EWM PM 301 W Operating Instructions Manual
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EWM PM 301 W Operating Instructions Manual

EWM PM 301 W Operating Instructions Manual

Welding torch
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Operating instructions
welding torch
EN
PM 301 W
PM 451 W
PM 551 W
099-700003-EW501
Observe additional system documents!
11.01.2019

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Summary of Contents for EWM PM 301 W

  • Page 1 Operating instructions welding torch PM 301 W PM 451 W PM 551 W 099-700003-EW501 Observe additional system documents! 11.01.2019...
  • Page 2 +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.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................5 Part of the complete documentation ....................6 3 Intended use ............................
  • Page 4 PM 301 / 451 / 551 W ........................37 9 Accessories ............................38 General accessories ........................38 10 Replaceable parts ..........................39 10.1 PM 301 W............................. 39 10.2 PM 451 W............................. 40 10.3 PM 551 W............................. 42 11 Service documents..........................44 11.1 Circuit diagrams ...........................

  • Page 5: For Your Safety

    For your safety Notes on the use of these operating instructions For your safety Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. •...

  • Page 6: Part Of The Complete Documentation

    For your safety Part of the complete documentation Symbol Description Symbol Description Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use Part of the complete documentation These operating instructions are part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system.

  • Page 7: Intended Use

    3.2.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.2.2 Declaration of Conformity The labelled product complies with the following EC directives in terms of its design and construction: •...

  • Page 8: Product Description - Quick Reference

    Product description – quick reference Product variants Product description – quick reference Product variants Version Functions Performance class Professional MIG PM221/301/401G, PM301/451/551W Water-cooled PM301/451/551W You use the torch trigger to switch the welding process on and off. Interchangeable contact tip holder. Gas-cooled PM221/301/401G You use the torch trigger to switch the welding process on and...

  • Page 9: Standard Welding Torch

    Product description – quick reference Standard welding torch Standard welding torch Figure 4-1 Item Symbol Description Gas nozzle Grip plate Ball joint Torch neck 45° Torch trigger Anti-kink device 099-700003-EW501 11.01.2019...

  • Page 10: Function Torch

    Product description – quick reference Function torch Function torch Figure 4-2 Item Symbol Description Gas nozzle Torch neck 45° Operating elements > see 5.2.2 chapter Grip plate Ball joint LED lighting Torch trigger Anti-kink device 099-700003-EW501 11.01.2019...

  • Page 11: Euro Torch Connector Without Control Cable

    Product description – quick reference Euro torch connector without control cable Euro torch connector without control cable Figure 4-3 Item Symbol Description Anti-kink spring Euro central connection Welding current, shielding gas and torch trigger included Quick connect coupling, blue (coolant supply) Quick connect coupling, red (coolant return) Euro torch connector with control cable Figure 4-4...

  • Page 12: Design And Function

    Design and function Transport and installation 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! •...

  • Page 13: In Operation

    Design and function Transport and installation 5.1.2.1 In operation Temperature range of the ambient air: • -10 °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) 5.1.2.2 Transport and storage Storage in a closed area, temperature range of the ambient air:...

  • Page 14: Maximal Hose Package Length

    The full functional range of the PM function torch is only available in connection with the device series Titan XQ and the wire feeder drive XQ. If the function torch is connected to another EWM device series using Multimatrix, the welding torch switches to compatibility mode and is restricted in its functions.

  • Page 15: Operating Elements In The Machine

    Design and function Settings 5.2.1 Operating elements in the machine This setting affects the torch types 2U/D, and RD2. Figure 5-1 • Switch the"Program or up/down mode“ changeover switch at the welding machine to the up/down or program mode position (see chapter "Design and function"). The 'Program or up/down function' changeover switch may look different on your machine.

  • Page 16: Operating Elements For Rd2 Welding Torch

    Design and function Settings Item Symbol Description "A -" button (Program mode) Decrease program number "A -" button (Up/Down mode) Reduce welding performance (welding current/wire-feed speed) "A +" button (Program mode) Increase program number "A +" button (Up/Down mode) Increase welding performance (welding current/wire-feed speed) 5.2.3 Operating elements for RD2 welding torch The function of the operating elements depends on whether the welding machine is set in program mode...

  • Page 17: Welding Data Display

    Design and function Settings Item Symbol Description "A -" button (Program mode) Decrease program number "A -" button (Up/Down mode) Reduce welding performance (welding current/wire-feed speed) "A +" button (Program mode) Increase program number "A +" button (Up/Down mode) Increase welding performance (welding current/wire-feed speed) 5.2.4 Welding data display The display shows the currently selected welding parameter and the corresponding parameter value.

