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Related Manuals for EWM MT221G X Series
Summary of Contents for EWM MT221G X Series
- Page 1 Operating instructions welding torch MT221G MT301G MT401G MT221G...X MT301G...X MT401G...X 099-500050-EW501 Observe additional system documents! 20.10.2022...
- 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 Accessories ..........................46 List of tools ........................... 46 General accessories ......................46 10 Replaceable parts ......................... 47 10.1 MT221G ..........................47 10.2 MT301G ..........................48 10.3 MT401G ..........................50 10.4 MT221G F ..........................52 11 Circuit diagrams ...........................
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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 Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn... -
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
3.1.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.1.2 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 Applications 3.1.4 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
Welding torch with X technology – MT function torch without separate control cable The extended functions for MT221G...X, MT301G...X, MT401G...X welding torches are only available if the welding torches on EWM machines are connected to the following control: • M3.70-A Phoenix Expert •... -
Page 15: Standard Welding Torch
Product description – quick reference Standard welding torch Standard welding torch Figure 4-1 Item Symbol Description Gas nozzle Torch neck 45° Grip plate Torch trigger 099-500050-EW501 20.10.2022... -
Page 16: 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 4.3.1 Euro torch connector without control cable Figure 4-3 Item Symbol Description Anti-kink spring Euro central connection 099-500050-EW501 20.10.2022... -
Page 17: Euro Torch Connector With Control Cable
Product description – quick reference Welding fume extractor 4.3.2 Euro torch connector with control cable Figure 4-4 Item Symbol Description Anti-kink spring Euro central connection Control cable plug Only for control variant 2U/D. Version with control cable only with control variant 2U/D. Welding fume extractor Figure 4-5 Item Symbol... -
Page 18: Euro Central Connection
Product description – quick reference Welding fume extractor 4.4.1 Euro central connection Figure 4-6 Item Symbol Description Connection, extraction unit Connect to extraction device or central extraction unit Ø = 42.5 mm Anti-kink spring Euro central connection 099-500050-EW501 20.10.2022... -
Page 19: 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 20: 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 21: Configure Welding Torch
Design and function Configure welding torch Configure welding torch WARNING Risk of burns and electric shock on the welding torch! Welding torch (torch neck or torch head) and coolant (water-cooled version) heat up strongly during the welding process. During assembly work, you may come into touch with electrical voltage or hot components. -
Page 22: Using The Torch Key
Design and function Configure welding torch 5.4.1 Using the torch key To prevent torch damage, carried out the assembly in a clockwise direction and disassembly in an anti-clockwise direction. 5.4.1.1 Contact tip The illustration serves as an example only. Figure 5-2 •... -
Page 23: Turning The Torch Neck
Design and function Configure welding torch 5.4.2 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 24 Design and function Configure welding torch Figure 5-5 Item Symbol Description Grip plate Crown nut Torch neck 45° Gas nozzle Contact tip holder Liner Contact tip Connect welding torch after performing the maintenance and rinse using the "Gas Test" with shield gas.
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Page 25: Equipment Recommendations
Design and function Equipment recommendations Equipment recommendations Figure 5-6 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 26 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 27: 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 > see 10 chapter. • Use a steel liner inside the torch hose package to guide hard, unalloyed wire electrodes (steel)! •... - Page 28 Design and function Adapting the Euro torch connection on the device Figure 5-8 Figure 5-9 Figure 5-10 Adjust the brass liner > see 5.5 chapter. Figure 5-11 099-500050-EW501 20.10.2022...
- Page 29 Design and function Adapting the Euro torch connection on the device Figure 5-12 Figure 5-13 Figure 5-14 Figure 5-15 099-500050-EW501 20.10.2022...
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Page 30: Guide Spiral
Design and function Adapting the Euro torch connection on the device 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 > see 9 chapter Guiding tube for welding torch Euro torch connector 5.6.3.2 Guide spiral... - Page 31 Design and function Adapting the Euro torch connection on the device Figure 5-17 Figure 5-18 Figure 5-19 Figure 5-20 099-500050-EW501 20.10.2022...
