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
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 ...
Page 2: ...pment No other form of liability regardless of type shall be accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are observed during installation operation usage and maintenance of the equipment An incorrectly performed installation can result i...
Page 3: ...function 20 5 1 Transport and installation 21 5 1 1 Adjusting the length of the carrying strap 21 5 2 Machine cooling 22 5 3 Workpiece lead general 22 5 4 Mains connection 23 5 4 1 Mains configuration 23 5 5 MMA welding 24 5 5 1 Connecting the electrode holder and workpiece lead 24 5 5 2 Selecting MMA welding 25 5 5 2 1 MMA pulsed welding 26 5 5 2 2 Hotstart current and Hotstart time 28 5 5 2 3 An...
Page 4: ... Maintenance work 38 6 4 Disposing of equipment 38 6 4 1 Manufacturer s declaration to the end user 38 6 5 Meeting the requirements of RoHS 38 7 Rectifying faults 39 7 1 Checklist for rectifying faults 39 7 2 Machine faults error messages 40 7 3 Display machine control software version 41 7 4 Resetting welding parameters to the factory settings 42 8 Technical data 43 8 1 Pico 220 cel puls 43 9 Acc...
Page 5: ...Contents Notes on the use of these operating instructions 099 002057 EW501 28 04 2014 5 ...
Page 6: ...ol in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading with a general warning symbol The risk is explained using a symbol on the edge of the page CAUTION Working and operating procedures which must be followed precisely to avoid damaging or destroying t...
Page 7: ...ress Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exit the menu 4 s 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: ...ks and burns on contact Even low voltages can cause you to get a shock and lead to accidents Do not touch any live parts in or on the machine Connection cables and leads must be free of faults Switching off alone is not sufficient Place welding torch and stick electrode holder on an insulated surface The unit should only be opened by specialist staff after the mains plug has been unplugged Only we...
Page 9: ... accidents if these safety instructions are not observed Non observance of these safety instructions is potentially fatal Carefully read the safety information in this manual Observe the accident prevention regulations in your country Inform persons in the working area that they must observe the regulations Danger when coupling multiple power sources Coupling multiple power sources in parallel or ...
Page 10: ...g currents Stray welding currents can destroy protective earth conductors damage equipment and electronic devices and cause overheating of components leading to fire Make sure all welding leads are securely connected and check regularly Always ensure a proper and secure electrical connection to the workpiece Set up attach or suspend all conductive power source components like casing transport vehi...
Page 11: ...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 user must consider the following see also EN 60974 10 Appendix A Mains control signal and telecommunication lines Radios and televisions Computers and other control systems Safety equipment The health of neighbouring persons especi...
Page 12: ...uitable for transport by hand only The machine may not be lifted by crane or suspended CAUTION Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to IEC 60974 1 Set up and transport the machine on level solid ground Secure add on parts using suitable equipme...
Page 13: ...ities of dust acid corrosive gases or substances may damage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambient conditions Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Keep the cooling air inlet and outlet clear Observe the minimum distan...
Page 14: ...cterised by the fact that the arc burns between a melting electrode and the molten pool There is no external protection any protection against the atmosphere comes from the electrode 3 1 2 TIG Liftarc welding TIG welding process with arc ignition by means of workpiece contact 3 2 Machine variants 3 2 1 Voltage reduction device VRD machine version To increase safety particularly in hazardous enviro...
Page 15: ...ed with the unit 3 3 3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be used in environments with an increased electrical hazard 3 3 4 Service documents spare parts and circuit diagrams DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repaired or mod...
Page 16: ... See Machine control operating elements chapter 3 Connection socket welding current TIG Welding current lead connection for TIG welding torch MMA Electrode holder or workpiece lead connection 4 Connection socket welding current TIG Connection for workpiece lead MMA Electrode holder or workpiece lead connection 5 Connection socket 19 pole Remote control connection 6 Cooling air outlet 7 Machine fee...
Page 17: ...Machine description quick overview Rear view 099 002057 EW501 28 04 2014 17 4 2 Rear view Figure 4 2 Item Symbol Description 0 1 Main switch machine on off 2 Cooling air inlet 3 Mains connection cable ...
