EWM PICO 230 CEL Operating Instructions Manual Download Page 41

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Spare parts list

PICO 230; 230 CEL

Item No.: 099-002032-EWM01

10.1.4

Right-hand side

4
5

Figure 10-4

Item Designation

Type

Item

number

1 Mains

switch

MAINS

SWITCH 25A/3PHASE

074-000279-00003

2 Flat

band

cable

PKS-LC/26POLIG/340MM 094-007715-00000

3 Fan

120x120x38mm

NMB4715KL-05W-B40-P00

094-007861-00000

4 MINI-FIT

housing

5559-02P

044-002252-00000

MINI-FIT contact pin

5558-TL/AWG 16

044-002251-00000

6 Bridge

rectifier

074-002908-00000

IND choke

PICO 230 SECONDARY AIR CHOKE

032-000201-00000

PCB current transformer

SW1

042-000787-00000

9 DIO

MODULE

BYT200PIV-400/ISOTOP 044-002601-00000

Cable harness

KB " PICO 230 CEL ADD-ON"

094-008937-00000

PCB SEC. connections

CELL 1 (PICO 230 CELL)

042-000786-00000

PCB SEC. connections

KON 2 (PICO 230)

042-000785-00000

Summary of Contents for PICO 230 CEL

Page 1: ...ing 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 be...

Page 2: ...ody future oriented advanced technology at the utmost level of quality Each of our products is carefully checked we guarantee that the material and processing of our products is faultless These operat...

Page 3: ...ields CE EWM HIGHTEC WELDING GMBH D 56271 M NDERSBACH TYP ART SNR PROJ GEPR FT CONTROL Name of Customer company Adress Post code Place Country Stamp Signature of EWM distibutor Date of purchase Name o...

Page 4: ...Electrode type allocation 19 5 3 3 Selecting hotstart 19 5 3 4 Antistick 20 5 4 TIG welding 20 5 4 1 TIG welding selection 20 5 4 2 TIG arc ignition 21 5 5 Remote control 21 5 5 1 Manual remote contro...

Page 5: ...ne 32 7 4 Repair Work 33 7 5 Disposing of equipment 34 7 5 1 Manufacturer s declaration to the end user 34 7 6 Meeting the requirements of RoHS 34 8 3 Year Warranty 35 8 1 General Validity 35 8 2 Warr...

Page 6: ...otective clothing e g gloves Protect eyes and face with protective visor Electric shocks can be fatal Do not touch any live parts in or on the machine The machine may only be connected to correctly ea...

Page 7: ...Before beginning welding work ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source N...

Page 8: ...ny risk of explosion exists The following conditions must be observed during operation Temperature range of the ambient air During welding 10 C to 40 C For transport and storage 25 C to 55 C Using the...

Page 9: ...h are graded as follows depending on their importance Please note Technical features which users must observe Warning Working and operating procedures which must be followed precisely to avoid damagin...

Page 10: ...en circuit voltage 99 V MMA open circuit voltage with VRD option 12 V TIG open circuit voltage 12 V Mains voltage tolerances 3x400 V 20 to 25 3x415 V 15 to 25 Frequency 50 60 Hz Mains fuse safety fuse...

Page 11: ...V MMA open circuit voltage with VRD option 12 V TIG open circuit voltage 12 V Mains voltage tolerances 3x400 V 20 to 25 3x415 V 15 to 25 Frequency 50 60 Hz Mains fuse safety fuse slow blow 16 A Mains...

Page 12: ...99 V MMA open circuit voltage with VRD option 12 V TIG open circuit voltage 12 V Mains voltage tolerances 3x400 V 20 to 25 3x415 V 15 to 25 Frequency 50 60 Hz Mains fuse safety fuse slow blow 16 A Mai...

Page 13: ...em Symbol Description 0 1 Carrying strap 2 Transport bar 3 Carrying handle 4 Control Operating elements see chapter Function specification 5 Cooling air inlet 6 Connection socket welding current Workp...

Page 14: ...tion PICO 300 300 CEL 300 CEL PWS 14 Item No 099 002032 EWM01 4 1 3 Rear view 1 2 3 Figure 4 2 Item Symbol Description 0 1 Main switch machine on off 2 Strain relief with mains connection cable 3 Cool...

Page 15: ...on socket electrode holder The welding current polarity or are based on the setting of the Welding current polarity changeover switch 8 Rubber feet 9 Welding current potential changeover switch The ch...