  • Page 18: Welding Data Display

    Design and function Settings Item Symbol Description Parameter selection push-button Welding parameters are selected one after the other. Push-button “+” Increase JOB number or parameter value. Push-button “-” Decrease JOB number or parameter value 5.2.6 Welding data display The display shows the currently selected welding parameter and the corresponding parameter value. When the welding machine is switched on, the display shows the nominal welding current set point set point set by the control unit.

  • Page 19: Programs, Setting Operating Points

    Design and function Settings 5.2.6.1 Programs, setting operating points Distinction is made between main and program level during the parameter setting. After switching on the welding machine, you are always at the main level. Process switching, program number, wire feed speed, dynamics (hard to soft arc), welding current and welding voltage are specified here.
  • Page 20 Design and function Settings Program level Figure 5-6 099-700003-EW501 11.01.2019...

  • Page 21: Component Management On The Welding Torch

    Design and function Settings 5.2.6.2 Component management on the welding torch The Xnet component management software can be used to manage components, to create welding sequence plans and assign WPS. The torch display shows seams and runs. After completion they can be acknowledged with the burner.

  • Page 22: Led Lighting

    Design and function Configure welding torch 5.2.7 LED lighting Integrated LED lighting makes welding in corners and dark areas of the working area easier. The lighting switches on independently of the burner button when the burner is moved. After approx. 10 seconds without movement, the light switches off automatically.

  • Page 23: Turning The Torch Neck

    Design and function Configure welding torch Item Symbol Description Torch connection block Grip plate Equipment damage and impurities of the welding result due to worn O-rings. Worn O-rings have a negative impact on the torch cooling. Insufficient cooling causes damage to the welding torch.
  • Page 24 Design and function Configure welding torch Figure 5-11 Item Symbol Description Grip plate Crown nut Torch neck 45° Gas nozzle Contact tip holder Liner Contact tip Re-connect the welding torch after completing any maintenance work, use the 'gas test' function to purge with shielding gas and vent >...

  • Page 25: Equipment Recommendations

    Design and function Equipment recommendations Equipment recommendations Figure 5-12 099-700003-EW501 11.01.2019...

  • Page 26: Adapting The Euro Torch Connection On The Device

    • Refer to the manufacturer instructions for the right wire feed unit equipment. Refer to Annex 1 in these operating instructions for the right EWM machine equipment. • Use a steel liner inside the torch hose package to guide hard, unalloyed wire electrodes (steel)! •...
  • Page 27 Design and function Assemble the wire guide The distance between the plastic liner and drive rollers should be as short as possible. Use only sharp, stable knives or special tongs for cutting to ensure that the plastic liner does not become misshapen! Always make sure the the hose package is straight when replacing the wire guide.
  • Page 28 Design and function Assemble the wire guide Figure 5-16 Adjust the brass liner > see 5.4 chapter. Figure 5-17 Figure 5-18 Figure 5-19 099-700003-EW501 11.01.2019...

  • Page 29: Guide Spiral

    Design and function Assemble the wire guide Figure 5-20 Figure 5-21 Item Symbol Description Gas nozzle Contact tip Contact tip holder Torch neck 45° Crown nut O-ring Collet Combined liner Euro central connection Connecting sleeve New combined liner Liner sharpener Guiding tube for welding torch Euro torch connector 5.6.2 Guide spiral...
  • Page 30 Design and function Assemble the wire guide Insert the grinded end towards the contact tip holder to ensure tight fit with the contact tip. Always make sure the the hose package is straight when replacing the wire guide. Figure 5-22 Figure 5-23 Figure 5-24 099-700003-EW501...
  • Page 31 Design and function Assemble the wire guide Figure 5-25 Figure 5-26 Figure 5-27 099-700003-EW501 11.01.2019...
  • Page 32 Design and function Assemble the wire guide Figure 5-28 Figure 5-29 Item Symbol Description Gas nozzle Contact tip Contact tip holder Welding torch neck Crown nut, welding torch central connection (euro) Centring sleeve old spiral guide Euro central connection new spiral guide Capillary tube 099-700003-EW501 11.01.2019...

  • Page 33: Maintenance, Care And Disposal

    Maintenance, care and disposal Maintenance work, intervals Maintenance, care and disposal CAUTION Electrical current! The following work must always be carried out with the power source switched off. Maintenance work, intervals 6.1.1 Daily maintenance tasks Figure 6-1 • Purge the wire guide from the direction of the Euro torch connector with oil- and condensate-free compressed air or shielding gas.

  • Page 34: Disposing Of Equipment

    In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives on the Declaration of Conformity on your machine).

  • Page 35: Rectifying Faults

    Rectifying faults Checklist for rectifying faults 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.

  • Page 36: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Unstable arc  Unsuitable or worn welding torch equipment  Adjust contact tip to wire diameter and -material and replace if necessary  Adjust wire guide to material in use, blow through and replace if necessary ...

