.1.6 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. 5.1.6.1 Deinstallation/Installation Figure 5-3... -
Page 22: Protective Flap, Welding Machine Control
Design and function Transport and installation 5.1.7 Protective flap, welding machine control 5.1.7.1 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 23: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.8 Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc (flickering). Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel. -
Page 24: Stray Welding Currents
Design and function Transport and installation 5.1.8.1 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. •... -
Page 25: Mains Configuration
Design and function Welding data display 5.1.9.1 Mains configuration The machine may be connected to: • a three-phase system with four conductors and an earthed neutral conductor • a three-phase system with three conductors of which any one can be earthed, e.g. -
Page 26: 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 27: Welding Task Selection
Design and function MMA welding 5.3.2 Welding task selection Figure 5-12 5.3.2.1 Arcforce (welding characteristics) During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current. This makes it easier to weld large-drop melting electrode types at low current strengths with a short arc in particular. -
Page 28: Hotstart Time
Design and function MMA welding 5.3.3.1 Hotstart time EXIT Figure 5-15 5.3.3.2 Hotstart current EXIT Figure 5-16 5.3.4 Antistick Anti-stick prevents the electrode from annealing. If the electrode sticks in spite of the Arcforce device, the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating. -
Page 29: Average Value Pulse Welding
Design and function MMA welding 5.3.5 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). -
Page 30: Expert Menu (Mma)
Design and function MMA welding 5.3.6 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 >... -
Page 31: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.4.1 Connecting the intermediate hose package to the power source With this machine series, the earth cable on the intermediate hose package must not be connected to the welding machine or wire feeder! Remove the earth cable or push back into the hose package! Figure 5-22 Item Symbol... -
Page 32: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function MIG/MAG welding 5.4.2 Shielding gas supply (shielding gas cylinder for welding machine) • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. Figure 5-23 Item Symbol Description Pressure regulator Shielding gas cylinder... -
Page 33: Mig/Mag Welding With Constant Voltage Characteristics (Cv)
Design and function MIG/MAG welding 5.4.3 MIG/MAG welding with constant voltage characteristics (CV) Default characteristics "CV constant voltage" for nearly all MIG/MAG processes 5.4.3.1 Welding task selection Figure 5-24 5.4.3.2 Expert menu The Expert menu has adjustable parameters stored that don’t require regular setting. The number of parameters shown may be limited, e.g. -
Page 34: Expert Menu
Design and function MIG/MAG welding 5.4.4.2 Expert menu 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 >... -
Page 35: Legend
Design and function MIG/MAG welding 5.4.5.3 Legend Symbol Description Shielding gas Welding machine supply voltage Welding current (minus potential) Welding current (plus potential) Welding torch Workpiece 5.4.5.4 Connecting the supply lines Figure 5-29 Item Symbol Description Workpiece "-" welding current connection socket •... -
Page 36: Tig Welding
Design and function TIG welding TIG welding 5.5.1 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 37: Connecting A Tig Welding Torch With Rotating Gas Valve
Design and function TIG welding 5.5.2 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 5-31 Item Symbol Description Workpiece Connection socket for "+" welding current Workpiece lead connection Output side of the pressure regulator Welding torch... -
Page 38: Welding Task Selection
Design and function TIG welding 5.5.3 Welding task selection Figure 5-32 5.5.4 Arc ignition 5.5.4.1 Liftarc Figure 5-33 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: Expert Menu (Tig)
Design and function Arc length restriction (USP) Selection Figure 5-35 5.5.6 Expert menu (TIG) 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 >... -
Page 40: Arc Length Restriction (Usp)
Design and function Arc length restriction (USP) Arc length restriction (USP) The arc length restriction function stops the welding process when an excessive arc voltage is detected (unusually high gap between electrode and workpiece). This function can be adjusted in the corresponding Expert menu, depending on the process: MMA welding >... -
Page 41: Machine Configuration Menu
Design and function Machine configuration menu 5.10 Machine configuration menu ENTER NAVIGATION EXIT Figure 5-37 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 >... -
Page 42: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Incorrect maintenance and testing! The machine may be cleaned, repaired and tested by skilled and qualified personnel only. A qualified person is one who, due to their training, knowledge and experience, can detect any hazards and possible consequential damage when checking the machine, and can take the necessary safety measures. -
Page 43: Daily Maintenance Tasks
For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. -
Page 44: Disposing Of Equipment
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives on the Declaration of Conformity on your machine). -
Page 45: 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 46: Display Machine Control Software Version
Rectifying faults Display machine control software version Error message Possible cause Remedy Electronics error Switch the machine on and off again. If the error persists, notify service department Adjustment error in voltage Switch off the machine, place the electrode recording holder in an insulated position and switch the machine back on. -
Page 47: 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 A–350 A Voltage setting range 20.4 V–34.0 V 10.4 V–24.0 V 14.5 V–31.5 V Duty cycle 40 °C 350 A... -
Page 48: 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 49: Appendix A
Appendix A Parameter overview – setting information Appendix A Parameter overview – setting information 10.1 Parameters/function Setting range Hot start current Hot start time 20,0 Arcforce correction Frequency correction (PF Pulse) Balance correction (PF Pulse) Pulse current correction (PF Pulse) Pulse frequency Pulse balance Pulse current... -
Page 50: Appendix B
Appendix B Overview of EWM branches Appendix B 11.1 Overview of EWM branches 099-002060-EW501 24.03.2017...
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