Operating instructions
MIG/MAG welding torch
MTR500W
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MTR500W PP
099-500073-EW501
Observe additional system documents! 25.06.2015
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•
•
•
• Confirm with a signature where appropriate.
General instructions
Read the operating instructions for all system components!
Observe accident prevention regulations!
Observe all local regulations!
In the event of queries on installation, commissioning, operation or special conditions at the installation
site, or on usage, please contact yo u r sales partner or our customer service department on
+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. This exclusion of liability shall be deemed accepted by the
user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are
observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this reason,
we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation,
improper operation or incorrect usage and maintenance or any actions connected to this in any way.
© EWM AG · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, including extr acts , onl y perm itted with wr itt en appr o val.
The content of this document has been prepared and reviewed with all reasonable care. The information provided is subject
to change, errors excepted.
25.06.2015
1 Contents
Contents .................................................................................................................................................. 3
1
2 Safety instructions ................................................................................................................................. 5
2.1 Notes on the use of these operating instructi ons .......................................................................... 5
2.2 Explanation of icons ....................................................................................................................... 6
2.3 General .......................................................................................................................................... 7
2.4 Transport ........................................................................................................................................ 9
2.5 Scope of delivery ........................................................................................................................... 9
2.6 Ambient conditions ......................................................................................................................... 9
2.6.1 In operation ..................................................................................................................... 9
2.6.2 Transport and storage .................................................................................................... 9
3 Intended use ......................................................................................................................................... 10
3.1 General ........................................................................................................................................ 10
3.2 Applications .................................................................................................................................. 10
3.2.1 MIG/MAG standard welding ......................................................................................... 10
3.2.2 MIG/MAG pulse welding ............................................................................................... 10
3.2.3 MIG/MAG cored wire welding ....................................................................................... 10
3.3 Documents which also apply ....................................................................................................... 11
3.3.1 Warranty ....................................................................................................................... 11
3.3.2 Declaration of Conformity ............................................................................................. 11
3.3.3 Service documents (spare parts) ................................................................................. 11
4 Machine description – quick overview .............................................................................................. 12
4.1 MTR500W .................................................................................................................................... 12
4.2 MTR500W PP .............................................................................................................................. 13
4.3 Welding torch connection ............................................................................................................ 14
4.3.1 Euro central connection ................................................................................................ 14
4.3.2 Euro central connection (EC-S) .................................................................................... 15
5 Design and function ............................................................................................................................. 16
5.1 General ........................................................................................................................................ 16
5.2 Welding torch ............................................................................................................................... 18
5.3 Configure welding torch ............................................................................................................... 20
5.3.1 Changing the torch neck............................................................................................... 21
5.4 Assemble the wire guide .............................................................................................................. 23
5.4.1 Plastic liner ................................................................................................................... 23
5.4.2 Guide spiral .................................................................................................................. 26
5.5 Assemble the wire guide (EC-S) .................................................................................................. 30
5.5.1 Plastic liner ................................................................................................................... 30
5.5.2 Guide spiral .................................................................................................................. 32
5.5.3 Wire Inching .................................................................................................................. 38
5.5.4 Replace inlet guide bush/wire guide bush .................................................................... 40
5.6 Converting Euro central connection (EC-S) to Euro central connection ..................................... 42
5.6.1 Assembly ...................................................................................................................... 42
5.6.2 Mounting the welding torch system on the robot .......................................................... 44
6 Maintenance, care and disposal ......................................................................................................... 45
6.1 Daily maintenance tasks .............................................................................................................. 45
6.2 Monthly maintenance tasks ......................................................................................................... 45
6.3 Maintenance work ........................................................................................................................ 46
6.4 Disposing of equipment ............................................................................................................... 46
6.4.1 Manufacturer's declaration to the end user .................................................................. 46
6.5 Meeting the requirements of RoHS ............................................................................................. 46
7 Rectifying faults ................................................................................................................................... 47
7.1 Checklist for rectifying faults ........................................................................................................ 47
7.2 Vent coolant circuit ....................................................................................................................... 49
8 Technical data ...................................................................................................................................... 50
8.1 MTR500W, MTR500W PP ........................................................................................................... 50
Contents
Notes on the use of these operating instructions
5.5.2.1 Changing the wire feed rollers ...................................................................... 36
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Contents
Notes on the use of these operating instructions
25.06.2015
9 Replaceable parts ................................................................................................................................. 51
9.1 General ......................................................................................................................................... 51
9.2 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
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DANGER
Working or operating procedures which must be closely observed to prevent imminent
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
• The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
• The hazard is explained using a symbol at the edge of the page.
