Pico Tig 160 Cel Plus 099-002129-Ew501

Operating instructions
Welding machine
Pico 160 cel puls

EN Pico 160 cel puls VRD (RU)
Pico 160 cel puls VRD (AUS)
099-002129-EW501 26.03.2018
General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the location where the machine is operated.
• Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
• Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the

installation site, or on usage, please contact your sales partner or our customer service
department on +49 2680 181-0.
A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers.
Liability relating 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 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 in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Strasse 8
56271 Mündersbach Germany
Tel.: +49 2680 181-0, Fax: -244
Email: info@ewm-group.com
www.ewm-group.com
The copyright to this document remains the property of the manufacturer.

Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.
Contents
Notes on the use of these operating instructions
1 Contents
1 Contents .................................................................................................................................................. 3
2 For your safety ....................................................................................................................................... 5
2.1 Notes on the use of these operating instructions .......................................................................... 5
2.2 Explanation of icons ....................................................................................................................... 5
2.2.1 Complete documentation ............................................................................................... 6
2.3 General .......................................................................................................................................... 6
3 Intended use ........................................................................................................................................... 7
3.1 Documents which also apply ......................................................................................................... 7
3.1.1 Warranty ......................................................................................................................... 7
3.1.2 Declaration of Conformity ............................................................................................... 7
3.1.3 Welding in environments with increased electrical hazards ........................................... 7
3.1.4 Calibration/Validation ..................................................................................................... 7
4 Machine description – quick overview ................................................................................................ 8
4.1 Front view ...................................................................................................................................... 8
4.2 Rear view ....................................................................................................................................... 9
4.3 Machine control – Operating elements ........................................................................................ 10
5 Design and function............................................................................................................................. 12
5.1 Transport and installation ............................................................................................................ 12
5.1.1 Machine cooling............................................................................................................ 12
5.1.2 Workpiece lead, general ............................................................................................... 12
5.1.3 Ambient conditions ....................................................................................................... 13
5.1.3.1 In operation ................................................................................................... 13
5.1.3.2 Transport and storage ................................................................................... 13
5.1.4 Adjusting the length of the carrying strap ..................................................................... 13
5.1.5 Notes on the installation of welding current leads ........................................................ 14
5.1.6 Stray welding currents .................................................................................................. 15
5.1.7 Mains connection.......................................................................................................... 15
5.1.7.1 Mains configuration ....................................................................................... 16
5.2 Operating the machine control..................................................................................................... 16
5.3 Machine display ........................................................................................................................... 16
5.3.1 Welding power setting .................................................................................................. 16
5.3.2 Welding parameter setting in the operation sequence ................................................. 16
5.3.3 Setting advanced welding parameters (Expert menu) ................................................. 16
5.3.4 Changing basic settings (machine configuration menu) .............................................. 16
5.4 MMA welding ............................................................................................................................... 17
5.4.1 Connecting the electrode holder and workpiece lead .................................................. 17
5.4.2 Welding task selection .................................................................................................. 18
5.4.3 Arcforce ........................................................................................................................ 18
5.4.4 Hotstart ......................................................................................................................... 18
5.4.5 Antistick ........................................................................................................................ 19
5.4.6 Average value pulse welding........................................................................................ 19
5.4.7 Expert menu (MMA) ..................................................................................................... 20
5.5 TIG welding .................................................................................................................................. 21
5.5.1 Connecting a TIG welding torch with rotating gas valve .............................................. 21
5.5.2 Shielding gas supply (shielding gas cylinder for welding machine) ............................. 21
5.5.3 Pressure regulator connection ..................................................................................... 22
5.5.4 Welding task selection .................................................................................................. 22
5.5.5 Gas test – setting the shielding gas volume ................................................................. 22
5.5.6 Arc ignition .................................................................................................................... 23
5.5.6.1 Liftarc ............................................................................................................ 23
5.5.7 Average value pulse welding........................................................................................ 23
5.5.8 Expert menu (TIG) ........................................................................................................ 24
5.6 Remote control............................................................................................................................. 25
5.7 Arc length restriction (USP) ......................................................................................................... 25
5.8 Power-saving mode (Standby) .................................................................................................... 25
5.9 Voltage reducing device .............................................................................................................. 25
5.10 Access control.............................................................................................................................. 25
5.11 Machine configuration menu ........................................................................................................ 26
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Contents
6 Maintenance, care and disposal ......................................................................................................... 28

