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EWM MTR500W PP, Operating Instructions Manual, Page: 10 / 56

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EWM MTR500W PP Operating Instructions Manual Download Page 10

Intended use 

General 

 

 

10 

099-500073-EW501 

25.06.2015

 

 

3 

Intended use 

3.1 

General

 

A MIG/MAG welding torch ready for operation consists of: hose package, handle and torch neck, 
including all necessary accessories and wearing parts. 

All elements together form a functional unit which, supplied with the relevant operating materials, 
generates an arc for welding. For welding, a wire electrode is fed through the hose package and the 
welding torch. The arc and molten pool are shielded using inert gas (MIG) or active gas (MAG).  

The wire electrode is a melting solid or cored wire which is fed through the 

contact tip

. The 

contact tip

 

transfers the welding current to the wire electrode. The arc is formed between the wire electrode and 
workpiece. 

 

 

   WARNING

 

 

 

 

Hazards due to improper usage! 
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 proper usage and by trained or expert staff! 
•  Do not modify or convert the equipment improperly! 

 

 

 

3.2 

Applications 

3.2.1 

MIG/MAG standard welding 

Metal arc welding using a wire electrode whereby gas from an external source surrounds the arc and the 
molten pool to protect them from the atmosphere. 

3.2.2 

MIG/MAG pulse welding 

Welding process for optimum welding results when joining stainless steel and aluminium thanks to 
controlled drop transfer and targeted, adapted heat input. 

3.2.3 

MIG/MAG cored wire welding 

Welding with cored wire electrodes consisting of a metal casing and a powder core. 

As with MIG/MAG standard welding, the arc is protected from the atmosphere by shielding gas. The gas 
is supplied either externally (gas shielded cored wires) or produced in the arc by means of the powder 
core (self-shielding cored wires). 

 

 

Summary of Contents for MTR500W PP

Page 1: ...ns MIG MAG welding torch MTR500W MTR500W PP 099 500073 EW501 Observe additional system documents 25 06 2015 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group com ...

Page 2: ... 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 re...

Page 3: ...14 4 3 2 Euro central connection EC S 15 5 Design and function 16 5 1 General 16 5 2 Welding torch 18 5 3 Configure welding torch 20 5 3 1 Changing the torch neck 21 5 4 Assemble the wire guide 23 5 4 1 Plastic liner 23 5 4 2 Guide spiral 26 5 5 Assemble the wire guide EC S 30 5 5 1 Plastic liner 30 5 5 2 Guide spiral 32 5 5 2 1 Changing the wire feed rollers 36 5 5 3 Wire Inching 38 5 5 4 Replace...

Page 4: ...e operating instructions 4 099 500073 EW501 25 06 2015 9 Replaceable parts 51 9 1 General 51 9 2 Wire feed rollers 53 10 Accessories 54 11 Circuit diagram 55 11 1 MTR500W MTR500W PP 55 12 Appendix A 56 12 1 Overview of EWM branches 56 ...

Page 5: ...he 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 CAUTION Working and operating procedures which must be followed p...

Page 6: ...erve Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exit the menu 4 s Time display example wait 4s press Interruption in the menu display other setting options possible Tool not required do not use Tool required use ...

Page 7: ... of pacemakers may be affected obtain advice from a doctor if necessary Validity of this document This document describes an accessory and is only valid in combination with the operating instructions for the power source being used welding machine Read the operating instructions in particular the safety instructions for the power source welding machine WARNING Risk of accidents if these safety ins...

Page 8: ...ng area must wear suitable ear protection CAUTION 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 EWG on the minimum regulations for safety and health protection when staff members use equi...

Page 9: ...ery 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 6 Ambient conditions CAUTION Eq...

Page 10: ...als 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 proper usage and by trained or expert staff Do not modify or convert the equipment improperly 3 2 Applications 3 2 1 MIG MAG standard welding Metal arc welding using a wire electrode whereby gas from an external source sur...

Page 11: ...oid in the event of unauthorised modifications improperly conducted repairs non observance of the deadlines for the repetition test and or non permitted conversion work not specifically authorised by the manufacturer The original copy of the declaration of conformity is enclosed with the unit 3 3 3 Service documents spare parts DANGER Do not carry out any unauthorised repairs or modifications To a...

