EWM Pico 180 Operating Instructions Manual
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Summary of Contents for EWM Pico 180
- Page 1 Operating instructions Welding machine Pico 180 Pico 180 VRD Pico 180 VRD 12V 099-002003-EW501 19.09.2011...
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Page 2: General Instructions
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer. -
Page 3: Table Of Contents
3.3.3 Welding in environments with increased electrical hazards......... 14 3.3.4 Service documents (spare parts and circuit diagrams) ..........14 4 Machine description – quick overview ....................15 Pico 180 ............................15 4.1.1 Front view ........................15 4.1.2 Rear view........................16 Machine control –... - Page 4 Display machine control software version..................34 Dynamic power adjustment......................35 Resetting welding parameters to the factory settings ..............36 8 Technical data............................37 Pico 180 ............................37 9 Accessories ............................38 Transport systems........................38 Remote controls and accessories....................38 General accessories ........................38 10 Appendix A............................39 10.1 Overview of EWM branches......................39 099-002003-EW501 19.09.2011...
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Page 5: 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 6: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine Switch on machine ENTER (enter the menu) NAVIGATION (Navigating in the menu) EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use... -
Page 7: 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 8 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 9 Safety instructions General CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...
- Page 10 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): 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 11: 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 12: Ambient Conditions
Safety instructions Ambient conditions Ambient conditions CAUTION Installation site! 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 13: Intended Use
Intended use Applications Intended use This machine has been manufactured according to the latest developments in technology and current regulations and standards. It must only be operated in line with the instructions on correct usage. WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. -
Page 14: Documents Which Also Apply
Intended use Documents which also apply Documents which also apply 3.3.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.3.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 15: Machine Description - Quick Overview
Machine description – quick overview Pico 180 Machine description – quick overview Pico 180 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: Welding current lead connection for TIG welding torch •... -
Page 16: Rear View
Machine description – quick overview Pico 180 4.1.2 Rear view Figure 4-2 Item Symbol Description Main switch, machine on/off Connection socket, 19-pole Remote control connection Mains connection cable Cooling air inlet 099-002003-EW501 19.09.2011... -
Page 17: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements T 1.80.2 AMP% Figure 4-3 Item Symbol Description Collective interference signal light For error messages, see the "Rectifying faults" 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 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 19: Transport And Installation
Design and function Transport and installation Transport and installation WARNING Risk of accident due to improper transport of machines that may not be lifted! Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only! •... -
Page 20: 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 (any phase sequence for three-phase machines)! -
Page 21: 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 22: Selecting Mma Welding
Design and function MMA welding 5.6.2 Selecting MMA welding Control element Action Result MMA welding signal light lights up Main current setting 5.6.3 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. -
Page 23: Antistick
Design and function MMA welding 5.6.4 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 24: Tig Welding
Design and function TIG welding TIG welding 5.7.1 Shielding gas supply (shielding gas cylinder for welding machine) 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 25: Connecting The Shielding Gas Supply
Design and function TIG welding 5.7.1.1 Connecting the shielding gas supply • Secure the shielding gas cylinder using a securing chain. Figure 5-7 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve • Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight. -
Page 26: Connecting A Tig Welding Torch With Rotating Gas Valve
Design and function TIG welding 5.7.2 Connecting a TIG welding torch with rotating gas valve Figure 5-8 Item Symbol Description Workpiece Connection socket for "+" welding current Workpiece lead connection Output side of the pressure regulator Welding torch Connection socket, "-" welding current Welding current lead connection for TIG welding torch •... -
Page 27: Tig Welding Selection
Design and function TIG welding 5.7.3 TIG welding selection Control element Action Result TIG welding signal light lights up Main current setting 5.7.4 TIG arc ignition Figure 5-9 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 28: Advanced Settings
Design and function TIG welding 5.7.5 Advanced settings 5.7.5.1 Setting the ignition current and upslope time NOTE To change the advanced setting parameters, hold down the "Welding parameters" button for 2 seconds after selecting the welding process. The following diagram shows the setting options. Figure 5-10 Display Setting/selection... -
Page 29: Voltage Reducing Device (Vrd)
Design and function Voltage reducing device (VRD) Voltage reducing device (VRD) The signal light (VRD open circuit voltage reduction) indicates when the voltage reduction device has been activated. This then ensures that the open circuit voltage between the electrode holder and the workpiece is reduced to the permissible values. -
Page 30: Remote Control
Design and function Remote control 5.10 Remote control NOTE The remote control is operated on the 19-pole remote control connection socket. 5.10.1 Manual remote control RT 1 Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. -
Page 31: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! •... -
Page 32: Maintenance Work
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 33: Rectifying Faults
Rectifying faults Machine faults (error messages) 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 34: Display Machine Control Software Version
Rectifying faults Display machine control software version Display machine control software version NOTE The query of the software versions only serves to inform the authorised service staff! Figure 7-1 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... -
Page 35: Dynamic Power Adjustment
Rectifying faults Dynamic power adjustment Dynamic power adjustment NOTE A correctly designed mains fuse is a prerequisite. • Observe the details about the mains fuse in the "Technical Data" chapter! The dynamic power adjustment automatically adjusts the welding performance to an uncritical level for the fuse. -
Page 36: Resetting Welding Parameters To The Factory Settings
Rectifying faults Resetting welding parameters to the factory settings 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 Dynamic power adjustment 20 A Setting for 20 A mains fuse protection (factory setting) -
Page 37: Technical Data
Dimensions L x W x H in mm 470 x 135 x 250 Weight 8,9 kg EMC class Constructed to standards Pico 180 IEC 60974-1, -10; Pico 180 VRD IEC 60974-1, -10; AS 1674.2-2003 Pico 180 VRD 12V IEC 60974-1, -10; ГОСТ 12.2 007.8 099-002003-EW501 19.09.2011... -
Page 38: Accessories
Accessories Transport systems Accessories Transport systems Type Designation Item no. Trolly 35-1 Transport vehicle 090-008629-00000 Remote controls and accessories Type Designation Item no. RT1 19POL Remote control current 090-008097-00000 RA5 19POL 5M Remote control e.g. connection cable 092-001470-00005 RA10 19POL 10M Remote control e.g. -
Page 39: Overview Of Ewm Branches
Appendix A Overview of EWM branches Appendix A 10.1 Overview of EWM branches 099-002003-EW501 19.09.2011...
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