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
PM 551 W Alu
099-700003-EW501
Observe additional system documents!
14.09.2020

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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 PM 551 W Alu 099-700003-EW501 Observe additional system documents! 14.09.2020...
  • 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 using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 2.2.1 Part of the complete documentation ............... 7 3 Intended use ........................... 8 Applications ..........................
  • Page 4 PM 301 / 451 / 551 W ......................41 9 Accessories ..........................42 General accessories ......................42 10 Replaceable parts ......................... 43 10.1 PM 301 W..........................43 10.2 PM 451 W..........................44 10.3 PM 551 W..........................46 11 Service documents........................49 11.1 Circuit diagrams ........................

  • Page 5: For Your Safety

    For your safety Notes on using these operating instructions For your safety Notes on using these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •...

  • Page 6: Explanation Of Icons

    For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the u- Activate and release / Tap / Tip ser must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Correct / Valid...

  • Page 7: Part Of The Complete Documentation

    For your safety Explanation of icons 2.2.1 Part of the complete documentation This document is 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 8: Intended Use

    Intended use Applications Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and stand- ards applicable for use in industry and trade. It may only be used for the welding proce- dures indicated at the rating plate.

  • Page 9: Documents Which Also Apply

    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 This product corresponds in its design and construction to the EU directives listed in the decla- ration.

  • Page 10: 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 Switching the welding process on and off with torch trigger. Gas-cooled PM221/301/401G Switching the welding process on and off with torch trigger. Short torch neck PM451/551W Extended torch neck...

  • Page 11: 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 Anti-kink device Lock ring Torch trigger Torch neck 45° 099-700003-EW501 14.09.2020...

  • Page 12: Function Torch

    Product description – quick reference Function torch Function torch Figure 4-2 Item Symbol Description Gas nozzle Torch neck 45° Operating elements Grip plate Ball joint Anti-kink device Lock ring Torch trigger LED lighting 099-700003-EW501 14.09.2020...

  • Page 13: Euro Torch Connector Without Control Cable

    Product description – quick reference Function torch 4.3.1 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) 4.3.2 Euro torch connector with control cable Figure 4-4...

  • Page 14: Design And Function

    Design and function Scope of delivery 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 15: Transport And Installation

    Design and function Transport and installation Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! •...

  • Page 16: 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 swit- ches to compatibility mode and is restricted in its functions.

  • Page 17: Operating Elements In The Machine

    Design and function Transport and installation 5.2.4 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 18: Operating Elements For Rd2 Welding Torch

    Design and function Transport and installation 5.2.6 Operating elements for RD2 welding torch Figure 5-3 Item Symbol Description OLED display Graphical display to show the functions. "B -" button (program mode) Decrease JOB number "B -" button (up/down mode) Welding voltage correction, decrease value "B +"...

  • Page 19: Welding Data Display

    Design and function Transport and installation 5.2.7 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 20: Welding Data Display

    Design and function Transport and installation 5.2.9 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 21: Programs, Setting Operating Points

    Design and function Transport and installation 5.2.9.1 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 22 Design and function Transport and installation Program level Figure 5-6 099-700003-EW501 14.09.2020...

  • Page 23: Component Management On The Welding Torch

    Design and function Transport and installation 5.2.9.2 Component management on the welding torch The Xnet component management software can be used to manage components, create welding se- quence plans and assign WPS. The display shows seams and runs. After completion they can be ack- nowledged with the burner.

  • Page 24: Led Lighting

    Design and function Configure welding torch 5.2.10 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 wit- hout movement, the light switches off automatically.

  • Page 25: Turning The Torch Neck

    Design and function Configure welding torch 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. Gas losses and the penetration of atmospheric oxygen can also occur and can adversely affect the welding result.
  • Page 26 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 27: Equipment Recommendations

    Design and function Equipment recommendations Equipment recommendations Figure 5-12 Low-alloy CT CuCrZr V-groove medium-alloy CT CuCrZr V-groove Hardfacing CT CuCrZr V-groove High-alloy CT CuCrZr V-groove Aluminium CTAL E-Cu U-groove Aluminium (AC) CT ZWK CuCrZr U-groove Copper alloy CT CuCrZr V-groove Low-alloy V-groove CT CuCrZr...
  • Page 28 Design and function Equipment recommendations 1.5 x 4.0 1.5 x 4.0 Low-alloy Steel liner 2.0 x 4.0 2.4 x 4.5 1.5 x 4.0 1.5 x 4.0 medium-alloy Combined liner 200 mm 2.0 x 4.0 2.3 x 4.7 1.5 x 4.0 1.5 x 4.0 Hardfacing Combined liner...

  • Page 29: Acarc Puls Xq

    • 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 30: Liner / Combined Liner

    Design and function Assemble the wire guide 5.6.1 Liner / combined liner Observe permissible torque! 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 31 Design and function Assemble the wire guide Figure 5-16 Adjust the brass liner . Figure 5-17 Figure 5-18 Figure 5-19 099-700003-EW501 14.09.2020...
  • Page 32 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 099-700003-EW501 14.09.2020...

  • Page 33: Guide Spiral

    Design and function Assemble the wire guide 5.6.2 Guide spiral Observe permissible torque! 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...
  • Page 34 Design and function Assemble the wire guide Figure 5-25 Figure 5-26 Figure 5-27 099-700003-EW501 14.09.2020...
  • Page 35 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 Centring sleeve old spiral guide Euro central connection new spiral guide Capillary tube 099-700003-EW501 14.09.2020...

  • Page 36: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal 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.

  • Page 37: Maintenance Work, Intervals

    Maintenance, care and disposal Maintenance work, intervals Maintenance work, intervals 6.2.1 Daily maintenance tasks Figure 6-1 • Purge the wire guide from the direction of the Euro torch connector with oil- and condensate-free com- pressed air or shielding gas. • Check that coolant connections are tight.