Page 12: ... 25 06 2015 4 Machine description quick overview The welding torch shown is an example only Depending on the type used torches may vary 4 1 MTR500W Figure 4 1 Item Symbol Description 0 1 Gas nozzle 2 Torch neck 45 3 Changeable body MTR500W 4 Sealing lips 5 Adapter ...

Page 13: ...description quick overview MTR500W PP 099 500073 EW501 25 06 2015 13 4 2 MTR500W PP Figure 4 2 Item Symbol Description 0 1 Gas nozzle 2 Torch neck 45 3 Changeable body MTR500W PP 4 Sealing lips 5 Cap 6 Adapter ...

Page 14: ...4 3 Welding torch connection 4 3 1 Euro central connection Figure 4 3 Item Symbol Description 0 1 Euro central connection Welding current and shielding included 2 Quick connect coupling blue coolant supply 3 Control lead cable plug 4 Quick connect coupling red coolant return 5 Air blast hose ...

Page 15: ...5 15 4 3 2 Euro central connection EC S Figure 4 4 Item Symbol Description 0 1 Welding torch central connector EC S Integrated welding current and shielding 2 Quick connect coupling blue coolant supply 3 Control lead cable plug 4 Quick connect coupling red coolant return 5 Air blast hose ...

Page 16: ...ection If the welding current connections are not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by turning in clockwise direction if necessary Risk 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 ...

Page 17: ...switched off Comprehensive descriptions can be found in the operating instructions for the relevant accessory components Accessory components are detected automatically after the power source is switched on Using protective dust caps Protective dust caps protect the connection sockets and therefore the machine against dirt and damage The protective dust cap must be fitted if there is no accessory ...

Page 18: ...steel liner with a capillary tube Depending on the wire electrode diameter or type either a steel liner or liner with the correct inner diameter must be inserted in the torch Recommendation Use a steel liner when welding hard unalloyed wire electrodes steel Use a chrome nickel liner when welding hard high alloy wire electrodes CrNi Use a liner to weld or braze soft wire electrodes high alloy wire ...

Page 19: ... the central plug for the welding torch into the Euro torch connector and screw together with crown nut Lock the connecting nipples on the cooling water tubes into place in the appropriate rapid action closure couplings Connect the red return line to red rapid action closure coupling coolant return and the blue supply line to the blue rapid action closure coupling coolant supply Insert the torch c...

Page 20: ... from the welding torch While removing replacement parts make sure the coolant sleeve doesn t become loose If the coolant circuit is opened keep the welding torch level to prevent coolant from escaping When replacing the torch neck make sure the torch level is above the cooling unit level Flush the welding torch with gas following any maintenance works Figure 5 2 Item Symbol Description 0 1 Gas no...

Page 21: ...015 21 5 3 1 Changing the torch neck Welding torches can be fitted with a 45 and 22 angled torch neck as an option To replace the torch neck follow these instructions Figure 5 3 Figure 5 4 Item Symbol Description 0 1 Changeable body MTR500W 2 Changeable body MTR500W PP ...

Page 22: ... 2 Tension arm 3 Clamp clip 4 Changeable body MTR500W PP 5 Sealing lips Insert the tension arm through the sealing lips of the clamp clip into the bore Move the tension arm forwards in the direction of the torch neck past the pressure point to the stop and take out the torch neck Insert the torch neck into the changeable body up to the stop Push the tension arm toward the rear up to the stop and t...

Page 23: ...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 5 4 1 Plastic li...

Page 24: ...Design and function Assemble the wire guide 24 099 500073 EW501 25 06 2015 Figure 5 8 Figure 5 9 Figure 5 10 Figure 5 11 ...

Page 25: ...d shielding included 4 New liner 5 Torch neck spiral 6 O ring 7 Collet 8 Guiding tube for welding torch Euro torch connector Cut off the Teflon core using a sharp knife 5mm after the end of the guide tube 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 ...

Page 26: ...Design and function Assemble the wire guide 26 099 500073 EW501 25 06 2015 5 4 2 Guide spiral Figure 5 12 Figure 5 13 Figure 5 14 ...

Page 27: ...Design and function Assemble the wire guide 099 500073 EW501 25 06 2015 27 Figure 5 15 Figure 5 16 Figure 5 17 ...

Page 28: ...Design and function Assemble the wire guide 28 099 500073 EW501 25 06 2015 Figure 5 18 Figure 5 19 Figure 5 20 Figure 5 21 ...

