EWM PM 221 G Operating Instructions Manual
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EWM PM 221 G Operating Instructions Manual

EWM PM 221 G Operating Instructions Manual

Welding torch
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Operating instructions
EN
099-700000-EW501
2024-02-13Susanne Altgeld2022-10-20Susanne AltgeldNeinEW5 (grau)Alle000Englisch15.01.2024welding torch099-
700000-EW501PM 221 G;PM 301 G;PM 401 GOperating instructionsEN099-700000-EW5xx - PM xx1 G
welding torch
PM 221 G
PM 301 G
PM 401 G
Observe additional system documents!
15.01.2024

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  • Page 1 Operating instructions welding torch PM 221 G PM 301 G PM 401 G 099-700000-EW501 Observe additional system documents! 15.01.2024 2024-02-13Susanne Altgeld2022-10-20Susanne AltgeldNeinEW5 (grau)Alle000Englisch15.01.2024welding torch099- 700000-EW501PM 221 G;PM 301 G;PM 401 GOperating instructionsEN099-700000-EW5xx - PM xx1 G...
  • 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 Safety instructions ........................ 7 Transport and installation ....................10 3 Intended use ..........................
  • Page 4 Option for retrofitting ......................46 General accessories ......................46 List of tools ......................... 46 10 Replaceable parts ........................47 10.1 PM 221 G ........................... 47 10.2 PM 301 G ........................... 48 10.3 PM 401 G ........................... 50 11 Service documents ........................52 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 Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn...

  • Page 7: Safety Instructions

    For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
  • Page 8 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
  • Page 9 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases may lead to shortness of breath and poisoning! The ultraviolet radia- tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso- nous phosgene. • Ensure sufficient fresh air! •...

  • Page 10: Transport And Installation

    For your safety Transport and installation CAUTION 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 int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.
  • Page 11 For your safety 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! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.

  • Page 12: 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 This product corresponds in its design and construction to the EU directives listed in the decla- ration.

  • Page 13: Part Of The Complete Documentation

    Intended use Documents which also apply 3.2.4 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 14: Product Description - Quick Reference

    Product description – quick reference Product variants Product description – quick reference Product variants Version Functions Rated output Professional MIG PM221/301/401G, PM301/451/551W Water-cooled PM301/451/551W Switching the welding process on and off with the torch trig- ger. Interchangeable contact tip holder. Gas-cooled PM221/301/401G Switching the welding process on and off with the torch trig-...

  • Page 15: 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° 099-700000-EW501 15.01.2024...

  • Page 16: Function Torch

    Product description – quick reference Function torch Function torch Figure 4-2 Item Symbol Description Gas nozzle Torch neck 45° Operating elements > see 5.2.3 chapter Grip plate Ball joint Anti-kink device Lock ring Torch trigger LED lighting Euro torch connector without control cable Figure 4-3 Item Symbol Description...

  • Page 17: Euro Torch Connector With Control Cable

    Product description – quick reference Euro torch connector with control cable Euro torch connector with control cable Figure 4-4 Item Symbol Description Anti-kink spring Euro central connection Control cable plug Only for control variant 2U/D. Version with control cable only with control variant 2U/D. 099-700000-EW501 15.01.2024...

  • Page 18: 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 19: Function Specification

    XQ MIG/MAG device series and the Drive XQ wire feeder. The welding torch has the function of process switching instead of JOB switching. When the RD3 X function torch is connected to another EWM device series with multi-matrix, the welding torch switches to compatibility mode and the functions are restricted to RD2 X.

  • Page 20: Operating Elements In The Machine

    Design and function Function specification 5.2.2 Operating elements in the machine This setting affects the torch types 2U/D, 2U/D X and RD2 X / RD3 X. 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").

  • Page 21: Operating Elements For The Rd2 X Welding Torch

    Design and function Function specification 5.2.4 Operating elements for the RD2 X 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 22: Welding Data Display

    Design and function Function specification 5.2.4.1 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. During the up/down operation, the corresponding parameter value is shown on the display when the para- meter is changed.

