EWM MTR500W Operating Instructions Manual
  1. Manuals
  2. Brands
  3. EWM Manuals
  4. Welding System
  5. MTR500W PP
  6. Operating instructions manual
EWM MTR500W Operating Instructions Manual

EWM MTR500W Operating Instructions Manual

Mig/mag welding torch
Hide thumbs Also See for MTR500W:
Table of Contents

Advertisement

Quick Links

Download this manual
Operating instructions
099-500073-EW501
Register now
and benefit!
Jetzt Registrieren
und Profitieren!
www.ewm-group.com
MIG/MAG welding torch
MTR500W
MTR500W PP
Observe additional system documents!
25.06.2015
*

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the MTR500W and is the answer not in the manual?

Questions and answers

Related Manuals for EWM MTR500W

Summary of Contents for EWM MTR500W

  • Page 1 Operating instructions 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...

  • 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. No other form of liability, regardless of type, shall be accepted.

  • Page 3: Table Of Contents

    Manufacturer's declaration to the end user ..............46 Meeting the requirements of RoHS ..................... 46 7 Rectifying faults ........................... 47 Checklist for rectifying faults ......................47 Vent coolant circuit ........................49 8 Technical data ............................50 MTR500W, MTR500W PP ......................50 099-500073-EW501 25.06.2015...
  • Page 4 9 Replaceable parts ..........................51 General ............................51 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......................56 099-500073-EW501 25.06.2015...

  • 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 Explanation of icons Explanation of icons Symbol Description Special technical points which users must observe. Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER ENTER (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu)

  • Page 7: General

    Safety instructions General General DANGER Electric shock! Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents. • Do not touch any live parts in or on the machine! •...
  • Page 8 Safety instructions General WARNING Risk of injury due to radiation or heat! Arc radiation results in injury to skin and eyes. Contact with hot workpieces and sparks results in burns. • Use welding shield or welding helmet with the appropriate safety level (depending on the application)! •...

  • Page 9: Transport

    Safety instructions Transport Transport CAUTION Damage due to supply lines not being disconnected! During transport, supply lines which have not been disconnected (mains supply leads, control leads, etc.) may cause hazards such as connected equipment tipping over and injuring persons! •...

  • Page 10: Intended Use

    Intended use General Intended use 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.

  • Page 11: Documents Which Also Apply

    3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •...

  • Page 12: Machine Description - Quick Overview

    Machine description – quick overview The welding torch shown is an example only. Depending on the type used, torches may vary. MTR500W Figure 4-1 Item Symbol Description Gas nozzle Torch neck 45° Changeable body MTR500W Sealing lips Adapter 099-500073-EW501 25.06.2015...

  • Page 13: Mtr500W Pp

    Machine description – quick overview MTR500W PP MTR500W PP Figure 4-2 Item Symbol Description Gas nozzle Torch neck 45° Changeable body MTR500W PP Sealing lips Adapter 099-500073-EW501 25.06.2015...

  • Page 14: Welding Torch Connection

    Machine description – quick overview Welding torch connection Welding torch connection 4.3.1 Euro central connection Figure 4-3 Item Symbol Description Euro central connection Welding current and shielding included. Quick connect coupling, blue (coolant supply) Control lead cable plug Quick connect coupling, red (coolant return) Air-blast hose 099-500073-EW501 25.06.2015...

  • Page 15: Euro Central Connection (Ec-S)

    Machine description – quick overview Welding torch connection 4.3.2 Euro central connection (EC-S) Figure 4-4 Item Symbol Description Welding torch central connector (EC-S) Integrated welding current and shielding. Quick connect coupling, blue (coolant supply) Control lead cable plug Quick connect coupling, red (coolant return) Air-blast hose 099-500073-EW501 25.06.2015...

  • Page 16: 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 17 Design and function General CAUTION Damage due to incorrect connection! Accessory components and the power source itself can be damaged by incorrect connection! • Only insert and lock accessory components into the relevant connection socket when the machine is switched off. •...