  • Page 38: Disposing Of Equipment

    • 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. 099-700003-EW501 14.09.2020...

  • Page 39: 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 dea- ler.

  • Page 40: 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 41: 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! PM 301 W PM 451 W PM 551 W Welding torch polarity Usually positive...

  • Page 42: Accessories

    Accessories General accessories Accessories General accessories Type Designation Item no. ON TT PM Standard Conversion kit, upper torch trigger, for PM standard 092-007938-00000 welding torch ON HSS  18-10 mm Heat shield for PM/MT welding torch 094-025359-00000 ON TH PM Optional pistol grip 092-007944-00000 ON TV PM LED...

  • Page 43: 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 hold- ers, remote controls, spare parts and replacement parts, etc.) from our range of products! •...

  • Page 44: Pm 451 W

    Replaceable parts PM 451 W Item Order number Type Name 094-016108-00000 CTAL E-CU M6X28MM D=1.2MM Contact tip, aluminium welding 094-005403-00000 CT M6 x 25 mm, 0.6 mm, CuCrZr Contact tip 094-020689-00000 CT M6 x 25 mm, 0.8 mm, CuCrZr Contact tip 094-020690-00000 CT M6 x 25 mm, 1.0 mm, CuCrZr Contact tip 094-020691-00000 CT M6 x 25 mm, 0.6 mm, E-Cu...
  • Page 45 Replaceable parts PM 451 W Item Order number Type Name 094-019821-00001 GN TR 22 65mm D=15mm Gas nozzle, short 094-019822-00001 GN TR 22 65mm D=18mm Gas nozzle, short Highly conical gas nozzle, narrow 094-019853-00001 GN NG TR22X4 71mm D=13mm gap welding 094-019554-00000 GN FCW TR 22x4 59.5MM Gas nozzle, inner shield 094-019626-00000 GN NG M12 73mm...

  • Page 46: Pm 551 W

    Replaceable parts PM 551 W Item Order number Type Name CT ZWK CuCrZr M9x35 mm Ø 1,6 094-025533-00001 Contact tip, forced contact 094-013109-00002 CTH CUCRZR M8 L=34.1MM Contact tip holder 094-013110-00002 CTH CUCRZR M8 L=37.1MM Contact tip holder 094-013539-00002 CTH M9 CuCrZr 34.5mm Contact tip holder 094-013540-00002 CTH M9 CuCrZr 37.5mm Contact tip holder...
  • Page 47 Replaceable parts PM 551 W Item Order number Type Name 094-013532-00000 CT CUCRZR M9X35MM D=1.4MM Contact tip 094-013533-00000 CT CUCRZR M9X35MM D=1.6MM Contact tip 094-013534-00000 CT CUCRZR M9X35MM D=2.0MM Contact tip 094-014024-00000 CT CUCRZR M8X30MM D=0.8MM Contact tip 094-013129-00000 CT CUCRZR M8X30MM D=0.9MM Contact tip 094-014222-00000 CT CUCRZR M8X30MM D=1.0MM Contact tip...
  • Page 48 Replaceable parts PM 551 W Item Order number Type Name 094-016425-00003 CTH CUCRZR M9 L=38MM Contact tip holder 094-015489-00003 CTH M8 x 35 mm, CuCrZr Contact tip holder 094-016018-00003 CTH M8 x 37,5 mm, CuCrZr Contact tip holder 094-013111-00002 GD D=20,2 mm; 25 mm Gas diffuser 094-019625-00000 IT ES M22X1,5 M12X1 Insulation part...

  • Page 49: Service Documents

    Service documents Circuit diagrams Service documents 11.1 Circuit diagrams The circuit diagrams are only intended for authorised service personnel! 11.1.1 PM 301 - 551 W Figure 11-1 099-700003-EW501 14.09.2020...

  • Page 50: 11.1.2 Pm 301 - 551 W Led

    Service documents Circuit diagrams 11.1.2 PM 301 - 551 W LED Figure 11-2 099-700003-EW501 14.09.2020...

  • Page 51: 11.1.3 Pm 301 - 551 W Tt

    Service documents Circuit diagrams 11.1.3 PM 301 - 551 W TT Figure 11-3 099-700003-EW501 14.09.2020...

  • Page 52: 11.1.4 Pm 301 - 551 W Tt Led

    Service documents Circuit diagrams 11.1.4 PM 301 - 551 W TT LED Figure 11-4 099-700003-EW501 14.09.2020...

  • Page 53: 11.1.5 Pm 301 - 551 W 2U/D

    Service documents Circuit diagrams 11.1.5 PM 301 - 551 W 2U/D Figure 11-5 099-700003-EW501 14.09.2020...

  • Page 54: 11.1.6 Pm 301 - 551 W 2U/Dx

    Service documents Circuit diagrams 11.1.6 PM 301 - 551 W 2U/DX Figure 11-6 099-700003-EW501 14.09.2020...

  • Page 55: Pm 301 - 551 W Rd2 X

    Service documents Circuit diagrams 11.1.7 PM 301 - 551 W RD2 X Figure 11-7 099-700003-EW501 14.09.2020...

  • Page 56: Pm 301 - 551 W Rd3 X

    Service documents Circuit diagrams 11.1.8 PM 301 - 551 W RD3 X Figure 11-8 099-700003-EW501 14.09.2020...

  • Page 57: Appendix

    Appendix Display, explanation of symbols Appendix 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 wiredArc...
  • Page 58 Appendix 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 59: Searching For A Dealer

    Appendix Searching for a dealer 12.2 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-700003-EW501 14.09.2020...

This manual is also suitable for:

Pm 451 wPm 551 wPm 551 w alu

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