Notes on the use of these operating instructions
2 Safety instructions
2.1 Notes on the use of these operating ins tr uc t ions
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
and even fatal injuries.
• Safety notes include the "WARNING " k e yword in the head ing wit h a gener al warn i ng
symbol.
Safety instructions
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
Special technical points which users mu st observe.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.
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Safety instructions
Explanation of icons
25.06.2015
Symbol
Description
Special technical points which users mu st observe.
Wrong
Press and keep pressed
Switch
Switch off machine
ENTERENTER
NAVIGATION
EXIT
EXIT (Exit the menu)
4 s
2.2 Explanation of icons
Correct
Press
Do not press
Turn
Switch on machine
ENTER (enter the menu)
NAVIGATION (Navigating in the menu)
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use
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General
25.06.2015
DANGER
fatal electric shocks
• Wait for 4 minutes until the capacitors have discharged!
Electromagnetic fields!
necessary).
(welding machine)!
WARNING
• Inform persons in the working area that they must observe the regulations!
Fire hazard!
• Connect welding leads correctl y!
2.3 General
Electric shock!
Welding machines use high voltages which can result in potentially
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!
• Connection cables and leads must be free of faults!
• Switching off alone is not sufficient!
• Place welding torch and stick electrode ho lder on an i ns ulat ed surf ac e!
• The unit should only be opened by specialist staff after the mains plug has been
• Only wear dry protective clothing!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
• Observe the maintenance instructions - See 6 Maintenance, care and disposal chapter!
• Unwind welding leads completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if
Safety instructions
unplugged!
Validity of this document!
This document describes an accessory and is only valid in combination with the
operating instructions for the power so u rce being used (welding machine)!
• Read the operating instructions, in particular the safety instructions for the power source
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructio n s is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding pr o cess.
Stray welding currents can also result in flames forming!
• Check for fire hazards in the working area!
• Do not carry any easily flammable objects such as matches or lighters.
• Keep appropriate fire extinguishing equipment to hand in the working area!
• Thoroughly remove any residue of flammable substances from the workpiece before
starting welding.
• Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
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Safety instructions
General
25.06.2015
WARNING
safety curtains!
Hazards due to improper usage!
• Do not modify or convert the equipment improperly!
CAUTION
Noise exposure!
• Persons located within the working area must wear suitable ear protection!
CAUTION
• Regular checks of the machine according to IEC 60974-4.
Damage due to the use of non-genuine parts!
machine is switched off.
Commissioning is reserved for persons who have the relevant expertise of working with
arc welding machines.
Risk of injury due to radiation or he at!
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)!
• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
• Protect persons not involved in the work against arc beams and the risk of glare using
Hazards may arise for persons, animals and material objects if the equipment is not
used correctly. No liability is accepted for any damages arising from improper usage!
• The equipment must only be used in line with proper usage and by trained or expert staff!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
Obligations of the operator!
The respective national directives and laws must be observed for operation of the
machine!
• National implementation of the framework directive (89/391/EWG), as well as the
associated individual directives.
• In particular, directive (89/655/EWG), on the minimum regulations for safety and health
protection when staff members use equipment during work.
• The regulations regarding work safety and accident prevention for the respective country.
• Setting up and operating the machine according to IEC 60974-9.
