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Summary of Contents for EWM MT301-451W F2
- Page 1 Operating instructions welding torch MT301-451W F2 MT301-551W (ON SRA-Kit) PM301-551W (ON SRA-Kit) 099-510058-EW501 Observe additional system documents! 07.01.2021...
- Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. 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.
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Page 3: Table Of Contents
Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use .......................... - Page 4 Contents Notes on using these operating instructions 9 Replaceable parts ......................... 40 MT301W F2.......................... 40 MT451W F2.......................... 42 MT- / PM 301W (ON SRA-KIT PM/MT301W-221G) ............44 MT- / PM 451W (ON SRA-KIT PM/MT451W) ..............46 MT- / PM 551W (ON SRA-KIT PM/MT551W) ..............48 10 Service documents........................
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Page 5: For Your Safety
For your safety Notes on using these operating instructions For your safety Notes on using 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
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the u- Activate and release / Tap / Tip ser must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Correct / Valid... -
Page 7: Safety Instructions
For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 8 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
- Page 9 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
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Page 10: Transport And Installation
For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines. - Page 11 For your safety Transport and installation 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! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.
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Page 12: Intended Use
3.2.1 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 Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 13: Part Of The Complete Documentation
Intended use Documents which also apply 3.2.4 Part of the complete documentation This document is part of the complete documentation and valid only in combination with all other parts of 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. -
Page 14: Product Description - Quick Reference
Product description – quick reference Product variants Product description – quick reference Product variants Version Functions Performance class Water-cooled MT301, MT451, MT551 PM301, PM451, PM551 Welding fume extractor MT301, MT451 The welding torch is designed to extract welding fumes and equipped with a ball joint. -
Page 15: Mt- / Pm 301W, - 451W,- 551W With Conversion Kit On Sra-Kit Pm / Mt
Product description – quick reference Welding fume extractor 4.2.2 MT- / PM 301W, - 451W,- 551W with conversion kit ON SRA-Kit PM / MT Figure 4-2 Item Symbol Description Bypass slider, extraction capacity Extraction nozzle Gas nozzle Welding torch hose package Connection, extraction unit Connection to the extraction unit or central extraction - Ø... -
Page 16: Design And Function
Design and function General Design and function General WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •... -
Page 17: Transport And Installation
Design and function Transport and installation Transport and installation 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! •... -
Page 18: Permitted Torch Coolant
All information relates to the total hose package length of the complete welding system and presents exemplary configurations (of components of the EWM product portfolio with standard lengths). A straight kink-free installation is to be ensured, taking into account the max. delivery height. - Page 19 Design and function Configure welding torch Switch off the extraction system. Figure 5-1 Item Symbol Description Extraction nozzle Gas nozzle Contact tip Contact tip holder Gas distributor O-ring Grip plate Impurities in the welding result from worn O-rings! Worn O-rings lead to gas losses or the penetration of atmospheric oxygen that may adversely affect the welding result.
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Page 20: Equipment Recommendations
Design and function Equipment recommendations Equipment recommendations Figure 5-2 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-groove Aluminium (AC) CT ZWK CuCrZr U-groove Copper alloy CT CuCrZr V-groove Low-alloy V-groove CT CuCrZr... - Page 21 Design and function Equipment recommendations 1.5 x 4.0 1.5 x 4.0 Low-alloy Steel liner 2.0 x 4.0 2.4 x 4.5 1.5 x 4.0 1.5 x 4.0 medium-alloy Combined liner 200 mm 2.0 x 4.0 2.3 x 4.7 1.5 x 4.0 1.5 x 4.0 Hardfacing Combined liner...
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Page 22: Adapting The Euro Torch Connection On The Device
• 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 23: Liner
Design and function Assemble the wire guide 5.7.1 Liner Observe permissible torque > see 8 chapter! 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 24 Design and function Assemble the wire guide Figure 5-6 Adjust the brass liner > see 5.5 chapter. Figure 5-7 Figure 5-8 Figure 5-9 099-510058-EW501 07.01.2021...
- Page 25 Design and function Assemble the wire guide Figure 5-10 Figure 5-11 Item Symbol Description Extraction nozzle 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 >...
