EWM Pico 220 cel puls Operating Instructions Manual
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Summary of Contents for EWM Pico 220 cel puls
- Page 1 Operating instructions Welding machine Pico 220 cel puls Pico 220 cel puls vrd (AUS) Pico 220 cel puls vrd (RU) 099-002057-EW501 Observe additional system documents! 8.02.2023...
- Page 2 +49 2680 181-0. 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 form of liability, regardless of type, shall be accepted.
- Page 3 Contents Notes on using these operating instructions 099-002057-EW501 8.02.2023...
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Page 4: Table Of Contents
Contents Notes on using these operating instructions Contents 1 Contents ............................4 2 For your safety..........................6 Notes on using these operating instructions ................6 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ..................... 11 3 Intended use ..........................13 Applications .......................... - Page 5 Resetting welding parameters to the factory settings ............39 8 Technical data ..........................40 Pico 220 cel puls ........................40 Pico 220 cel puls (AUS/RU) ....................41 9 Accessories ..........................42 Transport system ......................... 42 19-pole remote control ......................42 9.2.1...
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Page 6: For Your Safety
For your safety Notes on using these operating instructions For your safety 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. •... -
Page 7: Safety Instructions
For your safety Safety instructions 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 hold Incorrect / Invalid Switch Correct / Valid Turn Input Numerical value –... - Page 8 For your safety 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! •...
- Page 9 For your safety Safety instructions 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.
- Page 10 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases may lead to shortness of breath and poisoning! The ultraviolet radia- tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso- nous phosgene. • Ensure sufficient fresh air! •...
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Page 11: Transport And Installation
For your safety Transport and installation 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. - Page 12 For your safety Transport and installation 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.
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Page 13: Intended Use
3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 14: Part Of The Complete Documentation
Intended use Documents which also apply 3.3.6 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. -
Page 15: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Carrying strap > see 5.1.4.1 chapter Machine control > see 4.3 chapter Connection socket, "+" welding current • MMA: Electrode holder or workpiece lead connection •... -
Page 16: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Mains connection cable > see 5.1.7 chapter Cooling air inlet Main Switch Switching the machine on or off. 099-002057-EW501 8.02.2023... -
Page 17: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 Item Symbol Description Display, 3-digit Collective interference signal light For error messages, > see 7.2 chapter Excess temperature signal light In case of excess temperature, temperature monitors de-activate the power unit, and the excess temperature control lamp comes on. -
Page 18: Design And Function
Design and function Transport and installation Design and function 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! •... -
Page 19: Transport Belt
Design and function Transport and installation 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 5.1.5 Notes on the installation of welding current leads... -
Page 20: Mains Connection
Design and function Transport and installation WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. • Check that all welding current connections are firmly secured and electrical connections are in perfect condition. -
Page 21: Mains Configuration
Design and function MMA welding DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • The connection (mains plug or cable), the repair or voltage adjustment of the device must be carried out by a qualified electrician in accordance with the respective local laws or nati- onal regulations! •... - Page 22 Design and function MMA welding CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. • Use an insulated pair of tongs to remove the used stick electrode or to move welded work- pieces.
