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Rectifying faults

Checklist for rectifying faults

099-700003-EW501

14.09.2020

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



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



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

Содержание PM 301 W

Страница 1: ...Operating instructions EN welding torch PM 301 W PM 451 W PM 551 W PM 551 W Alu 099 700003 EW501 Observe additional system documents 14 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 f...

Страница 3: ...2 2 2 Maximal hose package length 16 5 2 3 Settings 16 5 2 4 Operating elements in the machine 17 5 2 5 Operating elements 2 for up down welding torch 17 5 2 6 Operating elements for RD2 welding torc...

Страница 4: ...PM 301 W 43 10 2 PM 451 W 44 10 3 PM 551 W 46 11 Service documents 49 11 1 Circuit diagrams 49 11 1 1 PM 301 551 W 49 11 1 2 PM 301 551 W LED 50 11 1 3 PM 301 551 W TT 51 11 1 4 PM 301 551 W TT LED 52...

Страница 5: ...s 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 ope...

Страница 6: ...tch 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 gr...

Страница 7: ...ther 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 F...

Страница 8: ...t 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 n...

Страница 9: ...with a relevant declaration of conformity in the original The manufacturer recommends carrying out the safety inspection according to national and in ternational standards and guidelines every 12 mont...

Страница 10: ...feed speed and the voltage correction or the program number can be changed on the welding torch PM221 301 401G PM301 451 551W RD2 Remote display 2 welding torch The welding power welding current wire...

Страница 11: ...ference Standard welding torch 099 700003 EW501 14 09 2020 11 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 To...

Страница 12: ...nction torch 12 099 700003 EW501 14 09 2020 4 3 Function torch Figure 4 2 Item Symbol Description 0 1 Gas nozzle 2 Torch neck 45 3 Operating elements 4 Grip plate 5 Ball joint 6 Anti kink device 7 Loc...

Страница 13: ...Welding current shielding gas and torch trigger included 3 Quick connect coupling blue coolant supply 4 Quick connect coupling red coolant return 4 3 2 Euro torch connector with control cable Figure 4...

Страница 14: ...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 regular intervals K...

Страница 15: ...dependent on coolant Observe the coolant temperature range of the torch coo ling 5 2 2 Welding torch cooling system Insufficient frost protection in the welding torch coolant Depending on the ambient...

Страница 16: ...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 5 2 3 Settings After the torch component has been connected the control elements of the weldi...

Страница 17: ...ing instructions for your power source to operate the switch 5 2 5 Operating elements 2 for up down welding torch Figure 5 2 Item Symbol Description 0 1 B button program mode Decrease JOB number B but...

Страница 18: ...ase 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 4 A button Pr...

Страница 19: ...t 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 curren...

Страница 20: ...urrent 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 change...

Страница 21: ...ter 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...

Страница 22: ...Design and function Transport and installation 22 099 700003 EW501 14 09 2020 Program level B A C B C A B C B C B C B C B C Figure 5 6...

Страница 23: ...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...

Страница 24: ...r 2 LED lighting 5 3 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 duri...

Страница 25: ...ck the O rings every time the welding torch is converted and grease or replace if neces sary 5 3 1 Turning the torch neck This function is only available with the CG and CW version Unfasten the crown...

Страница 26: ...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 Re connect the welding torch after completing any maintenanc...

Страница 27: ...eed rolls C Capillary tube guide tube D DWire electrodes Low alloy CT CuCrZr V groove medium alloy CT CuCrZr V groove Hardfacing CT CuCrZr V groove High alloy CT CuCrZr V groove Aluminium CTAL E Cu U...

Страница 28: ...0 x 4 0 1 6 2 3 x 4 7 High alloy 0 8 1 5 x 4 0 Combined liner 200 mm 1 0 1 5 x 4 0 1 2 2 0 x 4 0 1 6 2 3 x 4 7 Aluminium 0 8 1 5 x 4 0 Combined liner 30 mm 1 0 1 5 x 4 0 1 2 2 0 x 4 0 1 6 2 3 x 4 7 A...

