EWM MT301W Series Operating Instructions Manual Download Page 1

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Operating instructions

welding torch

MT301W
MT451W
MT551W
MT301W...X
MT451W...X
MT551W...X

099-500058-EW501

Observe additional system documents!

04.08.2016

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Summary of Contents for MT301W Series

Page 1: ...g torch MT301W MT451W MT551W MT301W X MT451W X MT551W X 099 500058 EW501 Observe additional system documents 04 08 2016 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group com ...

Page 2: ...found 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 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...

Page 3: ... welding torch 18 4 3 5 1 Welding data display 19 4 3 6 Euro torch connector with control cable 20 4 3 7 Euro torch connector without control cable 20 4 4 Fume extraction torch 21 4 4 1 Fume extraction torch Euro torch connector 22 4 5 Equipment recommendations 23 5 Design and function 24 5 1 General 24 5 2 Welding torch cooling system 25 5 2 1 Approved coolants overview 25 5 2 2 Maximal hose pack...

Page 4: ...Functional check PC1X PC2X 40 7 3 Vent coolant circuit 41 8 Technical data 42 8 1 MT 301 451 551 42 9 Replaceable parts 43 9 1 MT301W 43 9 2 MT451W 45 9 3 MT551W 47 9 4 MT301W F 49 9 5 MT451W F 50 10 Circuit diagrams 52 10 1 MT U D 52 10 2 MT U DX 53 10 3 MT 2U D 54 10 4 MT 2U DX 55 10 5 MT PC1 56 10 6 MT PC1X 57 10 7 MT PC2 58 10 8 MT PC2X 59 11 Appendix A 60 11 1 Overview of EWM branches 60 ...

Page 5: ...y 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 ...

Page 6: ...p 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 Signal light flashes green Exit menu Signal light lights up in red 4s Time representation e g wait 4 s activate Signal light flashes red Interruption in the menu display other setting options possib...

Page 7: ...ilable 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 them to contact any flammable materials Risk of injury due to radiation or heat Arc radiation results in injury to skin and eyes Contact with hot workpieces and sparks results in burns Use welding shiel...

Page 8: ...uctions 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 directives and laws must be observed for operation of the machine National implementation of the framework directive 89 391 EWG as well as the associated individual directives In particular directive 89 655 E...

Page 9: ...If 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 possible please use the original packaging and the original packaging material If you have any queries on packaging and protection during transport please contact your supplier 2 4 1 Ambient conditi...

Page 10: ...ww 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 Electromagnetic Compatibility Directive EMC 2014 30 EC Restriction of Hazardous Substance RoHS 2011 65 EC In case of unauthorised changes improper repairs non compliance with specified deadlines for Arc Welding ...

Page 11: ...he 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 MT301 MT451 MT551 PC1 POWERCONTROL1 welding torch The welding power welding current wire feed speed or the program number can be adjusted on the welding torch Values and changes are shown on the welding torch display MT301 MT451 MT551 PC2 POWERCONTRO...

Page 12: ...k reference Standard welding torch 12 099 500058 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 Welding torch hose package ...

Page 13: ...ference Function torch 099 500058 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 6 Welding torch hose package ...

Page 14: ...m 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 U D X 2 1 2 1 Figure 4 4 Item Symbol Description 0 1 A button Program mode Decrease program number A button Up Down mode Reduce welding performance welding current wire feed speed 2 A button Program ...

Page 15: ...m 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 current wire feed speed 3 B button program mode Increase JOB number B button up down mode Welding voltage correction increase value 4 B button program mode Decrease JOB number B button up down mode Weldi...

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

Page 17: ...itches 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 approx 5 seconds the display switches back to the values specified by the machine control A 3 2 1 Figure 4 7 Item Symbol Description 0 1 Three figure display Display of welding parameters see 4 3 4 1 ...

Page 18: ...ter 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 performance welding current wire feed speed 4 A button Program mode Decrease program number A button Up Down mode Reduce welding performance welding current wire feed speed 5 B button program mode Decr...

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 machine control V A JOB 4 3 2 1 5 Figure 4 9 Item Symbol Description 0 1 Three figure display Display of welding parameters see 4 3 5 1 chapter 2 A Welding current display signal lamp 3 Wire speed displa...

Page 20: ...3 Control cable plug With function torches only 4 Quick connect coupling blue coolant supply 5 Quick connect coupling red coolant return 4 3 7 Euro torch connector without control cable 3 4 1 2 Figure 4 11 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 coupl...

Page 21: ... Fume extraction torch 099 500058 EW501 04 08 2016 21 4 4 Fume extraction torch 4 5 6 3 2 1 Figure 4 12 Item Symbol Description 0 1 Gas nozzle 2 Extraction unit 3 Slider extraction capacity 4 Torch trigger 5 Grip plate 6 Extraction hose ...

Page 22: ...ction torch Euro torch connector 2 1 3 4 5 Figure 4 13 Item Symbol Description 0 1 Anti kink spring 2 Connection extraction unit Connect to extraction device or central extraction unit 42 5 mm 3 Euro central connection 4 Quick connect coupling blue coolant supply 5 Quick connect coupling red coolant return ...

