Related Manuals for EWM PP MTCG
Summary of Contents for EWM PP MTCG
- Page 1 Operating instructions welding torch PP MTCG PP MTCW 099-500108-EW501 Observe additional system documents! 09.05.2023...
- 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.
-
Page 3: Table Of Contents
Regular maintenance ................... 40 Disposing of equipment ....................... 41 7 Rectifying faults ........................... 42 Checklist for rectifying faults ....................42 Vent coolant circuit ....................... 44 8 Technical data ..........................45 PP MTCG ..........................45 PP MTCW ..........................46 099-500108-EW501 09.05.2023... - Page 4 Contents Notes on using these operating instructions 9 Accessories ..........................47 Torch neck..........................47 9.1.1 PP MT221CG ....................... 47 9.1.2 PP MT301CG ....................... 47 9.1.3 PP MT301CW ....................... 47 9.1.4 PP MT451CW ....................... 47 General ..........................47 Options ..........................47 Welding torch cooling system ....................
-
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 may lead to shortness of breath and poisoning! The ultraviolet radia- tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso- nous phosgene. • Ensure sufficient fresh air! •...
-
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.
-
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: Machine Description - Quick Overview
Machine description – quick overview Overview of components Machine description – quick overview Overview of components Figure 4-1 Item Symbol Description Gas- or water-cooled torch neck with different performance classes and bend angles Wire feed mechanism cover Gas- or water-cooled push/pull drive unit with different lengths Welding torch hose package Optional: Pistol handle 099-500108-EW501... -
Page 15: Machine Variants
Machine description – quick overview Machine variants Machine variants Version Functions Performance class Replaceable torch neck, gas-cooled MT301CG The torch can be equipped with a torch neck angled at 45°, 36°, 22° and 0°. The torch neck can be turned to the desired position. -
Page 16: Euro Central Connection
Machine description – quick overview Euro central connection Euro central connection Figure 4-3 Item Symbol Description Welding torch hose package Quick connect coupling, blue (coolant supply) Quick connect coupling, red (coolant return) Control cable plug Only for control variant 2U/D. Euro central connection Welding current, shielding gas and torch trigger included 099-500108-EW501... -
Page 17: Design And Function
Design and function General Design and function General 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 18: Scope Of Delivery
Design and function Scope of delivery Protective dust caps protect the connection sockets and therefore the machine against dirt and damage. • The protective dust cap must be fitted if there is no accessory component being operated on that connection. •... -
Page 19: Welding Torch Cooling System
Design and function Transport and installation Transport and storage Storage in a closed area, temperature range of the ambient air: • -25 °C to +55 °C (-13 F to 131 F) Relative humidity • up to 90 % at 20 °C (68 F) Ambient temperature dependent on coolant! Observe the coolant temperature range of the torch coo- ling 5.3.2... -
Page 20: Maximal Hose Package Length
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 21: Using The Torch Key
Design and function Configure welding torch Figure 5-1 Item Symbol Description Gas nozzle Contact tip Contact tip holder Gas distributor Torch neck 45° Crown nut O-ring 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. -
Page 22: Contact Tip Holder
Design and function Configure welding torch 5.4.1.2 Contact tip holder The illustration serves as an example only. Figure 5-3 • W hen assembling and disassembling the contact tip holder, use the appropriate hexagon on the torch key. 5.4.2 Turning the torch neck 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... - Page 23 Design and function Configure welding torch Figure 5-5 Item Symbol Description Gas nozzle Torch neck, 45° Crown nut Torch body O-ring Contact tip Old liner Contact tip holder Torch neck, 22° New liner Setting gauge 099-500108-EW501 09.05.2023...
-
Page 24: 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 > see 10 chapter. • Use a steel liner inside the torch hose package to guide hard, unalloyed wire electrodes (steel)! •... - Page 25 Design and function Configure welding torch Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 099-500108-EW501 09.05.2023...
- Page 26 Design and function Configure welding torch Figure 5-11 Item Symbol Description Crown nut Plastic liner Welding torch connection (Euro torch connector) Welding current, shielding gas and torch trigger integrated New plastic liner O-ring Collet Guiding tube for welding torch Euro torch connector Inlet guide bush •...
-
Page 27: Changing The Wire Feed Rollers
Design and function Configure welding torch 5.4.5.1 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 28: Inching The Wire Electrode
Design and function Configure welding torch Drive roll Pressure roller Meaning Steel Ø = 1.2 mm 5.4.5.2 Inching the wire electrode 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! •... - Page 29 Design and function Configure welding torch Figure 5-13 Item Symbol Description Wire electrode Tension arm Allen key, angled (size 3) Pressure roller setting opening Pressure roller Wire guide bush Drive roller Inlet guide bush • Extend and lay out the torch hose package. •...
