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Rectifying faults

Checklist for rectifying faults

099-510050-EW501

07.03.2022

Rectifying faults

All products are subject to rigorous production checks and final checks. If, despite this, something fails to

work at any time, please check the product using the following flowchart. If none of the fault rectification

procedures described leads to the correct functioning of the product, please inform your authorised dea-

ler.

7.1 Checklist for rectifying faults

The correct machine equipment for the material and process gas in use is a fundamental

requirement for perfect operation!

Legend

Symbol

Description



Fault/Cause



Remedy

Welding torch overheated



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



High welding fume load



Check the welding smoke flow rate using an airflow meter and if necessary correct



Clean the welding torch.



If necessary, close the bypass slider on the welding torch.

Wire feed problems



Unsuitable or worn welding torch equipment





Adjust contact tip to wire diameter and -material and replace if necessary



Adjust wire guide to material in use, blow through and replace if necessary



Kinked hose packages



Extend and lay out the torch hose package



Incompatible parameter settings



Check settings and correct if necessary



Contact tip blocked



Clean and, if necessary, replace.



Setting the spool brake



Check settings and correct if necessary



Setting pressure units



Check settings and correct if necessary



Worn wire rolls



Check and replace if necessary



Wire feed motor without supply voltage (automatic cutout triggered by overloading)



Reset triggered fuse (rear of the power source) by pressing the key button



Wire guide core or spiral is dirty or worn



Clean core or spiral; replace kinked or worn cores



Arc between gas nozzle and workpiece (metal vapour on the gas nozzle)





Replace gas nozzle



Clean the gas nozzle, contact tip, contact tip holder and gas diffuser and replace if they are

worn.

Содержание 092-007951-00000

Страница 1: ...Operating instructions EN welding torch MT221 301G F2 MT221 301G F3 MT221 401G ON SRA Kit PM221 401G ON SRA Kit 099 510050 EW501 Observe additional system documents 07 03 2022...

Страница 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...

Страница 3: ...5 3 1 Ambient conditions 18 5 4 Configure welding torch 18 5 5 Equipment recommendations 20 5 6 Adapting the Euro torch connection on the device 22 5 6 1 Liner 22 5 6 2 Replace steel liner 22 5 6 3 As...

Страница 4: ...rts 41 10 1 MT221 G F2 F3 41 10 2 MT301G F2 F3 43 10 3 MT PM 221G ON SRA Kit PM MT 221G 301W 45 10 4 MT PM 301G ON SRA Kit PM MT 301G 47 10 5 MT PM 401G ON SRA Kit PM MT 401G 49 11 Service documents 5...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 9: ...n limits 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...

Страница 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...

Страница 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...

Страница 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 Conformi...

Страница 13: ...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 Item Documentation A 1...

Страница 14: ...actor The welding torch is designed to extract welding fumes and equipped with a ball joint MT201 MT301 4 2 Welding fume extractor 4 2 1 MT 221 MT 301G F2 Figure 4 1 Item Symbol Description 0 1 Bypass...

Страница 15: ...scription 0 1 Grip plate 2 Bypass slider extraction capacity 3 Extraction nozzle 4 Gas nozzle 5 Welding torch hose package 6 Connection extraction unit 63 mm Connection to the extraction unit or the c...

Страница 16: ...MT PM 221G 301G 401G with conversion kit ON SRA 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 Extr...

Страница 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...

Страница 18: ...ion Temperature range of the ambient air 10 C to 40 C 13 F to 104 F 1 Relative humidity up to 50 at 40 C 104 F up to 90 at 20 C 68 F Transport and storage Storage in a closed area temperature range of...

Страница 19: ...n and function Configure welding torch 099 510050 EW501 07 03 2022 19 Figure 5 1 Item Symbol Description 0 1 Extraction nozzle 2 Gas nozzle 3 Contact tip 4 Contact tip holder 5 Gas distributor 6 Grip...

Страница 20: ...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...

Страница 21: ...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...

Страница 22: ...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...

Страница 23: ...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...

Страница 24: ...Design and function Adapting the Euro torch connection on the device 24 099 510050 EW501 07 03 2022 3 Figure 5 6 4 Adjust the brass liner see 5 5 chapter Figure 5 7 5 Figure 5 8 6 Figure 5 9...

Страница 25: ...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...

Страница 26: ...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...

Страница 27: ...Design and function Adapting the Euro torch connection on the device 099 510050 EW501 07 03 2022 27 3 Figure 5 15 4 Figure 5 16 5 Figure 5 17...

Страница 28: ...2022 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...

Страница 29: ...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...

Страница 30: ...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...

Страница 31: ...ety precautions Follow the maintenance instructions If any of the test requirements below are not met the unit must not be put back into opera tion until it has been repaired and tested again Repair a...

Страница 32: ...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...

Страница 33: ...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...

Страница 34: ...n airflow meter and if necessary correct Clean the welding torch If necessary close the bypass slider on the welding torch Wire feed problems Unsuitable or worn welding torch equipment Adjust contact...

Страница 35: ...k shielding gas setting and replace shielding gas cylinder if necessary Shield welding site with protective screens draughts affect the welding result Use gas lens for aluminium applications and high...

Страница 36: ...59 m h 15586 gal h 77 m h 20341 gal h Flow rate Nozzle Qvn 2 47 m h 12416 gal h 59 m h 15586 gal h Low pressure Connector pc 2 3 13570 Pa 6165 Pa Wire types Standard round wires Wire diameter 0 8 1 2...

Страница 37: ...2 8 m h 11307 gal h 79 8 m h 21081 gal h Low pressure Connector pc 2 3 4000 Pa 11000 Pa Wire types Standard round wires Wire diameter 0 8 1 2 mm 0 031 0 047 inch 0 8 1 6 mm 0 031 0 063 inch Ambient te...

Страница 38: ...l h Flow rate Nozzle Qvn 2 48 m h 12680 gal h 60 m h 15850 gal h 64 m h 16907 gal h Low pressure Connector pc 2 3 7357 Pa 8365 Pa 10813 Pa Wire types Standard round wires Wire diameter 0 8 1 2 mm 0 03...

Страница 39: ...Technical data Explanation of terms 099 510050 EW501 07 03 2022 39 8 4 Explanation of terms Figure 8 1 Item Symbol Description 0 1 Qvn Flow rate nozzle 2 pc Vacuum connector 3 Qvc Flow rate connector...

Страница 40: ...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...

Страница 41: ...TR 20 58mm Gas nozzle inner 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...

Страница 42: ...m 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 aluminiu...

Страница 43: ...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...

Страница 44: ...welding 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...

Страница 45: ...01 CT CUCRZR M7X30MM D 1 0MM Contact tip 2 094 013538 00001 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 C...

Страница 46: ...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 Contact tip forced contact 2 3 094 025536 00000 CT ZWK CuCrZr M7x30 mm...

Страница 47: ...ap welding 1 4 094 022226 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 00723...

Страница 48: ...9 00000 CTAL E CU M8X30MM D 1 4MM Contact tip aluminium welding 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...

Страница 49: ...zzle 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 C...

Страница 50: ...M8X30MM D 1 6MM Contact tip aluminium 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 weldi...

Страница 51: ...Service documents Circuit diagrams 099 510050 EW501 07 03 2022 51 11 Service documents 11 1 Circuit diagrams The circuit diagrams are only intended for authorised service personnel Figure 11 1...

Страница 52: ...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...

Страница 53: ...Appendix Searching for a dealer 099 510050 EW501 07 03 2022 53 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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