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EWM Pico 300 cel - User Manual

EWM Pico 300 cel
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EWM
HIGHTEC WELDING GmbH
Dr. Günter - Henle - Straße 8 • D-56271 Mündersbach
Phone: +49 2680 181 0 • Fax: +49 2680 181 244
www.ewm.deinfo@ewm.de
GB
Operating instructions
Welding machines for MMA welding
PICO 230
PICO 230 CEL
PICO 260
PICO 260 CEL
PICO 260 CEL PWS
PICO 300
PICO 300 CEL
PICO 300 CEL PWS
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.
© 2007 Subject to alteration.
Item No.: 099-002032-EWM01
Revised: 28.03.2007

Table of Contents

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Summary

Operating Instructions Overview

MMA Welding Machines

Details the specific type of welding machines covered in this manual.

Initial Commissioning Safety

Emphasizes reading instructions before commissioning and proper personnel operation.

Machine and Company Data Entry

Safety Instructions

General Operational Safety

Covers proper usage, risks of improper operation, and general safety principles.

Electrical Shock Hazards

Details critical warnings about touching live parts and safe electrical connections.

Health Hazards from Fumes

Addresses risks associated with breathing welding smoke and gases.

Safety Instructions Continued

Fire and Explosion Prevention

Warnings regarding sparks, hot materials, flammable substances, and fire avoidance.

Noise Exposure and Hearing Protection

Information on noise risks and the necessity of hearing protection.

Electromagnetic Interference Management

Discusses potential interference and methods for reduction.

Transport and Installation Safety

Safe Machine Transport

Guidelines for transporting the welding machine in an upright position.

Operating Ambient Conditions

Specifies requirements for temperature, humidity, and air quality during operation.

Using the Operating Instructions

Understanding Safety Symbols

Explains the meaning of warning, caution, and information symbols used in the manual.

Technical Data: PICO 230;230 CEL

PICO 230;230 CEL Specifications

Details technical parameters including setting range, operating time, and dimensions.

Technical Data: PICO 260 Series

PICO 260;260 CEL;260 CEL PWS Specs

Details technical parameters for PICO 260, 260 CEL, and 260 CEL PWS models.

Technical Data: PICO 300 Series

PICO 300;300 CEL;300 CEL PWS Specs

Details technical parameters for PICO 300, 300 CEL, and 300 CEL PWS models.

Machine Description: Front Views

PICO Model Series Identification

Lists the PICO models covered in this section.

Front Panel Component Layout

Identifies and describes components visible on the front panel.

Machine Description: Rear Views

Rear Panel Component Layout

Identifies and describes components visible on the rear panel.

PICO 260;300 CEL PWS Front View

Front Panel Components

Identifies and describes components on the front panel for specific models.

PICO 260;300 CEL PWS Rear View

Rear Panel Components

Identifies and describes components on the rear panel for specific models.

Functional Characteristics: Controls

Operating Elements Overview

Describes the main control panel and its interactive components.

Functional Characteristics: MMA

Welding Data Display and MMA Setup

Explains data display, MMA selection, and electrode type settings.

Functional Characteristics: MMA Continued

MMA Electrode Types and Hotstart

Details electrode type allocation and hotstart parameter settings.

Functional Characteristics: TIG & Hotstart

Hotstart, Antistick, and TIG Setup

Explains hotstart, antistick functions, and TIG welding selection.

Functional Characteristics: TIG & Remote

TIG Arc Ignition and Remote Controls

Covers TIG arc ignition methods and various remote control options.

Functional Characteristics: Advanced MMA

Advanced MMA Settings: Arcforce Correction

Details advanced MMA settings for arcforce adjustment.

Functional Characteristics: Advanced MMA II

Advanced MMA Settings: Arc Length & VRD

Explains arc length restriction and VRD options for MMA welding.

Commissioning Procedures

General Commissioning Guidelines

General safety warnings and connection procedures for commissioning.

Intended Use and Application

Defines the intended use and limitations of the welding machines.

Machine Installation Requirements

Specifies conditions for stable setup and adequate space.

Commissioning: Connections and Cooling

Dirt Filter Installation and Maintenance

Instructions for installing and maintaining the dirt filter.

Mains Connection and Safety

Details mains voltage, fuse protection, and connection by a qualified electrician.

Machine Cooling and Ventilation

Precautions for optimal duty cycle via ventilation.

Workpiece Lead Connection

Guidelines for connecting the workpiece lead for optimal current transfer.

Commissioning MMA Welding

MMA Connections for PICO 230;260;300

Details socket connections for electrode holders and workpiece leads.

