EWM PM 221 G Operating Instructions Manual Download Page 40

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Replaceable parts

PM 301 G

099-700000-EW501

22.09.2020

Item Order number

Type

Name

2.2

094-020690-00000 CT M6 x 25 mm, 1.0 mm, CuCrZr

Contact tip

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

2.3

094-025535-00000 CT ZWK CuCrZr M7x30 mm Ø

1,0mm

Contact tip zwangskontaktiert

2.3

094-025536-00000 CT ZWK CuCrZr M7x30 mm Ø

1,2mm

Contact tip zwangskontaktiert

094-013069-00002 CTH CUCRZR M6 L=30.5MM

Contact tip holder

094-013070-00002 CTH CUCRZR M6 L=33.5MM

Contact tip holder

094-013541-00002 CTH CUCRZR M7 L=31.5MM

Contact tip holder

094-013542-00002 CTH CUCRZR M7 L=34.5MM

Contact tip holder

3.1

094-020562-00000 CTH M6 CuCrZr 30.5mm

Contact tip holder

094-013094-00004 GD PM / MT 221G / 301W

Gas diffuser

094-016038-00001 TT SW5-SW12MM

Torch key

094-013967-00000 4,0MMX1,0MM

O-Ring for Euro torch connector

098-005149-00000 O-Ring Picker

O-Ring Picker

10.2 PM 301 G

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

094-019822-00001 GN TR 22 65mm D=18mm

Gas nozzle, short

1.1

094-019853-00001 GN NG TR22X4 71mm D=13mm

Gas nozzle Highly conical, Narrow

gap welding

Summary of Contents for PM 221 G

Page 1: ...Operating instructions EN welding torch PM 221 G PM 301 G PM 401 G 099 700000 EW501 Observe additional system documents 22 09 2020 ...

Page 2: ... 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 ac cepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or...

Page 3: ...n the machine 14 5 1 4 Operating elements 2 for up down welding torch 15 5 1 5 Operating elements for RD2 welding torch 15 5 1 6 Welding data display 16 5 1 7 Operating elements for RD3 welding torch 17 5 1 8 Welding data display 18 5 1 8 1 Programs setting operating points 19 5 1 8 2 Component management on the welding torch 21 5 1 9 LED lighting 22 5 2 Configure welding torch 22 5 2 1 Turning th...

Page 4: ...42 11 Service documents 44 11 1 Circuit diagrams 44 11 1 1 PM 301 551 W 44 11 1 2 PM 301 551 W LED 45 11 1 3 PM 301 551 W TT 46 11 1 4 PM 301 551 W TT LED 47 11 1 5 PM 301 551 W 2U D 48 11 1 6 PM 301 551 W 2U DX 49 11 1 7 PM 301 551 W RD2 X 50 11 1 8 PM 301 551 W RD3 X 51 12 Appendix 52 12 1 Display explanation of symbols 52 12 2 Searching for a dealer 54 ...

Page 5: ...us and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning sym bol 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 warn ing symbol The risk i...

Page 6: ...itch 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 ac tuate Signal light flashes red Interruption in the menu display other setting options possible Tool not required do not us...

Page 7: ...h 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 Item Documentation A 1 Wire feeder A 2 Remote adjuster A 3 Controller A 4 Power source A 5 Welding torch A Complete docume...

Page 8: ...rranty 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 The product comes with a relevant declaration of conformity in the original The manufacturer recomm...

Page 9: ...0 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 o...

Page 10: ...eference Standard welding torch 10 099 700000 EW501 22 09 2020 4 2 Standard welding torch Figure 4 1 Item Symbol Description 0 1 Gas nozzle 2 Grip plate 3 Ball joint 4 Anti kink device 5 Lock ring 6 Torch trigger 7 Torch neck 45 ...

