EWM MT301-451W F2 Operating Instructions Manual Download Page 53

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Service documents

Circuit diagrams

099-510058-EW501

27.09.2021

11 Service documents

11.1 Circuit diagrams

The circuit diagrams are only intended for authorised service personnel!

11.1.1 MT301-, MT451W F2

Figure 11-1

Summary of Contents for MT301-451W F2

Page 1: ...Operating instructions EN welding torch MT301 451W F2 MT301 451W F3 MT301 551W ON SRA Kit PM301 551W ON SRA Kit 099 510058 EW501 Observe additional system documents 27 09 2021...

Page 2: ...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...

Page 3: ...ding torch cooling system 18 5 3 2 1 Permitted torch coolant 18 5 3 2 2 Maximal hose package length 19 5 4 Configure welding torch 20 5 5 Equipment recommendations 21 5 6 Adapting the Euro torch conne...

Page 4: ...n 42 10 Replaceable parts 43 10 1 MT301W F2 F3 43 10 2 MT451W F2 F3 45 10 3 MT PM 301W ON SRA KIT PM MT301W 221G 47 10 4 MT PM 451W ON SRA KIT PM MT451W 49 10 5 MT PM 551W ON SRA KIT PM MT551W 51 11 S...

Page 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...

Page 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...

Page 7: ...cal specialist may interconnect the sources as per standard IEC 60974 9 2010 Installa tion and use and German Accident Prevention Regulation BVG D1 formerly VBG 15 or country specific regulations Befo...

Page 8: ...temperatures of 100 C or higher and arcing and work on live components Hearing protection against harming noise Explosion risk Apparently harmless substances in closed containers may generate excessi...

Page 9: ...specified in the standard The user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the user...

Page 10: ...placement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the ma chine is switched off Requirements for connection to the public...

Page 11: ...on or connection points can heat up significantly during operation water cooled version When opening the coolant circuit escaping coolant may cause scalding Open the coolant circuit only when the powe...

Page 12: ...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 Conform...

Page 13: ...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 3 1 The...

Page 14: ...act welding fumes and equipped with a ball joint MT301 MT451 4 2 Welding fume extractor 4 2 1 MT301 MT451W F2 Figure 4 1 Item Symbol Description 0 1 Bypass slider extraction capacity 2 Extraction nozz...

Page 15: ...apacity 3 Extraction nozzle 4 Gas nozzle 5 Welding torch hose package 6 Connection extraction unit 63 mm Connection to the extraction unit or the central extraction corresponding adap ters see 9 chapt...

Page 16: ...RA Kit PM MT Figure 4 3 Item Symbol Description 0 1 Bypass slider extraction capacity 2 Extraction nozzle 3 Gas nozzle 4 Welding torch hose package 5 Extraction hose 6 Connection extraction unit 7 Eur...

Page 17: ...aged by incorrect connection Only insert and lock accessory components into the relevant connection socket when the machine is switched off Comprehensive descriptions can be found in the operating ins...

Page 18: ...20 C 68 F 1 Ambient temperature dependent on coolant Observe the coolant temperature range of the torch coo ling 5 3 2 Welding torch cooling system Material damage due to unsuitable coolants Unsuitab...

Page 19: ...on is to be ensured taking into account the max delivery height Pump Pmax 3 5 bar 0 35 MPa Power source Hose package Wire feeder miniDrive Welding torch Max Compact 25 m 82 ft 5 m 16 ft 30 m 98 ft 20...

Page 20: ...hot components Wear proper protective equipment Switch off the power source or torch cooling and allow the welding torch to cool Switch off the extraction system Figure 5 1 Item Symbol Description 0 1...

Page 21: ...ed 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 g...

Page 22: ...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...

Page 23: ...making sure not to pinch it Loosen the welding torch connector and remove Cleanly trim the separated end of the liner 5 6 2 Replace steel liner Check the Euro torch connector for correct seating of th...

Page 24: ...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 misshape...

Page 25: ...Design and function Adapting the Euro torch connection on the device 099 510058 EW501 27 09 2021 25 3 Figure 5 6 4 Adjust the brass liner see 5 5 chapter Figure 5 7 5 Figure 5 8 6 Figure 5 9...

Page 26: ...e 5 11 Item Symbol Description 0 1 Extraction nozzle 2 Gas nozzle 3 Contact tip 4 Contact tip holder 5 Torch neck 45 6 Crown nut 7 O ring 8 Collet 9 Combined liner 10 Euro central connection 11 Connec...

Page 27: ...Guide spiral Observe permissible torque see 8 chapter Insert the grinded end towards the contact tip holder to ensure tight fit with the contact tip Always make sure the hose package is straight when...

Page 28: ...Design and function Adapting the Euro torch connection on the device 28 099 510058 EW501 27 09 2021 3 Figure 5 15 4 Figure 5 16 5 Figure 5 17...

Page 29: ...21 29 6 Figure 5 18 7 Figure 5 19 Item Symbol Description 0 1 Extraction nozzle 2 Gas nozzle 3 Contact tip 4 Contact tip holder 5 Torch neck 45 6 Crown nut welding torch central connection euro 7 Cent...