  • Page 23: Welding Data Display

    Design and function Function specification 5.2.5.1 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. During the up/down operation, the corresponding parameter value is shown on the display when the para- meter is changed.

  • Page 24: Programs, Setting Operating Points

    Design and function Function specification 5.2.5.2 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 25 Design and function Function specification Program level Figure 5-6 099-700000-EW501 15.01.2024...

  • Page 26: Component Management On The Welding Torch

    Design and function Function specification 5.2.5.3 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 27: Led Lighting

    Design and function Configure welding torch 5.2.5.4 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 28: Using The Torch Key

    Design and function Configure welding torch •  U nscrew the gas nozzle anti-clockwise by hand. •  L oosen the contact tip and contact tip holder with the torch key > see 5.3.1 chapter. • Unscrew the gas diffuser by hand. •...

  • Page 29: Turning The Torch Neck

    Design and function Configure welding torch 5.3.2 Turning the torch neck This function is only available with the "CG" and "CW" version! • Unfasten the crown nut by several turns from the handle until the torch neck can move freely. •...
  • Page 30 Design and function Configure welding torch Figure 5-13 Item Symbol Description Grip plate Crown nut Torch neck 45° Gas nozzle Contact tip holder Liner Contact tip Connect welding torch after performing the maintenance and rinse using the "Gas Test" with shield gas.

  • Page 31: Equipment Recommendations

    Design and function Equipment recommendations Equipment recommendations Figure 5-14 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 32 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 33: 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 > see 10 chapter. • Use a steel liner inside the torch hose package to guide hard, unalloyed wire electrodes (steel)! •...
  • Page 34 Design and function Adapting the Euro torch connection on the device Figure 5-16 Figure 5-17 Figure 5-18 Adjust the brass liner > see 5.4 chapter. Figure 5-19 099-700000-EW501 15.01.2024...
  • Page 35 Design and function Adapting the Euro torch connection on the device Figure 5-20 Figure 5-21 Figure 5-22 Figure 5-23 099-700000-EW501 15.01.2024...

  • Page 36: Guide Spiral

    Design and function Adapting the Euro torch connection on the device 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 > see 9 chapter Guiding tube for welding torch Euro torch connector 5.5.3.2 Guide spiral...
  • Page 37 Design and function Adapting the Euro torch connection on the device Figure 5-25 Figure 5-26 Figure 5-27 Figure 5-28 099-700000-EW501 15.01.2024...
  • Page 38 Design and function Adapting the Euro torch connection on the device Figure 5-29 Figure 5-30 099-700000-EW501 15.01.2024...
  • Page 39 Design and function Adapting the Euro torch connection on the device Figure 5-31 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 099-700000-EW501 15.01.2024...

  • Page 40: 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 41 Maintenance, care and disposal General Euro torch connector • The O-ring of the connecting nipple for shielding gas is defective or worn • The spring pins of the torch trigger are bent, jammed or dirty • The thread of the crown nut is dirty or damaged Grip •...

  • Page 42: Maintenance And Care Before Each Use

    Maintenance, care and disposal General 6.1.2 Maintenance and care before each use The illustration serves as an example only. Figure 6-2 • Loosen the gas nozzle, check the replacement parts for damage, replace if necessary and ensure a tight fit. •...

  • Page 43: Disposing Of Equipment

    Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html.

  • Page 44: 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 45: Technical Data

    Technical data PM 221-, 301-, 401 G Technical data PM 221-, 301-, 401 G Performance specifications and guarantee only in connection with original spare and replacement parts! -221 G -301 G -401 G Welding torch polarity Usually positive Guide type Manually operated Voltage type Direct voltage...

  • Page 46: Accessories

    Accessories Option for retrofitting Accessories Option for retrofitting Type Designation Item no. ON TT PM Standard Conversion kit, upper torch trigger, for PM standard 092-007938-00000 welding torch ON TT PM LED Torch trigger, on top with LED for PM welding torch 092-007939-00000 ON TV PM Standard Torch trigger extension for the PM standard welding 094-022327-00000...