• Check at regular intervals that users are working in a safety-conscious way.
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!
• Only insert and lock accessory components into the relevant connection socket when the
Trained personnel!
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CAUTION
• Disconnect supply lines!
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
• Avoid ambient air containing salt (sea air)!
2.4 Transport
Damage due to supply lines not being d isconnected!
During transport, supply lines which ha ve n o t b een disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
2.5 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
• Check the delivery for damage (visual inspection)!
In the event of complaints
If the delivery has been damaged during transport:
• Please contact the last haulier immediately!
• Keep the packaging (for possible checking by the haulier or for the return shipment).
Packaging for returns
If possible, please use the original packaging and the original packaging material. If you have any queries
on packaging and protection during transport, please contact your supplier.
Safety instructions
Transport
2.6 Ambient conditions
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
2.6.1 In operation
Temperature range of the ambient air:
• -10 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.6.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -25 °C to +55 °C
Relative air humidity
• Up to 90% at 20 °C
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Intended use
General
25.06.2015
WARNING
Hazards due to improper usage!
• Do not modify or convert the equipment improperly!
3 Intended use
3.1 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. For welding, a wire electrode is fed through the hose package and the
welding torch. The arc and molten pool are shielded using inert gas (MIG) or active gas (MAG).
The wire electrode is a melting solid or cored wire which is fed through the contact tip. The contact tip
transfers the welding current to the wire electrode. The arc is formed between the wire electrode and
3.2 Applications
3.2.1 MIG/MAG standard welding
3.2.2 MIG/MAG pulse welding
3.2.3 MIG/MAG cored wire welding
workpiece.
Hazards may arise for persons, animals and material objects if the equipment is not
used correctly. No liability is accepted for any damages arising from improper usage!
• The equipment must only be used in line with proper usage and by trained or expert staff!
Metal arc welding using a wire electrode whereby gas from an external source surrounds the arc and the
molten pool to protect them from the atmosphere.
Welding process for optimum welding results when joining stainless steel and aluminium thanks to
controlled drop transfer and targeted, adapted heat input.
Welding with cored wire electrodes consisting of a metal casing and a powder core.
As with MIG/MAG standard welding, the arc is protected from the atmosphere by shielding gas. The gas
is supplied either externally (gas shielded cored wires) or produced in the arc by means of the powder
core (self-shielding cored wires).
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The designated machine conforms to EC Directives and standards in terms of its design
and construction:
•
• EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly
conducted repairs, non
conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
DANGER
Do not carry out any unauthorised repairs o r modifications!
• Appoint only skilled persons for repair work (trained service personnel)!
3.3 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
EC Low Voltage Directive (2006/95/EC),
-observance of the deadlines for the repetition test and / or non-permitted
3.3.3 Service documents (spare parts)
To avoid injury and equipment dama g e, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
Intended use
Documents which also apply
!
Spare parts can be obtained from the relevant authorised dealer.
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Machine description
– quick overview
MTR500W
25.06.2015
Item
Symbol
Description 0
2
Sealing lips
Adapter
4 Machine description – quick overview
The welding torch shown is an example only. Depending on the type used, torches may vary .
4.1 MTR500W
Gas nozzle
1
3
4
5
Torch neck 45°
Changeable body MTR500W
Figure 4-1
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099-500073-EW501
quick overview
25.06.2015
Item
Symbol
Description 0
1
Changeable body MTR500W PP
4
Sealing lips
5
4.2 MTR500W PP
Machine description –
MTR500W PP
Gas nozzle
2
3
6
Torch neck 45°
Cap
Adapter
Figure 4-2
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Machine description
– quick overview
Welding torch connection
25.06.2015
Item
Symbol
Description 0
Control lead cable plug
4
Quick connect coupling, red (coolan t return)
5
4.3 Welding torch connecti on
4.3.1 Euro central connection
1
2
3
Euro central connection
Welding current and shielding included.