  • Page 37: Technical Data

    PM 301 / 451 / 551 W Technical data PM 301 / 451 / 551 W Performance specifications and guarantee only in connection with original spare and replacement parts! Type PM 301 W PM 451 W PM 551 W Welding torch polarity Usually positive Guide type...

  • Page 38: Accessories

    Accessories General accessories Accessories General accessories Type Designation Item no. ON TT Burner button above 092-007938-00000 099-700003-EW501 11.01.2019...

  • Page 39: Replaceable Parts

    Replaceable parts PM 301 W Replaceable parts 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! •...

  • Page 40: Pm 451 W

    Replaceable parts PM 451 W Item Order number Type Name 094-020691-00000 CT M6 x 25 mm, 0.6 mm, E-Cu Contact tip 094-020692-00000 CT M6 x 25 mm, 0.8 mm, E-Cu Contact tip 094-020693-00000 CT M6 x 25 mm, 0.9 mm, E-Cu Contact tip 094-020694-00000 CT M6 x 25 mm, 1.0 mm, E-Cu Contact tip...
  • Page 41 Replaceable parts PM 551 W Item Order number Type Description 094-013531-00000 CT CUCRZR M9X35MM D=1.2MM Contact tip 094-013532-00000 CT CUCRZR M9X35MM D=1.4MM Contact tip 094-013533-00000 CT CUCRZR M9X35MM D=1.6MM Contact tip 094-013543-00000 CTAL E-CU M9X35MM D=0.8MM Contact tip, aluminium welding 094-013544-00000 CTAL E-CU M9X35MM D=0.9MM Contact tip, aluminium welding 094-013545-00000 CTAL E-CU M9X35MM D=1.0MM...

  • Page 42: Pm 551 W

    Replaceable parts PM 551 W 10.3 PM 551 W Figure 10-3 Item Order number Type Description 094-014177-00001 GN TR 23 63mm D=15mm Gas nozzle 094-014178-00001 GN TR 23 66mm D=15mm Gas nozzle 094-014179-00001 GN TR 23 63mm D=17mm Gas nozzle 094-014180-00001 GN TR 23 66mm D=17mm Gas nozzle 094-014181-00001 GN TR 23 63mm D=19mm...
  • Page 43 Replaceable parts PM 551 W Item Order number Type Description 094-016110-00000 CT E-CU M8X30MM D=0.9MM Contact tip 094-016111-00000 CT E-CU M8X30MM D=1.0MM Contact tip 094-016112-00000 CT E-CU M8X30MM D=1.4MM Contact tip 094-016113-00000 CT E-CU M8X30MM D=1.6MM Contact tip 094-016114-00000 CT E-CU M8X30MM D=2.0MM Contact tip 094-016115-00000 CTAL E-CU M8X30MM D=0.8MM Contact tip, aluminium welding...

  • Page 44: Service Documents

    Service documents Circuit diagrams Service documents 11.1 Circuit diagrams The circuit diagrams are only intended for authorised service personnel! Figure 11-1 099-700003-EW501 11.01.2019...
  • Page 45 Service documents Circuit diagrams Figure 11-2 099-700003-EW501 11.01.2019...
  • Page 46 Service documents Circuit diagrams Figure 11-3 099-700003-EW501 11.01.2019...
  • Page 47 Service documents Circuit diagrams Figure 11-4 099-700003-EW501 11.01.2019...
  • Page 48 Service documents Circuit diagrams Figure 11-5 099-700003-EW501 11.01.2019...
  • Page 49 Service documents Circuit diagrams Figure 11-6 099-700003-EW501 11.01.2019...
  • Page 50 Service documents Circuit diagrams Figure 11-7 099-700003-EW501 11.01.2019...
  • Page 51 Service documents Circuit diagrams Figure 11-8 099-700003-EW501 11.01.2019...

  • Page 52: Display, Explanation Of Symbols

    Appendix A Display, explanation of symbols Appendix A 12.1 Display, explanation of symbols Main level Display Setting/selection Welding current Welding voltage Welding voltage correction Dynamics Wire feed speed Unit: m/min Wire feed speed Unit: ipm Program selection Welding procedure MIG/MAG Welding procedure forceArc Welding procedure...
  • Page 53 Appendix A Display, explanation of symbols Error messages, warnings Display Setting/selection Error Error - temperature Error - water Warning Warning wire end Component management, Miscellaneous Display Setting/selection Unit completed Scan component Free-welding mode Hold value Correction mode Seam run Seam end End of component End of component, confirmation WPS End...

  • Page 54: Searching For A Dealer

    Appendix B Searching for a dealer Appendix B 13.1 Searching for a dealer Sales & service parteners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-700003-EW501 11.01.2019...

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Pm 451 wPm 551 w

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