EWM MT221 Operating Instructions Manual Download Page 37 | Manualshive

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Rectifying faults

Checklist for rectifying faults

099-500050-EW501

04.08.2016

37

Pore formation

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Inadequate or missing gas shielding

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Check shielding gas setting and replace shielding gas cylinder if necessary

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Shield welding site with protective screens (draughts affect the welding result)

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Unsuitable or worn welding torch equipment



Check size of gas nozzle and replace if necessary

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Condensation (hydrogen) in the gas tube





Purge hose package with gas or replace

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Splashes in the gas nozzle

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Gas distributor out of order or missing

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Summary of Contents for MT221

Page 1: ...torch MT221G MT301G MT401G MT221G X MT301G X MT401G X 099 500050 EW501 Observe additional system documents 04 08 2016 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For...

Page 2: ...ound at www ewm group com 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 Th...

Page 3: ...elements for PC2 welding torch 18 4 3 7 Welding data display 19 4 3 8 Euro central connection 20 4 3 9 Multimatrix Euro torch connector 20 4 4 Fume extraction torch 21 4 4 1 Fume extraction torch Euro...

Page 4: ...data 39 8 1 MT 221G X MT 301G X MT 401G X 39 9 Replaceable parts 40 9 1 MT221G 40 9 2 MT301G 42 9 3 MT401G 44 9 4 MT221G F MT301G F 46 10 Circuit diagrams 47 10 1 MT U D 47 10 2 MT U DX 48 10 3 MT 2U...

Page 5: ...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 mar...

Page 6: ...l 0 Switch off machine Release do not activate l 0 Switch on machine Press and hold switch Wrong Turn Correct Numerical value adjustable Menu entry Signal light lights up in green Navigating the menu...

Page 7: ...lable in the working area Thoroughly remove any residue of flammable materials from the workpiece prior to starting to weld Only further process workpieces after they have cooled down Do not allow the...

Page 8: ...ctions for the product being used Read and observe the operating instructions for all system components especially the safety instructions Obligations of the operator The respective national directive...

Page 9: ...f 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...

Page 10: ...w 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 2014 35 EC Electromagne...

Page 11: ...er and program number can be adjusted on the welding torch MT221 MT301 MT401 PC1 POWERCONTROL1 welding torch The welding power welding current wire feed speed or the program number can be adjusted on...

Page 12: ...reference Standard welding torch 12 099 500050 EW501 04 08 2016 4 2 Standard welding torch 4 3 2 1 5 Figure 4 1 Item Symbol Description 0 1 Gas nozzle 2 Torch neck 45 3 Torch trigger 4 Grip plate 5 W...

Page 13: ...erence Function torch 099 500050 EW501 04 08 2016 13 4 3 Function torch 4 5 6 3 2 1 Figure 4 2 Item Symbol Description 0 1 Gas nozzle 2 Torch neck 45 3 Operating elements 4 Grip plate 5 Torch trigger...

Page 14: ...or up down function changeover switch may look different on your machine Use the operating instructions for your power source to operate the switch 4 3 2 Operating elements for up down welding torch...

Page 15: ...number A button Up Down mode Increase welding performance welding current wire feed speed 2 A button Program mode Decrease program number A button Up Down mode Reduce welding performance welding curr...

Page 16: ...4 6 Item Symbol Description 0 1 Three figure display Display of welding parameters see 4 3 5 chapter 2 A button Program mode Increase program number A button Up Down mode Increase welding performance...

Page 17: ...tches to the setpoint value for the welding current or wire speed In up down mode the corresponding parameter value is shown on the display for parameter changes If this parameter is not changed for a...

Page 18: ...r 2 B button program mode Increase JOB number B button up down mode Welding voltage correction increase value 3 A button Program mode Increase program number A button Up Down mode Increase welding per...

Page 19: ...mode the corresponding parameter value is shown on the display for parameter changes If this parameter is not changed for approx 5 seconds the display switches back to the values specified by the mach...

Page 20: ...2 Figure 4 10 Item Symbol Description 0 1 Anti kink spring 2 Euro central connection 3 Control cable plug With function torches only 4 3 9 Multimatrix Euro torch connector 1 2 Figure 4 11 Item Symbol...

Page 21: ...Description 0 1 Gas nozzle 2 Extraction unit 3 Slider extraction capacity 4 Torch trigger 5 Grip plate 6 Extraction hose 4 4 1 Fume extraction torch Euro torch connector 2 1 3 Figure 4 13 Item Symbol...

Page 22: ...4 0 1 2 2 0 x 4 0 1 6 2 3 x 4 7 EWM CuCrZr Steel liner insulated Euro torch connector V groove capillary tube knurled V groove knurled V groove Euro torch connector Euro torch connector Euro torch co...

Page 23: ...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 c...

Page 24: ...an be found in the operating instructions for the relevant accessory components Accessory components are detected automatically after the power source is switched on Protective dust caps protect the c...

