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EWM PM451 W F1 Operating Instructions Manual
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EWM PM451 W F1 Operating Instructions Manual

EWM PM451 W F1 Operating Instructions Manual

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Operating instructions
welding torch
PM301 W F1
EN
PM451 W F1
PM551 W F1
099-700053-EW501
Observe additional system documents!
21.08.2024

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Summary of Contents for EWM PM451 W F1

  • Page 1 Operating instructions welding torch PM301 W F1 PM451 W F1 PM551 W F1 099-700053-EW501 Observe additional system documents! 21.08.2024...
  • 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 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 Contents Notes on using these operating instructions 5.8.10 Commissioning ..................... 43 5.8.10.1 Hose package connection ..............43 5.8.10.2 Welding fume extractor ................. 43 6 Maintenance, care and disposal ....................44 General ..........................44 6.1.1 Identifying damage or worn components .............. 44 6.1.2 Maintenance and care before each use ...............
  • Page 5 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 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 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 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 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 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 variants Product description – quick reference Product variants Version Functions Rated output Professional MIG Water-cooled PM301, -451, -551W Switching the welding process on and off with the torch trig- ger. Interchangeable contact tip holder. Gas-cooled PM221, -301G Switching the welding process on and off with the torch trig-...
  • Page 15 Product description – quick reference Welding fume extractor Welding fume extractor 4.2.1 PM301-, PM451, PM551 W F1 Figure 4-1 Item Symbol Description Cap - standard Other versions > see 4.2.1.1 chapter. Lock ring Extraction elbow - integrated extraction nozzle Gas nozzle Torch trigger Welding torch hose package Connection, extraction unit...
  • Page 16 Product description – quick reference Welding fume extractor 4.2.1.1 Variants Figure 4-2 Item Symbol Description BK- Cap - standard BP - Bypass Bypass slider 4.2.2 PM301-, PM451, PM551 W F1 X 4.2.2.1 X-Technologie Figure 4-3 Item Symbol Description Operating elements > see 5.8.3 chapter Lock ring Extraction elbow - integrated extraction nozzle Gas nozzle...
  • Page 17 Product description – quick reference Welding fume extractor Item Symbol Description Welding torch hose package Connection, extraction unit Connect to extraction device or central extraction unit Ø = 42.5 mm Quick connect coupling, blue (coolant supply) Quick connect coupling, red (coolant return) Euro central connection Grip plate Torch hose package with leather hose...
  • Page 18 Design and function General Design and function General WARNING Risk of burns and electric shock on the welding torch! Welding torch (torch neck or torch head) and coolant (water-cooled version) heat up strongly during the welding process. During assembly work, you may come into touch with electrical voltage or hot components.
  • Page 19 Design and function Scope of delivery Read and observe the documentation to all system and accessory components! Scope of delivery The delivery is checked and packaged carefully before dispatch, however it is not possible to exclude the possibility of damage during transit. Receiving inspection •...
  • Page 20 All information relates to the total hose package length of the complete welding system and presents exemplary configurations (of components of the EWM product portfolio with standard lengths). A straight kink-free installation is to be ensured, taking into account the max. delivery height.
  • Page 21 Design and function Configure welding torch Configure welding torch WARNING Risk of burns and electric shock on the welding torch! Welding torch (torch neck or torch head) and coolant (water-cooled version) heat up strongly during the welding process. During assembly work, you may come into touch with electrical voltage or hot components.
  • Page 22 Design and function Configure welding torch 5.4.1 Using the torch key To prevent torch damage, carried out the assembly in a clockwise direction and disassembly in an anti-clockwise direction. 5.4.1.1 Contact tip The illustration serves as an example only. Figure 5-2 •...
  • Page 23 Design and function Equipment recommendations Equipment recommendations Figure 5-4 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 24 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 Hard-facing Combined liner...
  • Page 25 • 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 26 Design and function Adapting the Euro torch connection on the device 5.6.3.1 Liner Observe permissible torque > see 8 chapter! 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 hose package is straight when replacing the wire guide.
  • Page 27 Design and function Adapting the Euro torch connection on the device Figure 5-8 Adjust the brass liner > see 5.5 chapter. Figure 5-9 Figure 5-10 Figure 5-11 099-700053-EW501 21.08.2024...
