Operating instructions
EN
welding torch
PM 301 W
PM 451 W
PM 551 W
099-700003-EW501
Observe additional system documents!
11.01.2019
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.
General instructions
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
099-700003-EW501
11.01.2019
3
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
2.3 Part of the complete documentation .............................................................................................. 6
3 Intended use ........................................................................................................................................... 7
3.1 Applications .................................................................................................................................... 7
3.2 Documents which also apply ......................................................................................................... 7
3.2.1 Warranty ......................................................................................................................... 7
3.2.2 Declaration of Conformity ............................................................................................... 7
3.2.3 Service documents (spare parts) ................................................................................... 7
4 Product description – quick reference ................................................................................................ 8
4.1 Product variants ............................................................................................................................. 8
4.2 Standard welding torch .................................................................................................................. 9
4.3 Function torch .............................................................................................................................. 10
4.4 Euro torch connector without control cable.................................................................................. 11
4.5 Euro torch connector with control cable....................................................................................... 11
5 Design and function ............................................................................................................................. 12
5.1 Transport and installation ............................................................................................................ 12
5.1.1 Scope of delivery .......................................................................................................... 12
5.1.2 Ambient conditions ....................................................................................................... 12
5.1.3 Welding torch cooling system ....................................................................................... 13
5.2 Settings ........................................................................................................................................ 14
5.2.1 Operating elements in the machine .............................................................................. 15
5.2.2 Operating elements 2 for up/down welding torch ......................................................... 15
5.2.3 Operating elements for RD2 welding torch .................................................................. 16
5.2.4 Welding data display .................................................................................................... 17
5.2.5 Operating elements for RD3 welding torch .................................................................. 17
5.2.6 Welding data display .................................................................................................... 18
5.2.7 LED lighting .................................................................................................................. 22
5.3 Configure welding torch ............................................................................................................... 22
5.3.1 Turning the torch neck .................................................................................................. 23
5.3.2 Changing the torch neck............................................................................................... 23
5.4 Equipment recommendations ...................................................................................................... 25
5.5 Adapting the Euro torch connection on the device ...................................................................... 26
5.5.1 Liner .............................................................................................................................. 26
5.5.2 Replace steel liner ........................................................................................................ 26
5.6 Assemble the wire guide .............................................................................................................. 26
5.6.1 Liner .............................................................................................................................. 26
5.6.2 Guide spiral .................................................................................................................. 29
6 Maintenance, care and disposal ......................................................................................................... 33
6.1 Maintenance work, intervals ........................................................................................................ 33
6.1.1 Daily maintenance tasks............................................................................................... 33
6.1.2 Monthly maintenance tasks .......................................................................................... 33
6.2 Maintenance work ........................................................................................................................ 33
6.3 Disposing of equipment ............................................................................................................... 34
6.4 Meeting the requirements of RoHS ............................................................................................. 34
7 Rectifying faults ................................................................................................................................... 35
7.1 Checklist for rectifying faults ........................................................................................................ 35
7.2 Vent coolant circuit ....................................................................................................................... 36
5.1.2.1 In operation ................................................................................................... 13
5.1.2.2 Transport and storage ................................................................................... 13
5.1.3.1 Permitted torch coolant ................................................................................. 13
5.1.3.2 Maximal hose package length ...................................................................... 14
5.2.6.1 Programs, setting operating points ............................................................... 19
5.2.6.2 Component management on the welding torch ............................................ 21
Contents
Notes on the use of these operating instructions
4
099-700003-EW501
11.01.2019
8 Technical data ....................................................................................................................................... 37
8.1 PM 301 / 451 / 551 W .................................................................................................................. 37
9 Accessories .......................................................................................................................................... 38
9.1 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 ........................................................................................................................... 44
12 Appendix A ............................................................................................................................................ 52
12.1 Display, explanation of symbols ................................................................................................... 52
13 Appendix B ............................................................................................................................................ 54
13.1 Searching for a dealer .................................................................................................................. 54
For your safety
Notes on the use of these operating instructions
099-700003-EW501
11.01.2019
5
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.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
• The risk is explained using a symbol on the edge of the page.
Technical aspects which the user must observe to avoid material or equipment damage.
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release / Tap / Tip
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 /
actuate)
Signal light flashes red
2 For your safety
2.1 Notes on the use of these operating instructions
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.
2.2 Explanation of icons
For your safety
Part of the complete documentation
6
099-700003-EW501
11.01.2019
Symbol
Description
Symbol
Description
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use
Item
Documentation
A.1
Wire feeder
A.2
Remote adjuster
A.3
Controller
A.4
Power source
A.5
Welding torch
A
Complete documentation
2.3 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.
Figure 2-1
The illustration shows a general example of a welding system.
Intended use
Applications
099-700003-EW501
11.01.2019
7
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!
The labelled product 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.
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)!
3 Intended use
3.1 Applications
Welding torch for arc welding machines for GMAW.
3.2 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
3.2.3 Service documents (spare parts)
Spare parts can be obtained from the relevant authorised dealer.
Product description – quick reference
Product variants
8
099-700003-EW501
11.01.2019
Version
Functions
Performance class
PM
Professional MIG
PM221/301/401G,
PM301/451/551W
W
Water-cooled
You use the torch trigger to switch the welding process on and
off. Interchangeable contact tip holder.
PM301/451/551W
G
Gas-cooled
You use the torch trigger to switch the welding process on and
off. Interchangeable contact tip holder.
PM221/301/401G
S
Short torch neck
For welding narrow operating points.
PM451/551W
L
Extended torch neck
For welding operating points which are difficult to reach.
High duty cycle.
PM451/551W
C
Interchangeable torch neck
Torch neck can be continuously fixed through 360°.
PM221/301G
PM301/451W
2U/D
2 up/down welding torch
The welding power (welding current/wire feed speed) and the
voltage correction or the JOB number and program number
can be adjusted on the welding torch.