Quick connect coupling, blue (coolan t supply)
Air-blast hose
Figure 4-3
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quick overview
25.06.2015
Item
Symbol
Description 0
Welding torch central connector (EC-S)
Integrated welding current and shielding.
Quick connect coupling, blue (coolant supply)
3
4
Air-blast hose
4.3.2 Euro central connection (EC-S)
Machine description –
Welding torch connection
1
2
5
Control lead cable plug
Quick connect coupling, red (coola n t return)
Figure 4-4
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Design and function
General
25.06.2015
WARNING
Risk of injury from electric shock!
interfaces) may only be connected when the machine is switched off!
CAUTION
Insulate the arc welder from welding voltage!
Not all active parts of the welding current circuit can be shielded from direc t contact. To
• Always place torches and electrode holders on an insulated surface!
if necessary.
Risk of injury due to moving parts!
• Keep casing covers or protective caps closed during operation!
• Keep all casing covers or protective caps closed during operation!
Risk from electrical current!
surface before starting work and during breaks.
5 Design and function
5.1 General
Contact with live parts, e.g. welding current sockets, is potentially fatal!
• Follow safety instructions on the opening pages of the operating instructions.
• Commissioning ma y only be carried out by persons who hav e the relev ant ex pertise of
working with arc welding machines!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
avoid any associated risks it is vital for the welder to adhere to the relevant safety
regulations. Even low voltages can cause a shock and lead to accidents.
• Wear dry and undamaged protective clothing (shoes with rubber soles/welder's gloves
made from leather without any studs or braces)!
• Avoid direct contact with non-insulated connection sockets or connectors!
Risk of burns on the welding current connection!
If the welding current connections are not locked, connections and leads heat up an d
can cause burns, if touched!
• Check the welding current connections every day and lock by turning in clockwise direction,
The wire feeders are equipped with moving pa rts, which can trap hands, hair, clothing
or tools and thus injure persons!
• Do not reach into rotating or moving parts or drive components!
Risk of injury due to welding wire es caping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may
escape in an uncontrolled manner and i n jure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the
welding torch!
• Remove the pressure rollers from the wire feeder if no welding torch is fitted!
• Check wire guide at regular intervals!
If welding is carried out alternately using different methods and if a welding torch and
an electrode holder remain connected to the machine, the open-circuit/welding voltage
is applied simultaneously on all cables.
• The torch and the electrode holder should therefore always be placed on an insulated
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General
25.06.2015
CAUTION
Damage due to incorrect connection!
• Accessory components are detected automatically after the power source is switched on.
• The cap must be replaced if faulty or if lost!
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.
• Comprehensive descriptions can be found in the operating instructions for the relevant
accessory components.
Using protective dust caps!
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 oper ate d
on that connection.
Design and function
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Design and function
Welding torch
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CAUTION
Equipment damage due to improperly conn ected coolant pipes!
See 10 Accessories chapter.
• Operate welding torches with a steel liner > with a capillary tube.
Item
Symbol
Description 0
5.2 Welding torch
If the coolant pipes are not properly connected or a gas-cooled welding torch is used,
the coolant circuit is interrupte d and equipment damage can occur.
• Connect all coolant pipes correctly!
• Completely unroll the hose package and the torch hose package!
• Observe maximal hose package length - See 10 Accessories chapter.
• When using a gas-cooled welding torch, use a hose bridge to establish the coolant circuit -
On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a
steel liner. Conversion is necessary if a welding torch with a liner is used!
• Operate welding torches with a liner > with a guide tube.
Depending on the wire electrode d iameter or type, either a steel liner or liner with the correct inner
diameter must be inserted in the torch!
Recommendation:
• Use a steel liner when welding hard, unalloyed wire ele c tr odes (s teel).
• Use a chrome nickel liner when welding hard, high-alloy wire electrodes (CrNi).
• Use a liner to weld or braze soft wire electrodes, high-alloy wire electrodes or aluminium materials.
