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 28.04.2014...
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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. No other form of liability, regardless of type, shall be accepted. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 General ............................8 Transport and installation ......................12 2.4.1 Ambient conditions ....................... - Page 4 Display machine control software version ..................41 Resetting welding parameters to the factory settings ..............42 8 Technical data............................43 Pico 220 cel puls .......................... 43 9 Accessories ............................44 Transport systems ........................44 Remote controls and accessories ....................44 General accessories ........................
- Page 5 Contents Notes on the use of these operating instructions 099-002057-EW501 28.04.2014...
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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 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: 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 (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu) EXIT 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 8: 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 9 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 10 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
- Page 11 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 12: 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 13: Ambient Conditions
Safety instructions Transport and installation 2.4.1 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 14: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with proper usage and by trained or expert staff! •... -
Page 15: 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 16: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview 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 17: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Main switch, machine on/off Cooling air inlet Mains connection cable 099-002057-EW501 28.04.2014... -
Page 18: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements 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 19 Machine description – quick overview Machine control – Operating elements Item Symbol Description Welding procedure button Selection of welding procedure MMA/setting electrode type: Signal lamp illuminated green = Electrode type rutile Signal lamp illuminated red = Electrode type rutile basic Signal lamp illuminated green = Electrode type basic/rutile cellulose Signal lamp...
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Page 20: Design And Function
Design and function Machine control – Operating elements 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. •... -
Page 21: 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 22: Machine Cooling
Design and function Machine cooling Machine cooling To obtain an optimal duty cycle from the power components, the following precautions should be observed: • Ensure that the working area is adequately ventilated. • Do not obstruct the air inlets and outlets of the machine. •... -
Page 23: 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! •... -
Page 24: 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 25: Selecting Mma Welding
Design and function MMA welding 5.5.2 Selecting MMA welding AM P AM P% Pulse ON/OFF Freq Figure 5-4 Item Symbol Description Welding procedure button Selection of welding procedure MMA/setting electrode type: Signal lamp illuminated green = Electrode type rutile Signal lamp illuminated red = Electrode type rutile basic Signal lamp illuminated green = Electrode type basic/rutile cellulose... -
Page 26: Mma Pulsed Welding
Design and function MMA welding 5.5.2.1 MMA pulsed welding Welding characteristics: • Especially suitable for root welding • Fine-flaked weld surface with a TIG look for final passes • Less finishing work thanks to less spatter • Highly suitable for difficult electrodes •... - Page 27 Design and function MMA welding Figure 5-6 AMP = Main current; e.g. 100 A IP1 = Pulse current = IP1 x AMP; e.g. 170% x 100 A = 170 A IP2 = Pulse pause current = IP2 x AMP; e.g. 70% x 100 A = 70 A Tpuls = Duration of one pulse cycle = 1/FrE;...
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Page 28: Hotstart Current And Hotstart Time
Design and function MMA welding 5.5.2.2 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. When the stick electrode has been struck, the arc ignites at the adjusted hotstart current AMP% (factory setting: 120 % of main current) and welds at this current until the hotstart time in seconds has elapsed (factory setting: 1 second). -
Page 29: Advanced Settings
Design and function MMA welding 5.5.3 Advanced settings 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. ENTER EXIT Figure 5-9 Display Setting/selection Arcforce correction (setting -10 to 10, factory setting 0) -
Page 30: Tig Welding
Design and function TIG welding TIG welding 5.6.1 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 31: Connecting The Shielding Gas Supply
Design and function TIG welding 5.6.1.1 Connecting the shielding gas supply • Secure the shielding gas cylinder using a securing chain. Figure 5-10 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 32: Connecting A Tig Welding Torch With Rotating Gas Valve
Design and function TIG welding 5.6.2 Connecting a TIG welding torch with rotating gas valve NOTE Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-11 Item Symbol Description Workpiece Connection socket for "+" welding current Workpiece lead connection Output side of the pressure regulator Welding torch... -
Page 33: Tig Welding Selection
Design and function TIG welding 5.6.2.1 TIG welding selection Figure 5-12 5.6.2.2 TIG arc ignition Figure 5-13 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 34: Advanced Settings
Design and function TIG welding 5.6.3 Advanced settings 5.6.3.1 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. ENTER EXIT Figure 5-14... -
Page 35: Dirt Filter
Design and function Dirt filter Dirt filter NOTE These accessory components can be retrofitted as an option, see Accessories chapter. Figure 5-15 • As shown in the diagram, insert the dirt filter into the rear of the machine, above the air inlet, using both clips (1). -
Page 36: Remote Control
Design and function Remote control Remote control NOTE Insert the remote control control cable into the 19-pole connection socket for remote control connection and lock. 5.8.1 Manual remote control RT1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. -
Page 37: 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 38: Maintenance Work
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC). -
Page 39: 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 40: Machine Faults (Error Messages)
Rectifying faults Machine faults (error messages) Machine faults (error messages) NOTE A welding machine error is indicated by the collective fault signal lamp (A1) lighting up and an error code (see table) being displayed in the machine control display. In the event of a machine error, the power unit shuts down. -
Page 41: 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! ENTER EXIT 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 Service menu... -
Page 42: Resetting Welding Parameters To The Factory Settings
Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings. RESET Figure 7-2 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 "InI"... -
Page 43: Technical Data
Technical data Pico 220 cel puls Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Pico 220 cel puls Setting range for welding current 10 A–220 A Setting range for welding voltage 10.4 V–18.8 V 20.4 V–28.8 V... -
Page 44: Accessories
Accessories Transport systems Accessories NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Transport systems Type Designation Item no. Trolly 35-1 Transport vehicle 090-008629-00000 Remote controls and accessories Type Designation Item no. -
Page 45: Overview Of Ewm Branches
Appendix A Overview of EWM branches Appendix A 10.1 Overview of EWM branches 099-002057-EW501 28.04.2014...
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