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EWM Pico 200 cel puls Operating Instructions Manual
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EWM Pico 200 cel puls Operating Instructions Manual

EWM Pico 200 cel puls Operating Instructions Manual

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Operating instructions
Welding machine
Pico 200 cel puls
EN
099-002130-EW501
Observe additional system documents!
09.09.2024

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Summary of Contents for EWM Pico 200 cel puls

  • Page 1 Operating instructions Welding machine Pico 200 cel puls 099-002130-EW501 Observe additional system documents! 09.09.2024...
  • 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 Contents 1 Contents ............................3 2 For your safety ..........................7 Notes on using these operating instructions ................ 7 Explanation of icons ......................8 Safety instructions ........................ 9 Transport and installation ....................12 3 Intended use ..........................
  • Page 4 Dynamic power adjustment ....................57 Resetting welding parameters to the factory settings ............58 Power-saving mode (Standby) ................... 58 8 Technical data ..........................59 Pico 200 cel puls ........................ 59 8.1.1 Mains voltage 230 V ................... 59 8.1.2 Mains voltage 120 V ................... 60 9 Accessories ..........................
  • Page 5 Contents Notes on using these operating instructions 10.1.2 TIG welding ......................63 10.1.3 Basic parameters (independent of process) ............64 10.2 Average shielding gas usage ..................... 64 10.3 Searching for a dealer ......................65 099-002130-EW501 09.09.2024...
  • Page 6 Contents Notes on using these operating instructions 099-002130-EW501 09.09.2024...
  • Page 7 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 8 For your safety Explanation of icons 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 hold Incorrect / Invalid Switch Correct / Valid Turn...
  • Page 9 For your safety Safety instructions 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 10 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 11 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! •...
  • Page 12 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 13 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.
  • Page 14 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 15 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 16 Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-002130-EW501 09.09.2024...
  • Page 17 Machine description – quick overview Front view / rear view Item Symbol Description Transport handle with additional integrated functions • Wear part compartment > see 5.1.9 chapter • Transport belt > see 5.1.1 chapter Machine control > see 4.2 chapter Connection socket 19-pole Remote control connection Connection socket (+) welding current...
  • Page 18 Machine description – quick overview Machine control – Operating elements Machine control – Operating elements 4.2.1 Overview of control sections For description purposes, the machine control has been divided into two sections (A, B) to ensure maximum clarity. The setting ranges for the parameter values are summarised in the parameter overview section >...
  • Page 19 Machine description – quick overview Machine control – Operating elements 4.2.1.1 Control section A Figure 4-3 Item Symbol Description Machine display The machine display primarily shows the welding power as a nominal value of the cur- rent. Other machine or welding parameters and their values are displayed depending on the current operation >...
  • Page 20 Machine description – quick overview Machine control – Operating elements 4.2.1.2 Control section B Figure 4-4 Item Symbol Description Hot-start current signal light Hot-start time signal light Signal light for Arcforce - welding characteristics > see 5.2.4 chapter Signal light for pulse welding MMA > see 5.2.6 chapter, TIG welding >...
  • Page 21 Machine description – quick overview Operating the machine control Operating the machine control 4.3.1 Main screen After switching on the machine or finishing a setting, the machine control changes to the main screen. This means that the previously selected settings are adopted (indicated by signal lights where applicable) and the nominal value of the current (A) is shown in the welding data display.
  • Page 22 Design and function Transport and installation 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! •...
  • Page 23 Design and function Transport and installation 5.1.2 Ambient conditions The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work.
  • Page 24 Design and function Transport and installation 5.1.6 Notes on the installation of welding current leads • Use an individual welding lead to the workpiece for each welding machine! Figure 5-3 • Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! •...
  • Page 25 Design and function Transport and installation 5.1.7.1 Mains configuration The machine may only be connected to a one-phase system with two conductors and an earthed neutral conductor. Figure 5-5 Legend Item Designation Colour code Outer conductor brown Neutral conductor blue Protective conductor green-yellow •...
  • Page 26 Design and function Transport and installation 5.1.8 Protective flap, welding machine control Figure 5-6 • Open the protective cap. • Apply slight pressure to the left and/or right connecting bridge (illustration) until the protective cap can be removed. 5.1.9 Wear part compartment The transport handle of this machine series holds a wear parts compartment for storing typical small wear parts.
  • Page 27 Design and function MMA welding MMA welding 5.2.1 Connecting the electrode holder and workpiece lead CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. •...