Page 18: ... and the output voltage is reduced to a value specified in the relevant standard see technical data The voltage reduction device is only active on VRD machine versions 4 AMP Hotstart current signal light 50 to 200 of the main current 5 Welding parameter setting rotary transducer Setting of welding current and other welding parameter and their values 6 sec Hotstart time signal light 0 1 s to 20 s 7...
Page 19: ...ction of welding procedure MMA setting electrode type Signal lamp R RB illuminated green Electrode type rutile Signal lamp R RB illuminated red Electrode type rutile basic Signal lamp RC B C illuminated green Electrode type basic rutile cellulose Signal lamp RC B C illuminated red Electrode type cellulose Selection of TIG welding procedure 11 Display 3 digit ...
Page 20: ...rns on the welding current connection If the welding current connections are not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by turning in clockwise direction if necessary Risk from electrical current If welding is carried out alternately using different methods and if a welding torch and an electrode holder remain co...
Page 21: ...e lifted by crane or suspended 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 Safe operation of the machine must be guaranteed at all times 5 1 1 Adjusting the length of the carrying...
Page 22: ...not allow metal parts dust or other objects to get into the machine 5 3 Workpiece lead general CAUTION Risk of burns due to incorrect connection of the workpiece lead Paint rust and dirt on the connection restrict the power flow and may lead to stray welding currents Stray welding currents may cause fires and injuries Clean the connections Fix the workpiece lead securely Do not use structural part...
Page 23: ...network has to be suitable for operating devices according to protection class 1 5 4 1 Mains configuration NOTE The machine may be connected to a three phase system with four conductors and an earthed neutral conductor a three phase system with three conductors of which any one can be earthed e g the outer conductor Figure 5 2 Legend Item Designation Colour code L1 Outer conductor 1 brown L2 Outer...
Page 24: ...r and workpiece lead NOTE Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging Figure 5 3 Item Symbol Description 0 1 Workpiece 2 Connection socket for welding current Electrode holder or workpiece lead connection 3 Electrode holder 4 Connection socket welding current Workpiece lead or electrode holder connection Insert cable plug of the electrode h...
Page 25: ...e cellulose Selection of TIG welding procedure 2 Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used 3 AMP Main current signal light Imin to Imax 1 A increments 4 AMP Hotstart current signal light 50 to 200 of the main current 5 sec Hotstart time signal light 0 1 s to 20 s 6 Signal light MMA pulsed welding O...
Page 26: ...asses Less finishing work thanks to less spatter Highly suitable for difficult electrodes Outstanding gap bridging with no sagging of the root side Less distortion thanks to controlled heat input ON OFF Freq Pulse Figure 5 5 Display Setting selection MMA pulsed welding On Function switched on Off Function switched off ex works Frequency MMA pulsed welding Setting range 0 2 Hz to 500 Hz ex works 5 ...
Page 27: ...100 A 70 A Tpuls Duration of one pulse cycle 1 FrE e g 1 1 Hz 1 sec Pdc Pulse duration Pdc x Tpuls e g 30 x 1 sec 0 3 sec NOTE The pulse parameters are pre set as standard in such a way that the average welding current value corresponds to the pre selected main current AMP If the pulse parameters in the sub menu are changed the average value of the welding current changes it deviates from AMP ...
Page 28: ...ime in seconds has elapsed factory setting 1 second The hotstart current then reduces to the main current set Symbol Meaning AMP Main current AMP Hotstart current sec Hotstart time Figure 5 7 NOTE A hot start is carried out without pulsing and the pulse sequence begins with one pulse after the hot start 5 5 2 3 Antistick Anti stick prevents the electrode from annealing If the electrode sticks in s...
Page 29: ...process The following diagram shows the setting options EXIT ENTER 2 s 2 s Figure 5 9 Display Setting selection Arcforce correction setting 10 to 10 factory setting 0 Increase value harder arc Decrease value softer arc Pulse duration setting 1 to 99 ex works 50 Percentage of time from pulse cycle Tpuls for pulse current IP1 Pulse current setting 1 to 200 ex works 140 Pulse pause current setting 1 ...
Page 30: ...linder Do not attach any element to the shielding gas cylinder valve Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air Avoid heating the shielding gas cylinder CAUTION Faults in the shielding gas supply An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum w...