Page 23: ...x 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 connector Euro torch connector guide tube V groove V groove V groove guide tube U groove guide tube V groove PA combi liner EWM Alu E Cu PA combi liner 30 mm EWM CuCrZr capillary tube Torch neck Euro t...

Page 24: ...can be conveyed at very high speeds and if conveyed incorrectly may escape 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 Remove the pressure rollers from the wire feeder if no welding torch is fitted Check wire guide at regular intervals Keep all casing covers or protective caps closed during oper...

Page 25: ...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 German waste code number 70104 May not be disposed of in household waste Prevent entry into sewers Absorb with liquid binding material sand gravel acid binding agents universal bindin...

Page 26: ...e power source and let the torch cool down Wear dry and undamaged protective clothing shoes with rubber soles welder s gloves made from leather without any studs or braces Figure 5 1 Item Symbol Description 0 1 Gas nozzle 2 Gas distributor 3 Contact tip 4 Contact tip holder 5 Torch neck 45 6 Crown nut 7 O ring 8 Connection block 9 Grip plate Damage to the machine due to worn O rings Worn O rings h...

Page 27: ...he 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 with hot components or voltage when turning or changing the torch neck Switch off the power source and let the torch cool down Wear dry and undamaged protective clothing shoes with rubber soles welder s gloves made f...

Page 28: ...ck 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 3 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 maintenance work use the gas test function to purge with shielding gas and vent see 7 3 chapter ...

Page 29: ... and remove the central plug on the welding torch Cleanly remove the burr from the separated end of the plastic core 5 4 2 Preparation work on the central connector to connect welding torches with spiral guides 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 c...

Page 30: ...installed 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 liner does not become misshapen Always make sure the the hose package is straight when replacing the wire guide Figure 5 4 1 1 2 3 4 Figure 5 5 2 alt old 9 8 6 7 5 Figure 5 6 ...

Page 31: ...ion Assemble the wire guide 099 500058 EW501 04 08 2016 31 3 alt old 8 10 4 Figure 5 7 4 Adjust steel liner see 4 5 chapter neu new 11 10 12 Figure 5 8 5 neu new 9 11 11 10 4 100 120 mm Figure 5 9 6 1 2 3 4 Figure 5 10 ...

Page 32: ... 11 8 9 11 13 Figure 5 12 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 ...

Page 33: ...8 2016 33 5 5 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 guide Figure 5 13 1 1 2 3 4 Figure 5 14 2 alt old 8 7 6 5 Figure 5 15 ...

Page 34: ...Design and function Assemble the wire guide 34 099 500058 EW501 04 08 2016 3 neu new 9 6 Figure 5 16 4 neu new 8 6 9 5 Figure 5 17 5 9 3 3 9 Figure 5 18 ...

Page 35: ... 2 3 4 Figure 5 19 7 10 Figure 5 20 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 old spiral guide 8 Euro central connection 9 new spiral guide 10 Capillary tube ...

Page 36: ...ary Spray the gas nozzle with a splash protection agent 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 the wire guide Ch...

Page 37: ...for 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 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 househ...

Page 38: ...necessary Eliminate kinks in conduit system hose packages Completely unroll the hose package and the torch hose package Vent coolant circuit see 7 3 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 Tighten contact tip correctly Overload Check and correct welding current sett...

Page 39: ...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 Purg...

Page 40: ...the 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 the push button is pressed again Applies for all PC1X PC2X welding torches and in combination with the drive 4X wire feeder only 1 l 0 l 0 V A JOB 3 EXIT V A JOB 2 V A JOB V A JOB V A JOB V A JOB V A J...

Page 41: ...eep as possible inside the system close to the coolant tank max max 1 2 ca 5s 3 4 7 6 5 KLICK CLICK KLICK CLICK 092 007861 00000 blau blue l 0 l 0 l 0 Figure 7 2 Complete the following steps to vent the welding torch Connect the welding torch to the cooling unit Switch on the welding machine Tao the torch trigger Venting the welding torch starts and lasts for approx 5 to 6 minutes ...

Page 42: ...urrent M21 300 A 450 A 550 A Maximum welding current pulse M21 260 A 350 A 500 A Maximum welding current CO2 350 A 500 A 650 A Switching voltage microswitch 15 V Switching current microswitch 10 mA Required cooling capacity min 800 W Torch input pressure for coolant min max 3 to 6 bar Wire types Standard round wires Wire diameter 0 8 to 1 2 mm 0 8 to 1 6 mm 0 8 to 2 0 mm Ambient temperature 10 C t...

Page 43: ...UCRZR 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 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 ...

Page 44: ...0000 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 Contact tip aluminium welding 3 094 013069 00002 CTH CUCRZR M6 L 30 5MM Contackt tip holder 3 094 013070 00002 CTH CUCRZR M6 L 33 5MM Contackt tip holder 3 094 013542 00002 CTH CUCRZR M7 L 34 5MM Contack...

Page 45: ...X35MM 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 013532 00000 CT CUCRZR M9X35MM D 1 4MM Contact tip 2 094 013533 00000 CT CUCRZR M9X35MM D 1 6MM Contact tip 2 094 013543 00000 CTAL E CU M9X35MM D 0 8MM Contact tip aluminium welding 2 094 013544 00000 CT...