Page 29: ...own nut welding torch central connection euro 5 old spiral guide 6 Euro central connection Welding current and shielding included 7 Holding nipple 8 new spiral guide 9 Capillary tube Insert the grinded end towards the contact tip holder to ensure tight fit with the contact tip Re assemble the torch head in the reverse order in which it was disassembled ...

Page 30: ... 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 5 5 1 Plastic line...

Page 31: ...ding current and shielding included 4 New liner 5 Torch neck spiral 6 Wire feed tube 7 Intake nipple Cut off the Teflon core using a sharp knife 5mm after the end of the guide tube 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 ...

Page 32: ...Design and function Assemble the wire guide EC S 32 099 500073 EW501 25 06 2015 5 5 2 Guide spiral Figure 5 27 Figure 5 28 Figure 5 29 ...

Page 33: ...Design and function Assemble the wire guide EC S 099 500073 EW501 25 06 2015 33 Figure 5 30 Figure 5 31 Figure 5 32 ...

Page 34: ...Design and function Assemble the wire guide EC S 34 099 500073 EW501 25 06 2015 Figure 5 33 Figure 5 34 Figure 5 35 Figure 5 36 ...

Page 35: ...rch neck 4 Crown nut 5 old spiral guide 6 Euro central connection Welding current and shielding included 7 Wire feed tube 8 Holding nipple 9 new spiral guide 10 Capillary tube Insert the grinded end towards the contact tip holder to ensure tight fit with the contact tip Re assemble the torch head in the reverse order in which it was disassembled ...

Page 36: ...the drive roll to the wire diameter and material Figure 5 37 Item Symbol Description 0 1 Cap 2 Pressure roller 3 Flat spring 4 Carrier pin For fixing the drive roller 5 Drive roller 6 Plain washer 7 Hexagon nut Remove cap Reverse inch the wire electrode Relieve the leaf spring tension and swing out the pressure roller Loosen the hexagonal socket screws Remove hexagonal nut and plain washer Remove ...

Page 37: ...de EC S 099 500073 EW501 25 06 2015 37 Drive roll Meaning Steel Ø 0 8 mm Steel Ø 0 9 mm Steel Ø 1 0 mm Steel Ø 1 2 mm Steel Ø 1 4 mm Steel Ø 1 6 mm Aluminium Ø 0 8 mm Aluminium Ø 0 9 mm Aluminium Ø 1 0 mm Aluminium Ø 1 2 mm Aluminium Ø 1 6 mm ...

Page 38: ...pool 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 operation Risk of injury due to welding wire escaping from the welding torch The welding wire can escape from the welding torch at high speed and cause bodily injury including injuries to the face and ...

Page 39: ...ng key button The pressure force of the pressure roller has been factory pre set Do not change the contact pressure by bending leaf spring but only via the fine adjustment if required Remove cap Insert the wire in the wire feed unit as specified by the manufacturer Relieve the leaf spring tension and swing out the pressure roller Press button wire inching Assemble by following these steps in the r...

Page 40: ...Design and function Assemble the wire guide EC S 40 099 500073 EW501 25 06 2015 5 5 4 Replace inlet guide bush wire guide bush Figure 5 39 ...

Page 41: ... 5 Drive roller 6 Plain washer 7 Hexagon nut 8 Pressure roller Remove cap Reverse inch the wire electrode Relieve the leaf spring tension and swing out the pressure roller Loosen the hexagonal socket screws Remove hexagonal nut and plain washer Remove drive roll Unfasten and remove wire guide bush Install the new replacement parts Assemble by following these steps in the reverse order ...

Page 42: ...rting Euro central connection EC S to Euro central connection 42 099 500073 EW501 25 06 2015 5 6 Converting Euro central connection EC S to Euro central connection 5 6 1 Assembly Figure 5 40 Figure 5 41 Figure 5 42 Figure 5 43 ...

Page 43: ...4 Figure 5 45 Figure 5 46 Item Symbol Description 0 1 Crown nut welding torch central connection euro 2 Old liner 3 Euro central connection Welding current and shielding included 4 New liner 5 Torch neck spiral 6 Wire feed tube 7 Collet 8 Guiding tube for welding torch Euro torch connector 9 Crown nut 10 Intake nipple 11 O ring ...