Page 11: ...ption 0 1 Gas nozzle 2 Torch neck 45 3 Operating elements 4 Grip plate 5 Ball joint 6 Anti kink device 7 Lock ring 8 Torch trigger 9 LED lighting 4 4 Euro torch connector without control cable Figure 4 3 Item Symbol Description 0 1 Anti kink spring 2 Euro central connection Welding current shielding gas and torch trigger included ...

Page 12: ...cable 12 099 700000 EW501 22 09 2020 4 5 Euro torch connector with control cable Figure 4 4 Item Symbol Description 0 1 Anti kink spring 2 Euro central connection 3 Control cable plug Only for control variant 2U D Version with control cable only with control variant 2U D ...

Page 13: ...onents 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 es cape 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 reg...

Page 14: ...ion with the device series Titan XQ and the wire feeder drive XQ If the function torch is connected to another EWM device series using Multimatrix the welding torch swit ches to compatibility mode and is restricted in its functions Depending on the torch version the user can change the following welding parameters of the main pro grams control welding torch 2U D RD2 RD3 Program switching JOB switc...

Page 15: ...lding voltage correction increase value 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 5 1 5 Operating elements for RD2 welding torch Figure 5 3 Item Symbol Description 0 1 OLED display G...

Page 16: ...feed speed 5 1 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 para meter is changed If this parameter...

Page 17: ...l Description 0 1 OLED display Graphical display to show the functions 2 Parameter selection push button Welding parameters are selected one after the other 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 ...

Page 18: ...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 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 Welding parameters Display Welding current Wire ...

Page 19: ...fter 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 pro gram level The following illustration is an example of use Main level A B C A C C B B A B A C Figure 5...

Page 20: ...Design and function Transport and installation 20 099 700000 EW501 22 09 2020 Program level B A C B C A B C B C B C B C B C Figure 5 6 ...

Page 21: ...n the torch The following illustration is an example of use C D B A B B B 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 ...

Page 22: ...r 2 LED lighting 5 2 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 Wear proper protective equipment Switch off the power source or torch cooling and allow th...

Page 23: ...eck the O rings every time the welding torch is converted and grease or replace if neces sary 5 2 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...

Page 24: ...000 EW501 22 09 2020 Figure 5 11 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 Connect welding torch after performing the maintenance and rinse using the Gas Test with shield gas ...

Page 25: ...Design and function Equipment recommendations 099 700000 EW501 22 09 2020 25 5 3 Equipment recommendations Figure 5 12 ...

Page 26: ...ctor and remove Cleanly trim the separated end of the liner 5 4 2 Replace steel liner Check the Euro torch connector for correct seating of the capillary tube Insert the welding torch connector into the Euro torch connector and screw hand tight using the crown nut 5 5 Assemble the wire guide Use the correct wire guide from spool to molten pool The wire guide has to be adjusted to the wire electrod...

Page 27: ...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 ...

Page 28: ...Design and function Assemble the wire guide 28 099 700000 EW501 22 09 2020 3 Figure 5 16 4 Adjust the brass liner Figure 5 17 5 Figure 5 18 6 Figure 5 19 ...

Page 29: ... Figure 5 21 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 ...

Page 30: ...09 2020 5 5 2 Guide spiral Observe permissible torque Insert the grinded end towards the contact tip holder to ensure tight fit with the contact tip Always make sure the the hose package is straight when replacing the wire guide Figure 5 22 1 Figure 5 23 2 Figure 5 24 ...

Page 31: ...Design and function Assemble the wire guide 099 700000 EW501 22 09 2020 31 3 Figure 5 25 4 Figure 5 26 5 Figure 5 27 ...

Page 32: ...000 EW501 22 09 2020 6 Figure 5 28 7 Figure 5 29 Item Symbol Description 0 1 Gas nozzle 2 Contact tip 3 Contact tip holder 4 Welding torch neck 5 Crown nut 6 Centring sleeve 7 old spiral guide 8 Euro central connection 9 new spiral guide 10 Capillary tube ...