  • Page 18: Welding Torch

    Design and function Welding torch Welding torch CAUTION Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •...
  • Page 19 Design and function Welding torch Item Symbol Description Welding torch Welding torch hose package 19-pole connection socket (analogue) Connection socket for analogue control signals (collision protection, etc.) G ¼" connecting nipple Compressed air for torch nozzle cleaning Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply...

  • Page 20: Configure Welding Torch

    Design and function Configure welding torch Configure welding torch WARNING Electric shock! When cleaning or when replacing worn parts on the welding torch, there is a risk of coming into contact with fatal levels of live current or hot components. •...

  • Page 21: 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 Changeable body MTR500W Changeable body MTR500W PP 099-500073-EW501 25.06.2015...
  • Page 22 Item Symbol Description Torch neck 45° Tension arm Clamp clip Changeable body MTR500W PP 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.

  • Page 23: Assemble The Wire Guide

    • 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 24 Design and function Assemble the wire guide Figure 5-8 Figure 5-9 Figure 5-10 Figure 5-11 099-500073-EW501 25.06.2015...
  • Page 25 Design and function Assemble the wire guide Item Symbol Description Crown nut, welding torch central connection (euro) Old liner Euro central connection Welding current and shielding included. New liner Torch neck spiral O-ring Collet Guiding tube for welding torch Euro torch connector •...

  • Page 26: Guide Spiral

    Design and function Assemble the wire guide 5.4.2 Guide spiral Figure 5-12 Figure 5-13 Figure 5-14 099-500073-EW501 25.06.2015...
  • Page 27 Design and function Assemble the wire guide Figure 5-15 Figure 5-16 Figure 5-17 099-500073-EW501 25.06.2015...
  • Page 28 Design and function Assemble the wire guide Figure 5-18 Figure 5-19 Figure 5-20 Figure 5-21 099-500073-EW501 25.06.2015...
  • Page 29 Design and function Assemble the wire guide Item Symbol Description Gas nozzle Contact tip Welding torch neck Crown nut, welding torch central connection (euro) old spiral guide Euro central connection Welding current and shielding included. Holding nipple new spiral guide Capillary tube Insert the grinded end towards the contact tip holder to ensure tight fit with the contact tip.

  • Page 30: Assemble The Wire Guide (Ec-S)

    • 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 31 Design and function Assemble the wire guide (EC-S) Figure 5-25 Figure 5-26 Item Symbol Description Crown nut Old liner Euro central connection Welding current and shielding included. New liner Torch neck spiral Wire feed tube 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.

  • Page 32: Guide Spiral

    Design and function Assemble the wire guide (EC-S) 5.5.2 Guide spiral Figure 5-27 Figure 5-28 Figure 5-29 099-500073-EW501 25.06.2015...
  • Page 33 Design and function Assemble the wire guide (EC-S) Figure 5-30 Figure 5-31 Figure 5-32 099-500073-EW501 25.06.2015...
  • Page 34 Design and function Assemble the wire guide (EC-S) Figure 5-33 Figure 5-34 Figure 5-35 Figure 5-36 099-500073-EW501 25.06.2015...
  • Page 35 Design and function Assemble the wire guide (EC-S) Item Symbol Description Gas nozzle Contact tip Welding torch neck Crown nut old spiral guide Euro central connection Welding current and shielding included. Wire feed tube Holding nipple new spiral guide Capillary tube Insert the grinded end towards the contact tip holder to ensure tight fit with the contact tip.

  • Page 36: Changing The Wire Feed Rollers

    Design and function Assemble the wire guide (EC-S) 5.5.2.1 Changing the wire feed rollers Unsatisfactory welding results due to faulty wire feeding! Wire feed rollers must be suitable for the wire diameter and the material. • Check the colour code to verify that the rollers are suitable for the wire diameter. Change if necessary.
  • Page 37 Design and function Assemble the wire guide (EC-S) 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...

  • Page 38: Wire Inching

    Design and function Assemble the wire guide (EC-S) 5.5.3 Wire Inching CAUTION 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 or moving parts or drive components! •...
  • Page 39 Design and function Assemble the wire guide (EC-S) Figure 5-38 Item Symbol Description Changeable body MTR500W Flat spring Pressure roller Slotted screw Wire inching 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.

