EWM Pico 160 Operating Instructions Manual Download Page 35

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Service documents

Spare and replacement parts

099-002128-EW501

26.01.2022

Position Order number

Designation

Type

1 094-015236-E0501 Carrying strap

TG3-E

2 094-021818-E0501 Casing

BG BH276,5X201,5X124,2

3 094-021826-00000 Insulating paper

4 040-001129-E0000 Printed circuit board (PCB) - replace-

ment

E161

5 094-021994-00000 Light guide

LL8X6

6 094-023159-00001 Plastic insulation

KID

7 094-022197-00500 Adhesive film

KLF-E 1.06

8 074-000315-00002 Arrow indicator

ARROW INDICATOR 23MM

9 074-000315-00000 Rotary knob

KNOB 23MM

10 094-015043-00001 Rotary knob cover

KNOB COVER 23MM

11 094-021514-00000 Cover cap

KKS

12 094-021511-00001 Welding current socket

EB/35-50QMM

13 094-021795-00502 Adhesive film

LOGO/PLUS/MINUS

14 094-023137-00000 Cover plate

BAAF20X44,5

15 094-022172-00002 Spacer

KA57,3X33,5X17,5

16 092-003293-00000 Choke

WD/D=4/N=15

17 094-021509-00000 Casing, lower section

KBG

18 094-014311-00000 Sheet metal nut

M5/21X15X6

19 094-021508-00000 Insulating paper

IPL

20 094-015248-00001 Fan frame

S95X48X23

21 092-019418-00000 Fan

92X92X32

22 094-008045-10000 Mains switch

WS 250V/20A 2POLE

23 092-003003-00001 Mains cable

3X2.5QMM/3.5M SCHUKO

24 094-021478-00000 Casing, back panel

KRG

25 094-019537-00000 Nut

M20x1,5

26 094-022075-00500 Adhesive film

27 040-001132-E0000 Inverter circuit board

DW160

28 094-012942-00000 Screw

M5X14/DELTA-PT-SCHRAUBE

29 094-010089-00000 Screw, Torx

M3X8-DG-SCHRAUBE

30 094-015135-00000 Screw

M5X16/KOMBITORX PLUS T25

31 094-021833-00000 Screw

M5X10/DIN6900-5 Z9/8.8/VERZ.

32 094-022122-00000 Clamping screw

M5X16/DIN6900-5 Z9/8.8/VERZ.

33 094-021477-00001 Casing, front section

KFG

34 094-023134-00000 Insulating paper

IP73,5X101

35 094-009542-00000 Toroidal core

T60006-E4019-W539

Summary of Contents for Pico 160

Page 1: ...Operating instructions EN Welding machine Pico 160 Pico 160 VRD AUS 099 002128 EW501 Observe additional system documents 26 01 2022...

Page 2: ...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 This exclusion of liability shall be deemed ac...

Page 3: ...ng strap 19 5 1 5 Notes on the installation of welding current leads 20 5 1 6 Stray welding currents 21 5 1 7 Mains connection 22 5 1 7 1 Mains configuration 22 5 2 MMA welding 23 5 2 1 Connecting the...

Page 4: ...501 26 01 2022 9 Accessories 33 9 1 Electrode holder workpiece lead 33 9 2 TIG welding torch 33 9 3 General accessories 33 9 4 Options 33 10 Service documents 34 10 1 Spare and replacement parts 34 10...

Page 5: ...Contents Notes on using these operating instructions 099 002128 EW501 26 01 2022 5...

Page 6: ...s and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning sym bol The hazard is also highlighted using a symbol in the page margin CAUTION Working or ope...

Page 7: ...tch off machine Release Switch on machine Press and hold Switch Incorrect Invalid Turn Correct Valid Numerical value adjustable Input Signal light lights up in green Navigation Signal light flashes gr...

Page 8: ...cal specialist may interconnect the sources as per standard IEC 60974 9 2010 Installa tion and use and German Accident Prevention Regulation BVG D1 formerly VBG 15 or country specific regulations Befo...

Page 9: ...temperatures of 100 C or higher and arcing and work on live components Hearing protection against harming noise Explosion risk Apparently harmless substances in closed containers may generate excessi...

Page 10: ...s specified in the standard The user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the use...

Page 11: ...placement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the ma chine is switched off Requirements for connection to the public...

Page 12: ...on or connection points can heat up significantly during operation water cooled version When opening the coolant circuit escaping coolant may cause scalding Open the coolant circuit only when the powe...

Page 13: ...e dures indicated at the rating plate 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 u...