6.1 General......................................................................................................................................... 28
6.1.1 Cleaning ........................................................................................................................ 28
6.1.2 Dirt filter......................................................................................................................... 28
6.2 Maintenance work, intervals ........................................................................................................ 29
6.2.1 Daily maintenance tasks ............................................................................................... 29
6.2.2 Monthly maintenance tasks .......................................................................................... 29
6.2.3 Annual test (inspection and testing during operation) .................................................. 29
6.3 Disposing of equipment................................................................................................................ 30
7 Rectifying faults.................................................................................................................................... 31
7.1 Error messages (power source) ................................................................................................... 31
7.2 Checklist for rectifying faults ........................................................................................................ 32
7.3 Display machine control software version.................................................................................... 32
7.4 Dynamic power adjustment .......................................................................................................... 32
7.5 Resetting welding parameters to the factory settings .................................................................. 33
8 Technical data....................................................................................................................................... 34
8.1 Pico 160 cel puls .......................................................................................................................... 34
9 Accessories .......................................................................................................................................... 35
9.1 Electrode holder / workpiece lead ................................................................................................ 35
9.2 Remote controls and accessories ................................................................................................ 35
9.3 TIG welding torch ......................................................................................................................... 35
9.4 General accessories .................................................................................................................... 35
9.5 Options ......................................................................................................................................... 35
10 Service documents .............................................................................................................................. 36
10.1 Spare and replacement parts ....................................................................................................... 36
10.2 Circuit diagram ............................................................................................................................. 38
11 Appendix A............................................................................................................................................ 39
11.1 Parameter overview – setting ranges .......................................................................................... 39
12 Appendix B............................................................................................................................................ 40
12.1 Searching for a dealer .................................................................................................................. 40
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For your safety
2 For your safety

2.1 Notes on the use of these operating instructions
2.2 Explanation of icons
Symbol Description Symbol Description
Indicates technical aspects which the Activate and release / Tap / Tip
user must observe.
Switch 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 green
Output Signal light lights up in red
Time representation (e.g.: wait 4 s / Signal light flashes red

actuate)
Interruption in the menu display (other

setting options possible)
Tool not required/do not use
Tool required/use
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For your safety
General
2.2.1 Complete documentation

These operating instructions are part of the complete documentation and valid only in
combination with the "Safety instructions”!
Read and observe the documents for all system components!
Figure 2-1
Item Documentation
A.1 Safety instructions
A.2 Power source
A.3 Electrode holder/welding torch
A.4 Remote control
A Complete documentation
2.3 General
Obligations of the operator!
The respective national directives and laws must be complied with when operating the machine!
• Implementation of national legislation relating to framework directive 89/391/EEC on the
introduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
• In particular, directive 89/655/EEC concerning the minimum safety and health requirements for
the use of work equipment by workers at work.
• The regulations applicable to occupational safety and accident prevention in the country
concerned.
• Setting up and operating the machine as per IEC 60974.-9.
• Brief the user on safety-conscious work practices on a regular basis.
• Regularly inspect the machine as per IEC 60974.-4.
The manufacturer's warranty becomes void if non-genuine parts are used!

• Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Requirements for connection to the public mains network

High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of the
operator, where necessary in consultation with the mains network operator, to ensure that the
machine can be connected.
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Intended use
Documents which also apply
3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures 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 usage!
• The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
Arc welding machine for MMA DC welding with TIG DC welding with lift arc (touch starting) as secondary
process.
3.1 Documents which also apply
3.1.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.1.2 Declaration of Conformity

The labelled machine complies with the following EC directives in terms of its design and
construction:
• Low Voltage Directive (LVD)
• Electromagnetic Compatibility Directive (EMC)
• Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment – Inspection and Testing during Operation," and/or prohibited modifications which
have not been explicitly authorised by the manufacturer, this declaration shall be voided. An original
document of the specific declaration of conformity is included with every product.
3.1.3 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.
3.1.4 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months
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Machine description – quick overview
Front view
4 Machine description – quick overview

4.1 Front view
Figure 4-1
Item Symbol Description 0

1 Carrying strap > see 5.1.4 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 workpiece lead
5 Cooling air outlet
6 Connection socket, “-” welding current
• MMA: Connection of electrode holder or workpiece lead
• TIG: Connection of TIG welding torch
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Rear view
4.2 Rear view
Figure 4-2

1 Main switch, machine on/off
2 Cooling air inlet

3 Mains connection cable > see 5.1.7 chapter
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Machine control – Operating elements
4.3 Machine control – Operating elements

The setting ranges for the parameter values are summarised in the Parameter overview
section > see 11.1 chapter.
Figure 4-3

1 Excess 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 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 5.9 chapter
4 AMP% Hotstart current signal light
5 sec Hotstart time signal light
6 Pulsed welding/power-saving mode push-button
MMA ---- pulse welding > see 5.4.6 chapter
TIG ------ pulse welding > see 5.5.7 chapter
Press for 2 s to put the machine into power-saving mode. To reactivate, activate one of
the operating elements > see 5.8 chapter.
7 Control button
Central control button to be pressed or turned > see 5.2 chapter.
8 3-pole connection socket

Remote control control cable
9 Welding procedure push-button
------ MMA welding
------ MMA welding (Cel characteristics)
-------- TIG welding
10 AMP Main current signal light
Imin to Imax (1 A increments)
11 Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 5.3 chapter
12 A “Welding current unit" signal light
Illuminates when welding currents are displayed.
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Machine control – Operating elements

13 Access control active signal light
Signal light is on when access control is active on the machine
control > see 5.10 chapter.
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Design and function
Transport and installation
5 Design and function

WARNING
Risk of injury from electrical voltage!
Contact with live parts, e.g. power connections, can be fatal!
• Observe the safety information on the first pages of the operating instructions!
• Commissioning must be carried out by persons who are specifically trained in handling
power sources!
• Connect connection or power cables while the machine is switched off!
Read and observe the documentation to all system and accessory components!
5.1 Transport and installation

WARNING
Risk of accident due to improper transport of machines that must not be lifted!
Do not lift or suspend the machine! The machine can drop and 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.
The units are designed for operation in an upright position!

Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant
accessory components.
• Accessory components are detected automatically after the power source is switched on.
5.1.1 Machine cooling

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 distance of 0.5 m from obstacles!
5.1.2 Workpiece lead, general
CAUTION
Risk of burning due to incorrect welding current connection!
If the welding current plugs (machine connections) are not locked or if the workpiece
connection is contaminated (paint, corrosion), these connections and leads can heat up
and cause burns when touched!
• Check welding current connections on a daily basis and lock by turning to the right when
necessary.
• Clean workpiece connection thoroughly and secure properly. Do not use structural parts of
the workpiece as welding current return lead!
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Design and function
5.1.3 Ambient conditions

T he 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.
Equipment damage due to contamination!

Unusually high amounts of dust, acids, corrosive 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!
5.1.3.1 In operation
Temperature range of the ambient air:
• -25 °C to +40 °C (-13 F to 104 F)
Relative humidity:
• up to 50 % at 40 °C (104 F)
• up to 90 % at 20 °C (68 F)
5.1.3.2 Transport and storage
Storage in a closed room, temperature range of the ambient air:
• -30 °C to +70 °C (-22 F to 158 F)
Relative humidity
• up to 90 % at 20 °C (68 F)
5.1.4 Adjusting the length of the carrying strap

To demonstrate adjustment, lengthening the strap is shown in the figure. To shorten, the strap's
loops must be inched in the opposite direction.
Figure 5-1
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Design and function
5.1.5 Notes on the installation 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. Avoid
loops!
Always keep leads as short as possible!
Lay any excess cable lengths in meanders.
Figure 5-3
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Design and function
5.1.6 Stray welding currents
WARNING
Risk of injury due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage machines and
electronic devices and cause overheating of components, leading to fire.
• Check 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,
transport vehicles and crane frames so they are insulated.
• Do not place any other electronic devices such as drills or angle grinders on the power
source, transport vehicle or crane frames unless they are insulated.
• Always put welding torches and electrode holders on an insulated surface when they are
not in use.
Figure 5-4
5.1.7 Mains connection
DANGER
Hazards caused by improper mains connection!
An improper mains connection can cause injuries or damage property!
• The connection (mains plug or cable), the repair or voltage adjustment of the device must
be carried out by a qualified electrician in accordance with the respective local laws or
national regulations!
• The mains voltage indicated on the rating plate must match the supply voltage.
• Only 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 ensure it is earthed as stipulated in the operating
instructions. The network created must be suitable for operating machines according to
protection class I.
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Design and function
Operating the machine control
5.1.7.1 Mains configuration

The machine may only be connected to a one-phase system with two conductors and an earthed
neutral conductor.
Figure 5-5
Legend
Item Designation Colour code
L Outer conductor brown
N Neutral conductor blue
PE Protective conductor green-yellow
• Insert mains plug of the switched-off machine into the appropriate socket.
5.2 Operating the machine control

5.3 Machine display
The machine control switches to the main screen after it has been turned on or a setting has been
completed. This means that the previously selected settings (indicated by signal lights where applicable)
have been applied and the current nominal value (A) is displayed in the welding data display.
5.3.1 Welding power setting
The welding power is set using the control button. You can also adjust the parameters in the operation
sequence or settings in the different machine menus.
5.3.2 Welding parameter setting in the operation sequence
During the operation sequence you can set a welding parameter by briefly pressing the control button
(navigate the parameters) and then turning the button (set the parameter).
5.3.3 Setting advanced welding parameters (Expert menu)
The Expert menu contains functions and parameters which cannot be set directly in the machine control
or which do not need to be et on a regular basis. The number and display of these parameters depends
on the previously selected welding procedure or the functions.
5.3.4 Changing basic settings (machine configuration menu)
The basic welding system functions can be adjusted in the machine configuration menu. Only
experienced users should change the settings > see 5.11 chapter.
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Design and function
MMA welding
5.4 MMA welding

5.4.1 Connecting the electrode holder and workpiece lead
CAUTION
Risk of crushing and burns!
When changing stick electrodes there is a risk of crushing and burns!
• Wear appropriate and dry protective gloves.
• Use an insulated pair of tongs to remove the used stick electrode or to move welded
workpieces.
Figure 5-6