Страница 29: ...the Euro torch connector and remove it there Insert the guide tube from the Euro torch connection Insert the welding torch connector with the excessively long liner carefully into the Euro torch conn...

Страница 30: ...e 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 mis...

Страница 31: ...Design and function Assemble the wire guide 099 700003 EW501 14 09 2020 31 3 Figure 5 16 4 Adjust the brass liner Figure 5 17 5 Figure 5 18 6 Figure 5 19...

Страница 32: ...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 N...

Страница 33: ...020 33 5 6 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 wh...

Страница 34: ...Design and function Assemble the wire guide 34 099 700003 EW501 14 09 2020 3 Figure 5 25 4 Figure 5 26 5 Figure 5 27...

Страница 35: ...EW501 14 09 2020 35 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 c...

Страница 36: ...ve 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 ne...

Страница 37: ...nd 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 cool...

Страница 38: ...r 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...

Страница 39: ...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 connec...

Страница 40: ...ng 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 Pu...

Страница 41: ...ax Flow temperature 65 C Torch input pressure coolant 3 to 6 bar min max Flow volume min 1 2 l min 0 31 gal min 1 4 l min 0 37 gal min Wire types Standard round wires Wire diameter 0 8 to 1 2 mm 0 03...

Страница 42: ...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 tr...

Страница 43: ...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 00001 CT CUCRZR M7X30MM D 0 8MM Contact tip 2 094 013536 00001 CT CUCRZR M7X30MM D 0 9MM Co...

Страница 44: ...lding 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 1 0mm Contact tip forced contact 2 3 094 025536 00000 CT ZWK CuCrZr M...

Страница 45: ...9X35MM 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 C...

Страница 46: ...M 551 W Figure 10 3 Item Order number Type Name 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...

Страница 47: ...w gap welding 2 2 094 013543 00000 CTAL E CU M9X35MM D 0 8MM Contact tip aluminium welding 2 2 094 013544 00000 CTAL E CU M9X35MM D 0 9MM Contact tip aluminium welding 2 2 094 013545 00000 CTAL E CU M...

Страница 48: ...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 7 094 022875 00000...

Страница 49: ...e documents Circuit diagrams 099 700003 EW501 14 09 2020 49 11 Service documents 11 1 Circuit diagrams The circuit diagrams are only intended for authorised service personnel 11 1 1 PM 301 551 W Figur...

Страница 50: ...Service documents Circuit diagrams 50 099 700003 EW501 14 09 2020 11 1 2 PM 301 551 W LED Figure 11 2...

Страница 51: ...Service documents Circuit diagrams 099 700003 EW501 14 09 2020 51 11 1 3 PM 301 551 W TT Figure 11 3...

Страница 52: ...Service documents Circuit diagrams 52 099 700003 EW501 14 09 2020 11 1 4 PM 301 551 W TT LED Figure 11 4...

Страница 53: ...Service documents Circuit diagrams 099 700003 EW501 14 09 2020 53 11 1 5 PM 301 551 W 2U D Figure 11 5...

Страница 54: ...Service documents Circuit diagrams 54 099 700003 EW501 14 09 2020 11 1 6 PM 301 551 W 2U DX Figure 11 6...

Страница 55: ...Service documents Circuit diagrams 099 700003 EW501 14 09 2020 55 11 1 7 PM 301 551 W RD2 X Figure 11 7...

Страница 56: ...Service documents Circuit diagrams 56 099 700003 EW501 14 09 2020 11 1 8 PM 301 551 W RD3 X Figure 11 8...

Страница 57: ...n 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 l...

Страница 58: ...lay 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 val...

Страница 59: ...Appendix Searching for a dealer 099 700003 EW501 14 09 2020 59 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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