PM221/301/401G,
PM301/451/551W
RD2
Remote display 2-welding torch
The welding power (welding current/wire feed speed) and the
voltage correction or the JOB number and program number
can be adjusted on the welding torch. Values and changes
are shown on the welding torch display.
PM221/301/401G,
PM301/451/551W
RD3
Remote display 3-welding torch
The welding power (welding current / wire feed speed),
welding voltage correction, program number, dynamics and
welding procedure can be changed from the welding torch.
Values, changes, faults and error messages are displayed on
the welding torch display.
PM221/301/401G,
PM301/451/551W
X
X Technology
Welding torch with X technology – function torch without
separate control cable
PM221/301/401G,
PM301/451/551W
4 Product description – quick reference
4.1 Product variants
Product description – quick reference
Standard welding torch
099-700003-EW501
11.01.2019
9
Item
Symbol
Description 0
1
Gas nozzle
2
Grip plate
3
Ball joint
4
Torch neck 45°
5
Torch trigger
6
Anti-kink device
4.2 Standard welding torch
Figure 4-1
Product description – quick reference
Function torch
10
099-700003-EW501
11.01.2019
Item
Symbol
Description 0
1
Gas nozzle
2
Torch neck 45°
3
Operating elements > see 5.2.2 chapter
4
Grip plate
5
Ball joint
6
LED lighting
7
Torch trigger
8
Anti-kink device
4.3 Function torch
Figure 4-2
Product description – quick reference
Euro torch connector without control cable
099-700003-EW501
11.01.2019
11
Item
Symbol
Description 0
1
Anti-kink spring
2
Euro central connection
Welding current, shielding gas and torch trigger included
3
Quick connect coupling, blue (coolant supply)
4
Quick connect coupling, red (coolant return)
Item
Symbol
Description 0
1
Anti-kink spring
2
Euro central connection
3
Control cable plug
Functiontorch only
4
Quick connect coupling, blue (coolant supply)
5
Quick connect coupling, red (coolant return)
4.4 Euro torch connector without control cable
Figure 4-3
4.5 Euro torch connector with control cable
Figure 4-4
Version with control cable only with control variant 2U/D.
Design and function
Transport and installation
12
099-700003-EW501
11.01.2019
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!
CAUTION
Risk of injury due to moving parts!
The wire feeders are equipped with moving parts, which can trap hands, hair, clothing
or tools and thus injure persons!
• Do not reach into rotating or moving parts or drive components!
• Keep casing covers or protective caps closed during operation!
Risk of injury due to welding wire escaping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may
escape in an uncontrolled manner and injure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the
welding torch!
• Check wire guide at regular intervals!
• Keep all casing covers or protective caps closed during operation!
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!
Equipment damage due to contamination!
Unusually high amounts of dust, acids, corrosive gases or substances can damage the machine
(observe maintenance intervals > see 6.1 chapter).
• Avoid large amounts of smoke, steam, oily fumes, grinding dust and corrosive ambient air!
5 Design and function
5.1 Transport and installation
Read and observe the documentation to all system and accessory components!
5.1.1 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
• Check that the delivery is complete using the delivery note!
In the event of damage to the packaging
• Check the delivery for damage (visual inspection)!
In the event of complaints
If the delivery has been damaged during transport:
• Please contact the last haulier immediately!
• Keep the packaging (for possible checking by the haulier or for the return shipment).
Packaging for returns
If possible, please use the original packaging and the original packaging material. If you have any queries
5.1.2 Ambient conditions
on packaging and protection during transport, please contact your supplier.
Design and function
Transport and installation
099-700003-EW501
11.01.2019
13
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch > see 5.1.3.1 chapter.
Coolants with frost protection (KF 23E) must be checked regularly to ensure that the frost
protection is adequate to prevent damage to the machine or the accessory components.
• The coolant must be checked for adequate frost protection with the TYP 1 frost protection
tester .
• Replace coolant as necessary if frost protection is inadequate!
Coolant mixtures!
Mixtures with other liquids or the use of unsuitable coolants result in material damage and
renders the manufacturer's warranty void!
• Only use the coolant described in this manual (overview of coolants).
• Do not mix different coolants.
• When changing the coolant, the entire volume of liquid must be changed.
Coolant
Temperature range
KF 23E
-10 °C to +40 °C
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:
• -25 °C to +55 °C (-13 F to 131 F)
Relative humidity
5.1.3 Welding torch cooling system
• up to 90 % at 20 °C (68 F)
Dispose of the coolant in accordance with local regulations and the material safety data sheets.
5.1.3.1 Permitted torch coolant
Design and function
Settings
14
099-700003-EW501
11.01.2019
--------------------------------------------------------------------------------------------------------------------- ►
Power source
Hose package
Wire feeder
miniDrive
Welding torch
Max.
Compact
(25 m / 82 ft.)
(5 m / 16 ft.)
30 m
98 ft.
(20 m / 65 ft.)
(5 m / 16 ft.)
Decompact
(25 m / 82 ft.)
(5 m / 16 ft.)
(15 m / 49 ft.)
(10 m / 32 ft.)
(5 m / 16 ft.)
--------------------------------------------------------------------------------------------------------------------- ►
Power source
Hose package
Wire feeder
miniDrive
Welding torch
Max.
Compact
(25 m / 82 ft.)
(5 m / 16 ft.)
30 m
98 ft.
(30 m / 98 ft.)
(5 m / 16 ft.)
40 m
131 ft.
Decompact
(40 m / 131 ft.)
(5 m / 16 ft.)
45 m
147 ft.
(40 m / 131 ft.)
(25 m / 82 ft.)
(5 m / 16 ft.)
70 m
229 ft.
Program
switching
JOB switching
Process
switching
Operating mode
Welding method
Wire feed speed
Voltage
correction
Dynamics
2U/D control
Welding torch
RD2 control
Welding torch
RD3 control
Welding torch
5.1.3.2 Maximal hose package length
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.
