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Rectifying faults 

Checklist for rectifying faults 

 

099-510058-EW501 

27.09.2021

 

35

 

 

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 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 

 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

 

  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 

 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. 

 

Check the control line connections for damage. 

 

 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. 

 

Содержание MT301-451W F2

Страница 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...

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: ...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...

Страница 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...

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: ...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...

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 Conform...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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