Page 16: ...2032 EWM01 4 2 2 Rear view 1 2 3 4 5 Figure 4 4 Item Symbol Description 0 1 Main switch machine on off 2 Strain relief with mains connection cable 3 Cooling air outlet 4 F4 Fuse Solenoid switch pole r...

Page 17: ...ss temperature signal light In case of excess temperature temperature monitors de activate the power unit and the excess temperature control lamp comes on Once the machine has cooled down welding can...

Page 18: ...voltage Further parameter displays are described later on in this chapter 5 3 MMA welding 5 3 1 Selecting MMA welding Control element Action Result Display x x MMA welding signal light lights up The...

Page 19: ...see chapter Arcforce correction 5 3 3 Selecting hotstart Hotstart current Control element Action Result Display 1 x Signal light AMP lights up Hotstart current is shown in Hotstart current is set as a...

Page 20: ...rrent then reduces to the main current set Symbol Meaning AMP Main current AMP Hotstart current sec Hotstart time t AMP AMP I sec Figure 5 3 5 3 4 Antistick Anti stick prevents the electrode from anne...

Page 21: ...when the machine is switched off The remote control is detected automatically when the welding machine is switched on 5 5 1 Manual remote control RT 1 Functions Infinitely adjustable welding current 0...

Page 22: ...individually for the relevant electrode types and their welding properties in addition to the selecting the electrode type Control element Action Result Display X x The corresponding signal light dis...

Page 23: ...on the display Welding current or voltage is displayed 5 6 3 VRD open circuit voltage reduction optional Item Description 1 VRD open circuit voltage reduction signal light AMP AMP sec T 1 22 AMP VOLT...

Page 24: ...ellulose electrode types PICO 230 260 CEL PICO 260 300 CEL PWS MMA direct current welding for rutile rutile basic basic rutile cellulose and cellulose electrode types Any other use is regarded as impr...

Page 25: ...ne The connection must be made by a qualified electrician in compliance with the relevant local laws and regulations The phase sequence for three phase machines is optional and has no effect on the fa...

Page 26: ...ion Caution Risk of injury from crushing Suitable protective gloves should be worn when changing spent stick electrodes When pausing work always place the electrode holder on an insulated surface Inse...

Page 27: ...he welding current polarity or of the electrode holder and workpiece lead connection sockets Welding current polarity on connection socket Welding current polarity on connection socket 4 Connection so...

Page 28: ...ns Insert the welding current plug in the welding current connection socket and lock by turning to the right For machines with pole reversal switch PWS the welding current polarity is changed as follo...

Page 29: ...d into the or welding current connection socket and lock by turning to the right For machines with pole reversal switch PWS the welding current polarity is changed as follows after selecting TIG weldi...

Page 30: ...moisture free compressed air Electronics Do not blast electronic components or circuit boards with compressed air but instead use suction from a vacuum cleaner for cleaning purposes 7 3 Repetition te...

Page 31: ...achine must be marked if the test is successful e g with a test plate This plate must include the date of the next repetition test 7 3 3 Visual inspection Given below are the main points in the full t...

Page 32: ...r the frequency response measurement please refer to DIN EN 61010 1 Appendix A Measuring Circuit A1 For these measurements the welding machine must be switched on and supplying open circuit voltage 1...

Page 33: ...servicing 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 We hereby confirm that the servicing and...

Page 34: ...eled bins indicates the requirement to separate this waste Help to protect the environment and ensure that this equipment when you no longer want to use it is disposed of in the relevant system of sep...

Page 35: ...t manufactured by other companies e g motors pumps fans torches etc Non reproducible software errors and parts subject to mechanical aging are excluded from the warranty e g WF rollers wheels solenoid...

Page 36: ...that are damaged due to accidents misuse improper operation incorrect installation use of force disregard of the specifications and operating instructions inadequate maintenance see chapter Maintenanc...

Page 37: ...cs error Switch the machine off and back on again If the error persists inform the service dept E 2 Temperature error Allow machine to cool down E 3 Electronics error See E 1 E 4 Electronics error See...

Page 38: ...3 00003 3 D25X1 5X548MM TUBE Hand grip 094 007501 00003 4 40x1500MM Carrying strap 094 007543 00000 T1 22 PCB control 040 000662 E0000 5 T1 2 PCB control 040 000645 E0000 6 2523060 Rotary dial 074 000...