  • Page 28 Design and function MMA welding 5.2.3.1 Hotstart current The hot-start current is set directly using the machine control. Figure 5-11 5.2.3.2 Hotstart time Figure 5-12 The hot-start time is set directly using the machine control. 5.2.4 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current.
  • Page 29 Design and function MMA welding 5.2.5 Antistick The Antistick feature prevents the electrode from annealing. Should the electrode stick despite the Arcforce feature, the machine au- tomatically switches to the minimum current within approx. one second. This prevents the electrode from annealing. Check the welding current setting and correct for the welding task in hand.
  • Page 30 Design and function MMA welding 5.2.7 Arc length restriction (USP) The function of arc length restriction stops the welding process when an excessive arc voltage is de- tected (an unusually large gap between electrode and workpiece). This function can be switched on or off in the Expert menu >...
  • Page 31 Design and function TIG welding TIG welding 5.3.1 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 5-18 Item Symbol Description Workpiece Connection socket for (+) welding current Workpiece lead connection Output side of the pressure regulator Welding torch with rotary gas valve...
  • Page 32 Design and function TIG welding 5.3.2 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 33 Design and function TIG welding 5.3.4 Arc ignition 5.3.4.1 Liftarc Figure 5-21 The arc is ignited on contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip against the workpiece (lift arc current flows independently of the set main current) b) Angle the welding torch above the torch gas nozzle until the distance between the electrode tip and the workpiece is approx.
  • Page 34 Design and function TIG welding 5.3.5.2 spotArc The procedure can be used for spot welding. Figure 5-22 With the spotArc function enabled, automated pulsing is activated as well. If required, pulse welding can also be deactivated using the pulse LED during the process or you can switch between the pulse variants average value pulsing or automatic pulsing...
  • Page 35 Design and function TIG welding 5.3.7 Pulse welding 5.3.7.1 Average value pulse welding A special feature with average value pulses is that the power source will always maintain the preset average value. This makes this method especially suitable for welding according to welding procedure specifications.
  • Page 36 Design and function TIG welding 5.3.8 RTF 1 foot-operated remote control The remote control allows the continuous adjustment of the welding current (0% to 100%) depending on the preselected main current on the welding machine. Further individual parameter settings affect the remote control behaviour: •...
  • Page 37 Design and function TIG welding 5.3.8.2 Start program The start program “ ” can be enabled or disabled in the machine configuration menu > see 5.7 chapter. Enabled start program At the start of the process, the start program ensures the necessary arc stability until the main current “...
  • Page 38 Design and function TIG welding Display Setting/selection Downslope time End current as a percentage - dependent on main current End current time - duration of end current Slope times (spotArc) Slope times (t and t ------- Slope times are activated. ------- Slope times are deactivated (hidden).
  • Page 39 Design and function Remote control Remote control The remote controls are operated on the 19-pole remote control connection socket (analogue). 5.4.1 RTF-X TIG 19Pol Functions • Infinitely adjustable welding current (0% to 100%) depending on the main current preselected at the welding machine. •...
  • Page 40 Design and function Access control Access control The machine control can be locked to prevent unauthorised or accidental adjustments. The access lock has the following effect: • The parameters and their settings in the machine configuration menu, expert menu and the function sequence can only be viewed but not changed.
  • Page 41 Design and function Machine configuration menu Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.7.1 Selecting, changing and saving parameters Figure 5-30 Display Setting/selection Exit the menu Exit Power source menu Time-based power-saving mode > see 7.7 chapter Time to activation of the power-saving mode in case of inactivity.
  • Page 42 Design and function Machine configuration menu Display Setting/selection Start program of foot-operated remote control > see 5.3.8.2 chapter ------- Function enabled (factory setting). ------ Function disabled. Service menu Any changes to the service menu should be agreed with the authorised service person- nel.
  • Page 43 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 44 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! 099-002130-EW501 09.09.2024...
  • Page 45 Maintenance, care and disposal Calibration / validation Calibration / validation In this mode, the inverter can be started and stopped and the current can be adjusted from minimum to maximum without being disturbed by welding process characteristics. 6.3.1 Machine control – Operating elements Figure 6-1 Item Symbol Description...
  • Page 46 Maintenance, care and disposal Calibration / validation 6.3.2 Activating the calibration and validation mode Figure 6-2 Display Setting/selection Calibration and validation mode > see 6.3.2 chapter ------ Function disabled (factory setting) ------- Function enabled 6.3.3 Turning the inverter of the power source on and off WARNING Risk of injury from electrical voltage! When the inverter is switched on, the welding current sockets are live.