- Page 32 Design and function Adapting the Euro torch connection on the device Figure 5-21 Figure 5-22 099-500050-EW501 20.10.2022...
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Page 33: Operating Elements In The Machine
Design and function Adapting the Euro torch connection on the device Figure 5-23 Item Symbol Description Gas nozzle Contact tip Contact tip holder Welding torch neck Crown nut Centring sleeve old spiral guide Euro central connection new spiral guide Capillary tube 5.6.4 Operating elements in the machine This setting affects the torch types 2U/D / 2U/D X, PC1 / PC1X and PC2 / PC2X. -
Page 34: Operating Elements For The U/D / U/D X Welding Torch
Design and function Adapting the Euro torch connection on the device 5.6.5 Operating elements for the U/D / U/D X welding torch Figure 5-25 Item Symbol Description "A -" button (Program mode) Decrease program number "A -" button (Up/Down mode) Reduce welding performance (welding current/wire-feed speed) "A +"... -
Page 35: Operating Elements For The Pc1 / Pc1X Welding Torch
Design and function Adapting the Euro torch connection on the device Item Symbol Description "B +" button (program mode) Increase JOB number "B +" button (up/down mode) Welding voltage correction, increase value 5.6.7 Operating elements for the PC1 / PC1X welding torch Figure 5-27 Item Symbol Description... -
Page 36: Operating Elements For The Pc2 / Pc2X Welding Torch
Design and function Adapting the Euro torch connection on the device Example displays for welding parameters in the welding data display Welding parameters Display Welding current Wire speed Programs 5.6.8 Operating elements for the PC2 / PC2X welding torch Figure 5-29 Item Symbol Description Three-digit display... -
Page 37: Welding Data Display
Design and function Adapting the Euro torch connection on the device 5.6.8.1 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. -
Page 38: 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 39 Maintenance, care and disposal General Euro torch connector • The O-ring of the connecting nipple for shielding gas is defective or worn • The spring pins of the torch trigger are bent, jammed or dirty • The thread of the crown nut is dirty or damaged •...
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Page 40: Maintenance And Care Before Each Use
Maintenance, care and disposal General 6.1.2 Maintenance and care before each use Figure 6-2 • Loosen the gas nozzle, check the replacement parts for damage, replace if necessary and ensure a tight fit. • If necessary, clean the welding torch, remove particularly dirt and weld spatter from the replacement parts and replace worn or defective parts. -
Page 41: Regular Maintenance
Maintenance, care and disposal General 6.1.3 Regular maintenance The regular maintenance of a welding torch depends heavily on the duration of use and the stress and must be specified by the operator / owner. As a rule of thumb, every time the wire spool or wire basket is replaced or, if necessary, at a change of shift. -
Page 42: Disposing Of Equipment
Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html. -
Page 43: 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 44: Functional Check Pc1X - Pc2X
Rectifying faults Functional check PC1X – PC2X Pore formation Inadequate or missing gas shielding Check shielding gas setting and 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 replace if necessary ... -
Page 45: Technical Data
Technical data MT 221G/X, MT 301G/X, MT 401G/X Technical data MT 221G/X, MT 301G/X, MT 401G/X Performance specifications and guarantee only in connection with original spare and replacement parts! -221 G -301 G -401 G Welding torch polarity Usually positive Guide type Manually operated Voltage type... -
Page 46: Accessories
Accessories List of tools Accessories List of tools Type Designation Item no. Cutter Hose cutter 094-016585-00000 Sharpener for liner 094-010427-00000 SW5-SW12MM Torch key 094-016038-00001 O-Ring Picker O-ring picker 098-005149-00000 Zylinderbürsten Mes 15mm Cylinder brushes, brass wire 15mm 098-005208-00000 Zylinderbürsten Mes 20mm Cylinder brushes, brass wire 20mm 098-005209-00000 General accessories... -
Page 47: Replaceable Parts
Replaceable parts MT221G 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 48: Mt301G
Replaceable parts MT301G Item Order number Type Name 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 Contact tip 094-020690-00000 CT M6 x 25 mm, 1.0 mm, CuCrZr Contact tip 094-020691-00000 CT M6 x 25 mm, 0.6 mm, E-Cu Contact tip... - Page 49 Replaceable parts MT301G Item Order number Type Name 094-019822-00001 GN TR 22 65mm D=18mm Gas nozzle, short Gas nozzle Highly conical, Narrow 094-019853-00001 GN NG TR22X4 71mm D=13mm gap welding Gas nozzle, Inner shield 094-019554-00000 GN FCW TR 22x4 59.5MM 094-019626-00000 GN NG M12 73mm Gas nozzle, Narrow gap welding 094-022226-00000 GN NG M12 76mm...