Page 31: ...cylinder Slowly open the gas cylinder valve Open the rotating valve on the welding torch Before each welding process the rotating valve must be opened after the welding process it must be closed Set the required amount of shielding gas on the pressure reducer about 4 15 l min depending on the current strength and the material NOTE Incorrect shielding gas setting If the shielding gas setting is too...
Page 32: ...iece lead connection 3 Output side of the pressure regulator 4 Welding torch 5 Connection socket welding current Welding current lead connection for TIG welding torch Insert the welding current plug on the welding torch into the welding current connection socket and lock by turning to the right Insert the cable plug on the work piece lead into the welding current connection socket and lock by turn...
Page 33: ...current flowing regardless of the main current set b Incline the torch towards the torch gas nozzle until there is a gap of approx 2 3mm between the tip of the electrode and the workpiece arc ignites current increases to the main current set c Lift off the torch and swivel to the normal position Ending the welding process Remove the torch from the workpiece until the arc goes out If an RTF 1 foot ...
Page 34: ...tting parameters hold down the Welding parameters button for 2 seconds after selecting the welding process The following diagram shows the setting options ENTER EXIT 2 s 2 s Figure 5 14 Display Setting selection Ignition current Setting 1 to 200 of main current AMP depending on main current Upslope time to main current Setting 0 0 sec to 20 0 sec factory setting 1 0 sec ...
Page 35: ...above the air inlet using both clips 1 Fold down the dirt filter 2 Fasten the dirt filter to the underside of the machine 3 using fixing screws NOTE 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 dep...
Page 36: ...epending on the preselected main current on the welding machine Start stop welding operation TIG 5 8 4 RTG1 19POL manual remote control Functions Infinite setting of the welding current 0 to 100 depending on the main current preselected at the welding machine 5 9 Voltage reducing device VRD To increase safety particularly in hazardous environments like shipbuilding pipe construction or mining the ...
Page 37: ...tion 6 2 1 2 Functional test Welding current cables check that they are fitted correctly and secured Gas cylinder securing elements Operating message safety and adjustment devices Functional test 6 2 2 Monthly maintenance tasks 6 2 2 1 Visual inspection Casing damage front rear and side walls Transport elements strap lifting lugs handle 6 2 2 2 Functional test Selector switches command devices eme...
Page 38: ...ng to European provisions guideline 2002 96 EG of the European Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be collected separately The symbol depicting a waste container on wheels indicates that the equipment must be collected separately This machine is to be placed for disposal or recycling in t...
Page 39: ... NOTE The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation Legend Symbol Description Fault Cause Remedy Excess temperature signal light illuminates Excess temperature welding machine Allow the machine to cool down whilst still switched on Functional errors Machine control without displaying the signal lights after switching on Pha...
Page 40: ...ice department E 9 Secondary overvoltage E12 Voltage reduction error VRD E13 Electronics error E14 Alignment error in current recording Switch off the machine place the electrode holder in an insulated position and switch the machine back on If the error persists notify service department E15 Error in one of the electronics supply voltages Switch machine on and off again If the error persists noti...
Page 41: ...s only serves to inform the authorised service staff ENTER EXIT l 0 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 Modifications to the service menu may only be carried out by authorised maintenance staff Software version of the machine control Version display ...
Page 42: ... to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings RESET l 0 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 is shown on the display ...
Page 43: ...g 4 min pause Open circuit voltage 97 V Open circuit voltage VRD AUS 12 V 33 V Open circuit voltage VRD RU 12 V 12 V Mains voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 10 A Mains connection line H07RN F4G1 5 Max connected load 5 2 kVA 8 0 kVA Recommended generator rating 10 8 kVA cos 0 99 Insulation class protection classification H IP 23 Ambient te...
Page 44: ... cable 090 008764 00000 RTG1 19POL Remote control current 090 008106 00000 RA5 19POL 5M Remote control e g connection cable 092 001470 00005 RA10 19POL 10M Remote control e g connection cable 092 001470 00010 RA20 19POL 20M Remote control e g connection cable 092 001470 00020 RTF1 19POLE 5M Foot operated remote control current with connection cable 094 006680 00000 RV5M19 19POLE 5M Extension cable...
Page 45: ...Appendix A Overview of EWM branches 099 002057 EW501 28 04 2014 45 10 Appendix A 10 1 Overview of EWM branches ...