  • Page 47 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 48 Rectifying faults Software version of the machine control 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 49 Rectifying faults Error messages (power source) Error 6: Mains undervoltage Category A  Mains voltage is too low. Check the mains voltages and compare them with the connection voltages of the power source.  Error 7: Low coolant level Category B ...
  • Page 50 Rectifying faults Error messages (power source) Error 16: Pilot arc power source - collective error Category A  The external emergency stop circuit has been interrupted. Check the emergency stop circuit and eliminate the cause of the error.   The emergency stop circuit of the power source has been activated (internally configurable). Deactivate the emergency stop circuit.
  • Page 51 Rectifying faults Error messages (power source) Error 20: Low coolant level Category B  Low flow rate. Fill with coolant.  Check coolant flow - remove kinks in the hose package.  Adjust the flow threshold  Clean the cooler. ...
  • Page 52 Rectifying faults Error messages (power source) Error 26: Excess pilot arc module temperature Category A  The power source is overheating. Allow the switched-on machine to cool.   Fan is blocked, dirty or faulty. Check the fan and clean or replace it. ...
  • Page 53 Rectifying faults Error messages (power source) Error 40: Electronics error  Error in the power supply of the electronics Request service.  Error 47: Radio link (BT) Category B  Connection error between the welding machine and peripheral unit. Note the documentation for the data interface with radio transmission. ...
  • Page 54 Rectifying faults Error messages (power source) Error 55: Excess wire feeder current Category B  Excess current detected in the wire feed mechanism. Do not lay the liner in tight radii.  Check the liner for ease of movement.  Error 56: Mains phase failure ...
  • Page 55 Rectifying faults Warnings Warnings Depending on the display options of the machine display, a warning message is displayed as follows: Display type - machine control Display Graphic display two 7-segment displays one 7-segment display The cause of the warning is indicated by a corresponding warning number (see table). •...
  • Page 56 Rectifying faults Checklist for rectifying faults Warning Potential cause / remedy 24 Coolant flow warning Check the coolant supply. Check the coolant level and top up if necessary. Check flow and switching thresholds. 25 Flow 2 reserved 26 Flow 3 reserved 27 Flow 4 reserved...
  • Page 57 Rectifying faults Dynamic power adjustment Functional errors  Several parameters cannot be set (machines with access block) Entry level is blocked, disable access lock > see 5.5 chapter   All machine control signal lights are illuminated after switching on ...
  • Page 58 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. To reset the welding parameters or machine settings to the factory settings, select parameter in the service menu >...
  • Page 59 Technical data Pico 200 cel puls Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Pico 200 cel puls 8.1.1 Mains voltage 230 V Welding current I 5 A to 220 A 5 A to 200 A...
  • Page 60 Technical data Pico 200 cel puls 8.1.2 Mains voltage 120 V The performance specifications refer to machines with several mains voltage variants (multivolt capability). Please note the information on the relevant rating plate. The increased current consumption at a lower mains voltage requires the installation of a suitable mains plug >...
  • Page 61 Accessories Welding torch Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Welding torch Type Designation Item no. TIG 26 GDV 4m TIG welding torch, rotary gas valve, gas-cooled, de- 094-511621-00100 central TIG 26 GDV 8m...
  • Page 62 Accessories General accessories General accessories Type Designation Item no. SKGS 16A 250V CEE7/7, Protective contact plug, solid rubber 094-001756-00000 DIN 49440/441 32A 5POLE/CEE Machine plug 094-000207-00000 ADAP CEE16/SCHUKO Earth contact coupling/CEE16A plug 092-000812-00000 KLF-L1-N-PE-NETZ Mains-cable label 094-014869-00001 099-002130-EW501 09.09.2024...
  • Page 63 Appendix Parameter overview – setting ranges Appendix 10.1 Parameter overview – setting ranges 10.1.1 MMA welding Parameter / function Setting range Hot-start current Hot-start time 20,0 Main current Pulse welding ( Pulse frequency Pulse balance Pulse current Arcforce correction Arc length restriction 10.1.2 TIG welding Parameter / function Setting range...
  • Page 64 Appendix Average shielding gas usage 10.1.3 Basic parameters (independent of process) Parameter / function Setting range Time-based energy-saving function Dynamic power adjustment (230V) Dynamic power adjustment (120V) Current display switching Remote control response Start program of the remote control Antistick for TIG Arc detection for welding helmets (TIG) Calibration and validation mode 10.2...
  • Page 65 Appendix Searching for a dealer 10.3 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-002130-EW501 09.09.2024...