Pump: Pmax = 3,5 bar (0.35 MPa)
Pump: Pmax = 4.5 bar (0.45 MPa)
5.2 Settings
After the torch component has been connected, the control elements of the welding machine control are
no longer in operation, other accessories for remote control must not be connected.
Parameter changes are saved immediately and displayed on the welding machine control!
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.
Depending on the torch version, the user can change the following welding parameters of the main
programs.
Design and function
Settings
099-700003-EW501
11.01.2019
15
Display
Setting/selection
JOB list changeover
0 = -------- task-oriented JOB list
1 = -------- actual JOB list (Ex works)
2 = -------- actual JOB list, JOB changeover activated via accessories
Lower limit remote JOB switching
JOB range of the function torches (PM 2U/D, PM RD2)
Lower limit: 129 (ex works)
Upper limit remote JOB switching
JOBarea of the function torch (PM 2U/D, PM RD2)
Upper limit: 169 (ex works)
Item
Symbol
Description 0
1
"B -" button (program mode)
Decrease JOB number
"B -" button (up/down mode)
Welding voltage correction, decrease value
2
"B +" button (program mode)
Increase JOB number
"B +" button (up/down mode)
Welding voltage correction, increase value
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. Use
the operating instructions for your power source to operate the switch.
5.2.2 Operating elements 2 for up/down welding torch
The function of the operating elements depends on whether the welding machine is set in program mode
or up/down mode > see 5.2.1 chapter. The device must be configured accordingly. For JOB switching
(JOB 129-169), special P12 parameter must have converted on the device control to 2 (see
corresponding operating instructions). Special parameters P13 and P14 also have an effect on JOB
remote switching. The special parameters P12-14 are listed below.
Special parameter
Figure 5-2
Design and function
Settings
16
099-700003-EW501
11.01.2019
Item
Symbol
Description 0
3
"A -" button (Program mode)
Decrease program number
"A -" button (Up/Down mode)
Reduce welding performance (welding current/wire-feed speed)
4
"A +" button (Program mode)
Increase program number
"A +" button (Up/Down mode)
Increase welding performance (welding current/wire-feed speed)
Display
Setting/selection
JOB list changeover
0 = ------- task-oriented JOB list
1 = ------- actual JOB list (Ex works)
2 = ------- actual JOB list, JOB changeover activated via accessories
Lower limit remote JOB switching
JOB range of the function torches (PM 2U/D, PM RD2)
Lower limit: 129 (ex works)
Upper limit remote JOB switching
JOBarea of the function torch (PM 2U/D, PM RD2)
Upper limit: 169 (ex works)
Item
Symbol
Description 0
1
OLED display
Graphical display to show the functions.
2
"B -" button (program mode)
Decrease JOB number
"B -" button (up/down mode)
Welding voltage correction, decrease value
3
"B +" button (program mode)
Increase JOB number
"B +" button (up/down mode)
Welding voltage correction, increase value
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
or up/down mode > see 5.2.1 chapter. The device must be configured accordingly. For JOB switching
(JOB 129-169), special P12 parameter must have converted on the device control to 2 (see
corresponding operating instructions). Special parameters P13 and P14 also have an effect on JOB
remote switching. The special parameters P12-14 are listed below.
Special parameter
Figure 5-3
Design and function
Settings
099-700003-EW501
11.01.2019
17
Item
Symbol
Description 0
4
"A -" button (Program mode)
Decrease program number
"A -" button (Up/Down mode)
Reduce welding performance (welding current/wire-feed speed)
5
"A +" button (Program mode)
Increase program number
"A +" button (Up/Down mode)
Increase welding performance (welding current/wire-feed speed)
Welding parameters
Display
Welding current
Wire feed speed
Voltage correction
Programs
JOB number
Item
Symbol
Description 0
1
OLED display
Graphical display to show the functions.
2
Parameter selection push-button
Welding parameters are selected one after the other.
5.2.4 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
parameter is changed. If this parameter is not changed for more than approx. 5 s, the display switches
back to the values set by the control unit.
Examples for welding parameters in the welding data display
5.2.5 Operating elements for RD3 welding torch
Figure 5-4
Design and function
Settings
18
099-700003-EW501
11.01.2019
Item
Symbol
Description 0
3
Parameter selection push-button
Welding parameters are selected one after the other.
4
Push-button “+”
Increase JOB number or parameter value.
5
Push-button “-”
Decrease JOB number or parameter value
Welding parameters
Display
Welding current
Wire feed speed
Welding voltage
Programs
Welding procedure
Dynamics
Fault, error message
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.
During the up/down operation, the corresponding parameter value is shown on the display when the
parameter is changed. If this parameter is not changed for more than approx. 5 s, the display switches
back to the values set by the control unit.
Examples for welding parameters in the welding data display
Design and function
Settings
099-700003-EW501
11.01.2019
19
A
B
C
A
C
C
B
B
A
...
B
A
C
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.
Welding type (standard or pulse welding) and operating mode (2-cycle, 4-cycle, etc.) are set at the
program level.
The following illustration is an example of use:
Main level
Figure 5-5
Design and function
Settings
20
099-700003-EW501
11.01.2019
B
A
C
B/C
A
B/C
B/C
B/C
B/C
B/C
Program level
Figure 5-6
Design and function
Settings
099-700003-EW501
11.01.2019
21
C D
BA
B
B
B
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. A temporary exit (free-welding mode) from the seam sequence is possible
by pressing a key on the torch.
The following illustration is an example of use:
Figure 5-7
The arrow key on the right can be used to acknowledge welding beads. To enter the submenu, hold
button for 3s. After 3s without selection, the component mode is displayed again.
The free-welding mode is activated via the arrow key on the left of . Press and hold button 3s. The
display shows a symbol. Free-welding mode for e. g. tacking is now activated. Pressing and holding
repeatedly will get you back to component mode.
