Related Manuals for EWM MT551W Series
Summary of Contents for EWM MT551W Series
- Page 1 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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Page 2: General Instructions
+49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents Contents ..............................3 Safety instructions ..........................5 Notes on the use of these operating instructions ................5 2.1.1 Explanation of icons ....................... 6 ... - Page 4 MT PC1 ............................56 10.6 MT PC1X ............................57 10.7 MT PC2 ............................58 10.8 MT PC2X ............................59 Appendix A ............................60 11.1 Overview of EWM branches......................60 099-500058-EW501 04.08.2016...
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Page 5: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 6: Explanation Of Icons
Safety instructions Notes on the use of these operating instructions 2.1.1 Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release/tap/tip user must observe. Switch off machine Release/do not activate Switch on machine Press and hold switch Wrong Turn... -
Page 7: General
Safety instructions General General WARNING Risk of injury from electrical voltage! Voltages can cause potentially fatal electric shocks and burns on contact. Even low voltages can cause a shock and lead to accidents. • Never touch live components such as welding current sockets or stick, tungsten or wire electrodes! •... - Page 8 Safety instructions General CAUTION Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •...
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Page 9: Transport
Safety instructions Transport Transport CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Scope of delivery The delivery is checked and packaged carefully before dispatch, however it is not possible to exclude the possibility of damage during transit. -
Page 10: Intended Use
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product. -
Page 11: Product Description - Quick Reference
Welding torch with X technology – MT function torch without separate control cable The extended functions for welding torches MT301W…X, MT451W…X and MT551W…X are only available if the welding torches on EWM machines are connected to the following control: M3.70-A Phoenix Expert M3.71-A Phoenix Progress M3.72-A Alpha Q Progress... -
Page 12: Standard Welding Torch
Product description – quick reference Standard welding torch Standard welding torch Figure 4-1 Item Symbol Description Gas nozzle Torch neck 45° Torch trigger Grip plate Welding torch hose package 099-500058-EW501 04.08.2016... -
Page 13: Function Torch
Product description – quick reference Function torch Function torch Figure 4-2 Item Symbol Description Gas nozzle Torch neck 45° Operating elements Grip plate Torch trigger Welding torch hose package 099-500058-EW501 04.08.2016... -
Page 14: Operating Elements
Product description – quick reference Function torch 4.3.1 Operating elements Programm Programm Up / Down Up / Down Figure 4-3 • Switch the"Program or up/down mode“ changeover switch at the welding machine to the up/down or program mode position (see chapter "Design and function"). The 'Program or up/down function' changeover switch may look different on your machine. -
Page 15: Operating Elements 2 For Up/Down Welding Torch
Product description – quick reference Function torch 4.3.3 Operating elements 2 for up/down welding torch 2U/D Figure 4-5 Item Symbol Description "A +" button (Program mode) Increase program number "A +" button (Up/Down mode) Increase welding performance (welding current/wire-feed speed) "A -"... -
Page 16: Operating Elements For Pc1 Welding Torch
Product description – quick reference Function torch 4.3.4 Operating elements for PC1 welding torch Pc 1 Figure 4-6 Item Symbol Description Three-figure display Display of welding parameters > see 4.3.4.1 chapter. "A +" button (Program mode) Increase program number "A +" button (Up/Down mode) Increase welding performance (welding current/wire-feed speed) "A -"... -
Page 17: Welding Data Display
Product description – quick reference Function torch 4.3.4.1 Welding data display The signal lamps in the lower part of the torch display indicate the welding parameters currently selected. The corresponding parameter value is shown on the three-digit display. After the welding machine is switched on, the active JOB number is shown on the display for approx. 3 seconds. -
Page 18: Operating Elements For Pc2 Welding Torch
Product description – quick reference Function torch 4.3.5 Operating elements for PC2 welding torch V Job V Job Figure 4-8 Item Symbol Description Three-figure display Display of welding parameters > see 4.3.4.1 chapter. "B +" button (program mode) Increase JOB number "B +"... -
Page 19: Welding Data Display
Product description – quick reference Function torch 4.3.5.1 Welding data display The signal lamps in the lower part of the torch display indicate the welding parameters currently selected. The corresponding parameter value is shown on the three-digit display. After the welding machine is switched on, the active JOB number is shown on the display for approx. 3 seconds. -
Page 20: Euro Torch Connector With Control Cable
Product description – quick reference Function torch 4.3.6 Euro torch connector with control cable Figure 4-10 Item Symbol Description Anti-kink spring Euro central connection Control cable plug With function torches only Quick connect coupling, blue (coolant supply) Quick connect coupling, red (coolant return) 4.3.7 Euro torch connector without control cable Figure 4-11... -
Page 21: Fume Extraction Torch