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
Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.
• Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and
lock by turning to the right.
• Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and
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Design and function
MMA welding
5.4.2 Welding task selection
R
RB
C
B
RC
Figure 5-7
Type Electrode type
R Rutile
RB Rutile-basic
B Basic
RC Rutile cellulose
C Cellulose
5.4.3 Arcforce
During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in
current. This makes it easier to weld large-drop melting electrode types at low current strengths with a
short arc in particular.
For parameter setting, > see 5.4.7 chapter.
5.4.4 Hotstart
The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent
metal at the beginning of the welding process. The ignition takes place here with increased current (hot
start current) over a certain time (hot start time).
A = Hot start current
B = Hot start time
C = Main current
I= Current
t= Time
Figure 5-8
Setting
EXIT EXIT
Figure 5-9
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Design and function
MMA welding
5.4.5 Antistick
The Antistick feature prevents the electrode from annealing.
Should the electrode stick despite the Arcforce feature, the machine
automatically switches to the minimum current within approx. one
second. This prevents the electrode from annealing. Check the welding
current setting and correct for the welding task in hand.
Figure 5-10
5.4.6 Average value pulse welding

Average value pulse welding means that two currents are switched periodically, a current average value
(AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The
predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the
parameter as a percentage of the current average value (AMP). The pulse pause current (IPP) requires
no setting. This value is calculated by the machine control, so that the welding current average value
(AMP) is maintained at all times.
Figure 5-11
AMP = Main current; e.g. 100 A
Ipuls = Pulse current = x AMP; e.g. 140% x 100 A = 140 A
IPP = Pulse pause current
Tpuls = Duration of one pulse cycle = 1/ ; e.g. 1/1 Hz = 1 s
= Balance
Selection
Figure 5-12
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Design and function
MMA welding
5.4.7 Expert menu (MMA)

The Expert menu has adjustable parameters stored that don’t require regular setting. The number of
parameters shown may be limited, e.g. if a function is deactivated.
ENTER EXIT
2s 2s
NAVIGATION
Figure 5-13
Display Setting/selection
Arcforce correction
• Increase value > harder arc
• Decrease value > softer arc
Pulse frequency
Pulse balance
Pulse current > see 5.4.6 chapter
Arc length restriction > see 5.7 chapter

------- Function switched on
------- Function switched off
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Design and function
TIG welding
5.5 TIG welding

5.5.1 Connecting a TIG welding torch with rotating gas valve
Prepare welding torch according to the welding task in hand (see operating instructions for the torch).
Figure 5-14

1 Workpiece
2 Connection socket for "+" welding current
Workpiece 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
• Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by
turning to the right.
• Screw the shielding gas hose of the welding torch to the pressure regulator outlet.
5.5.2 Shielding gas supply (shielding gas cylinder for welding machine)
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders
can cause serious injuries!
• Place shielding gas cylinder into the designated holder and secure with
fastening elements (chain/belt)!
• Attach the fastening elements within the upper half of the shielding gas
cylinder!
• The fastening elements must tightly enclose the shielding gas cylinder!
An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a
fundamental requirement for optimum welding results. In addition, a blocked shielding gas
supply may result in the welding torch being destroyed.
• All shielding gas connections must be gas tight.
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Design and function
TIG welding
5.5.3 Pressure regulator connection
Figure 5-15

1 Pressure regulator
2 Shielding gas cylinder
3 Output side of the pressure regulator
4 Cylinder valve
• Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow
out any dirt.
• Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.
5.5.4 Welding task selection
Figure 5-16
5.5.5 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 valve). The rotary valve must be opened before each welding
procedure and closed after each welding procedure.
If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause
pores to form. Adjust the shielding gas quantity to suit the welding task!
Rule of thumb for the gas flow rate:
Diameter of gas nozzle in mm corresponds to gas flow in l/min.
Example: 7mm gas nozzle corresponds to 7l/min gas flow.
• Slowly open the gas cylinder valve.
• Set the relevant gas quantity for the application on the pressure regulator.
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Design and function
TIG welding
5.5.6 Arc ignition

5.5.6.1 Liftarc
Figure 5-17
The arc ignites through contact with the workpiece:
a) Carefully place the torch gas nozzle and tungsten electrode tip against the workpiece (lift arc current
flows independent of the set main current)
b) Angle the torch above the torch gas nozzle until the distance between electrode tip and workpiece is
approx. 2–3 mm (arc ignites, current increases to the set main current).
c) Lift the torch off and bring into normal position.
Complete the welding task: Remove the torch from the workpiece so that the arc
extinguishes > see 5.7 chapter.
5.5.7 Average value pulse welding
Average value pulse welding means that two currents are switched periodically, a current average value
(AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The
predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the
parameter as a percentage of the current average value (AMP). The pulse pause current (IPP) requires
no setting. This value is calculated by the machine control, so that the welding current average value
(AMP) is maintained at all times.
Figure 5-18
AMP = Main current; e.g. 100 A
IPL = Pulse current = IP1 x AMP; e.g. 170% x 100 A = 170 A
IPP = Pulse pause current
Tpuls = Duration of one pulse cycle = 1/FrE; e.g. 1/1 Hz = 1 s
bAL = Balance
Selection
Figure 5-19
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Design and function
TIG welding
5.5.8 Expert menu (TIG)