  • Page 40: Replace Inlet Guide Bush/Wire Guide Bush

    Design and function Assemble the wire guide (EC-S) 5.5.4 Replace inlet guide bush/wire guide bush Figure 5-39 099-500073-EW501 25.06.2015...
  • Page 41 Design and function Assemble the wire guide (EC-S) Item Symbol Description Wire guide bush Flat spring Carrier pin For fixing the drive roller Drive roller Plain washer Hexagon nut Pressure roller • Remove cap • Reverse inch the wire electrode. •...

  • Page 42: Converting Euro Central Connection (Ec-S) To Euro Central Connection

    Design and function Converting Euro central connection (EC-S) to Euro central connection Converting Euro central connection (EC-S) to Euro central connection 5.6.1 Assembly Figure 5-40 Figure 5-41 Figure 5-42 Figure 5-43 099-500073-EW501 25.06.2015...
  • Page 43 Design and function Converting Euro central connection (EC-S) to Euro central connection Figure 5-44 Figure 5-45 Figure 5-46 Item Symbol Description Crown nut, welding torch central connection (euro) Old liner Euro central connection Welding current and shielding included. New liner Torch neck spiral Wire feed tube Collet...

  • Page 44: Mounting The Welding Torch System On The Robot

    5.6.2 Mounting the welding torch system on the robot Figure 5-47 Item Symbol Description Cylinder head screw, M3 x 10 mm Changeable body MTR500W Shoulder bolt, M8 x 30 mm Robot CAT torch holder Hexagon nut, M6 Plain washer, M6...

  • Page 45: Maintenance, Care And Disposal

    Maintenance, care and disposal Daily maintenance tasks 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. Daily maintenance tasks •...

  • Page 46: Maintenance Work

    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 47: 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 48 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 ...

  • Page 49: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit If there is less coolant in the coolant tank than the 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".

  • Page 50: Technical Data

    Technical data MTR500W, MTR500W PP Technical data MTR500W, MTR500W PP Performance specifications and guarantee only in connection with original spare and replacement parts! Electrodes' polarity Normally negative Guide type Machine-operated Voltage type DC direct voltage Voltage measurement 141 V (peak value)

  • Page 51: Replaceable Parts

    Replaceable parts General Replaceable parts General CAUTION Damage due to the use of non-genuine 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 52 72.5MM RGN 500W S3 K15/-1.1 Gas nozzle, bottle-shape 094-016512-00500 75.5mm SPLS 500W HD Splash protection, high-temperature-resistant 094-013862-00000 LST RED EWM RT 3603.20m Steel liner 094-011627-00500 0.8-1.2mm Steel liner, red LST RED EWM RT 3605.00m 094-012655-00500 0.8-1.2mm LST BLUE EWM RT...

  • Page 53: Wire Feed Rollers

    Replaceable parts Wire feed rollers Wire feed rollers Figure 9-2 Item Symbol Description Drive roller Type Designation Item no. WFR U-GROOVE 0.8 Drive roll for aluminium (U-groove) 094-010186-00500 WFR U-GROOVE 0.9 Drive roll for aluminium (U-groove) 094-016542-00500 WFR U-GROOVE 1.0 Drive roll for aluminium (U-groove) 094-010187-00500 WFR U-GROOVE 1.2...

  • Page 54: Accessories

    Designation Item no. STANHOL Standard holder 094-010162-00500 CAT2-XL Collision sensor 094-008501-00500 RTN 500W 22DG Torch neck EWM RT 22° 094-016505-00500 BH WH W500 22° X=239 Torch neck 094-021366-00000 Y=45 RTN 500W 45DG Torch neck EWM RT 45° 094-016507-00500 TBROB RT-PP W I=17.1:1...

  • Page 55: Circuit Diagram

    Circuit diagram MTR500W, MTR500W PP Circuit diagram The circuit diagrams are only intended for authorised service personnel! 11.1 MTR500W, MTR500W PP Figure 11-1 099-500073-EW501 25.06.2015...

  • Page 56: Overview Of Ewm Branches

    Appendix A Overview of EWM branches Appendix A 12.1 Overview of EWM branches 099-500073-EW501 25.06.2015...

Table of Contents