EWM MTR242W Operating Instructions Manual
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EWM MTR242W Operating Instructions Manual

EWM MTR242W Operating Instructions Manual

Welding torch
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Operating instructions
welding torch
MTR242W
EN
MTR242W PP
MTR500W
MTR500W PP
099-500073-EW501
Observe additional system documents!
22.02.2023

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Summary of Contents for EWM MTR242W

  • Page 1 Operating instructions welding torch MTR242W MTR242W PP MTR500W MTR500W PP 099-500073-EW501 Observe additional system documents! 22.02.2023...
  • 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

    7 Rectifying faults ........................... 48 Checklist for rectifying faults ....................48 Vent coolant circuit ....................... 49 8 Technical data ..........................51 MTR242W, MTR242W PP, MTR500W, MTR500W PP ............51 9 Accessories ..........................52 General accessories ......................52 Torch neck ........................... 52 099-500073-EW501 22.02.2023...
  • Page 4 Contents Notes on using these operating instructions Collision protection ....................... 52 Torch hose package ......................52 9.4.1 Push/pull ....................... 52 9.4.2 General ......................... 53 Welding torch cooling system ....................53 9.5.1 Coolant - type blueCool ..................53 9.5.2 Coolant - type KF ....................53 10 Replaceable parts .........................

  • 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 poison- ous 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 in- troduction 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 compo- nents, especially the safety instructions! Figure 3-1 Item...

  • Page 14: Machine Description - Quick Overview

    Machine description – quick overview MTR242W, MTR500W Machine description – quick overview The welding torch shown is an example only. Depending on the type used, torches may vary. MTR242W, MTR500W Figure 4-1 Item Symbol Description Gas nozzle Torch neck 45°...

  • Page 15: Mtr242W Pp, Mtr500W Pp

    Machine description – quick overview MTR242W PP, MTR500W PP MTR242W PP, MTR500W PP Figure 4-2 Item Symbol Description Gas nozzle Torch neck 45° Changeable body MTR500W PP > see 5.5.1 chapter Adapter Sealing lips 099-500073-EW501 22.02.2023...

  • Page 16: 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. Air-blast hose Quick connect coupling, red (coolant return) Control lead cable plug Quick connect coupling, blue (coolant supply) 099-500073-EW501 22.02.2023...

  • Page 17: 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. Air-blast hose Quick connect coupling, red (coolant return) Control lead cable plug Quick connect coupling, blue (coolant supply) 099-500073-EW501 22.02.2023...

  • Page 18: 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 19: Scope Of Delivery

    Design and function Scope of delivery 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. Receiving inspection • Check that the delivery is complete using the delivery note! In the event of damage to the packaging •...

  • Page 20: Welding Torch Cooling System

    All information relates to the total hose package length of the complete welding system and presents ex- emplary 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: Welding Torch Connection

    Design and function Welding torch connection Welding torch connection 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 cool- ant circuit is interrupted and equipment damage can occur. •...

  • Page 22: Configure Welding Torch

    Design and function Configure welding torch Item Symbol Description Welding torch connection (Euro or EC-S) Welding current and shielding integrated. G ¼" connecting nipple Compressed air for torch nozzle cleaning Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply •...

  • Page 23: Changing The Torch Neck

    Design and function Configure welding torch Item Symbol Description Welding spatter guard Contact tip Contact tip holder Torch neck 45° O-ring Equipment kit 5.5.1 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.
  • Page 24 Design and function Configure welding torch Do not change the hand lever position during the change procedure! This will result in malfunc- tions. Figure 5-5 Item Symbol Description Tension arm Torch neck 45° Changeable body MTR500W PP Sealing lips • Insert the tension arm through the sealing lips of the clamp clip into the bore.

  • Page 25: 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 26 Design and function Configure welding torch Figure 5-8 Figure 5-9 Adjust the brass liner . Figure 5-10 099-500073-EW501 22.02.2023...
  • Page 27 Design and function Configure welding torch Figure 5-11 Figure 5-12 Figure 5-13 Figure 5-14 099-500073-EW501 22.02.2023...

  • Page 28: Guide Spiral

    Design and function Configure welding torch 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 5.5.4 Guide spiral Observe permissible torque!
  • Page 29 Design and function Configure welding torch Figure 5-16 Figure 5-17 Figure 5-18 Figure 5-19 099-500073-EW501 22.02.2023...
  • Page 30 Design and function Configure welding torch Figure 5-20 Figure 5-21 Figure 5-22 099-500073-EW501 22.02.2023...

  • Page 31: 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 > see 10 chapter. • Use a steel liner inside the torch hose package to guide hard, unalloyed wire electrodes (steel)! •...
  • Page 32 Design and function Assemble the wire guide (EC-S) Figure 5-24 Figure 5-25 Figure 5-26 099-500073-EW501 22.02.2023...