  • Page 28 Design and function Adapting the Euro torch connection on the device Figure 5-12 Figure 5-13 Item Symbol Description Gas nozzle Contact tip Contact tip holder Extraction elbow - integrated extraction nozzle Torch neck 45° Crown nut O-ring Collet Combined liner Euro central connection Connecting sleeve New combined liner...
  • Page 29 Design and function Adapting the Euro torch connection on the device 5.6.3.2 Guide spiral Observe permissible torque > see 8 chapter! Insert the grinded end towards the contact tip holder to ensure tight fit with the contact tip. Always make sure the hose package is straight when replacing the wire guide. The illustration serves as an example only.
  • Page 30 Design and function Adapting the Euro torch connection on the device Figure 5-17 Figure 5-18 Figure 5-19 099-700053-EW501 21.08.2024...
  • Page 31 Design and function Setting the welding smoke flow rate Figure 5-20 Figure 5-21 Item Symbol Description Gas nozzle Contact tip Contact tip holder Extraction elbow - integrated extraction nozzle Torch neck 45° Crown nut, welding torch central connection (euro) Centring sleeve old spiral guide Euro central connection new spiral guide...
  • Page 32 Design and function Setting the welding smoke flow rate • Before checking the flow rate, it is necessary to measure the amount of shielding gas. • The quantity of shielding gas is measured at the gas nozzle of the welding torch and is set either di- rectly on the pressure regulator or, if available, on the gas control unit of the wire feeder or power source.
  • Page 33 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 34 Design and function Functional characteristics Control 2U/D X RD2 X RD3 X *) Faults and error messages Xnet Welding task selec- tion Xnet component manage- ment LED work light only for the XQ series 5.8.2 Operating elements in the machine This setting affects the torch types 2U/D, 2U/D X and RD2 X / RD3 X.
  • Page 35 Design and function Functional characteristics 5.8.4 Operating elements 2U/D X - welding torch Figure 5-25 Item Symbol Description "B -" button (program mode) Decrease JOB number "B -" button (up/down mode) Welding voltage correction, decrease value "B +" button (program mode) Increase JOB number "B +"...
  • Page 36 Design and function Functional characteristics Item Symbol Description "B +" button (program mode) Increase JOB number "B +" button (up/down mode) Welding voltage correction, increase value "A -" button (Program mode) Decrease program number "A -" button (Up/Down mode) Reduce welding performance (welding current/wire-feed speed) "A +"...
  • Page 37 Design and function Functional characteristics 5.8.6 Operating elements for the RD3 X welding torch Figure 5-27 Item Symbol Description OLED display Graphical display to show the functions. Parameter selection push-button Welding parameters are selected one after the other. Parameter selection push-button Welding parameters are selected one after the other.
  • Page 38 Design and function Functional characteristics 5.8.6.1 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 39 Design and function Functional characteristics 5.8.6.2 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 40 Design and function Functional characteristics Program level Figure 5-29 099-700053-EW501 21.08.2024...
  • Page 41 Design and function Functional characteristics 5.8.6.3 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 42 Design and function Functional characteristics 5.8.7 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 wit- hout movement, the light switches off automatically.
  • Page 43 Design and function Functional characteristics 5.8.10 Commissioning 5.8.10.1 Hose package connection Information on the connection of the torch hose package can be found in the corresponding operating instructions for the power source. 5.8.10.2 Welding fume extractor To prevent damage and to ensure full functionality of the fume extraction torch, comply with the points below: •...
  • Page 44 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 45 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 •...
  • Page 46 Maintenance, care and disposal General 6.1.2 Maintenance and care before each use Figure 6-2 Welding spatter protection spray must not be used on the gas nozzle of the welding fume extractor torch or other components. The aerosols clog the filters of the extraction system. •...
  • Page 47 Maintenance, care and disposal General 6.1.3 Regular maintenance The regular maintenance of a welding torch depends heavily on the duration of use and the stress and must be specified by the operator / owner. As a rule of thumb, every time the wire spool or wire basket is replaced or, if necessary, at a change of shift.
  • Page 48 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 49 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 50 Rectifying faults Checklist for rectifying faults Wire feed problems  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 51 Rectifying faults Vent coolant circuit Vent coolant circuit Figure 7-1 • Switch off the machine and fill the coolant tank to the maximum level. • Unlock the quick-connect coupling with a suitable tool (connection open). To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-2 •...