The keys and allow the navigation of the seams and runs. Long pressing of the button skips to the
last not yet acknowledged weld bead.
Design and function
Configure welding torch
22
099-700003-EW501
11.01.2019
Item
Symbol
Description 0
1
Torch trigger
2
LED lighting
WARNING
Risk of burning or electric shock at the torch neck!
The torch neck and coolant (with water-cooled machines) become very hot during
welding.
You may get into contact with hot components or voltage when turning or changing the
torch neck.
• Switch off the power source and let the torch cool down!
• Wear dry and undamaged protective clothing (shoes with rubber soles/welder's gloves made
from leather without any studs or braces)!
Item
Symbol
Description 0
1
Gas nozzle
2
Gas distributor
3
Contact tip
4
Contact tip holder
5
Torch neck 45°
6
Crown nut
7
O-ring
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.
5.3 Configure welding torch
Figure 5-8
Figure 5-9
Design and function
Configure welding torch
099-700003-EW501
11.01.2019
23
Item
Symbol
Description 0
8
Torch connection block
9
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. Gas losses and the penetration of atmospheric oxygen can also occur and can
adversely affect the welding result.
• Check the O-rings every time the welding torch is converted and grease or replace if
necessary.
5.3.1 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.
• Rotate the torch neck into the required position.
• Tighten the crown nut hand-tight until the torch neck can no longer be moved.
5.3.2 Changing the torch neck
Welding torches can be fitted with a 45°, 36°, 22° and 0° angled torch neck as an option. To replace the
torch neck follow these instructions.
Figure 5-10
Design and function
Configure welding torch
24
099-700003-EW501
11.01.2019
Item
Symbol
Description 0
1
Grip plate
2
Crown nut
3
Torch neck 45°
4
Gas nozzle
5
Contact tip holder
6
Liner
7
Contact tip
Figure 5-11
Re-connect the welding torch after completing any maintenance work, use the 'gas test' function
to purge with shielding gas and vent > see 7.2 chapter.
Design and function
Equipment recommendations
099-700003-EW501
11.01.2019
25
5.4 Equipment recommendations
Figure 5-12
Design and function
Adapting the Euro torch connection on the device
26
099-700003-EW501
11.01.2019
Observe permissible torque > see 8 chapter!
5.5 Adapting the Euro torch connection on the device
On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with steel
liners!
5.5.1 Liner
• Push forward the capillary tube on the wire feed side in the direction of the Euro torch connector and
remove it there.
• Insert the guide tube from the Euro torch connection.
• Carefully insert the welding torch connector with as yet too long a liner into the Euro torch connector
and secure with a crown nut.
• Cut off the liner using a special cutter or sharp knife just before the wire feed roller, making sure not to
pinch it.
• Loosen the welding torch connector and remove.
• Cleanly trim the separated end of the liner!
5.5.2 Replace steel liner
• Check that the capillary tube is correctly positioned in relation to the central connector!
• Insert the central plug for the welding torch into the central connector and screw together with crown
nut.
5.6 Assemble the wire guide
Use the correct wire guide from spool to molten pool!
The wire guide has to be adjusted to the wire electrode type and diameter in order to achieve good
welding results!
• Equip the wire feeder according to wire electrode type and diameter!
• 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)!
• Use a plastic liner inside the torch hose package to guide soft or alloyed wire electrodes!
> see 10 chapter
A steel liner is installed at the connection side, whereas a combined liner is installed at the torch
5.6.1 Liner
side.
Design and function
Assemble the wire guide
099-700003-EW501
11.01.2019
27
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.
Figure 5-13
1.
Figure 5-14
2.
Figure 5-15
Design and function
Assemble the wire guide
28
099-700003-EW501
11.01.2019
3.
Figure 5-16
4.
Adjust the brass liner > see 5.4 chapter.
Figure 5-17
5.
Figure 5-18
6.
Figure 5-19
Design and function
Assemble the wire guide
099-700003-EW501
11.01.2019
29
Item
Symbol
Description 0
1
Gas nozzle
2
Contact tip
3
Contact tip holder
4
Torch neck 45°
5
Crown nut
6
O-ring
7
Collet
8
Combined liner
9
Euro central connection
10
Connecting sleeve
11
New combined liner
12
Liner sharpener
13
Guiding tube for welding torch Euro torch connector
Observe permissible torque > see 8 chapter!
7.
Figure 5-20
8.
5.6.2 Guide spiral
Figure 5-21
Design and function
Assemble the wire guide
30
099-700003-EW501
11.01.2019
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
1.
Figure 5-23
2.
Figure 5-24
Design and function
Assemble the wire guide
099-700003-EW501
11.01.2019
31
3.
Figure 5-25
4.
Figure 5-26
5.
Figure 5-27
Design and function
Assemble the wire guide
32
099-700003-EW501
11.01.2019
Item
Symbol
Description 0
1
Gas nozzle
2
Contact tip
3
Contact tip holder
4
Welding torch neck
5
Crown nut, welding torch central connection (euro)
6
Centring sleeve
7
old spiral guide
8
Euro central connection
9
new spiral guide
10
Capillary tube
6.
Figure 5-28
7.
Figure 5-29
Maintenance, care and disposal
Maintenance work, intervals
099-700003-EW501
11.01.2019
33
CAUTION
Electrical current!
The following work must always be carried out with the power source switched off.
Electric current!
Repairs may only be carried out by authorised specialist staff!
• Do not remove the torch from the hose package!
• Never clamp the torch body in a vice or similar, as this can cause the torch to be irreparably
destroyed!
• If damage occurs to the torch or to the hose package which cannot be corrected as part of the
maintenance work, the entire torch must be returned to the manufacturer
6 Maintenance, care and disposal
6.1 Maintenance work, intervals
6.1.1 Daily maintenance tasks
• Purge the wire guide from the direction of the Euro torch connector with oil- and condensate-free
compressed air or shielding gas.