Electrode Holder Connection Safety

Safety precautions and connection method for the electrode holder.

Workpiece Lead Connection Polarity

How to connect the workpiece lead and polarity considerations.

Commissioning PICO 260;300 CEL PWS

Polarity Settings for PICO 260;300 CEL PWS

Explains connection sockets and polarity changeover switch functions.

Pole Reversal Switch Operation

How to use the pole reversal switch without unplugging leads.

Commissioning TIG Welding

TIG Electrode Holder and Workpiece Connections

Details connections for TIG welding, including polarity.

Shielding Gas Cylinder Setup

Covers connecting and preparing the shielding gas cylinder.

Commissioning TIG Welding Continued

TIG Workpiece Lead Connection

Specifics on connecting the workpiece lead for TIG welding.

Maintenance and Care

General Maintenance Overview

General care, cleaning, and checking requirements for fault-free operation.

Safe Cleaning Procedures

Steps for safely cleaning the machine, including precautions.

Repetition Test Requirements

Explains the need and scope of repetition tests for warranty.

Maintenance and Care: Repetition Tests

Repetition Test Intervals and Scope

Defines frequency and types of tests (partial vs. full).

Test Documentation and Visual Inspection

Requirements for test documentation and visual checks.

Protective Conductor Resistance Test

Procedure for measuring protective conductor resistance.

Maintenance and Care: Electrical Tests

Insulation and Leakage Current Tests

Procedures for measuring insulation resistance and leakage current.

Open Circuit Voltage Measurement

How to measure open circuit voltage and its limits.

Welding Machine Function Test

Checks of safety devices, controls, and switches for proper function.

Maintenance and Care: Repairs

Repair Work and Warranty Claims

Guidelines for qualified personnel performing repairs and warranty claims.

Maintenance and Care: Disposal

Equipment Disposal Guidelines

Instructions for environmentally friendly disposal of the machine.

RoHS Compliance Statement

Confirmation of compliance with RoHS directive.

Warranty Information

General Warranty Validity Periods

Outlines the duration of warranty for various machine components and accessories.

Warranty Information Continued

Warranty Declaration Terms

Details the terms, conditions, exclusions, and limitations of the warranty.

Troubleshooting

Power Source Error Messages

Lists error codes and their possible causes and remedies.

Spare Parts List: PICO 230;230 CEL

Front View Part Identification

Lists and identifies spare parts visible on the front of the machine.

Spare Parts List: PICO 230;230 CEL Continued

Rear View Part Identification

Lists and identifies spare parts visible on the rear of the machine.

Spare Parts List: PICO 230;230 CEL Continued II

Left-Hand Side Components

Lists and identifies spare parts on the left-hand side of the machine.

Spare Parts List: PICO 230;230 CEL Continued III

Right-Hand Side Components

Lists and identifies spare parts on the right-hand side of the machine.

Accessories and Options

Remote Controls and Connection Cables

Lists various remote control units and connection cables.

Welding Accessories

Includes electrode holders, workpiece leads, TIG torches, and general accessories.

Optional Equipment

Lists optional retrofit kits like dirt filters and VRD.

Circuit Diagrams

PICO 230 Circuit Diagram

Provides the electrical circuit diagram for the PICO 230 model.

Circuit Diagrams Continued

PICO 230 CEL Circuit Diagram

Provides the electrical circuit diagram for the PICO 230 CEL model.

Circuit Diagrams Continued II

PICO 260 Circuit Diagram

Provides the electrical circuit diagram for the PICO 260 model.

Circuit Diagrams Continued III

PICO 260 CEL Circuit Diagram

Provides the electrical circuit diagram for the PICO 260 CEL model.

Circuit Diagrams Continued IV

PICO 260 CEL PWS Circuit Diagram

Provides the electrical circuit diagram for the PICO 260 CEL PWS model.

Circuit Diagrams Continued V

PICO 300 Circuit Diagram

Provides the electrical circuit diagram for the PICO 300 model.

Circuit Diagrams Continued VI

PICO 300 CEL Circuit Diagram

Provides the electrical circuit diagram for the PICO 300 CEL model.

Circuit Diagrams Continued VII

PICO 300 CEL PWS Circuit Diagram

Provides the electrical circuit diagram for the PICO 300 CEL PWS model.

Appendix A: Declaration of Conformity

EC Conformity Declaration

Official statement confirming the machine meets EC safety and EMC directives.

EWM Pico 300 cel Specifications

General IconGeneral
Mains voltage230 V
Mains frequency50/60 Hz
Mains fuse (slow-blowing)16 A
Welding current range5 - 300 A
Protection classIP23
Insulation classF

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