Product description – quick reference Fume extraction torch Fume extraction torch Figure 4-12 Item Symbol Description Gas nozzle Extraction unit Slider, extraction capacity Torch trigger Grip plate Extraction hose 099-500058-EW501 04.08.2016... -
Page 22: Fume Extraction Torch Euro Torch Connector
Product description – quick reference Fume extraction torch 4.4.1 Fume extraction torch Euro torch connector Figure 4-13 Item Symbol Description Anti-kink spring Connection, extraction unit Connect to extraction device or central extraction unit = 42.5 mm Euro central connection Quick connect coupling, blue (coolant supply) Quick connect coupling, red (coolant return) 099-500058-EW501 04.08.2016... -
Page 23: Equipment Recommendations
Stainless Steel PA combi liner 200 mm V groove CuCrZr connector tube 2,0 x 4,0 2,3 x 4,7 1,5 x 4,0 EWM Alu guide 1,5 x 4,0 Alumininium PA combi liner 30 mm Torch neck U groove E-Cu tube 2,0 x 4,0... -
Page 24: Design And Function
Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 25: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system Insufficient frost protection in the welding torch coolant! Depending on the ambient conditions, different liquids are used for cooling the welding torch > see 5.2.1 chapter. Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components. -
Page 26: Configure Welding Torch
Design and function Configure welding torch Configure welding torch 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. -
Page 27: Turning The Torch Neck
Design and function Configure welding torch 5.3.1 Turning the torch neck This function is only available with the "CG" and "CW" version! • Unfasten the crown nut by several turns from the handle until the torch neck can move freely. •... - Page 28 Design and function Configure welding torch Switch off the welding machine before unfastening the torch neck! alt/old neu/new Figure 5-3 Item Symbol Description Grip plate Crown nut Torch neck 45° Gas nozzle Contact tip holder Liner Contact tip Re-connect the welding torch after completing any maintenance work, use the 'gas test' function to purge with shielding gas and vent >...
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Page 29: Adjusting The Welding Machine Euro Torch Connector
• 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)! •... -
Page 30: Combined Liner
Design and function Assemble the wire guide 5.5.1 Combined liner A steel liner is installed at the connection side, whereas a combined liner is 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. - Page 31 Design and function Assemble the wire guide alt/old Figure 5-7 Adjust steel liner > see 4.5 chapter. neu/new Figure 5-8 neu/new 100 - 120 mm Figure 5-9 Figure 5-10 099-500058-EW501 04.08.2016...
- Page 32 Design and function Assemble the wire guide neu/new Figure 5-11 Figure 5-12 Item Symbol Description Gas nozzle Contact tip Contact tip holder Torch neck 45° Crown nut O-ring Collet Combined liner Euro central connection Connecting sleeve New combined liner Liner sharpener Guiding tube for welding torch Euro torch connector 099-500058-EW501 04.08.2016...
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Page 33: Guide Spiral
Design and function Assemble the wire guide 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 Figure 5-14 alt/old... - Page 34 Design and function Assemble the wire guide neu/new Figure 5-16 neu/new Figure 5-17 Figure 5-18 099-500058-EW501 04.08.2016...
- Page 35 Design and function Assemble the wire guide Figure 5-19 Figure 5-20 Item Symbol Description Gas nozzle Contact tip Contact tip holder Welding torch neck Crown nut, welding torch central connection (euro) Centring sleeve old spiral guide Euro central connection new spiral guide Capillary tube 099-500058-EW501 04.08.2016...
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Page 36: Maintenance, Care And Disposal
Maintenance, care and disposal Maintenance work, intervals Maintenance, care and disposal CAUTION Electrical current! The following work must always be carried out with the power source switched off. Disconnect the welding torch from the connected device, before maintenance. Maintenance work, intervals 6.1.1 Daily maintenance tasks •... -
Page 37: Disposing Of Equipment
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU). -
Page 38: Rectifying Faults
Rectifying faults Checklist for rectifying faults 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. - Page 39 Rectifying faults Checklist for rectifying faults 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 ...
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Page 40: Functional Check Pc1X - Pc2X
Rectifying faults Functional check PC1X – PC2X Functional check PC1X – PC2X The welding torch shown is an example only. Depending on the type used, torches may vary. Mode for checking 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. -
Page 41: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit 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)! blau / blue ca. 5s KLICK CLICK KLICK CLICK... -
Page 42: Technical Data
Technical data MT 301 / 451 / 551 Technical data MT 301 / 451 / 551 Performance specifications and guarantee only in connection with original spare and replacement parts! Type MT301W MT451W MT551W MT301WX MT451WX MT551WX Welding torch polarity Usually positive Guide type Manually operated Voltage type... -
Page 43: Replaceable Parts
Replaceable parts MT301W Replaceable parts The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •... - Page 44 Replaceable parts MT301W Item. Order number Type Designation Contact tip 094-020691-00000 CT M6 x 25 mm, 0.6 mm, E-Cu Contact tip 094-020692-00000 CT M6 x 25 mm, 0.8 mm, E-Cu Contact tip 094-020693-00000 CT M6 x 25 mm, 0.9 mm, E-Cu Contact tip 094-020694-00000 CT M6 x 25 mm, 1.0 mm, E-Cu Contact tip, aluminium welding...