The Expert menu has adjustable parameters stored that don’t require regular setting. The number of
parameters shown may be limited, e.g. if a function is deactivated.
2s 2s
Figure 5-20
Ignition current (as percentage, dependent on main current)
Upslope time to main current
Pulse frequency
Pulse balance
Pulse current > see 5.5.7 chapter
Arc length restriction > see 5.7 chapter

------- Function switched on
------- Function switched off
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Design and function
Remote control
5.6 Remote control

Remote controls are used for the remote operation of various machine functions. The 2-pin remote
control connection is installed on the device controller > see 4.3 chapter.
5.7 Arc length restriction (USP)
The arc length restriction function stops the welding process when an excessive arc voltage is
detected (unusually high gap between electrode and workpiece). This function can be adjusted in the
corresponding Expert menu, depending on the process:
MMA welding > see 5.4.7 chapter
TIG welding > see 5.5.8 chapter
The arc length restriction cannot be used for cel characteristics (if available).
5.8 Power-saving mode (Standby)

You can activate the power-saving mode by either pressing the push-button > see 4.3 chapter for a
prolonged time or by setting a parameter in the machine configuration menu (time-controlled power-
saving mode ) > see 5.11 chapter.
When power-saving mode is activated, the machine displays show the horizontal digit in the
centre of the display only.
Pressing any operating element (e.g. turning a rotary knob) deactivates power-saving mode and the
machine is ready for welding again.
5.9 Voltage reducing device

Only machine variants with the (VRD/AUS/RU) code are equipped with a voltage reduction device (VRD).
The VRD is used for increased safety, especially in hazardous environments such as shipbuilding, pipe
construction or mining.
A VRD is mandatory in some countries and required by many on-site safety instructions for power
sources.
The VRD > see 4.3 chapter signal light is illuminated when the voltage reduction device is operating
without fault and the output voltage is reduced to a value specified in the relevant standard (see technical
data > see 8 chapter).
5.10 Access control

The control can be locked to secure some basic parameters against unauthorised or unintentional
adjustment of machine settings. The access block operates as follows:
• The parameters and their settings in the machine configuration menu, Expert menu and operation
sequence can only be viewed but not changed.
• Welding procedure cannot be changed.
The parameters for the access block are configured in the machine configuration
menu > see 5.11 chapter.
Enabling the access block
• Assign the access code for the access block: Select parameter and select a number code (000–
999).
• Enable the access block: Set parameter to access block enabled .
The access block activation is indicated by the "Access block active" signal light > see 4.3 chapter.
Disabling the access block
• Enter the access code for the access block: Select parameter and enter the previously selected
number code (000–999).
• Disable the access block: Set parameter to access block disabled . The only way to disable
the access block is to enter the previously selected number code.
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Design and function
Machine configuration menu
5.11 Machine configuration menu

Basic machine settings are defined in the machine configuration menu.
+
0 0
A
l l
B
A
B B
A A
B B
A A
Figure 5-21
Calibration
The machine will be calibrated for approx 2 seconds each time it is switched on.
Exit the menu
Exit
Machine configuration
Settings for machine functions and parameter display
Dynamic power adjustment > see 7.4 chapter
Time-based power-saving mode > see 5.8 chapter

Time to activation of the power-saving mode in case of inactivity.
Setting = disabled or numerical value 5– 60 min. (ex works: 20).
Expert menu
Access control – access code

Setting: 000 to 999 (000 ex works)
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Design and function
Machine configuration menu
Access control > see 5.10 chapter
------- Function enabled
------- Function disabled (ex works)
Service menu
Any changes to the service menu should be agreed with the authorised service
personnel.
Software version of the machine control
Version display
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Maintenance, care and disposal
General
6 Maintenance, care and disposal

6.1 General
DANGER
Risk of injury due to electrical voltage after switching off!
Working on an open machine can lead to fatal injuries!
Capacitors are loaded with electrical voltage during operation. Voltage remains present
for up to four minutes after the mains plug is removed.
1. Switch off machine.
2. Remove the mains plug.
3. Wait for at last 4 minutes until the capacitors have discharged!
WARNING
Incorrect maintenance, testing and repair!
Maintenance, testing and repair of the machine may only be carried out by skilled and
qualified personnel. A qualified person is one who, because of his or her training,
knowledge and experience, is able to recognise the dangers that can occur while testing
welding power sources as well as possible subsequent damage, and who is able to
implement the required safety procedures.
Observe the maintenance instructions > see 6.2 chapter.
• In the event that the provisions of one of the below-stated tests are not met, the machine
must not be operated again until it has been repaired and a new test has been carried out!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service 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 spare parts. When ordering spare parts, please quote the
machine type, serial number and item number of the machine, as well as the type designation and item
number of the spare part.
Under the specified ambient conditions and normal working conditions this machine is essentially
maintenance-free and requires just a minimum of care.
Contamination of the machine may impair service life and duty cycle. The cleaning intervals depend on
the ambient conditions and the resulting contamination of the machine. The minimum interval is every six
months.
6.1.1 Cleaning
• Clean the outer surfaces with a moist cloth (no aggressive cleaning agents).
• Purge the machine venting channel and cooling fins (if present) with oil- and water-free compressed
air. Compressed air may overspeed and destroy the machine fans. Never direct the compressed air
directly at the machine fans. Mechanically block the fans, if required.
• Check the coolant for contaminants and replace, if necessary.
6.1.2 Dirt filter