Page 25: ...2 Changing the torch neck 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 wit...

Page 26: ...orch neck 1 2 3 6 5 alt old 1 2 3 4 neu new 1 2 3 5 4 1 2 3 5 7 4 Figure 5 2 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...

Page 27: ...and remove the central plug on the welding torch Cleanly remove the burr from the separated end of the plastic core 5 3 2 Preparation work on the central connector to connect welding torches with spir...

Page 28: ...nstalled at the torch side 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...

Page 29: ...on Assemble the wire guide 099 500050 EW501 04 08 2016 29 3 alt old 8 10 4 Figure 5 6 4 Adjust steel liner see 4 5 chapter neu new 11 10 12 Figure 5 7 5 neu new 9 11 11 10 4 100 120 mm Figure 5 8 6 1...

Page 30: ...10 8 9 11 13 Figure 5 11 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 Connectin...

Page 31: ...2016 31 5 4 2 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 gui...

Page 32: ...Design and function Assemble the wire guide 32 099 500050 EW501 04 08 2016 3 neu new 9 6 Figure 5 15 4 neu new 8 6 9 5 Figure 5 16 5 9 3 3 9 Figure 5 17...

Page 33: ...2 3 4 Figure 5 18 7 10 Figure 5 19 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...

Page 34: ...connections and wearing parts are hand tight and tighten if necessary Remove any spatter 6 1 2 Monthly maintenance tasks Check and clean the welding torch Deposits in the torch can cause short circui...

Page 35: ...or this purpose According to German law law governing the distribution taking back and environmentally correct disposal of electric and electronic equipment ElektroG from 16 03 2005 used machines are...

Page 36: ...nd 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 ar...

Page 37: ...d 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 rep...

Page 38: ...he display and push buttons at the welding torch Pressing the push buttons will select the separate LEDs on the display one after the other At the same time individual bars will flash and skip once th...

Page 39: ...uty cycle 35 60 35 60 35 Maximum welding current M21 250 A 220 A 330 A 300 A 400 A Maximum welding current pulse M21 170 A 150 A 220 A 200 A 260 A Maximum welding current CO2 300 A 250 A 380 A 330 A 4...

Page 40: ...CRZR 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...

Page 41: ...000 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 Cont...

Page 42: ...35MM 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 01353...

Page 43: ...2 1 094 019616 00000 CT M9 x 100 mm 1 0 mm CuCrZr Contact tip narrow gap welding 2 1 094 019617 00000 CT M9 x 100 mm 1 2 mm CuCrZr Contact tip narrow gap welding 2 1 094 019618 00000 CT M9 x 100 mm 1...

Page 44: ...31 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...

Page 45: ...00000 CTAL E CU M8X30MM D 2 0MM Contact tip aluminium welding 2 1 094 019616 00000 CT M9 x 100 mm 1 0 mm CuCrZr Contact tip narrow gap welding 2 1 094 019617 00000 CT M9 x 100 mm 1 2 mm CuCrZr Contac...

Page 46: ...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 ti...

Page 47: ...Circuit diagrams MT U D 099 500050 EW501 04 08 2016 47 10 Circuit diagrams The circuit diagrams are only intended for authorised service personnel 10 1 MT U D Figure 10 1...

Page 48: ...ek hlt watercooled gasgek hlt gascooled BRT Brenneranschluss Draufsicht torch connector top view Brenner Draufsicht torch top view Datum gezeichnet gepr ft von 07 05 2014 NIEDENTHAL nderung nderung nd...

Page 49: ...Circuit diagrams MT 2U D 099 500050 EW501 04 08 2016 49 10 3 MT 2U D Figure 10 3...

Page 50: ...watercooled gasgek hlt gascooled BRT Brenneranschluss Draufsicht torch connector top view 2 U D X Brenner Draufsicht torch top view Datum gezeichnet gepr ft von 07 05 2014 NIEDENTHAL nderung nderung...

Page 51: ...Circuit diagrams MT PC1 099 500050 EW501 04 08 2016 51 10 5 MT PC1 Figure 10 5...

Page 52: ...gek hlt watercooled gasgek hlt gascooled BRT Brenneranschluss Draufsicht torch connector top view Brenner Draufsicht torch top view Datum gezeichnet gepr ft von 07 05 2014 NIEDENTHAL nderung nderung n...

Page 53: ...Circuit diagrams MT PC2 099 500050 EW501 04 08 2016 53 10 7 MT PC2 Figure 10 7...

Page 54: ...gek hlt watercooled gasgek hlt gascooled BRT Brenneranschluss Draufsicht torch connector top view Brenner Draufsicht torch top view Datum gezeichnet gepr ft von 07 05 2014 NIEDENTHAL nderung nderung n...

Page 55: ...Appendix A Overview of EWM branches 099 500050 EW501 04 08 2016 55 11 Appendix A 11 1 Overview of EWM branches...

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