EWM UM 15 G EZA User manual

Operating instructions
EN
welding torch
UM 15 G EZA
UM 24 G EZA
UM 25 G EZA
UM 36 G EZA
UM 240 W EZA
UM 401 W EZA
UM 501 W EZA
099-600010-EW501
Observe additional system documents!
27.02.2018

General instructions
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.
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 [phone].
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.: [phone], Fax: -244
Email: [e-mail]
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
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1 Contents
1Contents..................................................................................................................................................3
2For your safety .......................................................................................................................................4
2.1 Notes on the use of these operating instructions ..........................................................................4
2.2 Explanation of icons.......................................................................................................................5
2.3 Part of the complete documentation..............................................................................................6
3Intended 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
4Product description –quick reference ................................................................................................8
4.1 Welding torch.................................................................................................................................8
4.2 UM 15 G , UM 24 G, UM 25 G, UM 36 G ......................................................................................8
4.2.1 Euro central connection..................................................................................................8
4.3 UM 240 W, UM 401 W, UM 501 W................................................................................................9
4.3.1 Euro central connection..................................................................................................9
5Design and function.............................................................................................................................10
5.1.1 Welding torch cooling system.......................................................................................10
5.1.1.1 Approved coolants overview.........................................................................10
5.1.1.2 Maximal hose package length ......................................................................10
5.2 Adapting the Euro torch connection on the device......................................................................11
5.2.1 Liner..............................................................................................................................11
5.2.2 Replace steel liner........................................................................................................11
5.3 Assemble the wire guide..............................................................................................................12
5.3.1 Guide spiral ..................................................................................................................12
5.3.2 Combined liner .............................................................................................................16
6Maintenance, care and disposal.........................................................................................................19
6.1 Maintenance work, intervals ........................................................................................................19
6.1.1 Daily maintenance tasks...............................................................................................19
6.1.2 Monthly maintenance tasks..........................................................................................19
6.2 Maintenance work........................................................................................................................19
6.3 Disposing of equipment ...............................................................................................................19
6.4Disposing of equipment ...............................................................................................................20
6.5 Meeting the requirements of RoHS .............................................................................................20
7Rectifying faults ...................................................................................................................................21
7.1 Checklist for rectifying faults........................................................................................................21
7.2 Vent coolant circuit.......................................................................................................................22
8Technical data ......................................................................................................................................23
8.1 UM 15 G , UM 24 G, UM 25 G, UM 36 G ....................................................................................23
8.2 UM 240 W, UM 401 W, UM 501 W..............................................................................................24
9Replaceable parts ................................................................................................................................25
9.1 UM 15 G.......................................................................................................................................25
9.2 UM 24 G.......................................................................................................................................26
9.3 UM 25 G.......................................................................................................................................27
9.4 UM 36 G.......................................................................................................................................28
9.5 UM 240 W....................................................................................................................................29
9.6 UM 401 W / UM 501 W................................................................................................................30
10 Appendix A ...........................................................................................................................................31
10.1 Searching for a dealer..................................................................................................................31

For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
•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.
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.

For your safety
Explanation of icons
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2.2 Explanation of icons
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 keep pressed
Switch
Wrong
Turn
Correct
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/activate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use

For your safety
Part of the complete documentation
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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
Item
Documentation
A.1
Wire feeder
A.2
Conversion instructions
A.3
Power source
A.4
Cooling unit, voltage converter, tool box etc.
A.5
Trolley
A.6
Welding torch
A.7
Remote control
A.8
Control
A
Complete documentation

Intended use
Applications
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3 Intended use
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!
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
The labelled machine 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.
3.2.3 Service documents (spare parts)
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)!
Spare parts can be obtained from the relevant authorised dealer.

Product description –quick reference
Welding torch
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4 Product description – quick reference
4.1 Welding torch
Figure 4-1
Item
Symbol
Description 0
1
Gas nozzle
2
Torch neck 45°
3
Torch trigger
4
Grip plate
5
Hose package
4.2 UM 15 G , UM 24 G, UM 25 G, UM 36 G
4.2.1 Euro central connection
Figure 4-2
Item
Symbol
Description 0
1
Anti-kink spring
2
Euro central connection
Welding current, shielding gas and torch trigger included

Product description –quick reference
UM 240 W, UM 401 W, UM 501 W
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4.3 UM 240 W, UM 401 W, UM 501 W
4.3.1 Euro central connection
Figure 4-3
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)

Design and function
UM 240 W, UM 401 W, UM 501 W
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5 Design and function
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!
Read and observe the documentation to all system and accessory components!
5.1.1 Welding torch cooling system
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch > see 5.1.1.1 chapter.
Coolants with frost protection (KF 37E or 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.
Dispose of the coolant in accordance with local regulations and the material safety data sheets.
5.1.1.1 Approved coolants overview
Coolant
Temperature range
KF 23E (Standard)
-10 °C to +40 °C
KF 37E
-20 °C to +10 °C
5.1.1.2 Maximal hose package length
Pump 3.5 bar
Pump 4.5 bar
Machines with or without separate wire feeder
30 m
60 m
Compact machines with additional intermediate
drive (example. miniDrive)
20 m
30 m
Machines with separate wire feeder and additional
intermediate drive (example: miniDrive)
20 m
60 m
Data as a rule refer to the entire hose package length
including welding torch. The pump output is shown on the type plate (parameter: Pmax).
Pump 3.5 bar: Pmax = 0.35 MPa (3.5 bar)
Pump 4.5 bar: Pmax = 0.45 MPa (4.5 bar)

Design and function
Adapting the Euro torch connection on the device
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5.2 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!
5.2.1 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!
5.2.2 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.

Design and function
Assemble the wire guide
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5.3 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 9 chapter
A steel liner is installed at the connection side, whereas a combined liner is installed at the torch
side.
5.3.1 Guide spiral
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 5-1
1.
Figure 5-2

Design and function
Assemble the wire guide
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2.
Figure 5-3
3.
Figure 5-4
4.
Figure 5-5

Design and function
Assemble the wire guide
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5.
Figure 5-6
6.
Figure 5-7

Design and function
Assemble the wire guide
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7.
Figure 5-8
Item
Symbol
Description 0
1
Gas nozzle
2
Contact tip
3
Gas distributor
4
Contact tip holder
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

Design and function
Assemble the wire guide
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5.3.2 Combined liner
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 5-9
1.
Figure 5-10
2.
Figure 5-11

Design and function
Assemble the wire guide
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3.
Figure 5-12
4.
Adjust the brass liner.
Material
Length
Aluminium
40 mm
CrNi/high-alloy
200 mm
Figure 5-13
5.
Figure 5-14

Design and function
Assemble the wire guide
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6.
Figure 5-15
7.
Figure 5-16
8.
Figure 5-17
Item
Symbol
Description 0
1
Gas nozzle
2
Contact tip
3
Gas distributor
4
Contact tip holder
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

Maintenance, care and disposal
Maintenance work, intervals
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6 Maintenance, care and disposal
CAUTION
Electrical current!
The following work must always be carried out with the power source switched off.
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 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.
6.2 Maintenance work
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
6.3 Disposing of equipment
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!

Maintenance, care and disposal
Disposing of equipment
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6.4 Disposing of equipment
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!
•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.
6.5 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).