EWM PICO 162 Operating Instructions Manual
Welding machine for mma welding
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Operating instructions
Welding machines for MMA welding
PICO 162
PICO 162 MV
N. B. These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machines may only be operated by personnel who are familiar with the appropriate safety
regulations.
The machines bear the conformity mark and thus comply with the
•
EC Low Voltage Directive (2006/95/ EG)
•
EC EMC Directive (2004/108/ EG)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.
The content of the operating instructions does not constitute grounds for any claims on the part
©
of the buyer.
The copyright to these operating instructions remains with the manufacturer.
Reprinting, including extracts, only with written approval.
© 2009
Subject to alteration.
Dr. Günter-Henle-Straße 8
Fon +49 2680 181-0
Item No.: 099-002040-EWM01
HIGHTEC WELDING GmbH
D-56271 Mündersbach
Fax +49 2680 181-244
www.ewm.de
info@ewm.de
Revised: 2009-03-10
EWM
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Table of Contents
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Summary of Contents for EWM PICO 162
- Page 1 Operating instructions Welding machines for MMA welding PICO 162 PICO 162 MV N. B. These operating instructions must be read before commissioning. Failure to do so may be dangerous. Machines may only be operated by personnel who are familiar with the appropriate safety regulations.
- Page 2 Perfection doesn't happen by coincidence: Every single component is 100% tested and the machine is “free welded” before it is delivered. Our comprehensive service offer and the highly developed modern EWM quality management system guarantee worldwide premium quality “Made in Germany” and a three-year warranty.
- Page 3 Machine and Company Data Please enter the EWM machine data and your company’s data in the appropriate fields. EWM HIGHTEC WELDING GMBH D-56271 MÜNDERSBACH TYP: SNR: ART: PROJ: GEPRÜFT/CONTROL: Name of Customer / company Name of Customer / company Adress...
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Page 4: Table Of Contents
Transport and installation......................11 Ambient conditions........................12 2.4.1 In operation........................12 2.4.2 Transport and storage ....................12 3 Technical data............................13 PICO 162, PICO 162 MV ......................13 4 Machine description..........................14 PICO 162, PICO 162 MV ......................14 4.1.1 Front view ........................14 4.1.2 Rear view........................15 5 Functional characteristics........................16 Machine control –... - Page 5 10.2 TIG welding..........................35 10.3 Options............................35 10.4 General accessories ........................35 11 Circuit diagrams........................... 36 11.1 PICO 162 ............................. 36 11.2 PICO 162 MV..........................37 12 Appendix A ............................38 12.1 Declaration of Conformity ......................38 Item No.: 099-002040-EWM01...
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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 NOTE Special technical points which users must observe. • Notes include the "NOTE" keyword in the heading without a general warning symbol. •... - Page 7 Safety instructions Notes on the use of these operating instructions Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet points, e.g.: • Insert the welding current lead socket into the relevant socket and lock. Symbol Description Press Do not press...
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Page 8: General
Safety instructions General General CAUTION Risk of accidents if these safety instructions are not observed! Non-observance of these safety instructions is potentially fatal! • Carefully read the safety information in this manual! • Observe the accident prevention regulations in your country. •... - Page 9 Safety instructions General CAUTION Risk of injury due to radiation or heat! Arc radiation results in injury to skin and eyes. Contact with hot workpieces and sparks results in burns. • Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant regulations in the country in question! •...
- Page 10 Safety instructions 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. •...
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Page 11: Transport And Installation
Safety instructions Transport and installation Transport and installation CAUTION Equipment damage when not operated in an upright position! 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! CAUTION Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself... -
Page 12: Ambient Conditions
Safety instructions Ambient conditions Ambient conditions CAUTION Equipment damage due to dirt accumulation! 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)! Non-permissible ambient conditions! Insufficient ventilation results in a reduction in performance and equipment damage. -
Page 13: Technical Data
-20°C to +40°C Machine cooling / torch cooling Fan / Gas Workpiece lead 16 qmm Dimensions L/W/H 430 x 116 x 224 mm Weight 4.8 kg (PICO 162 MV: 5.1 kg) Constructed to standards IEC 60974-1, -3, -10 Item No.: 099-002040-EWM01... -
Page 14: Machine Description
Machine description PICO 162, PICO 162 MV Machine description PICO 162, PICO 162 MV 4.1.1 Front view Figure 4-1 Item Symbol Description Carrying strap Machine control See Machine control – operating elements chapter Connection socket, "+" welding current • TIG: Connection for workpiece lead •... -
Page 15: Rear View
Machine description PICO 162, PICO 162 MV 4.1.2 Rear view Figure 4-2 Item Symbol Description Strain relief with mains connection cable Cooling air inlet Main switch, machine on/off Item No.: 099-002040-EWM01... -
Page 16: Functional Characteristics
Functional characteristics Machine control – Operating elements Functional characteristics Machine control – Operating elements Figure 5-1 Item Symbol Description Welding current rotary dial Infinite adjustment of the welding current from 10A to maximum current Welding process changeover switch • = MMA welding •... -
Page 17: Antistick