Page 14: ...2 3 Welding in environments with increased electrical hazards Power sources with this marking can be used for welding in an environment with increased electrical hazard e g boilers For this purpose ap...

Page 15: ...ion 0 1 Carrying strap see 5 1 4 1 chapter 2 Machine control see 4 3 chapter 3 Protective cap 4 Connection socket welding current MMA Electrode holder or workpiece lead connection TIG Connection for w...

Page 16: ...n quick overview Rear view 16 099 002128 EW501 26 01 2022 4 2 Rear view Figure 4 2 Item Symbol Description 0 1 Main Switch Switching the machine on or off 2 Cooling air inlet 3 Mains connection cable...

Page 17: ...as cooled down welding can continue without any further measures 2 Collective interference signal light For error messages see 7 chapter 3 VRD Voltage reduction device VRD signal light see 5 4 chapter...

Page 18: ...d cause injuries The handles straps or brackets are suitable for transport by hand only The machine must not be suspended or lifted using a crane 5 1 1 Machine cooling Insufficient ventilation results...

Page 19: ...gases or substances can damage the machine observe maintenance intervals see 6 2 chapter Avoid large amounts of smoke steam oily fumes grinding dust and corrosive ambient air In operation Temperature...

Page 20: ...ation of welding current leads Use an individual welding lead to the workpiece for each welding machine Figure 5 2 Fully unroll welding current leads torch hose packages and intermediate hose packages...

Page 21: ...heck that all welding current connections are firmly secured and electrical connections are in perfect condition Set up attach or suspend all conductive power source components such as casing trans po...

Page 22: ...operate machine using a socket that has correctly fitted protective earth Mains plug socket and lead must be checked by a qualified electrician on a regular basis When operating the generator always e...

Page 23: ...ctrode or to move welded work pieces Figure 5 6 Item Symbol Description 0 1 Workpiece 2 Connection socket for welding current Electrode holder or workpiece lead connection 3 Electrode holder 4 Connect...

Page 24: ...Hot start time C Main current I Current t Time Figure 5 8 5 2 4 Arcforce During the welding process arcforce prevents the electrode sticking in the weld pool with increases in current This makes it ea...

Page 25: ...ion socket and lock by turning to the right Screw the shielding gas hose of the welding torch to the pressure regulator outlet 5 3 2 Shielding gas supply shielding gas cylinder for welding machine WAR...

Page 26: ...selection Figure 5 12 5 3 3 1 Gas test setting the shielding gas volume If the rotary gas valve is open the shielding gas flows permanently from the welding torch no adjustment with a separate gas va...

Page 27: ...off and bring into normal position Complete the welding task Remove the torch from the workpiece so that the arc extinguishes 5 4 Voltage reducing device Only machine variants with the VRD SVRD AUS RU...

Page 28: ...ce matters always consult the dealer who supplied the machine Return deliveries of defective equipment subject to warranty may only be made through your dealer When replacing parts use only original s...

Page 29: ...rollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks Visual inspection Casing damage front rear and side walls Wheels and their securing elements Transport ele...

Page 30: ...tem separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private households can be disposed of free of...

Page 31: ...perating status The supply voltage is present and the machine is switched on Flashes Mains overvoltage The supply voltage is too high e g during generator operation Check the mains supply voltage and...

Page 32: ...enerator rating Rec 9 9 kVA Cos efficiency 0 99 83 Protection class Overvoltage category Contamination level 3 Insulation class protection classification H IP 23 Residual current circuit breaker Type...

Page 33: ...4 511621 00100 TIG 26 GDV 8m TIG welding torch rotary gas valve gas cooled de central 094 511621 00108 DM 842 Ar CO2 230bar 30l D Pressure regulator with manometer 394 002910 00030 GH 2X1 4 2M Gas hos...

Page 34: ...o avoid injury and equipment damage the unit must only be repaired or modified by specialist skilled persons The warranty becomes null and void in the event of unauthorised interference Appoint only s...

Page 35: ...15 094 022172 00002 Spacer KA57 3X33 5X17 5 16 092 003293 00000 Choke WD D 4 N 15 17 094 021509 00000 Casing lower section KBG 18 094 014311 00000 Sheet metal nut M5 21X15X6 19 094 021508 00000 Insul...

Page 36: ...Service documents Circuit diagram 36 099 002128 EW501 26 01 2022 10 2 Circuit diagram Figure 10 2...

Page 37: ...ndix Searching for a dealer 099 002128 EW501 26 01 2022 37 11 Appendix 11 1 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners world...

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