The duty cycle of the welding machine decreases as an effect of the reduced cooling air volume. The dirt
filter must be remove at regular intervals and cleaned by blowing out with compressed air (depending on
the level of soiling).
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Maintenance work, intervals
6.2 Maintenance work, intervals

6.2.1 Daily maintenance tasks
Visual inspection
• Mains supply lead and its strain relief
• Gas cylinder securing elements
• Check hose package and power connections for exterior damage and replace or have repaired by
specialist staff as necessary!
• Gas tubes and their switching equipment (solenoid valve)
• Check that all connections and wearing parts are hand-tight and tighten if necessary.
• Check correct mounting of the wire spool.
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
• Other, general condition
Functional test
• Operating, message, safety and adjustment devices (Functional test)
• Welding current cables (check that they are fitted correctly and secured)
• Gas tubes and their switching equipment (solenoid valve)
• Gas cylinder securing elements
• Check correct mounting of the wire spool.
• Check that all screw and plug connections and replaceable parts are secured correctly, tighten if
necessary.
• Remove any spatter.
• Clean the wire feed 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 elements (strap, lifting lugs, handle)
• Check coolant tubes and their connections for impurities
Functional test
• Selector switches, command devices, emergency stop devices, voltage reducing devices, message
and control lamps
• Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
• Check coolant tubes and their connections for impurities
• Check and clean the welding torch. Deposits in the torch can cause short circuits and have a negative
impact on the welding result, ultimately causing damage to the torch.
6.2.3 Annual test (inspection and testing during operation)

A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition
to the regulations on testing given here, the relevant local laws and regulations must also be observed.
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
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Disposing of equipment
6.3 Disposing of equipment

Proper disposal!
The machine contains valuable raw materials, which should be recycled, and electronic
components, which must be disposed of.
• Do not dispose of in household waste!
• Observe the local regulations regarding disposal!
• According to European provisions (Directive 2012/19/EU on Waste of Electrical and Electronic
Equipment), 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 has to be disposed of, or recycled, in accordance with the waste separation systems in
use.
• According to German law (law governing the distribution, taking back and environmentally correct
disposal of electric and electronic equipment (ElektroG)), used machines are to be placed in a
collection system 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 charge.
• Information about returning used equipment or about collections can be obtained from the respective
municipal administration office.
• In addition to this, returns are also possible throughout Europe via EWM sales partners.
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Rectifying faults
Error messages (power source)
7 Rectifying faults
All products are subject to rigorous production checks and final checks. If, despite this, something fails to
work at any time, please check the product using the following flowchart. If none of the fault rectification
procedures described leads to the correct functioning of the product, please inform your authorised
dealer.
7.1 Error messages (power source)

A welding machine error will be signalled by an error code (see table) on the control display. In
the event of an error, the power unit shuts down.
The display of possible error numbers depends on the machine version (interfaces/functions).
• Document machine errors and inform service staff as necessary.
• If multiple errors occur, these are displayed in succession.
Error message Possible cause Remedy
E0 Start signal set in the event of Do not press the torch trigger or the foot-
errors operated remote control
E4 Temperature error Allow the machine to cool down
E5 Mains overvoltage Switch off the machine and check the mains
E6 Mains undervoltage voltage
E7 Electronics error Switch the machine on and off again.
E9 Secondary overvoltage If the error persists, notify service department
E12 Voltage reduction error (VRD)
E13 Electronics error
E14 Adjustment error in current Switch off the machine, place the electrode
recording holder in an insulated position and switch the
machine back on. If the error persists, notify
service department
E15 Error in on of the electronics Switch the machine off and on again.
supply voltages If the error persists, notify service department
If the error persists, notify service department
E33 Adjustment error in voltage Switch off the machine, place the electrode
recording holder in an insulated position and switch the
machine back on. If the error persists, notify
service department
If the error persists, notify service department
E40 Motor fault Check wire feed unit,
switch the machine off and on again, inform the
service department if the fault persists.
E55 Failure of a mains phase Switch off the machine and check the mains
voltage
E58 Short circuit in welding circuit Switch off machine and check welding current
leads for correct installation, e.g., put down
electrode holder in an electrically insulated
manner, disconnect degausser current lead.
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Rectifying faults
Checklist for rectifying faults
7.2 Checklist for rectifying faults

