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Rectifying faults

Checklist for rectifying faults

099-700000-EW501

22.09.2020

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.

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!

Legend

Symbol

Description



Fault/Cause



Remedy

Welding torch overheated



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

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

Содержание PM 221 G

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

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

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

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

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

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

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

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

Страница 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...

Страница 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 ...

Страница 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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