• Check that coolant connections are tight.
• Check that the welding torch, and where applicable the power source cooling, are functioning
correctly.
• Check the coolant level.
• Check whether there is the O-ring on the gas nipple of the Euro torch connector and whether it is not
damaged. Replace defective O-ring.
• Check torch, hose package and power connections for exterior damage and replace or have repaired
by specialist staff as necessary!
• Check the wearing parts in the torch.
6.1.2 Monthly maintenance tasks
• Check the coolant container for sludge deposits and check the coolant for cloudiness.
Clean the coolant container if contaminated, and change the coolant.
• If the coolant is dirty, rinse through the welding torch alternately several times with fresh coolant using
the coolant return and supply.
• Check that all connections and wearing parts are hand-tight and tighten if necessary.
• 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.
• Check the wire guide.
• Check that all screw and plug connections and replaceable parts are secured correctly, tighten if
necessary.
Figure 6-1
6.2 Maintenance work
Maintenance, care and disposal
Disposing of equipment
34
099-700003-EW501
11.01.2019
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!
6.3 Disposing of equipment
• 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.
6.4 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).
Rectifying faults
Checklist for rectifying faults
099-700003-EW501
11.01.2019
35
Legend
Symbol
Description
Fault/Cause
Remedy
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 Checklist for rectifying faults
The correct machine equipment for the material and process gas in use is a fundamental
requirement for perfect operation!
Welding torch overheated
Check coolant flow rate
Insufficient coolant flow
Check coolant level and refill if necessary
Eliminate kinks in conduit system (hose packages)
Completely unroll the hose package and the torch hose package
Vent coolant circuit > see 7.2 chapter
Loose welding current connections
Tighten power connections on the torch and/or on the workpiece
Screw contact tip holder and gas nozzle tightly into place correctly
Tighten contact tip correctly
Overload
Check and correct welding current setting
Use a more powerful welding torch
Functional error with the welding torch operating elements
Connection problems
Make control lead connections and check that they are fitted correctly.
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
Kinked hose packages
Extend and lay out the torch hose package
Incompatible parameter settings
Check settings and correct if necessary
Rectifying faults
Vent coolant circuit
36
099-700003-EW501
11.01.2019
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
Incompatible parameter settings
Check settings and correct if necessary
Pore formation
Inadequate or missing gas shielding
Check shielding gas setting and replace shielding gas cylinder if necessary
Shield welding site with protective screens (draughts affect the welding result)
Unsuitable or worn welding torch equipment
Check size of gas nozzle and replace if necessary
Condensation (hydrogen) in the gas tube
Purge hose package with gas or replace
Splashes in the gas nozzle
Gas distributor out of order or missing
7.2 Vent coolant circuit
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)!
Complete the following steps to vent the welding torch:
• Connect the welding torch to the cooling unit
• Switch on the welding machine
• Tao the torch trigger
Venting the welding torch starts and lasts for approx. 5 to 6 minutes.
Figure 7-1
Technical data
PM 301 / 451 / 551 W
099-700003-EW501
11.01.2019
37
Type
PM 301 W
PM 451 W
PM 551 W
Welding torch polarity
Usually positive
Guide type
Manually operated
Voltage type
DC
Shielding gas
CO2 or mixed gas M21 according to DIN EN 439
Duty cycle (at 40 °C flow temperature)
≥ 100 %
Maximum welding current, M21
290 A
450 A
550 A
Maximum welding current, pulse M21
250 A
350 A
500 A
Maximum welding current, CO2
330 A
500 A
650 A
Microswitch for switching voltage
15 V
Microswitch for switching current
10 mA
Required cooling capacity
Min. 800 W
Max. flow temperature
65 °C
Torch input pressure, coolant
3 to 6 bar (min.–max.)
Flow quantity (min.)
1.2 l/min
1.4 l/min
Wire types
Standard round wires
Wire diameter
0.8 to 1.2 mm
0.8 to 1.6 mm
0.8 to 2.0 mm
Ambient temperature
-10 °C to +40 °C
Voltage measurement
113 V (peak value)
Protection classification of the machine
Connections (EN 60529)
IP3X
Gas flow
10 to 25 l/min
Hose package length
3 m/4 m/5 m
Tightening torques of contact tip
holders
15 Nm
20 Nm
Tightening torques of contact tips
10 Nm
15 Nm
Connection
Euro torch connector
Safety marking
Applied harmonised standards
See declaration of conformity (appliance documents)
Operating weight
1.03 kg
2.27 lb
1.09 kg
2.4 lb
1.1 kg
2.43 lb
8 Technical data
8.1 PM 301 / 451 / 551 W
Performance specifications and guarantee only in connection with original spare and replacement
parts!
Accessories
General accessories
38
099-700003-EW501
11.01.2019
Type
Designation
Item no.
ON TT
Burner button above
092-007938-00000
9 Accessories
9.1 General accessories
Replaceable parts
PM 301 W
099-700003-EW501
11.01.2019
39
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.