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
 All machine control signal lights are illuminated after switching on
 No machine control signal light is illuminated after switching on
 No welding power
 Phase failure > check mains connection (fuses)
 Connection problems
 Make control lead connections and check that they are fitted correctly.
 Loose welding current connections
 Tighten power connections on the torch and/or on the workpiece
 Tighten contact tip correctly
7.3 Display machine control software version

The query of the software versions only serves to inform the authorised service staff. It is available in the
machine configuration menu > see 5.11 chapter.
7.4 Dynamic power adjustment

This requires use of the appropriate mains fuse.
Observe mains fuse specification > see 8 chapter!
This function enables aligning the machine to the mains connection fusing to avoid continuous tripping of
the mains fuse. The maximum power input of the machine is limited by an exemplary value for the
existing mains fuse (several levels available).
You can predefine this value in the machine configuration menu > see 5.11 chapter using parameter .
The selected value will be shown on the machine display for two seconds after the machine has been
switched on.
The function automatically adjusts the welding power to an uncritical level for the mains fuse.
When using a 20-A mains fuse, a suitable mains plug has to be installed by a qualified electrician.
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Rectifying faults
Resetting welding parameters to the factory settings
7.5 Resetting welding parameters to the factory settings

All customised welding parameters that are stored will be replaced by the factory settings.
RESET
+ +
Figure 7-1
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.
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Technical data
Pico 160 cel puls
8 Technical data
Performance specifications and guarantee only in connection with original spare and
replacement parts!
8.1 Pico 160 cel puls

MMA TIG
Current setting range 5 A - 150 A 5 A - 160 A
Voltage setting range 20.2 V - 26.0 V 10.2 V - 16.4 V
Duty cycle 40 °C
30% 150 A 160 A
60% 120 A
100% 110 A
Load cycle 10min. (60% DC ≙ 6 m in
Open circuit voltage 94 V
Reduced open circuit voltage (VRD AUS) 33 V 12 V
Reduced open circuit voltage (VRD RU) 12 V 12 V
Mains voltage (tolerances) 1 x 230 V (-40 % to +15 %)
Maximum mains impedance (@PCC) Zmax XXX mΩ [1]
Frequency 50/60 Hz
Mains fuse (safety fuse, slow-blow) 20 A [2]
Continuous primary current (100 %) 20 A 13 A
Mains connection cable H07RN-F3G2,5
Maximum connected load 7.3 kVA 4.9 kVA
Recommended generator power 10 kVA
cosϕ / efficiency 0.99 / 83 %
Ambient temperature -25 °C to +40 °C
Machine cooling / torch cooling AF / gas
Noise level < 70 dB(A) [3]
Workpiece lead (minimum) 16 mm2
Insulation class / protection classification H / IP 23
EMC class A
Safety marking / /
Applied harmonised standards See declaration of conformity (appliance documents)
Dimensions L/W/H 370 x 129 x 236 mm
14.6 x 5.1 x 9.3 inch
Weight 4.9 kg
10.8 lb
[1]
This welding direction does not conform to IEC 61000-3-12. When connecting a welding machine to a
public low-voltage supply system, the manufacturer or operator has to consult the electricity utilities to
make sure the welding machine may be connected.
[2]
Safety fuses are recommended DIAZED xxA gG. When using automatic cutouts, the "C" trigger
characteristic must be used.
[3]
Noise level during idle mode and operation under standard load according to IEC 60974-1 at the
maximum operating point.
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Accessories
Electrode holder / workpiece lead
9 Accessories
9.1 Electrode holder / workpiece lead
Type Designation Item no.
EH25 QMM 4M Electrode holder 094-005800-00000
WK16mm² 170A/60% 4m/K Workpiece lead 094-005801-00000
9.2 Remote controls and accessories

RG13 Remote control 090-008113-00000
9.3 TIG welding torch

TIG 26 GDV 4m TIG welding torch, rotary gas valve, gas-cooled, 094-511621-00100
decentral
TIG 26 GDV 8m TIG welding torch, rotary gas valve, gas-cooled, 094-511621-00108
decentral
DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030
GH 2X1/4'' 2M Gas hose 094-000010-00001
9.4 General accessories

SKGS 16A 250V CEE7/7, DIN Safety plug 094-001756-00000
49440/441
ADAP CEE16/SCHUKO Earth contact coupling/CEE16A plug 092-000812-00000
9.5 Options
ON Filter Pico160 Air inlet dirt filter, retrofit option 092-003206-00000
ON Handle Pico 160 Grip, retrofit option 092-003205-00000
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Service documents
Spare and replacement parts
10 Service documents
WARNING
Do not carry out any unauthorised repairs or modifications!
To 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 skilled persons for repair work (trained service personnel)!
10.1 Spare and replacement parts

Spare parts can be obtained from the relevant authorised dealer.
Figure 10-1
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Service documents
Spare and replacement parts
Item Order number Name Type

