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Rectifying faults

Checklist for rectifying faults

36

099-500050-EW501

04.08.2016

7 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
dealer.

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

Functional error with the welding torch operating elements



Connection problems





Make control lead connections and check that they are fitted correctly.



Machine immediately switches to start mode or the 7-bar display remains inactive



Check polarity of the torch trigger lead at the Euro torch connector.

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

Unstable arc



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



Incompatible parameter settings





Check settings and correct if necessary

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Содержание MT221

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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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