Page 44: ... Symbol Description 0 1 Cylinder head screw M3 x 10 mm 2 Changeable body MTR500W 3 Shoulder bolt M8 x 30 mm 4 Robot 5 CAT torch holder 6 Hexagon nut M6 7 Plain washer M6 8 Plain washer M8 9 Hexagon nut M8 10 Shoulder bolt M6 x 28 mm 11 Mounting bracket Mount the mounting bracket at the changeable body using the pan head screws M3 x 10 mm Mount the mounting bracket to the CAT torchholder ...

Page 45: ...r connections for exterior damage and replace or have repaired by specialist staff as necessary Check the wearing parts in the torch Check that all connections and wearing parts are hand tight and tighten if necessary Spray the gas nozzle with a splash protection agent 6 2 Monthly maintenance tasks Check the coolant container for sludge deposits and check the coolant for cloudiness Clean the coola...

Page 46: ...arately The symbol depicting a waste container on wheels indicates that the equipment must be collected separately This machine is to be placed for disposal or recycling in the waste separation systems provided 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 m...

Page 47: ...liminate kinks in conduit system hose packages Vent coolant circuit Loose welding current connections Tighten power connections on the torch and or on the workpiece Tighten contact tip 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 t...

Page 48: ...ng gas cylinder 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 Purge hose package with gas or rep...

Page 49: ...e minimum required you may need to vent the coolant circuit In this case the welding machine will automatically shut down the coolant pump and signal an error See 7 Rectifying faults chapter 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 1 ...

Page 50: ...d mixtures Duty cycle 100 Maximum welding current M21 500 A Maximum welding current CO2 550 A Wire diameter 0 8 1 6 mm Ambient temperature 10 C to 40 C Protection rating for the machine connections EN 60529 IP3X Tube package length 1 5 m 3 2 m 4 2 m 5 2 m Torch cooling Coolant mixture Cooling capacity min 800 W Maxmum coolant pressure 3 5 bar Flow rate of coolant 1 0 l min Gas flow 10 20 l min Coo...

Page 51: ... torches electrode holders remote controls spare parts and replacement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the machine is switched off The welding torch shown is an example only Depending on the type used torches may vary Figure 9 1 Item Symbol Description 0 1 Gas nozzle 2 Welding spatter guard 3 Contact tip 4 Cont...

Page 52: ...stant 094 013862 00000 LST RED EWM RT 3603 20m 0 8 1 2mm Steel liner 094 011627 00500 LST RED EWM RT 3605 00m 0 8 1 2mm Steel liner red 094 012655 00500 LST BLUE EWM RT 3603 20m 1 4 1 6mm Steel liner 094 010579 00500 LST BLUE EWM RT 3605 00m 1 4 1 6mm Steel liner blue 094 012640 00500 NLS RED 195mm 1 0 1 2mm 0 22DG Liner BSLred for steel 0 22 094 016521 00500 NLS 0 22 1 4 1 6MM L 195MM BSLblue lin...

Page 53: ...groove 094 010187 00500 WFR U GROOVE 1 2 Drive roll for aluminium U groove 094 010188 00500 WFR U GROOVE 1 6 Drive roll for aluminium U groove 094 016545 00500 WFR V GROOVE 0 8 Drive roll universal V groove 094 016546 00500 WFR V GROOVE 0 9 Drive roll universal V groove 094 016547 00500 WFROLL UNI V 1 0 Drive roll universal V groove 094 010194 00500 WFROLL UNI V 1 2 Drive roll universal V groove 0...

Page 54: ...1 50 EWM RT PP W hose package 094 016535 00501 TBROB RT PP W I 17 1 1 2 20 EWM RT PP W hose package 094 016535 00503 TBROB RT PP W I 17 1 1 3 20 EWM RT PP W hose package 094 016535 00505 TBROB RT PP W I 17 1 1 4 20 EWM RT PP W hose package 094 016535 00506 TBROB RT W 1 05 EWM RT W hose package 094 012720 00500 TBROB RT W 1 15 EWM RT W hose package 094 012720 00501 TBROB RT W 1 25 EWM RT W hose pac...

Page 55: ...Circuit diagram MTR500W MTR500W PP 099 500073 EW501 25 06 2015 55 11 Circuit diagram The circuit diagrams are only intended for authorised service personnel 11 1 MTR500W MTR500W PP Figure 11 1 ...

Page 56: ...Appendix A Overview of EWM branches 56 099 500073 EW501 25 06 2015 12 Appendix A 12 1 Overview of EWM branches ...

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