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Page 23: Welding Task Selection
Design and function MMA welding 5.2.2 Welding task selection AM P AM P% Figure 5-7 Item Symbol Description Welding procedure/power-saving mode push-button --------- Selection of MMA welding procedure/electrode type setting Signal light illuminated in green = electrode type rutile Signal light illuminated in red = electrode type rutile basic Signal light illuminated in green = electrode type basic/rutile cellulose... -
Page 24: Hotstart
Design and function MMA welding 5.2.3 Hotstart The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent metal at the beginning of the welding process. The ignition takes place here with increased current (hot start current) over a certain time (hot start time). -
Page 25: Average Value Pulse Welding
Design and function MMA welding 5.2.6 Average value pulse welding Average value pulse welding means that two currents are switched periodically, a current average value (AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the para- meter as a percentage of the current average value (AMP). -
Page 26: Expert Menu (Mma)
Design and function TIG welding 5.2.7 Expert menu (MMA) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa- rameters shown may be limited, e.g. if a function is deactivated. Figure 5-13 Display Setting/selection Arcforce correction •... -
Page 27: Connecting The Shielding Gas Supply
Design and function TIG welding WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! • Place shielding gas cylinder into the designated holder and secure with fastening elements (chain/belt)! •... -
Page 28: Connecting A Tig Welding Torch With Rotating Gas Valve
Design and function TIG welding 5.3.2 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 29: Arc Ignition
Design and function TIG welding 5.3.4 Arc ignition 5.3.4.1 Liftarc Figure 5-17 The arc ignites through contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip against the workpiece (lift arc current flows independent of the set main current) b) Angle the torch above the torch gas nozzle until the distance between electrode tip and workpiece is approx. -
Page 30: Expert Menu (Tig)
Design and function TIG welding Figure 5-19 Display Setting/selection Pulse welding (average value pulses) ------- Function switched on ------- Function switched off (ex works) Pulse frequency More parameters can be set in the Expert menu > see 5.3.6 chapter. 5.3.6 Expert menu (TIG) The Expert menu has adjustable parameters stored that don’t require regular setting. -
Page 31: Dirt Filter
Design and function Dirt filter Display Setting/selection Start current (as percentage, dependent on main current) Upslope time to main current Pulse balance Pulse current > see 5.3.5 chapter Arc length restriction > see 5.7 chapter ------ Function switched on ------ Function switched off The setting ranges for the parameter values are summarised in the Parameter overview sec- tion >... -
Page 32: Rtg1 19Pol
Design and function Power-saving mode (Standby) 5.5.2 RTG1 19POL Functions • Infinite setting of the welding current (0% to 100%) depending on the main current preselected at the welding machine 5.5.3 RTF1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. -
Page 33: Machine Configuration Menu
Design and function Machine configuration menu Machine configuration menu Figure 5-22 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 34: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed. -
Page 35: Maintenance Work, Intervals
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. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-002057-EW501 8.02.2023... -
Page 36: Disposing Of Equipment
Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html. -
Page 37: 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 dea- ler. -
Page 38: Software Version Of The Machine Control
Rectifying faults Software version of the machine control Error message Possible cause Remedy Secondary overvoltage Switch the machine off and on again. If the error persists, notify service department Voltage reduction error (VRD) Electronics error Alignment error in current recording Switch off the machine, place the electrode holder in an insulated position and switch the machine back on. -
Page 39: 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. Figure 7-1 Display Setting/selection Calibration The machine will be calibrated for approx 2 seconds each time it is switched on. Initialising Keep the push-button pressed until is shown on the display. -
Page 40: Technical Data
Technical data Pico 220 cel puls Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Pico 220 cel puls Welding current (I 10 A to 220 A Welding voltage according to standard (U 20,4 V to 28,8 V 10,4 V to 18,8 V Duty cycle DC at 40°... -
Page 41: Pico 220 Cel Puls (Aus/Ru)
Technical data Pico 220 cel puls (AUS/RU) Pico 220 cel puls (AUS/RU) Welding current (I 10 A to 220 A Welding voltage according to standard (U 20,4 V to 28,8 V 10,4 V to 18,8 V Duty cycle DC at 40° C... -
Page 42: Accessories
Accessories Transport system Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Transport system Type Designation Item no. Trolly 35-1 Transport vehicle 090-008629-00000 19-pole remote control Type Designation Item no. RT1 19POL Remote control current 090-008097-00000... -
Page 43: Appendix
Appendix Parameter overview Appendix 10.1 Parameter overview 10.1.1 MMA welding Parameters/function Setting range Pulse welding Pulse frequency Hot start current (AMP%) Hot start time 20,0 Arcforce correction Pulse balance Pulse current Arc length restriction 10.1.2 TIG welding Parameters/function Setting range Pulse welding Pulse frequency - 2000... -
Page 44: Basic Parameters (Independent Of Process)
Appendix Parameter overview 10.1.3 Basic parameters (independent of process) Parameters/function Setting range Switched on Switched off Calibration Initialisation Machine configuration Time-based power-saving mode min. Arc detection for welding helmets (TIG) Exit menu Service menu Software version of the machine control Power-saving mode is active 099-002057-EW501 8.02.2023... -
Page 45: Searching For A Dealer
Appendix Searching for a dealer 10.2 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-002057-EW501 8.02.2023...
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