EWM PICO 162 Operating Instructions Manual
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EWM PICO 162 Operating Instructions Manual

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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.
© 2008
Subject to alteration.
Dr. Günter - Henle - Straße 8 • D-56271 Mündersbach
Phone: +49 2680 181 0 • Fax: +49 2680 181 244
Item No.: 099-002040-EWM01
HIGHTEC WELDING GmbH
www.ewm.de
•
info@ewm.de
Revised: 04.03.2008
EWM

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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 Congratulations! You have chosen a quality product from EWM HIGHTEC WELDING GmbH. EWM machines provide results of the highest perfection thanks to their PREMIUM quality. Therefore we are happy to provide you with a full 3-year warranty according to our operating instructions.
  • 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...

  • Page 4: Table Of Contents

    For your safety ..........................6 Transport and installation.......................8 2.2.1 Ambient conditions ......................8 Notes on the use of these operating instructions................9 3 Technical data............................10 PICO 162, PICO 162 MV ......................10 4 Machine description..........................11 PICO 162, PICO 162 MV ......................11 4.1.1 Front view ........................11 4.1.2 Rear view........................12...
  • Page 5 9 Operating problems, causes and remedies ..................27 General ............................27 Error messages (power source) ....................27 Customer checklist........................28 10 Spare parts list ............................. 29 10.1 PICO 162, PICO 162 MV......................29 10.1.1 Front view ........................29 10.1.2 Rear view........................30 10.1.3...

  • Page 6: Safety Instructions

    Safety instructions For your safety Safety instructions For your safety Observe accident prevention regulations! Ignoring the following safety procedures can be fatal! Proper usage This machine has been manufactured according to the latest developments in technology and current regulations and standards. It is to be operated only for the use for which it was designed (see chapter Commissioning/Area of application).
  • Page 7 Safety instructions For your safety Workpiece, flying sparks and droplets are hot! • Keep children and animals well away from the working area. Their behaviour is unpredictable. • Move containers with inflammable or explosive liquids away from the working area. There is a danger of fire and explosion.

  • Page 8: Transport And Installation

    Safety instructions Transport and installation Transport and installation The machines may only be transported and operated in an upright position. Before carrying away or moving, pull out mains plug and place on the machine. When setting up the machine, resistance to tilting is only guaranteed up to an angle of 10° (as specified in EN 60974-1).

  • Page 9: Notes On The Use Of These Operating Instructions

    Safety instructions Notes on the use of these operating instructions Notes on the use of these operating instructions These operating instructions are arranged into chapters. To help you find your way around more quickly, in the margins you will occasionally see symbols along with the sub-headings.

  • Page 10: Technical Data

    16 qmm Workpiece lead 365 x 116 x 224 mm Dimensions L/W/H Weight 4.8 kg (PICO 162 MV: 5.1 kg) Constructed to standards IEC 60974 / EN 60974 / VDE 0544 EN 50199 / VDE 0544 Part 206 Item No.: 099-002040-EWM01...

  • Page 11: 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 Control / Operating elements (see chapter Function specification) Connection socket, “+” welding current Workpiece lead or electrode holder connection...

  • Page 12: 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 13: 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 14: 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 15: Commissioning

    Insert mains plug of the switched-off machine into the appropriate socket. 6.4.1 PICO 162, PICO 162 MV The correct mains plug must be attached to the mains supply lead on the machine. The connection must be made by a qualified electrician in compliance with the relevant local laws and regulations.

  • Page 16: Dirt Filter

    Commissioning Workpiece lead, general 6.5.1 Dirt filter 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 17: Mma Welding

    Commissioning MMA welding MMA welding 6.7.1 PICO 162, PICO 162 MV Figure 6-2 Item Symbol Description Connection socket, “+” welding current Workpiece lead or electrode holder connection “-” Welding current connection socket Electrode holder or workpiece lead connection 6.7.1.1 Electrode holder connection Caution: Risk of injury from crushing! Suitable protective gloves should be worn when changing spent stick electrodes.

  • Page 18: 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 19: Shielding Gas Supply

    Commissioning TIG welding 6.8.1.3 Shielding Gas Supply No dirt must be allowed to enter the shielding gas supply, as this would cause blockages in the shielding gas supply. All shielding gas connections must be gastight. • Place shielding gas cylinder in the retainer provided for it and secure with chains. Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to blow out •...

  • Page 20: Maintenance And Testing

    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 21: 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 22: 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 23: 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 24: Disposing Of Equipment

    Your administrative office will be pleased to inform you of the options. 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 25: 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 26: 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 27: 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 28: 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 29: Spare Parts List

    Spare parts list PICO 162, PICO 162 MV Spare parts list 10.1 PICO 162, PICO 162 MV 10.1.1 Front view Figure 10-1 Item Designation Type Item Number 40 x 1500 mm Carrying strap 094-007543-00000 2523060 Rotary dial 074-000315-00000 4123002 074-000315-00001...

  • Page 30: 10.1.2 Rear View

    Mains cable MAINS CABLE 3 X 2.5 qmm/3.5 m SHOCK- 094-010342-00000 PROOF Casing back panel, plastic BRG257.5 X 185 X 44 094-009532-00000 Mains switch (PICO 162) ROCKER, 2-POLE 250V/20A 094-008045-00000 Mains switch (PICO 162 MV) ROCKER, 2-POLE/2XUM 094-010053-10000 Item No.: 099-002040-EWM01...

  • Page 31: 10.1.3 Inside View

    Spare parts list PICO 162, PICO 162 MV 10.1.3 Inside view Figure 10-3 Item Description Type Item Number PCB (PICO 162) PCB INVERTER BOARD 040-000675-E0000 PCB (PICO 162 MV) PCB INVERTER BOARD 040-000692-E0000 3612KL-05W-B50-E00 094-009798-10000 Item No.: 099-002040-EWM01...

  • Page 32: Accessories, Options

    Accessories, options MMA welding Accessories, options 11.1 MMA welding Type Description / Name Item number EH16 QMM 4M Electrode holder 094-005313-00000 11.2 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 33: Circuit Diagrams

    Circuit diagrams PICO 162 Circuit diagrams Original format circuit diagrams are located inside the machine. 12.1 PICO 162 Figure 12-1 Item No.: 099-002040-EWM01...

  • Page 34: Pico 162 Mv

    Circuit diagrams PICO 162 MV 12.2 PICO 162 MV X5/1 X1/1 +40V +40V X1/2 X5/2 X4/1 X4/2 L1´ L 1 ´ L 1 ´ A1 /1 A2 /1 A1 /2 A2 /2 Figure 12-2 Item No.: 099-002040-EWM01...

  • Page 35: 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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