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Page 45: Mt451W
Replaceable parts MT451W MT451W Figure 9-2 Item Order number Type Description 094-013105-00001 GN TR 22 71mm D=13mm Gas nozzle 094-013106-00001 GN TR 22 71mm D=15mm Gas nozzle 094-013107-00001 GN TR 22 71mm D=18mm Gas nozzle 094-019821-00001 GN TR 22 65mm D=15mm Gas nozzle, short 094-019822-00001 GN TR 22 65mm D=18mm Gas nozzle, short... - Page 46 Replaceable parts MT451W Item Order number Type Description 094-016112-00000 CT E-CU M8X30MM D=1.4MM Contact tip 094-016113-00000 CT E-CU M8X30MM D=1.6MM Contact tip 094-016115-00000 CTAL E-CU M8X30MM D=0.8MM Contact tip, aluminium welding 094-016116-00000 CTAL E-CU M8X30MM D=0.9MM Contact tip, aluminium welding 094-016117-00000 CTAL E-CU M8X30MM D=1.0MM Contact tip, aluminium welding 094-016118-00000 CTAL E-CU M8X30MM D=1.2MM...
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Page 47: Mt551W
Replaceable parts MT551W MT551W Figure 9-3 Item Order number Type Description 094-014177-00001 GN TR 23 63mm D=15mm Gas nozzle 094-014178-00001 GN TR 23 66mm D=15mm Gas nozzle 094-014179-00001 GN TR 23 63mm D=17mm Gas nozzle 094-014180-00001 GN TR 23 66mm D=17mm Gas nozzle 094-014181-00001 GN TR 23 63mm D=19mm Gas nozzle... - Page 48 Replaceable parts MT551W Item Order number Type Description 094-016112-00000 CT E-CU M8X30MM D=1.4MM Contact tip 094-016113-00000 CT E-CU M8X30MM D=1.6MM Contact tip 094-016114-00000 CT E-CU M8X30MM D=2.0MM Contact tip 094-016115-00000 CTAL E-CU M8X30MM D=0.8MM Contact tip, aluminium welding 094-016116-00000 CTAL E-CU M8X30MM D=0.9MM Contact tip, aluminium welding 094-016117-00000 CTAL E-CU M8X30MM D=1.0MM Contact tip, aluminium welding...
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Page 49: Mt301W F
Replaceable parts MT301W F MT301W F Figure 9-4 Item. Order number Type Designation Gas nozzle 094-013061-00001 GN TR 20 66mm D=13mm Gas nozzle 094-013062-00001 GN TR 20 66mm D=11mm Gas nozzle 094-013063-00001 GN TR 20 66mm D=16mm 094-013071-00000 CT M6 CuCrZr, D=0,8 mm Contact tip Contact tip 094-013072-00000... -
Page 50: Mt451W F
Replaceable parts MT451W F MT451W F Figure 9-5 Item Order number Type Description 094-013105-00001 GN TR 22 71mm D=13mm Gas nozzle 094-013106-00001 GN TR 22 71mm D=15mm Gas nozzle 094-013107-00001 GN TR 22 71mm D=18mm Gas nozzle 094-019821-00001 GN TR 22 65mm D=15mm Gas nozzle, short 094-019822-00001 GN TR 22 65mm D=18mm... - Page 51 Replaceable parts MT451W F Item Order number Type Description 094-013096-00003 GD MT301/451 Gas diffuser 094-014997-00000 RAD MT451 WF Extraction nozzle 094-016038-00001 TT SW5-SW12MM Torch key 099-500058-EW501 04.08.2016...
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Page 52: Circuit Diagrams
Circuit diagrams MT U/D Circuit diagrams The circuit diagrams are only intended for authorised service personnel! 10.1 MT U/D Figure 10-1 099-500058-EW501 04.08.2016... -
Page 53: Mt U/Dx
Circuit diagrams MT U/DX 10.2 MT U/DX Figure 10-2 099-500058-EW501 04.08.2016... -
Page 54: Mt 2U/D
Circuit diagrams MT 2U/D 10.3 MT 2U/D Figure 10-3 099-500058-EW501 04.08.2016... -
Page 55: Mt 2U/Dx
Circuit diagrams MT 2U/DX 10.4 MT 2U/DX Figure 10-4 099-500058-EW501 04.08.2016... -
Page 56: Mt Pc1
Circuit diagrams MT PC1 10.5 MT PC1 Figure 10-5 099-500058-EW501 04.08.2016... -
Page 57: Mt Pc1X
Circuit diagrams MT PC1X 10.6 MT PC1X Figure 10-6 099-500058-EW501 04.08.2016... -
Page 58: Mt Pc2
Circuit diagrams MT PC2 10.7 MT PC2 Figure 10-7 099-500058-EW501 04.08.2016... -
Page 59: Mt Pc2X
Circuit diagrams MT PC2X 10.8 MT PC2X Figure 10-8 099-500058-EW501 04.08.2016... -
Page 60: Overview Of Ewm Branches
Appendix A Overview of EWM branches Appendix A 11.1 Overview of EWM branches 099-500058-EW501 04.08.2016...
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