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Page 26: Guide Spiral
Design and function Assemble the wire guide 5.7.2 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 the hose package is straight when replacing the wire guide. The illustration serves as an example only. - Page 27 Design and function Assemble the wire guide Figure 5-15 Figure 5-16 Figure 5-17 099-510058-EW501 07.01.2021...
- Page 28 Design and function Assemble the wire guide Figure 5-18 Figure 5-19 Item Symbol Description Extraction nozzle Gas nozzle Contact tip Contact tip holder Torch neck 45° Crown nut, welding torch central connection (euro) Centring sleeve old spiral guide Euro central connection new spiral guide Capillary tube 099-510058-EW501...
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Page 29: Setting The Welding Smoke Flow Rate
Design and function Setting the welding smoke flow rate Setting the welding smoke flow rate • Before measuring the flow rate, it is necessary to measure the amount of shielding gas. • The quantity of shielding gas is measured at the gas nozzle of the welding torch and is set either di- rectly on the pressure regulator or, if available, on the gas control unit of the wire feeder or power source. -
Page 30: Measuring The Welding Fume Flow Rate
Design and function Setting the welding smoke flow rate 5.8.2 Measuring the welding fume flow rate • Setting values of the welding smoke flow rate > see 8 chapter. • Calculate the welding smoke flow rate as a function of the altitude > see 11.1 chapter. •... -
Page 31: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed. -
Page 32: Maintenance Work, Intervals
Maintenance, care and disposal Maintenance work, intervals Maintenance work, intervals 6.2.1 Daily maintenance tasks The illustration serves as an example only. Figure 6-1 Welding spatter protection spray must not be used on the gas nozzle of the welding fume extractor torch or other components. The aerosols clog the filters of the extraction system. •... -
Page 33: Maintenance Work
• Information about returning used equipment or about collections can be obtained from the respective municipal administration office. • In addition to this, returns are also possible throughout Europe via EWM sales partners. 099-510058-EW501 07.01.2021... -
Page 34: 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 dea- ler. - Page 35 Rectifying faults Checklist for rectifying faults 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 ...
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Page 36: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit Figure 7-1 • Switch off the machine and fill the coolant tank to the maximum level. • Unlock the quick-connect coupling 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 •... -
Page 37: Technical Data
Technical data MT301-, MT451W F2 Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! MT301-, MT451W F2 MT301 W F2 MT451 W F2 Welding torch polarity Usually positive Guide type Manually operated Voltage type Direct voltage DC Shielding gas Shielding gas according to ISO 14175... -
Page 38: Mt- / Pm 301W, - 451W,- 551W With Conversion Kit On Sra-Kit Pm / Mt
Technical data MT- / PM 301W, - 451W,- 551W with conversion kit ON SRA-Kit PM / MT MT- / PM 301W, - 451W,- 551W with conversion kit ON SRA-Kit PM / MT / PM 301 W 451 W 551 W Welding torch polarity Usually positive Guide type... -
Page 39: Explanation Of Terms
Technical data Explanation of terms Explanation of terms The illustration serves as an example only. Figure 8-1 Item Symbol Description Flow-rate nozzle ∆ Vacuum connector Flow rate connector General accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Type Designation Item no. -
Page 40: Replaceable Parts
Replaceable parts MT301W F2 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 hold- ers, remote controls, spare parts and replacement parts, etc.) from our range of products! •... - Page 41 Replaceable parts MT301W F2 Item Order number Type Name 094-016103-00000 CT M6x28mm 1.0mm E-CU Contact tip 094-016104-00000 CT M6x28mm 1.2mm E-CU Contact tip 094-016105-00000 CTAL E-CU M6X28MM D=0.8MM Contact tip, aluminium welding 094-016106-00000 CTAL E-CU M6X28MM D=0.9MM Contact tip, aluminium welding 094-016107-00000 CTAL E-CU M6X28MM D=1.0MM Contact tip, aluminium welding...