-
Page 30: Replace Inlet Guide Bush/Wire Guide Bush
Design and function Configure welding torch 5.4.6 Replace inlet guide bush/wire guide bush Figure 5-14 Item Symbol Description Inlet guide bush Wire guide bush Pressure roller Liner Crown nut, torch neck Allen screw Drive roller Hold-down device Screwdriver 099-500108-EW501 09.05.2023... -
Page 31: Adapting The Euro Torch Connection On The Device
Design and function Adapting the Euro torch connection on the device • Remove cap • Loosen the hexagonal socket screws. • Remove wire feed rollers. • Loosen and remove the hold-down device. • Remove the inlet guide bush. • Separate the welding torch neck from the handle. •... -
Page 32: Machine Control - Operating Elements
Design and function Function specification 5.6.2 Machine control – Operating elements 5.6.2.1 Up/Down-torch • 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"). Figure 5-16 Item Symbol Description "A -"... -
Page 33: Powercontrol-1-Torch
Design and function Function specification 5.6.2.2 Powercontrol-1-torch • 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"). Figure 5-17 Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values >... -
Page 34: Powercontrol-2-Torch
Design and function Function specification Item Symbol Description Wire speed display signal lamp Example displays for welding parameters in the welding data display Welding parameters Display Welding current Wire speed Programs 5.6.2.3 Powercontrol-2-torch • 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"). - Page 35 Design and function Function specification Item Symbol Description "A -" button (Program mode) Decrease program number "A -" button (Up/Down mode) Reduce welding performance (welding current/wire-feed speed) "A +" button (Program mode) Increase program number "A +" button (Up/Down mode) Increase welding performance (welding current/wire-feed speed) "B +"...
- Page 36 Design and function Function specification Example displays for welding parameters in the welding data display Welding parameters Display Welding current Wire speed Voltage correction Programs JOB number 099-500108-EW501 09.05.2023...
-
Page 37: 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 38 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 •...
-
Page 39: Maintenance And Care Before Each Use
Maintenance, care and disposal General 6.1.2 Maintenance and care before each use The illustration serves as an example only. Figure 6-2 • Loosen the gas nozzle, check the replacement parts for damage, replace if necessary and ensure a tight fit. •... -
Page 40: 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 41: 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 42: 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 43 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 44: 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 45: Technical Data
Technical data PP MTCG Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! PP MTCG PP MT221CG PP MT301CG Welding torch polarity Usually positive Guide type Manually operated Voltage type Direct voltage DC Shielding gas CO2 or mixed gas M21 according to DIN EN ISO Duty cycle DC at 40°... -
Page 46: Pp Mtcw
Technical data PP MTCW PP MTCW PP MT301CW PP MT451CW Welding torch polarity Usually positive Guide type Manually operated Voltage type Direct voltage DC Shielding gas CO2 or mixed gas M21 according to DIN EN ISO Duty cycle DC at 40° C 100 % Maximum welding cur- 330 A... -
Page 47: Accessories
Accessories Torch neck Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Torch neck The following torch necks are available for push/pull welding torches: 9.1.1 PP MT221CG Type Designation Item no. TN MT221CG 0°... -
Page 48: Coolant - Type Bluecool
Accessories Welding torch cooling system 9.4.1 Coolant - type blueCool Type Designation Item no. blueCool -10 5 l Coolant up to -10 °C (14 °F), 5 l 094-024141-00005 blueCool -10 25 l Coolant up to -10 °C (14 °F), 25 l 094-024141-00025 blueCool -30 5 l Coolant up to -30 °C (22 °F), 5 l... -
Page 49: Replaceable Parts
Replaceable parts General Replaceable parts 10.1 General 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 50 Replaceable parts General Item Order number Type Designation 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 51: Ppcg 301, Ppcw 451
Replaceable parts General 10.1.2 PPCG 301, PPCW 451 Figure 10-2 Item Order number Type Designation 094-013105-00001 GN TR 22 71mm Ø 13mm Gas nozzle 094-013106-00001 GN TR 22 71mm Ø 15mm Gas nozzle 094-013107-00001 GN TR 22 71mm Ø 18mm Gas nozzle 094-019853-00001 GN NG TR22X4 71mm Ø... - Page 52 Replaceable parts General Item Order number Type Designation 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 M8 x 30mm Ø 0.8mm Contact tip 094-014191-00000 CT CuCrZr M8 x 30mm Ø 1.4mm Contact tip 094-014192-00000 CT CuCrZr M8 x 30mm Ø...
-
Page 53: 10.1.3 Wire Feed Rollers
Replaceable parts General *Only necessary for water-cooled torch series. 10.1.3 Wire feed rollers Figure 10-3 Item Order number Type Designation 094-019687-00000 ASB MTCG PP KPL Torch connection block 094-019334-00001 DFH M4 L=19MM Wire guide bush 094-019533-00000 M4X8MM S=2,5MM K=2,75MM Screw DK=7MM 094-019523-00000 SET ALU PP 0.8mm Aluminium roll set... -
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 11-1 099-500108-EW501 09.05.2023... -
Page 55: Mt Pc1
Circuit diagrams MT PC1 11.2 MT PC1 Figure 11-2 099-500108-EW501 09.05.2023... -
Page 56: Mt Pc2
Circuit diagrams MT PC2 11.3 MT PC2 Figure 11-3 099-500108-EW501 09.05.2023... -
Page 57: 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" 099-500108-EW501 09.05.2023...
Need help?
Do you have a question about the PP MTCG and is the answer not in the manual?
Questions and answers