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Page 50: Mt401G
Replaceable parts MT401G Item Order number Type Name 094-013109-00002 CTH CUCRZR M8 L=34.1MM Contact tip holder 094-013110-00002 CTH CUCRZR M8 L=37.1MM Contact tip holder 094-013539-00002 CTH M9 CuCrZr 34.5mm Contact tip holder Contact tip holder 094-013540-00002 CTH M9 CuCrZr 37.5mm 094-013096-00004 GD Ø11,7 mm, L=14 mm Gas diffuser 094-019625-00000 IT ES M22X1,5 M12X1... - Page 51 Replaceable parts MT401G Item Order number Type Name 094-013545-00001 CTAL E-CU M9X35MM D=1.0MM Contact tip, Aluminium welding 094-013546-00001 CTAL E-CU M9X35MM D=1.2MM Contact tip, Aluminium welding 094-013547-00001 CTAL E-CU M9X35MM D=1.4MM Contact tip, Aluminium welding Contact tip, Aluminium welding 094-013548-00001 CTAL E-CU M9X35MM D=1.6MM 094-013549-00001 CTAL E-CU M9X35MM D=2.0MM Contact tip, Aluminium welding Contact tip...
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Page 52: Mt221G F
Replaceable parts MT221G F 10.4 MT221G F Figure 10-4 Item Order number Type Designation 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 Gas nozzle 094-013071-00000 CT M6 CuCrZr, D=0,8 mm Contact tip 094-013072-00000 CT M6 CuCrZr, D=1,0 mm, L=28 mm... - Page 53 Replaceable parts MT221G F Item Order number Type Designation 098-005149-00000 O-Ring Picker O-ring picker 099-500050-EW501 20.10.2022...
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Page 54: Circuit Diagrams
Circuit diagrams MT U/D Circuit diagrams The circuit diagrams are only intended for authorised service personnel! 11.1 MT U/D Figure 11-1 099-500050-EW501 20.10.2022... -
Page 55: Mt U/Dx
Circuit diagrams MT U/DX 11.2 MT U/DX Figure 11-2 099-500050-EW501 20.10.2022... -
Page 56: Mt 2U/D
Circuit diagrams MT 2U/D 11.3 MT 2U/D Figure 11-3 099-500050-EW501 20.10.2022... -
Page 57: Mt 2U/Dx
Circuit diagrams MT 2U/DX 11.4 MT 2U/DX Figure 11-4 099-500050-EW501 20.10.2022... -
Page 58: Mt Pc1
Circuit diagrams MT PC1 11.5 MT PC1 Figure 11-5 099-500050-EW501 20.10.2022... -
Page 59: Mt Pc1X
Circuit diagrams MT PC1X 11.6 MT PC1X Figure 11-6 099-500050-EW501 20.10.2022... -
Page 60: Mt Pc2
Circuit diagrams MT PC2 11.7 MT PC2 Figure 11-7 099-500050-EW501 20.10.2022... -
Page 61: Mt Pc2X
Circuit diagrams MT PC2X 11.8 MT PC2X Figure 11-8 099-500050-EW501 20.10.2022... -
Page 62: Appendix
Appendix Searching for a dealer Appendix 12.1 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-500050-EW501 20.10.2022...
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