Item
Order number
Type
Name
1
094-013061-00001
GN TR 20 66mm D=13mm
Gas nozzle
1
094-013062-00001
GN TR 20 66mm D=11mm
Gas nozzle
1
094-013063-00001
GN TR 20 66mm D=16mm
Gas nozzle
1.2
094-020136-00000
GN TR 20x4 68mm D=10,5mm
Gas nozzle, cylinder neck
1.3
094-013644-00000
GN FCW TR 20 58mm
Gas nozzle, Innershield
1.6
094-020944-00000
GN TR 20, 75 mm, D=18 mm
Spot welding nozzle
2
094-013071-00000
CT M6 CuCrZr, D=0,8 mm
Contact tip
2
094-013072-00000
CT M6 CuCrZr, D=1,0 mm, L=28 mm
Contact tip
2
094-013122-00000
CT M6 CuCrZr, D=0,9 mm
Contact tip
2
094-013535-00000
CT CUCRZR M7X30MM D=0.8MM
Contact tip
2
094-013536-00000
CT CUCRZR M7X30MM D=0.9MM
Contact tip
2
094-013537-00000
CT CUCRZR M7X30MM D=1.0MM
Contact tip
2
094-013538-00000
CT CUCRZR M7X30MM D=1.2MM
Contact tip
2
094-013550-00000
CTAL E-CU M7X30MM D=0.8MM
Contact tip, aluminium welding
2
094-013551-00000
CTAL E-CU M7X30MM D=0.9MM
Contact tip, aluminium welding
2
094-013552-00000
CTAL E-CU M7X30MM D=1.0MM
Contact tip, aluminium welding
2
094-013553-00000
CTAL E-CU M7X30MM D=1.2MM
Contact tip, aluminium welding
2
094-014317-00000
CT M6 CuCrZr D=1,2 mm
Contact tip
2
094-016101-00000
CT M6x28mm 0.8mm E-CU
Contact tip
2
094-016102-00000
CT M6x28mm 0.9mm E-CU
Contact tip
2
094-016103-00000
CT M6x28mm 1.0mm E-CU
Contact tip
2
094-016104-00000
CT M6x28mm 1.2mm E-CU
Contact tip
2
094-016105-00000
CTAL E-CU M6X28MM D=0.8MM
Contact tip, aluminium welding
2
094-016106-00000
CTAL E-CU M6X28MM D=0.9MM
Contact tip, aluminium welding
2
094-016107-00000
CTAL E-CU M6X28MM D=1.0MM
Contact tip, aluminium welding
2
094-016108-00000
CTAL E-CU M6X28MM D=1.2MM
Contact tip, aluminium welding
2.2
094-005403-00000
CT M6 x 25 mm, 0.6 mm, CuCrZr
Contact tip
2.2
094-020689-00000
CT M6 x 25 mm, 0.8 mm, CuCrZr
Contact tip
2.2
094-020690-00000
CT M6 x 25 mm, 1.0 mm, CuCrZr
Contact tip
10 Replaceable parts
10.1 PM 301 W
Figure 10-1
Replaceable parts
PM 451 W
40
099-700003-EW501
11.01.2019
Item
Order number
Type
Name
2.2
094-020691-00000
CT M6 x 25 mm, 0.6 mm, E-Cu
Contact tip
2.2
094-020692-00000
CT M6 x 25 mm, 0.8 mm, E-Cu
Contact tip
2.2
094-020693-00000
CT M6 x 25 mm, 0.9 mm, E-Cu
Contact tip
2.2
094-020694-00000
CT M6 x 25 mm, 1.0 mm, E-Cu
Contact tip
2.2
094-020695-00000
CT M6 x 25 mm, 0.6 mm, E-Cu (Alu)
Contact tip, aluminium welding
2.2
094-020696-00000
CT M6 x 25 mm, 0.8 mm, E-Cu (Alu)
Contact tip, aluminium welding
2.2
094-020697-00000
CT M6 x 25 mm, 0.9 mm, E-Cu (Alu)
Contact tip, aluminium welding
2.2
094-020698-00000
CT M6 x 25 mm, 1.0 mm, E-Cu (Alu)
Contact tip, aluminium welding
3
094-013069-00002
CTH CUCRZR M6 L=30.5MM
Contact tip holder
3
094-013070-00002
CTH CUCRZR M6 L=33.5MM
Contact tip holder
3
094-013542-00002
CTH CUCRZR M7 L=34.5MM
Contact tip holder
3
094-013541-00002
CTH CUCRZR M7 L=31.5MM
Contact tip holder
3.1
094-020562-00000
CTH M6 CuCrZr 30.5mm
Contact tip holder
4
094-013094-00004
GD MT221G / MT301W
Gas diffuser
-
094-016038-00001
TT SW5-SW12MM
Torch key
Item
Order number
Type
Description
1
094-013105-00001
GN TR 22 71mm D=13mm
Gas nozzle
1
094-013106-00001
GN TR 22 71mm D=15mm
Gas nozzle
1
094-013107-00001
GN TR 22 71mm D=18mm
Gas nozzle
1
094-019821-00001
GN TR 22 65mm D=15mm
Gas nozzle, short
1
094-019822-00001
GN TR 22 65mm D=18mm
Gas nozzle, short
1.1
094-019853-00001
GN NG TR22X4 71mm D=13mm
Highly conical gas nozzle, narrow
gap welding
1.3
094-019554-00000
GN FCW TR 22x4 59.5MM
Gas nozzle, Innershield
1.4
094-019626-00000
GN NG M12 73mm
Gas nozzle, narrow gap welding
1.4
094-022226-00000
GN NG M12 76mm
Gas nozzle, narrow gap welding
1.5
094-019623-00000
GNC TR22x4
Gas nozzle body
1.6
094-020945-00000
GN TR 22, 80 mm, D=20 mm
Spot welding nozzle
2
094-007238-00000
CT E-CU M8X30MM D=1.2MM
Contact tip
2
094-013113-00000
CT M8 CuCrZr 30mm, 1.2mm
Contact tip
2
094-013129-00000
CT CUCRZR M8X30MM D=0.9MM
Contact tip
2
094-013528-00000
CT CUCRZR M9X35MM D=0.8MM
Contact tip
2
094-013529-00000
CT CUCRZR M9X35MM D=0.9MM
Contact tip
2
094-013530-00000
CT M9 CuCrZr 1.0mm
Contact tip
10.2 PM 451 W
Figure 10-2
Replaceable parts
PM 551 W
099-700003-EW501
11.01.2019
41
Item
Order number
Type