  • Page 33: Guide Spiral

    Design and function Assemble the wire guide (EC-S) Figure 5-27 Item Symbol Description Crown nut Wire feed nipple Old liner Wire feed tube Euro central connection Welding current and shielding included. New liner Torch neck spiral • 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 34 Design and function Assemble the wire guide (EC-S) Figure 5-29 Figure 5-30 Figure 5-31 Figure 5-32 099-500073-EW501 22.02.2023...
  • Page 35 Design and function Assemble the wire guide (EC-S) Figure 5-33 Figure 5-34 Figure 5-35 099-500073-EW501 22.02.2023...
  • Page 36 Design and function Assemble the wire guide (EC-S) Figure 5-36 Figure 5-37 Item Symbol Description Gas nozzle Contact tip Welding torch neck Crown nut Holding nipple old spiral guide Wire feed tube Euro central connection Welding current and shielding included. new spiral guide Capillary tube Insert the grinded end towards the contact tip holder to ensure tight fit with the contact tip.

  • Page 37: Wire Feed

    Design and function Wire feed Wire feed 5.7.1 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 38 Design and function Wire feed 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 = 0,8 mm Aluminium Ø...

  • Page 39: Wire Inching

    Design and function Wire feed 5.7.2 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 40 Design and function Wire feed Item Symbol Description Pressure roller Changeable body MTR500W > see 5.5.1 chapter Wire inching key button Flat spring Slotted screw 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 41: Replace Inlet Guide Bush/Wire Guide Bush

    Design and function Wire feed 5.7.3 Replace inlet guide bush/wire guide bush Figure 5-40 Item Symbol Description Flat spring Wire guide bush Carrier pin For fixing the drive roller Drive roller Plain washer Hexagon nut Pressure roller 099-500073-EW501 22.02.2023...

  • 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 • Remove cap • Reverse inch the wire electrode. • Relieve the leaf spring tension and swing out the pressure roller. • Loosen the hexagonal socket screws. • Remove hexagonal nut and plain washer.
  • Page 43 Design and function Converting Euro central connection (EC-S) to Euro central connection Figure 5-44 Figure 5-45 Figure 5-46 Figure 5-47 Item Symbol Description Crown nut 099-500073-EW501 22.02.2023...
  • Page 44 Design and function Converting Euro central connection (EC-S) to Euro central connection Item Symbol Description Wire feed nipple Old liner Wire feed tube Euro central connection Welding current and shielding included. New liner Torch neck spiral Crown nut, welding torch central connection (euro) O-ring Collet Guiding tube for welding torch Euro torch connector...

  • Page 45: Mounting The Welding Torch System On The Robot

    Design and function Mounting the welding torch system on the robot Mounting the welding torch system on the robot Figure 5-48 Item Symbol Description Changeable body MTR500W > see 5.5.1 chapter Cylinder head screw, M3 x 10 mm Mounting bracket Plain washer - M6 Shoulder bolt - M6 x 28 mm Hexagon nut, M8...

  • Page 46: 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 47: Monthly Maintenance Tasks

    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 48: 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 49: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit 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 50 Rectifying faults Vent coolant circuit Figure 7-2 • Position a suitable collection container for collecting the escaping coolant at the quick-connect cou- pling and switch on the machine for approx. 5s. • Lock the quick-connect coupling by pushing back the locking ring. 099-500073-EW501 22.02.2023...

  • Page 51: Technical Data

    Technical data MTR242W, MTR242W PP, MTR500W, MTR500W PP Technical data MTR242W, MTR242W PP, MTR500W, MTR500W PP Performance specifications and guarantee only in connection with original spare and replacement parts! MTR242W, MTR242W PP MTR500W, MTR500W PP Polarity of the cathode Usually positive...

  • Page 52: Accessories

    094-016038-00001 HOSE BRIDGE Tube bridge 092-007857-00000 Torch neck Type Designation Item no. 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 Collision protection...

  • Page 53: General

    Welding torch cooling system 9.4.2 General Type Designation Item no. TBROB RT W 1.05 EWM RT W hose package 094-012720-00500 TBROB RT W 1.15 EWM RT W hose package 094-012720-00501 TBROB RT W 1.25 EWM RT W hose package 094-012720-00502 TBROB RT W 1.45...

  • Page 54: 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 55 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 56: Wire Feed Rollers

    Replaceable parts Wire feed rollers 10.2 Wire feed rollers Figure 10-2 Item Symbol Description Drive roller Type Designation Item no. WFR U-GROOVE 0.8 Drive roll for aluminium (U-groove) 094-010186-00000 WFR U-GROOVE 0.9 Drive roll for aluminium (U-groove) 094-019519-00000 WFR U-GROOVE 1.0 Drive roll for aluminium (U-groove) 094-010187-00500 WFR U-GROOVE 1.2...

  • Page 57: Service Documents

    Service documents Circuit diagram Service documents 11.1 Circuit diagram The circuit diagrams are only intended for authorised service personnel! Figure 11-1 099-500073-EW501 22.02.2023...

  • Page 58: 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" 099-500073-EW501 22.02.2023...

This manual is also suitable for:

Mtr242w ppMtr500wMtr500w pp

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