1 094-015236-E0501 Carrying strap TG3-E
2 094-021818-E0501 Casing panel BH276,5X201,5X124,2
3 094-021826-00000 Insulating foil IP
4 040-001090-E0000 Operating panel assembly with E160
rotary transducer
5 044-004185-10015 Rotary transducer 30POS/1,5NCM
6 094-019308-00000 Plastic insulation for rotary KID/D23X7,3
transducer
7 094-021994-00000 Fibre optics LL8X6
8 094-021794-00502 Adhesive film KLF-E 1.05
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
12 094-021511-00000 Socket EB/35-50QMM
13 094-021795-00502 Adhesive film LOGO/PLUS/MINUS
14 094-021477-00000 Casing, front section KFG
15 094-022172-00002 Spacer AHD35X22X4
16 092-003193-00002 Choke WD
17 094-021509-00000 Casing, lower section KBG
18 094-014311-00000 Plate nut M5/21X15X6
19 094-021508-00000 Air duct IPL
20 094-015248-00000 Foam, fan support 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
23a 094-020188-00032 Mains cable - 1PHASIG/2.5 3.5M BOC
Pico 160 VRD (AUS)
24 094-021478-00000 Casing, back panel KRG
25 094-019537-00000 Nut M20x1,5
26 094-021796-00500 Adhesive film processes PICO CEL PULS
27 040-001084-E0000 PCB inverter circuit board HB160
27a 040-001424-E0000 PCB inverter circuit board - HB160 VRD
Pico 160 VRD (AUS)
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.
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Service documents
Circuit diagram
10.2 Circuit diagram
Figure 10-2
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Appendix A
Parameter overview – setting ranges
11 Appendix A
11.1 Parameter overview – setting ranges
Parameters/function Setting range
Welding data display
(ex works)
Standard
(3-digit)
Max.
Min.
Unit
MMA (MMA)
Main current (AMP) 100 5 - 150 A
Hot start current (AMP%) 120 50 - 200 %
Hot start time (sec) 0,5 0,1 - 20,0 s
Arcforce correction 0 -10 - 10
Pulse frequency 1,2 0,2 - 500 Hz
Pulse balance 30 1 - 99 %
Pulse current 142 1 - 200 %
Arc length restriction off off - on
TIG (TIG)
Main current AMP 100 5 - 160 A
Ignition current 20 1 - 200 %
Up-slope time 1,0 0,0 - 20,0 s
Pulse frequency 2,8 0,2 - 2000 Hz
Pulse balance 50 1 - 99 %
Pulse current 140 1 - 200 %
Arc length restriction on off - on
Basic parameters (independent of procedure)
Calibration
Exit menu
Machine configuration
Dynamic power adjustment 16 10 - 20 A
Time-based power-saving mode off 5 - 60 min.
Expert menu
Access control – access code 000 000 - 999
Access control off off - on
Service menu
Power-saving mode active
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Appendix B
Searching for a dealer
12 Appendix B
12.1 Searching for a dealer
Sales & service parteners
www.ewm-group.com/en/specialist-dealers
"More than 400 EWM sales partners worldwide"
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Operating instructions

Pico 160 cel puls

In the event of queries on installation, commissioning, operation or special conditions at the

The copyright to this document remains the property of the manufacturer.

6 Maintenance, care and disposal ......................................................................................................... 28

2 For your safety

Switch on machine Press and hold

Incorrect / Invalid Turn

Correct / Valid Numerical value – adjustable

Input Signal light lights up in green

Navigation Signal light flashes green

Output Signal light lights up in red

Time representation (e.g.: wait 4 s / Signal light flashes red

Interruption in the menu display (other

2.2.1 Complete documentation

The manufacturer's warranty becomes void if non-genuine parts are used!

Requirements for connection to the public mains network

3.1.2 Declaration of Conformity

3.1.3 Welding in environments with increased electrical hazards

4 Machine description – quick overview

Item Symbol Description 0

4.2 Rear view

Item Symbol Description 0

2 Cooling air inlet

4.3 Machine control – Operating elements

Item Symbol Description 0

8 3-pole connection socket

Item Symbol Description 0

5 Design and function

5.1 Transport and installation

The units are designed for operation in an upright position!

5.1.1 Machine cooling

5.1.2 Workpiece lead, general

5.1.3 Ambient conditions

Equipment damage due to contamination!

5.1.4 Adjusting the length of the carrying strap

5.1.5 Notes on the installation of welding current leads

Always keep leads as short as possible!

Lay any excess cable lengths in meanders.

5.1.6 Stray welding currents

5.1.7 Mains connection

5.1.7.1 Mains configuration

5.2 Operating the machine control

5.4 MMA welding

Item Symbol Description 0

4 Connection socket, “-” welding current

5.4.2 Welding task selection

5.4.6 Average value pulse welding

For parameter setting, > see 5.4.7 chapter.

5.4.7 Expert menu (MMA)

Pulse current > see 5.4.6 chapter

Arc length restriction > see 5.7 chapter

5.5 TIG welding

Item Symbol Description 0

3 Output side of the pressure regulator

5 Connection socket, "-" welding current

5.5.3 Pressure regulator connection

Item Symbol Description 0

5.5.4 Welding task selection