Preparation for connecting welding torches with a liner:
• Push forward the capillary tube on the wire feed side in the direction of the Euro torch connector and
remove it there.
• Insert the liner guide tube from the Euro torch connector side.
• Carefully insert the welding torch connec tor with as yet too long a liner into the Euro torch connector
and secure with a crown nut.
• Cut off the liner with a liner cutter just before the wire feed roller.
• Loosen the welding torch connector and remove.
• Carefully chamfer the cut off end of the liner with a liner sharpener and sharpen.
Figure 5-1
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Design and function
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Item
Symbol
Description 0
Welding torch
2
Compressed air for torch nozzle cleaning
coolant return
Quick connect coupling (blue)
coolant supply
Welding torch connection (Euro or EC-S)
Welding current and shielding integrated.
1
Welding torch hose package
3
19-pole connection socket (analogue)
Connection socket for analogue control signals (collision protection, etc.)
Welding torch
4
5
AIR
G ¼" connecting nipple
Quick connect coupling (red)
6
7
• Insert the central plug for the welding torch into the Euro torch connector and screw together with
crown nut.
• Lock the connecting nipples on the cooling water tubes into place in the appropriate rapid-action
closure couplings:
Connect the red return line to red rapid-action closure coupling (coolant return) and
the blue supply line to the blue rapid-action closure coupling (coolant supply).
• Insert the torch control lead plus into the 19-pole connection socket and lock.
• Screw the compressed air connection from the torch onto the "AIR" connecting nipple. (Only torches
supporting compressed air cleaning)
The compressed air connection must always be established with torches cleaned using
compressed air!
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Design and function
Configure welding torch
25.06.2015
WARNING
• Allow the welding torch to cool down before carrying out any maintenance work!
CAUTION
• Flush the welding torch with gas following any maintenance w orks.
Item
Symbol
Description 0
1
Contact tip
4
5
O-ring
Equipment kit
CAUTION
• Check and if necessary replace all O-rings when converting the torch!
5.3 Configure welding torch
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.
• Switch off the power source!
Risk of injuries due to hot coolant water!
Removing the coolant sleeve opens the co o lant circuit so that hot coolant water can
escape from the welding torch.
• While removing replacement parts, make sure the coolant sleeve doesn't become loose.
• If the coolant circuit is opened, keep the welding torch level to prevent coolant from
escaping.
• When replacing the torch neck make sure the torch level is above the cooling unit level.
2
3
6
Gas nozzle
Welding spatter guard
Contact tip holder
Torch neck 45°
Figure 5-2
7
Damage to the machine due to worn O-rings!
Worn O-rings have a negative impact on the torch cooling. Insufficient cooling causes
damage to the torch.
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Item
Symbol
Description 0
Changeable body MTR500W
Changeable body MTR500W PP
5.3.1 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 .
Figure 5-3
Design and function
Configure welding torch
1
2
099-500073-EW501
Figure 5-4
21
Design and function
Configure welding torch
25.06.2015
Item
Symbol
Description 0
1
Tension arm
Clamp clip
4
5
Do not change the hand lever positi o n d u ring the change procedure! This will result in
malfunctions.
Torch neck 45°
2
3
Changeable body MTR500W PP
Sealing lips
• Insert the tension ar m 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.
• Insert the torch neck into the changeable body up to the stop.
• Push the tension arm toward the rear up to the stop and take it out, after locking it.
Figure 5-5
22
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• Use a plastic liner inside the torch hose package to guide soft or alloyed wire electrodes!
5.4 Assemble the wire guide
Use the correct wire guide from spool to mo lten pool!
The wire guide has to be adjusted to the wire electrode type and diameter in order to achieve
good welding results!
• Equip the wire feeder according to wire electrode type and diameter!
• 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)!
5.4.1 Plastic liner
Design and function
Assemble the wire guide
Figure 5-6
Always make sure the the hose package is straight when replacing the wire guide.