Page 30: ...ce Connect the welding torch to the welding machine or wire feeder Connect the welding fume extractor hose to the welding torch using an adapter see 9 chapter Connect the welding fume extractor hose t...

Page 31: ...ndicated at the centre of the O ring of the floater on the scale of the airflow meter s measuring tube Readjust the welding fume flow rate on the controller of the extraction system until the specifie...

Page 32: ...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...

Page 33: ...se package and power connections for exterior damage and replace or have repaired by specialist staff as necessary Check and clean the welding torch Deposits in the welding torch may cause short circu...

Page 34: ...e According to German law law governing the distribution taking back and environmentally correct dispo sal of electrical and electronic equipment ElektroG used machines are to be placed in a collectio...

Page 35: ...torch overheated Insufficient coolant flow Check coolant flow rate Check coolant level and refill if necessary Eliminate kinks in conduit system hose packages Vent coolant circuit see 7 2 chapter Loo...

Page 36: ...or spiral is dirty or worn Clean core or spiral replace kinked or worn cores Unstable arc Unsuitable or worn welding torch equipment Adjust contact tip to wire diameter and material and replace if nec...

Page 37: ...with a suitable tool connection open To vent the cooling system always use the blue coolant connection which is located as deep as possible inside the system close to the coolant tank Figure 7 2 Posi...

Page 38: ...gal h 88 m h 23247 gal h Flow rate Nozzle Qvn 2 50 m h 13208 gal h 61 m h 16114 gal h Low pressure Connector pc 2 3 14127 Pa 7840 Pa Flow volume min 1 2 l min 0 32 gal min 1 4 l min 0 37 gal min Cool...

Page 39: ...56 gal h 58 9 m h 15560 gal h Low pressure Connector pc 2 3 5000 Pa 6300 Pa Flow volume min 1 2 l min 0 32 gal min 1 4 l min 0 37 gal min Coolant conductance 350 S cm Wire types Standard round wires W...

Page 40: ...Nozzle Qvn 2 58 m h 15322 gal h 61 m h 16115 gal h 64 m h 16907 gal h Low pressure Connector pc 2 3 7957 Pa 8161 Pa 10685 Pa Flow volume min 1 2 l min 0 32 gal min 1 4 l min 0 37 gal min Coolant cond...

Page 41: ...ation of terms 099 510058 EW501 27 09 2021 41 8 4 Explanation of terms The illustration serves as an example only Figure 8 1 Item Symbol Description 0 1 Qvn Flow rate nozzle 2 pc Vacuum connector 3 Qv...

Page 42: ...Adapter for extraction hose with nominal diameter of 44 mm 096 001280 00000 ADAP PVCE NW 51 Adapter for extraction hose with nominal diameter of 51 mm 398 004591 00000 9 3 Option Type Designation Item...

Page 43: ...shield 1 6 094 020944 00000 GN TR 20 75 mm D 18 mm Spot welding nozzle 2 094 013071 00000 CT M6 CuCrZr D 0 8 mm Contact tip 2 094 013072 00000 CT M6 CuCrZr D 1 0 mm L 28 mm Contact tip 2 094 013122 0...

Page 44: ...7 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 1 0mm C...

Page 45: ...22226 00000 GN NG M12 76mm Gas nozzle narrow gap welding 1 5 094 019623 00000 GNC TR22x4 Gas nozzle body 1 6 094 020945 00000 GN TR 22 80 mm D 20 mm Spot welding nozzle 2 094 007238 00000 CT E CU M8X3...

Page 46: ...2 094 016120 00000 CTAL E CU M8X30MM D 1 6MM 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...

Page 47: ...Contact tip 2 094 013535 00001 CT CUCRZR M7X30MM D 0 8MM Contact tip 2 094 013536 00001 CT CUCRZR M7X30MM D 0 9MM Contact tip 2 094 013537 00001 CT CUCRZR M7X30MM D 1 0MM Contact tip 2 094 013538 000...

Page 48: ...0697 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 1 0m...

Page 49: ...12 76mm Gas nozzle narrow gap welding 1 5 094 019623 00000 GNC TR22x4 Gas nozzle body 1 6 094 020945 00000 GN TR 22 80 mm D 20 mm Spot welding nozzle 2 094 007238 00000 CT E CU M8X30MM D 1 2MM Contact...

Page 50: ...016120 00000 CTAL E CU M8X30MM D 1 6MM 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...

Page 51: ...zle 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 013528 00001 CT CU...

Page 52: ...nium 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 1 0 mm CuCrZr Contact tip narrow gap welding 2 1 094 019617 00000 CT M9 x 10...

Page 53: ...documents Circuit diagrams 099 510058 EW501 27 09 2021 53 11 Service documents 11 1 Circuit diagrams The circuit diagrams are only intended for authorised service personnel 11 1 1 MT301 MT451W F2 Figu...

Page 54: ...o achieve the required welding fume flow rate at the welding nozzle Determine the corresponding factor in the following table Pc user Z f x pc Explanation Pc user Z Required vacuum connector f Factor...

Page 55: ...Appendix Searching for a dealer 099 510058 EW501 27 09 2021 55 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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