Description
2
094-013531-00000
CT CUCRZR M9X35MM D=1.2MM
Contact tip
2
094-013532-00000
CT CUCRZR M9X35MM D=1.4MM
Contact tip
2
094-013533-00000
CT CUCRZR M9X35MM D=1.6MM
Contact tip
2
094-013543-00000
CTAL E-CU M9X35MM D=0.8MM
Contact tip, aluminium welding
2
094-013544-00000
CTAL E-CU M9X35MM D=0.9MM
Contact tip, aluminium welding
2
094-013545-00000
CTAL E-CU M9X35MM D=1.0MM
Contact tip, aluminium welding
2
094-013546-00000
CTAL E-CU M9X35MM D=1.2MM
Contact tip, aluminium welding
2
094-013547-00000
CTAL E-CU M9X35MM D=1.4MM
Contact tip, aluminium welding
2
094-013548-00000
CTAL E-CU M9X35MM D=1.6MM
Contact tip, aluminium welding
2
094-014024-00000
CT CUCRZR M8X30MM D=0.8MM
Contact tip
2
094-014191-00000
CT CUCRZR M8X30MM D=1.4MM
Contact tip
2
094-014192-00000
CT CUCRZR M8X30MM D=1.6MM
Contact tip
2
094-014222-00000
CT CUCRZR M8X30MM D=1.0MM
Contact tip
2
094-016109-00000
CT E-CU M8X30MM D=0.8MM
Contact tip
2
094-016110-00000
CT E-CU M8X30MM D=0.9MM
Contact tip
2
094-016111-00000
CT E-CU M8X30MM D=1.0MM
Contact tip
2
094-016112-00000
CT E-CU M8X30MM D=1.4MM
Contact tip
2
094-016113-00000
CT E-CU M8X30MM D=1.6MM
Contact tip
2
094-016115-00000
CTAL E-CU M8X30MM D=0.8MM
Contact tip, aluminium welding
2
094-016116-00000
CTAL E-CU M8X30MM D=0.9MM
Contact tip, aluminium welding
2
094-016117-00000
CTAL E-CU M8X30MM D=1.0MM
Contact tip, aluminium welding
2
094-016118-00000
CTAL E-CU M8X30MM D=1.2MM
Contact tip, aluminium welding
2
094-016119-00000
CTAL E-CU M8X30MM D=1.4MM
Contact tip, aluminium welding
2
094-016120-00000
CTAL E-CU M8X30MM D=1.6MM
Contact tip, aluminium welding
2.1
094-019616-00000
CT M9 x 100 mm; Ø 1,0 mm CuCrZr
Contact tip, narrow gap welding
2.1
094-019617-00000
CT M9 x 100 mm; Ø 1,2 mm CuCrZr
Contact tip, narrow gap welding
2.1
094-019618-00000
CT M9 x 100 mm; Ø 1,6 mm CuCrZr
Contact tip, narrow gap welding
2.1
094-020019-00000
CT M9 x 100 mm; Ø 1,4 mm CuCrZr
Contact tip, narrow gap welding
2.1
094-021189-00000
CT M9 x 100 mm; Ø 0,8 mm CuCrZr
Contact tip, narrow gap welding
3
094-013109-00002
CTH CUCRZR M8 L=34.1MM
Contact tip holder
3
094-013110-00002
CTH CUCRZR M8 L=37.1MM
Contact tip holder
3
094-013539-00002
CTH M9 CuCrZr 34.5mm
Contact tip holder
3
094-013540-00002
CTH M9 CuCrZr 37.5mm
Contact tip holder
4
094-013096-00003
GD MT301/451
Gas diffuser
5
094-019625-00000
IT ES M22X1,5 M12X1
Insulation part
6
094-019627-00000
ZH GDE ID=5MM AD=10MM L=15MM
Centring sleeve
-
094-016038-00001
TT SW5-SW12MM
Torch key
Replaceable parts
PM 551 W
42
099-700003-EW501
11.01.2019
Item
Order number
Type
Description
1
094-014177-00001
GN TR 23 63mm D=15mm
Gas nozzle
1
094-014178-00001
GN TR 23 66mm D=15mm
Gas nozzle
1
094-014179-00001
GN TR 23 63mm D=17mm
Gas nozzle
1
094-014180-00001
GN TR 23 66mm D=17mm
Gas nozzle
1
094-014181-00001
GN TR 23 63mm D=19mm
Gas nozzle
1
094-014182-00001
GN TR 23 66mm D=19mm
Gas nozzle
1.1
094-019702-00000
GN NG TR23X4 63mm D=13mm
Highly conical gas nozzle, narrow
gap welding
1.1
094-022227-00000
GN NG TR23X4 66mm D=13mm
Highly conical gas nozzle, narrow
gap welding
1.4
094-019626-00000
GN NG M12 73mm
Gas nozzle, narrow gap welding
1.4
094-022226-00000
GN NG M12 76mm
Gas nozzle, narrow gap welding
1.5
094-019624-00000
GNC TR23x4
Gas nozzle body
2
094-007238-00000
CT E-CU M8X30MM D=1.2MM
Contact tip
2
094-013113-00000
CT M8 CuCrZr 30mm, 1.2mm
Contact tip
2
094-013129-00000
CT CUCRZR M8X30MM D=0.9MM
Contact tip
2
094-013528-00000
CT CUCRZR M9X35MM D=0.8MM
Contact tip
2
094-013529-00000
CT CUCRZR M9X35MM D=0.9MM
Contact tip
2
094-013530-00000
CT M9 CuCrZr 1.0mm
Contact tip
2
094-013531-00000
CT CUCRZR M9X35MM D=1.2MM
Contact tip
2
094-013532-00000
CT CUCRZR M9X35MM D=1.4MM
Contact tip
2
094-013533-00000
CT CUCRZR M9X35MM D=1.6MM
Contact tip
2
094-013534-00000
CT CUCRZR M9X35MM D=2.0MM
Contact tip
2
094-013543-00000
CTAL E-CU M9X35MM D=0.8MM
Contact tip, aluminium welding
2
094-013544-00000
CTAL E-CU M9X35MM D=0.9MM
Contact tip, aluminium welding
2
094-013545-00000
CTAL E-CU M9X35MM D=1.0MM
Contact tip, aluminium welding
2
094-013546-00000
CTAL E-CU M9X35MM D=1.2MM
Contact tip, aluminium welding
2
094-013547-00000