Figure 5-7
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Design and function
Assemble
25.06.2015
the wire guide
Figure 5-8
Figure 5-9
Figure 5-10
Figure 5-11
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Item
Symbol
Description 0
Crown nut, welding torch central connection (euro)
2
4
Torch neck spiral
O-ring
7
8
The distance between the plastic liner and drive rollers should be as short as possible.
become misshapen!
1
Old liner
3
Euro central connection
Welding current and shielding included.
New liner
5
6
Collet
Guiding tube for welding torch Eur o torch connector
• Cut off the Teflon core using a sharp knife 5mm after the end of the guide tube
Use only sharp, stable knives or special tongs for cutting to ensure that the plastic liner does not
Design and function
Assemble the wire guide
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Design and function
Assemble the wire guide
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5.4.2 Guide spiral
Figure 5-12
Figure 5-13
Figure 5-14
26
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Design and function
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Figure 5-15
Assemble the wire guide
099-500073-EW501
Figure 5-16
Figure 5-17
27
Design and function
Assemble the wire guide
25.06.2015
Figure 5-18
Figure 5-19
Figure 5-20
28
Figure 5-21
099-500073-EW501
Design and function
25.06.2015
Item
Symbol
Description 0
Gas nozzle
2
3
Crown nut, welding torch central connection (euro)
old spiral guide
7
8
Capillary tube
Insert the grinded end towards the contact tip holder to ensure tight fit with the c o n tact tip.
Assemble the wire guide
1
Contact tip
Welding torch neck
4
5
6
Euro central connection
Welding current and shielding included.
Holding nipple
new spiral guide
9
• Re-assemble the torch head in the reverse order in which it was disassembled.
099-500073-EW501
29
Design and function
Assemble the wire guide (EC
25.06.2015
• Use a plastic liner inside the torch hose package to guide soft or alloyed wire electrodes!
-S)
5.5 Assemble the wire guide (EC-S)
Use the correct wire guide from spool to mo lten pool!
The wire guide has to be adjusted to the wire electrode type and diameter in order to achieve
good welding results!
• Equip the wire feeder according to wire electrode type and diameter!
• 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)!
5.5.1 Plastic liner
Figure 5-22
Always make sure the the hose package is straight when replacing the wire guide.
Figure 5-23
Figure 5-24
30
099-500073-EW501
Design and function
S)
25.06.2015
Item
Symbol
Description 0
Crown nut
2
4
Torch neck spiral
Wire feed tube
7
become misshapen!
Figure 5-25
Assemble the wire guide (EC-
1
3
Old liner
Euro central connection
Welding current and shielding included.
New liner
5
6
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.
Use only sharp, stable knives or special tongs for cutting to ensure that the plastic liner does not
Figure 5-26
099-500073-EW501
31
Design and function
Assemble the wire guide (EC
25.06.2015
5.5.2 Guide spiral
-S)
Figure 5-27
Figure 5-28
Figure 5-29
32
099-500073-EW501
Design and function
S)
25.06.2015
Figure 5-30
Assemble the wire guide (EC-
Figure 5-31
Figure 5-32
099-500073-EW501
33
Design and function
Assemble the wire guide (EC
25.06.2015
-S)
Figure 5-33
Figure 5-34
Figure 5-35
Figure 5-36
34
099-500073-EW501
Design and function
S)
25.06.2015
Item
Symbol
Description 0
Gas nozzle
2
3
Crown nut
old spiral guide
7
8
new spiral guide
Capillary tube
Insert the grinded end towards the contact tip holder to ensure tight fit with the c o n tact tip.
Assemble the wire guide (EC-
1
4
Contact tip
Welding torch neck
5
6
Euro central connection
Welding current and shielding included.
Wire feed tube
Holding nipple
9
10
• Re-assemble the torch head in the reverse order in which it was disassembled.
099-500073-EW501
35
Design and function
Assemble the wire guide (EC
25.06.2015
Unsatisfactory welding results d u e to faulty wire feeding!