  • Page 47: Replaceable Parts

    Replaceable parts PM 221 G Replaceable parts Parts and / or wearing parts may only be replaced when the components have cooled down and switched off! 10.1 PM 221 G Figure 10-1 Item Order number Type Name 094-013061-00001 GN TR 20 66mm D=13mm...

  • Page 48: Pm 301 G

    Replaceable parts PM 301 G Item Order number Type Name 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 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...
  • Page 49 Replaceable parts PM 301 G Item Order number Type Designation 094-019554-00000 GN FCW TR 22x4 59.5MM Gasdüse, Inner shield 094-019626-00000 GN NG M12 73mm Gasdüse, Engspaltschweißen 094-022226-00000 GN NG M12 76mm Gasdüse, Engspaltschweißen 094-019623-00000 GNC TR22x4 Gas nozzle body 094-020945-00000 GN TR 22, 80 mm, D=20 mm Spot welding nozzle 094-007238-00000 CT E-CU M8X30MM D=1.2MM Contact tip...

  • Page 50: Pm 401 G

    Replaceable parts PM 401 G Item Order number Type Designation 094-013540-00002 CTH M9 CuCrZr 37.5mm Contact tip holder 094-013096-00004 GD Ø11,7 mm, L=14 mm Gas diffuser 094-019625-00000 IT ES M22X1,5 M12X1 Insulation part 094-019627-00000 ZH GDE ID=5MM AD=10MM L=15MM Centring sleeve 094-016038-00001 TT SW5-SW12MM Torch key 094-013967-00000 4,0MMX1,0MM...
  • Page 51 Replaceable parts PM 401 G Item Order number Type Designation 094-013548-00001 CTAL E-CU M9X35MM D=1.6MM Contact tip, aluminium welding 094-013549-00001 CTAL E-CU M9X35MM D=2.0MM Contact tip, aluminium welding 094-014024-00000 CT CUCRZR M8X30MM D=0.8MM Contact tip 094-014191-00000 CT CUCRZR M8X30MM D=1.4MM Contact tip 094-014192-00000 CT CUCRZR M8X30MM D=1.6MM Contact tip...

  • Page 52: 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 G, -W Figure 11-1 099-700000-EW501 15.01.2024...

  • Page 53: 11.1.2 Pm G, -W Led

    Service documents Circuit diagrams 11.1.2 PM G, -W LED Figure 11-2 099-700000-EW501 15.01.2024...

  • Page 54: Pm G, -W (On Tt Pm Standard)

    Service documents Circuit diagrams 11.1.3 PM G, -W (ON TT PM Standard) Figure 11-3 099-700000-EW501 15.01.2024...

  • Page 55: Pm G, -W Led (On Tt Pm Standard)

    Service documents Circuit diagrams 11.1.4 PM G, -W LED (ON TT PM Standard) Figure 11-4 099-700000-EW501 15.01.2024...

  • Page 56: 11.1.5 Pm G, -W 2U/D

    Service documents Circuit diagrams 11.1.5 PM G, -W 2U/D Figure 11-5 099-700000-EW501 15.01.2024...

  • Page 57: 11.1.6 Pm°G, -W 2U/Dx

    Service documents Circuit diagrams 11.1.6 PM°G, -W 2U/DX Figure 11-6 099-700000-EW501 15.01.2024...

  • Page 58: Pm°G, -W Rd2 X

    Service documents Circuit diagrams 11.1.7 PM°G, -W RD2 X Figure 11-7 099-700000-EW501 15.01.2024...

  • Page 59: Pm G, -W Rd3 X

    Service documents Circuit diagrams 11.1.8 PM G, -W RD3 X Figure 11-8 099-700000-EW501 15.01.2024...

  • Page 60: 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 61 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 62: 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" 099-700000-EW501 15.01.2024...

This manual is also suitable for:

Pm 301 gPm 401 g

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