  • Page 52 Performance specifications and guarantee only in connection with original spare and replacement parts! PM 301 W F1, -451 W F1, -551 W F1 8.1.1 3 m / 118.11 inch Hose package PM301 W F1 PM451 W F1 PM551 W F1 Welding torch polarity Usually positive Guide type Manually operated Voltage type /°Shielding gas...
  • Page 53 Technical data PM 301 W F1, -451 W F1, -551 W F1 Load cycle: 10 min. (60 % DC ≙ 6 min. welding, 4 min. pause) AC power sources: 50 Hz - waveform = square. > see 8.1.4.1 chapter Reference altitude sea level (SL) > see 12.2 chapter 099-700053-EW501 21.08.2024...
  • Page 54 Technical data PM 301 W F1, -451 W F1, -551 W F1 8.1.2 4 m / 157.48 inch Hose package PM301 W F1 PM451 W F1 PM551 W F1 Welding torch polarity Usually positive Guide type Manually operated Voltage type /°Shielding gas Direct voltage DC°/°Shielding gas according to ISO 14175...
  • Page 55 Technical data PM 301 W F1, -451 W F1, -551 W F1 8.1.3 5 m / 196.85 inch Hose package PM301 W F1 PM451 W F1 PM551 W F1 Welding torch polarity Usually positive Guide type Manually operated Voltage type /°Shielding gas Direct voltage DC°/°Shielding gas according to ISO 14175...
  • Page 56 Technical data PM 301 W F1, -451 W F1, -551 W F1 8.1.4 6,5 m / 255.906 inch Hose package PM301 W F1 PM451 W F1 PM551 W F1 Welding torch polarity Usually positive Guide type Manually operated Voltage type /°Shielding gas Direct voltage DC°/°Shielding gas according to ISO 14175...
  • Page 57 Technical data PM 301 W F1, -451 W F1, -551 W F1 8.1.4.1 Definition of terms The illustration serves as an example only. Figure 8-1 Item Symbol Description Flow-rate nozzle ∆ Vacuum connector Flow rate connector 099-700053-EW501 21.08.2024...
  • Page 58 Accessories List of tools Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. List of tools Type Designation Item no. Cutter Hose cutter 094-016585-00000 Sharpener for liner 094-010427-00000 SW5-SW12MM Torch key 094-016038-00001 O-Ring Picker O-ring picker...
  • Page 59 Accessories Replacement parts set Replacement parts set Type Designation Item no. SRP MT221G/MT301W Replacement parts set, steel/chrome nickel 092-013427-40000 ST/CR M6 SRP MT221G/MT301W AL Replacement parts set, aluminium 092-013427-40001 SRP MT221G/MT301W Replacement parts set, steel/chrome nickel 092-013427-30000 ST/CR M7 SRP MT221G/MT301W AL Replacement parts set, aluminium 092-013427-30001 SRP MT301G/MT451W...
  • Page 60 Accessories Welding torch cooling system 9.7.1 Coolant - type blueCool Type Designation Item no. blueCool -10 5 l Coolant up to -10 °C (14 °F), 5 l 094-024141-00005 blueCool -10 25 l Coolant up to -10 °C (14 °F), 25 l 094-024141-00025 blueCool -30 5 l Coolant up to -30 °C (22 °F), 5 l...
  • Page 61 Replaceable parts PM 301 W F1 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 62 Replaceable parts PM 301 W F1 Item Order number Type Name 094-016107-00000 CTAL E-CU M6X28MM D=1.0MM Contact tip, aluminium welding 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...
  • Page 63 Replaceable parts PM 451 W F1 10.2 PM 451 W F1 Figure 10-2 Item Order number Type Name 094-013105-00001 GN TR 22 71mm D=13mm Gas nozzle 094-013106-00001 GN TR 22 71mm D=15mm Gas nozzle 094-013107-00001 GN TR 22 71mm D=18mm Gas nozzle 094-019821-00001 GN TR 22 65mm D=15mm Gas nozzle, short...
  • Page 64 Replaceable parts PM 451 W F1 Item Order number Type Name 094-014222-00000 CT CUCRZR M8X30MM D=1.0MM Contact tip 094-016109-00000 CT E-CU M8X30MM D=0.8MM Contact tip 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...
  • Page 65 Replaceable parts PM 551 W F1 10.3 PM 551 W F1 Figure 10-3 Item Order number Type Name 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...
  • Page 66 Replaceable parts PM 551 W F1 Item Order number Type Name 094-016113-00000 CT E-CU M8X30MM D=1.6MM Contact tip 094-016114-00000 CT E-CU M8X30MM D=2.0MM Contact tip 094-019616-00000 CT M9 x 100 mm; Ø 1,0 mm CuCrZr Contact tip, narrow gap welding 094-019617-00000 CT M9 x 100 mm;...
  • Page 67 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 F1 BK Figure 11-1 099-700053-EW501 21.08.2024...
  • Page 68 Service documents Circuit diagrams 11.1.2 PM G, -W F1 BP Figure 11-2 099-700053-EW501 21.08.2024...
  • Page 69 Service documents Circuit diagrams 11.1.3 PM G, -W F1 LED X Figure 11-3 099-700053-EW501 21.08.2024...
  • Page 70 Service documents Circuit diagrams 11.1.4 PM G, -W F1 2U/D X Figure 11-4 099-700053-EW501 21.08.2024...
  • Page 71 Service documents Circuit diagrams 11.1.5 PM G, -W F1 RD2 X Figure 11-5 099-700053-EW501 21.08.2024...
  • Page 72 Service documents Circuit diagrams 11.1.6 PM G, -W F1 RD3 X Figure 11-6 099-700053-EW501 21.08.2024...
  • Page 73 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 74 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 75 Appendix Altitude alignment 12.2 Altitude alignment The higher the altitude, the less vacuum is required at the connection piece ∆pc of the welding torch to achieve the required welding fume flow rate at the welding nozzle. Determine the corresponding factor in the following table: (Z) = f x ∆...
  • Page 76 Appendix Searching for a dealer 12.5 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-700053-EW501 21.08.2024...

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Pm301 w f1Pm551 w f1