Page 39: ...1 4 2 Figure 10 2 Item Designation Type Item number 1 Cable assembly MAINS CABLE 4X1 5QMM 5 5M 092 001844 00000 2 Cap nut M20X1 5 SIZE THREADED JOINT METR 094 007871 00000 3 Mains switch MAINS SWITCH...

Page 40: ...ure 10 3 Item Description Type Item number 1 Mains switch MAINS SWITCH 25A 3PHASE 074 000279 00003 2 Lock nut M20X1 5 7035 COUNTERNUT METR 094 007878 00000 3 PCB primary circuit board DC 231 040 00064...

Page 41: ...5W B40 P00 094 007861 00000 4 MINI FIT pin housing 5559 02P 044 002252 00000 5 MINI FIT contact pin 5558 TL AWG 16 044 002251 00000 6 Bridge rectifier 074 002908 00000 7 IND choke PICO 230 SECONDARY A...

Page 42: ...Spare parts list PICO 260 260 CEL 260 CEL PWS 42 Item No 099 002032 EWM01 10 2 PICO 260 260 CEL 260 CEL PWS This chapter is currently in preparation...

Page 43: ...ote control current with connection cable 094 006680 00000 RV5M19 19POLE 5M Extension cable 092 000857 00000 11 2 Electrode holder workpiece lead Type Description Name Item number EH35QMM 4M Electrode...

Page 44: ...Circuit diagrams PICO 230 44 Item No 099 002032 EWM01 12 Circuit diagrams Original format circuit diagrams are located inside the machine 12 1 PICO 230 Figure 12 1...

Page 45: ...Circuit diagrams PICO 230 CEL Item No 099 002032 EWM01 45 12 2 PICO 230 CEL Figure 12 2...

Page 46: ...GRL3 U1 GR GR X5 1 X5 5 X5 4 X5 8 SPW TRI Spg Versorg Br cke A B Netzfreigabe Signal Spg Versorg X2 X1 X4 2 X4 1 R2 B2 US2 A2 X3 2 X3 1 R1 B1 US1 A1 TM TP Ud Ud NC NC 0V 24 0V 24 NC 15V NC UZWK 0V 15...

Page 47: ...2 GRL3 U1 GR GR X5 1 X5 5 X5 4 X5 8 SPW TRI Spg Versorg Br cke A B Netzfreigabe Signal Spg Versorg X2 X1 X4 2 X4 1 R2 B2 US2 A2 X3 2 X3 1 R1 B1 US1 A1 TM TP Ud Ud NC NC 0V 24 0V 24 NC 15V NC UZWK 0V 1...

Page 48: ...L1 GRL2 GRL3 U1 GR GR X5 1 X5 5 X5 4 X5 8 SPW TRI Spg Versorg Br cke A B Netzfreigabe Signal Spg Versorg X2 X1 X4 2 X4 1 R2 B2 US2 A2 X3 2 X3 1 R1 B1 US1 A1 TM TP Ud Ud NC NC 0V 24 0V 24 NC 15V NC UZW...

Page 49: ...8 X1 19 X1 20 X1 21 X1 22 X1 23 X1 24 X1 25 X1 26 NC NC 15V 15V 5V 5V 0V 0V NC NC 0V 0V OE NC NC NC Drehg A NC Drehg A NC CLK CLK CS2 CS1 RD WR1 X2 26 X2 25 X2 24 X2 23 X2 22 X2 21 X2 20 X2 19 X2 18 X...

Page 50: ...0 X1 21 X1 22 X1 23 X1 24 X1 25 X1 26 NC NC 15V 15V 5V 5V 0V 0V NC NC 0V 0V OE NC NC NC Drehg A NC Drehg A NC CLK CLK CS2 CS1 RD WR1 X2 26 X2 25 X2 24 X2 23 X2 22 X2 21 X2 20 X2 19 X2 18 X2 17 X2 16 X...

Page 51: ...NC Drehg A NC Drehg A NC CLK CLK CS2 CS1 RD WR1 X2 26 X2 25 X2 24 X2 23 X2 22 X2 21 X2 20 X2 19 X2 18 X2 17 X2 16 X2 15 X2 14 X2 13 X2 12 X2 11 X2 10 X2 9 X2 8 X2 7 X2 6 X2 5 X2 4 X2 3 X2 2 X2 1 TDW1...

Page 52: ...he event of unau thorised modifications improperly con ducted repairs non observance of the deadlines for the repetition test and or non permitted conversion work not specifically authorised by EWM Pa...

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