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Page 42: Mt451W F2
Replaceable parts MT451W F2 MT451W F2 Figure 9-2 Item Order number Type Name 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 43 Replaceable parts MT451W F2 Item Order number Type Name 094-013545-00000 CTAL E-CU M9X35MM D=1.0MM Contact tip, aluminium welding 094-013546-00000 CTAL E-CU M9X35MM D=1.2MM Contact tip, aluminium welding 094-013547-00000 CTAL E-CU M9X35MM D=1.4MM Contact tip, aluminium welding 094-013548-00000 CTAL E-CU M9X35MM D=1.6MM Contact tip, aluminium welding 094-014024-00000 CT CUCRZR M8X30MM D=0.8MM...
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Page 44: Mt- / Pm 301W (On Sra-Kit Pm/Mt301W-221G)
Replaceable parts MT- / PM 301W (ON SRA-KIT PM/MT301W-221G) Item Order number Type Name 098-005149-00000 O-Ring Picker O-ring for picker MT- / PM 301W (ON SRA-KIT PM/MT301W-221G) Figure 9-3 Item Order number Type Name 094-013061-00001 GN TR 20 66mm D=13mm Gas nozzle 094-013062-00001 GN TR 20 66mm D=11mm... - Page 45 Replaceable parts MT- / PM 301W (ON SRA-KIT PM/MT301W-221G) Item Order number Type Name 094-016107-00000 CTAL E-CU M6X28MM D=1.0MM Contact tip, aluminium welding 094-016108-00000 CTAL E-CU M6X28MM D=1.2MM Contact tip, aluminium welding 094-005403-00000 CT M6 x 25 mm, 0.6 mm, CuCrZr Contact tip 094-020689-00000 CT M6 x 25 mm, 0.8 mm, CuCrZr...
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Page 46: Mt- / Pm 451W (On Sra-Kit Pm/Mt451W)
Replaceable parts MT- / PM 451W (ON SRA-KIT PM/MT451W) MT- / PM 451W (ON SRA-KIT PM/MT451W) Figure 9-4 Item Order number Type Name 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... - Page 47 Replaceable parts MT- / PM 451W (ON SRA-KIT PM/MT451W) Item Order number Type Name 094-013546-00000 CTAL E-CU M9X35MM D=1.2MM Contact tip, aluminium welding 094-013547-00000 CTAL E-CU M9X35MM D=1.4MM Contact tip, aluminium welding 094-013548-00000 CTAL E-CU M9X35MM D=1.6MM Contact tip, aluminium welding 094-014024-00000 CT CUCRZR M8X30MM D=0.8MM Contact tip...
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Page 48: Mt- / Pm 551W (On Sra-Kit Pm/Mt551W)
Replaceable parts MT- / PM 551W (ON SRA-KIT PM/MT551W) MT- / PM 551W (ON SRA-KIT PM/MT551W) Figure 9-5 Item Order number Type Name 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... - Page 49 Replaceable parts MT- / PM 551W (ON SRA-KIT PM/MT551W) Item Order number Type Name 094-013549-00000 CTAL E-CU M9X35MM D=2.0MM Contact tip, aluminium welding 094-014024-00000 CT CUCRZR M8X30MM D=0.8MM Contact tip 094-014191-00000 CT CUCRZR M8X30MM D=1.4MM Contact tip 094-014192-00000 CT CUCRZR M8X30MM D=1.6MM Contact tip 094-014193-00000 CT CUCRZR M8X30MM D=2.0MM...
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Page 50: Service Documents
Service documents Circuit diagrams Service documents 10.1 Circuit diagrams The circuit diagrams are only intended for authorised service personnel! 10.1.1 MT301-, MT451W F2 Figure 10-1 099-510058-EW501 07.01.2021... -
Page 51: Appendix
Appendix Altitude alignment Appendix 11.1 Altitude alignment The higher the altitude, the less vacuum is required at the connection piece ∆pc of the welding torch to achieve the required welding fume flow rate at the welding nozzle. Determine the corresponding factor in the following table: (Z) = f x ∆... -
Page 52: Searching For A Dealer
Appendix Searching for a dealer 11.2 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-510058-EW501 07.01.2021...
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