CTAL E-CU M9X35MM D=1.4MM
Contact tip, aluminium welding
2
094-013548-00000
CTAL E-CU M9X35MM D=1.6MM
Contact tip, aluminium welding
2
094-013549-00000
CTAL E-CU M9X35MM D=2.0MM
Contact tip, aluminium welding
2
094-014024-00000
CT CUCRZR M8X30MM D=0.8MM
Contact tip
2
094-014191-00000
CT CUCRZR M8X30MM D=1.4MM
Contact tip
2
094-014192-00000
CT CUCRZR M8X30MM D=1.6MM
Contact tip
2
094-014193-00000
CT CUCRZR M8X30MM D=2.0MM
Contact tip
2
094-014222-00000
CT CUCRZR M8X30MM D=1.0MM
Contact tip
2
094-016109-00000
CT E-CU M8X30MM D=0.8MM
Contact tip
10.3 PM 551 W
Figure 10-3
Replaceable parts
PM 551 W
099-700003-EW501
11.01.2019
43
Item
Order number
Type
Description
2
094-016110-00000
CT E-CU M8X30MM D=0.9MM
Contact tip
2
094-016111-00000
CT E-CU M8X30MM D=1.0MM
Contact tip
2
094-016112-00000
CT E-CU M8X30MM D=1.4MM
Contact tip
2
094-016113-00000
CT E-CU M8X30MM D=1.6MM
Contact tip
2
094-016114-00000
CT E-CU M8X30MM D=2.0MM
Contact tip
2
094-016115-00000
CTAL E-CU M8X30MM D=0.8MM
Contact tip, aluminium welding
2
094-016116-00000
CTAL E-CU M8X30MM D=0.9MM
Contact tip, aluminium welding
2
094-016117-00000
CTAL E-CU M8X30MM D=1.0MM
Contact tip, aluminium welding
2
094-016118-00000
CTAL E-CU M8X30MM D=1.2MM
Contact tip, aluminium welding
2
094-016119-00000
CTAL E-CU M8X30MM D=1.4MM
Contact tip, aluminium welding
2
094-016120-00000
CTAL E-CU M8X30MM D=1.6MM
Contact tip, aluminium welding
2
094-016920-00000
CTAL E-CU M8X30MM D=2.0MM
Contact tip, aluminium welding
2.1
094-019616-00000
CT M9 x 100 mm; Ø 1,0 mm CuCrZr
Contact tip, narrow gap welding
2.1
094-019617-00000
CT M9 x 100 mm; Ø 1,2 mm CuCrZr
Contact tip, narrow gap welding
2.1
094-019618-00000
CT M9 x 100 mm; Ø 1,6 mm CuCrZr
Contact tip, narrow gap welding
2.1
094-020019-00000
CT M9 x 100 mm; Ø 1,4 mm CuCrZr
Contact tip, narrow gap welding
2.1
094-021189-00000
CT M9 x 100 mm; Ø 0,8 mm CuCrZr
Contact tip, narrow gap welding
3
094-013856-00003
CTH CUCRZR M9 L=35MM
Contact tip holder
3
094-015489-00003
CTH M8 x 35 mm, CuCrZr
Contact tip holder
3
094-016018-00003
CTH M8 x 37,5 mm, CuCrZr
Contact tip holder
3
094-016425-00003
CTH CUCRZR M9 L=38MM
Contact tip holder
4
094-013111-00002
GD D=20,2 mm; 25 mm
Gas diffuser
5
094-019625-00000
IT ES M22X1,5 M12X1
Insulation part
6
094-019627-00000
ZH GDE ID=5MM AD=10MM L=15MM
Centring sleeve
-
094-016038-00001
TT SW5-SW12MM
Torch key
Service documents
Circuit diagrams
44
099-700003-EW501
11.01.2019
11 Service documents
11.1 Circuit diagrams
The circuit diagrams are only intended for authorised service personnel!
Figure 11-1
Service documents
Circuit diagrams
099-700003-EW501
11.01.2019
45
Figure 11-2
Service documents
Circuit diagrams
46
099-700003-EW501
11.01.2019
Figure 11-3
Service documents
Circuit diagrams
099-700003-EW501
11.01.2019
47
Figure 11-4
Service documents
Circuit diagrams
48
099-700003-EW501
11.01.2019
Figure 11-5
Service documents
Circuit diagrams
099-700003-EW501
11.01.2019
49
Figure 11-6
Service documents
Circuit diagrams
50
099-700003-EW501
11.01.2019
Figure 11-7
Service documents
Circuit diagrams
099-700003-EW501
11.01.2019
51
Figure 11-8
Appendix A
Display, explanation of symbols
52
099-700003-EW501
11.01.2019
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
Welding procedure
rootArc
Welding procedure
coldArc
JOB selection
Display
Setting/selection
Welding method
Standard
Welding method
Pulse
Welding method
Position weld
Operating mode
Non-latched
Operating mode
Latched
Operating mode
Special non-latched
Operating mode
Special latched
Operating mode
Spot welding
12 Appendix A
12.1 Display, explanation of symbols
Main level
Program level
Appendix A
Display, explanation of symbols
099-700003-EW501
11.01.2019
53
Display
Setting/selection
Error
Error - temperature
Error - water
Warning
Warning wire end
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
Standby
Error messages, warnings
Component management, Miscellaneous
Appendix B
Searching for a dealer
54
099-700003-EW501
11.01.2019
13 Appendix B
13.1 Searching for a dealer
www.ewm-group.com/en/specialist-dealers
"More than 400 EWM sales partners worldwide"
Sales & service parteners
Loading...