Page 46: ... 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 Contact tip narrow gap welding 2 1 094 020019 00000 CT M9 x 100 mm Ø 1 4 mm CuCrZr Contact tip narrow gap welding 2 1 094 021189 00000 CT M9 x 100 mm Ø 0 8 mm CuCrZr Contact tip narrow ...

Page 47: ...531 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 2 0MM Contact tip 2 094 013543 00000 CTAL E CU M9X35MM D 0 8MM Contact tip aluminium welding 2 094 013544 00000 CTAL E CU M9X35MM D 0 9MM Contact tip aluminium welding 2 094 013545 00000 CTAL E CU M9...

Page 48: ...00 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 Contact tip narrow gap welding 2 1 094 020019 00000 CT M9 x 100 mm Ø 1 4 mm CuCrZr Contact tip narrow gap welding 2 1 094 0...

Page 49: ...552 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 tip 2 094 016101 00000 CT M6x28mm 0 8mm E CU Contact tip 2 094 016102 00000 CT M6x28mm 0 9mm E CU Contact tip 2 094 016103 00000 CT M6x28mm 1 0mm E CU Contact tip 2 094 016104 00000 CT M6x28mm 1 2mm E CU Contac...

Page 50: ...ntact tip aluminium welding 2 094 013547 00000 CTAL E CU M9X35MM 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 CUCRZR M8X30MM D 1 4MM Contact tip 2 094 014192 00000 CT CUCRZR M8X30MM D 1 6MM Contact tip 2 094 014222 00000 CT CUCRZR M8X30MM D 1 0MM Contac...

Page 51: ...arts MT451W F 099 500058 EW501 04 08 2016 51 Item Order number Type Description 4 094 013096 00003 GD MT301 451 Gas diffuser 7 094 014997 00000 RAD MT451 WF Extraction nozzle 094 016038 00001 TT SW5 SW12MM Torch key ...

Page 52: ...Circuit diagrams MT U D 52 099 500058 EW501 04 08 2016 10 Circuit diagrams The circuit diagrams are only intended for authorised service personnel 10 1 MT U D Figure 10 1 ...

Page 53: ...kühlt watercooled gasgekühlt gascooled BRT Brenneranschluss Draufsicht torch connector top view Brenner Draufsicht torch top view Datum gezeichnet geprüft von 07 05 2014 NIEDENTHAL Änderung Änderung Änderung Änderung Blatt SANDMANN 4 1 07 05 2014 Name Bez 3 Bez 1 U D X MULTIMATRIX G W Bez 2 SCHWEISSBRENNER MT SERIE Schutzvermerk ISO16016 beachten Refer to protection notice ISO16016 Artikelnummer 1...

Page 54: ...Circuit diagrams MT 2U D 54 099 500058 EW501 04 08 2016 10 3 MT 2U D Figure 10 3 ...

Page 55: ...watercooled gasgekühlt gascooled BRT Brenneranschluss Draufsicht torch connector top view 2 U D X Brenner Draufsicht torch top view Datum gezeichnet geprüft von 07 05 2014 NIEDENTHAL Änderung Änderung Änderung Änderung Blatt SANDMANN 4 2 07 05 2014 Name Bez 3 Bez 1 2U D X MULTIMATRIX G W Bez 2 SCHWEISSBRENNER MT SERIE Schutzvermerk ISO16016 beachten Refer to protection notice ISO16016 Artikelnumme...

Page 56: ...Circuit diagrams MT PC1 56 099 500058 EW501 04 08 2016 10 5 MT PC1 Figure 10 5 ...

Page 57: ...ekühlt watercooled gasgekühlt gascooled BRT Brenneranschluss Draufsicht torch connector top view Brenner Draufsicht torch top view Datum gezeichnet geprüft von 07 05 2014 NIEDENTHAL Änderung Änderung Änderung Änderung Blatt SANDMANN 4 3 07 05 2014 Name Bez 3 Bez 1 PC1 X MULTIMATRIX G W Bez 2 SCHWEISSBRENNER MT SERIE Schutzvermerk ISO16016 beachten Refer to protection notice ISO16016 Artikelnummer ...

Page 58: ...Circuit diagrams MT PC2 58 099 500058 EW501 04 08 2016 10 7 MT PC2 Figure 10 7 ...

Page 59: ...ekühlt watercooled gasgekühlt gascooled BRT Brenneranschluss Draufsicht torch connector top view Brenner Draufsicht torch top view Datum gezeichnet geprüft von 07 05 2014 NIEDENTHAL Änderung Änderung Änderung Änderung Blatt SANDMANN 4 4 07 05 2014 Name Bez 3 Bez 1 PC2 X MULTIMATRIX G W Bez 2 SCHWEISSBRENNER MT SERIE Schutzvermerk ISO16016 beachten Refer to protection notice ISO16016 Artikelnummer ...

Page 60: ...Appendix A Overview of EWM branches 60 099 500058 EW501 04 08 2016 11 Appendix A 11 1 Overview of EWM branches ...

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