Functional characteristics TIG welding 5.2.4 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. Check the welding current setting and correct according to the welding task! Figure 5-2 TIG welding... -
Page 18: Commissioning
Commissioning General Commissioning General DANGER 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: Installation
For mains fuse protection, please refer to the “Technical data” chapter! • Insert mains plug of the switched-off machine into the appropriate socket. 6.4.1 PICO 162, PICO 162 MV CAUTION Connect a suitable mains plug! A suitable mains plug must be connected to the mains supply lead to avoid damage! •... -
Page 20: Dirt Filter
Commissioning Machine cooling 6.5.1 Dirt filter NOTE These accessory components can be retrofitted as an option, see 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. The filter must be disassembled and cleaned regularly depending on the level of dirt (blow out with compressed air). -
Page 21: Workpiece Lead, General
Do not use structural parts of the workpiece as a return lead for the welding current! • Take care to ensure faultless power connections! MMA welding 6.7.1 PICO 162, PICO 162 MV Figure 6-2 Item Symbol Description Connection socket, "+" welding current •... -
Page 22: Electrode Holder Connection
Commissioning MMA welding 6.7.1.1 Electrode holder connection 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 23: Tig Welding
Commissioning TIG welding TIG welding 6.8.1 PICO 162, PICO 162 MV Figure 6-3 Item Symbol Description Connection socket, “+” welding current Connection for workpiece lead “-” Welding current connection socket TIG welding torch welding current lead connection 6.8.1.1 Connecting a TIG welding torch with rotating gas valve When pausing work, always place the welding torch on an insulated surface. -
Page 24: Shielding Gas Supply
Commissioning TIG welding 6.8.1.3 Shielding Gas Supply CAUTION 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 25: Maintenance And Testing
NOTE The maintenance, cleaning and testing work described below must be conducted correctly and on an annual basis in order qualify for claims under the EWM warranty. General When used in the specified environmental conditions and under normal operating conditions, this machine is largely maintenance-free and requires a minimum of care. -
Page 26: Test
DIN EN 61010-1 Appendix A – Measuring Circuit A1. You as the user are tasked with ensuring that your EWM machines conform to the standard IEC/DIN EN 60974-4 and are tested with the relevant test equipment and measuring devices given above. -
Page 27: Scope Of The Test
Maintenance and testing Test 7.3.2 Scope of the test a) Visual inspection b) Electrical test: measurement of • open circuit voltage • insulation resistance, or alternatively • leakage currents • protective conductor resistance c) Functional test d) Documentation 7.3.3 Visual inspection The key areas in the test are: 1. -
Page 28: Measuring The Leakage Current (Protective Conductor And Contact Current)
Note: Even if the leakage current measurement according to the standard is only an alternative to the insulation resistance measurement, EWM recommends always performing both measurements, especially following repair work. The leakage current is based for the greater part on a physical effect other than the insulation resistance. -
Page 29: Repair Work
Returns of defective equipment subject to warranty may only be made through your EWM sales partner. In the event of problems or queries, please contact the EWM Service Department directly (+49 (0) 2680 181 0). Use only genuine spare parts and replacement parts when replacing. When placing an order, please quote the type designation and item number, as well as the type, serial number and item number of the relevant equipment. -
Page 30: Disposing Of Equipment
Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922. •... -
Page 31: Warranty
• Wire feeds • Cooling units • Trolleys * If these are operated with genuine EWM accessories (such as intermediate tube package, remote control, remote control extension cable, coolant, etc.). 1-year warranty on: • Used EWM machines • Automation and mechanisation components •... -
Page 32: Warranty Declaration
This limitation does not apply to personal injuries or damage to property caused by negligent behaviour on the part of EWM. In no way will EWM be responsible for lost profits, indirect or subsequent damage. EWM is not liable for damages based on the claims of third parties. -
Page 33: Operating Problems, Causes And Remedies
Operating problems, causes and remedies General Operating problems, causes and remedies General All machines are subject to rigorous production checks and final checks. If despite this, anything fails to work at any time, please check the machine using the following chart. If none of the fault rectification procedures described leads to the correct functioning of the machine, please inform your authorised dealer. -
Page 34: Customer Checklist
Operating problems, causes and remedies Customer checklist Customer checklist Switch on machine at the mains switch • Mains plug not inserted Machine ready for operation • Mains fuse faulty ("Ready for operation" signal light is on, fan is running) • Mains supply interrupted •... -
Page 35: Accessories, Options
Accessories, options MMA welding Accessories, options 10.1 MMA welding Type Description / Name Item number EH16 QMM 4M Electrode holder 094-005313-00000 10.2 TIG welding Type Description / Name Item number TIG 17 GDV 4M TIG welding torch, rotary gas valve, gas, decentral 094-007866-00000 DM1 32L/MIN Manometer pressure reducer... -
Page 36: Circuit Diagrams
Circuit diagrams PICO 162 Circuit diagrams NOTE Original format circuit diagrams are located inside the machine. 11.1 PICO 162 Figure 11-1 Item No.: 099-002040-EWM01... -
Page 37: Pico 162 Mv
Circuit diagrams PICO 162 MV 11.2 PICO 162 MV Figure 11-2 Item No.: 099-002040-EWM01... -
Page 38: Declaration Of Conformity
Umbauten, die nicht ausdrücklich von authorised by EWM. bées n’ayant pas été autorisés expressé- EWM autorisiert sind, verliert diese ment par EWM, cette déclaration devient Erklärung ihre Gültigkeit. caduque. Gerätebezeichnung: Description of the machine: Déscription de la machine: Gerätetyp:...
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