Page 33: ...rve the maintenance instructions see 6 2 chapter In the event that the provisions of one of the below stated tests are not met the machine must not be operated again until it has been repaired and a new test has been carried out Repair and maintenance work may only be performed by qualified authorised personnel otherwise the right to claim under warranty is void In all service matters always consu...

Page 34: ...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 ci...

Page 35: ...er 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 dis posal of electric and electronic equipment ElektroG used machines are to be placed in a collection system separate from unsorted...

Page 36: ...erating 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 param...

Page 37: ...ng voltage 15 V Microswitch for switching current 10 mA Wire types Standard round wires Wire diameter 0 8 to 1 2 mm 0 03 to 0 047 inch 0 8 to 1 6 mm 0 03 to 0 063 inch 0 8 to 2 0 mm 0 03 to 0 079inch Ambient temperature 10 C to 40 C Voltage measurement 113 V Peak value Protection classification for the ma chine connections EN 60529 IP3X Gas flow 10 to 20 l min 2 6 gal min to 6 6 gal min Hose packa...

Page 38: ... shield for PM MT welding torch 094 025359 00000 ON TH PM Optional pistol grip 092 007944 00000 ON TV PM LED Torch trigger extension for PM welding torch with LED 094 023891 00000 ON TT PM LED Torch trigger on top with LED for PM welding torch 092 007939 00000 ON LED PM Standard Retrofit kit LED lighting for PM standard welding torch 092 007940 00000 ON KB STD TV PM SERIE Torch trigger extension f...

Page 39: ...0001 CT CUCRZR M7X30MM D 1 0MM Contact tip 2 094 013538 00001 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 ...

Page 40: ... 094 025536 00000 CT ZWK CuCrZr M7x30 mm Ø 1 2mm Contact tip zwangskontaktiert 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 013541 00002 CTH CUCRZR M7 L 31 5MM Contact tip holder 3 094 013542 00002 CTH CUCRZR M7 L 34 5MM Contact tip holder 3 1 094 020562 00000 CTH M6 CuCrZr 30 5mm Contact tip holder 4 094 013094 000...

Page 41: ...4192 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 ...

Page 42: ...m Gas nozzle Highly conical 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 ...

Page 43: ...M 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 ...

Page 44: ...ce documents Circuit diagrams 44 099 700000 EW501 22 09 2020 11 Service documents 11 1 Circuit diagrams The circuit diagrams are only intended for authorised service personnel 11 1 1 PM 301 551 W Figure 11 1 ...

Page 45: ...Service documents Circuit diagrams 099 700000 EW501 22 09 2020 45 11 1 2 PM 301 551 W LED Figure 11 2 ...

Page 46: ...Service documents Circuit diagrams 46 099 700000 EW501 22 09 2020 11 1 3 PM 301 551 W TT Figure 11 3 ...

Page 47: ...Service documents Circuit diagrams 099 700000 EW501 22 09 2020 47 11 1 4 PM 301 551 W TT LED Figure 11 4 ...

Page 48: ...Service documents Circuit diagrams 48 099 700000 EW501 22 09 2020 11 1 5 PM 301 551 W 2U D Figure 11 5 ...

Page 49: ...Service documents Circuit diagrams 099 700000 EW501 22 09 2020 49 11 1 6 PM 301 551 W 2U DX Figure 11 6 ...

Page 50: ...Service documents Circuit diagrams 50 099 700000 EW501 22 09 2020 11 1 7 PM 301 551 W RD2 X Figure 11 7 ...

Page 51: ...Service documents Circuit diagrams 099 700000 EW501 22 09 2020 51 11 1 8 PM 301 551 W RD3 X Figure 11 8 ...

Page 52: ...in 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 Program level 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...

Page 53: ...play 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 Standby ...

Page 54: ...Appendix Searching for a dealer 54 099 700000 EW501 22 09 2020 12 2 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide ...

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EWM PM 221 G, Operating Instructions Manual

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