• Match the drive roll to the wire diameter and material.
Item
Symbol
Description 0
Cap
Pressure roller
3
For fixing the drive roller
Drive roller
Plain washer
7
-S)
5.5.2.1 Changing the wire feed rollers
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.
1
2
Flat spring
4
Carrier pin
5
6
Hexagon nut
• 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.
• Remove drive roll.
• Insert drive roller (see colour code and labelin g) and secure with the plain washer and hexagon nut.
• Assemble by following these steps in the reverse order
Figure 5-37
36
099-500073-EW501
Design and function
S)
25.06.2015
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
Assemble the wire guide (EC-
Aluminium Ø = 0,9 mm
Aluminium Ø = 1,0 mm
Aluminium Ø = 1,2 mm
Aluminium Ø = 1,6 mm
099-500073-EW501
37
Design and function
Assemble the wire guide (EC
25.06.2015
CAUTION
• Keep casing covers or protective caps closed during operation!
• Keep all casing covers or protective caps closed during operation!
• Never direct the welding torch towards your own bod y or towards other pers ons !
CAUTION
• Set the contact pressure of the front rollers (in wire feed direction) to a higher value!
5.5.3 Wire Inching
Risk of injury due to moving parts!
The wire feeders are equipped with moving pa rts, which can trap hands, hair, clothing
or tools and thus injure persons!
• Do not reach into rotating or moving parts or drive components!
Risk of injury due to welding wire es caping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may
escape in an uncontrolled manner and i n jure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the
welding torch!
• Remove the pressure rollers from the wire feeder if no welding torch is fitted!
• Check wire guide at regular intervals!
Risk of injury due to welding wire es caping from the welding torch!
The welding wire can escape from the welding torch at high speed and cause bodily
injury including injuries to the face and eyes!
-S)
Extensive wear due to incorrect contact pressure!
Incorrect contact pressure will cause extensive wear of the wire feed rollers!
• With the adjusting nuts of the pressure units set the contact pressure so that the wire
electrode is conveyed but will still slip through if the wire spool jams.
38
099-500073-EW501
Design and function
S)
25.06.2015
Item
Symbol
Description 0
Cap
2
3
Pressure roller
Slotted screw
6
Assemble the wire guide (EC-
1
Changeable body MTR500W
Flat spring
4
5
The pressure force of the pressure roller has been factory pre-set. Do not
Wire inching key button
change the contact pressure by bending leaf spring, but only via the fine
adjustment, if required.
• Remove cap
• Insert the wire in the wire feed unit as specified by the manufacturer.
• Relieve the leaf spring tension and swing out the pressure roller.
• Press button, wire inching.
• Assemble by following these steps in the reverse order
Figure 5-38
099-500073-EW501
39
Design and function
Assemble the wire guide (EC
25.06.2015
-S)
5.5.4 Replace inlet guide bush/wire guide bush
40
Figure 5-39
099-500073-EW501
Design and function
S)
25.06.2015
Item
Symbol
Description 0
Cap
2
3
Carrier pin
For fixing the drive roller
Drive roller
6
7
Pressure roller
1
Wire guide bush
Flat spring
Assemble the wire guide (EC-
4
5
Plain washer
Hexagon nut
8
• 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.
• Remove drive roll.
• Unfasten and remove wire guide bush.
• Install the new replacement parts.
• Assemble by following these steps in the reverse order
099-500073-EW501
41
Design and function
Converting Euro
25.06.2015
central connection (EC-S) to Euro central connection
5.6 Converting Euro centra l conne c t ion (EC-S) to Euro central connection
5.6.1 Assembly
Figure 5-40
Figure 5-41
Figure 5-42
Figure 5-43
42
099-500073-EW501
Design and function
25.06.2015
Item
Symbol
Description 0
1
Old liner
Euro central connection
New liner
5
6
Collet
Guiding tube for welding torch Euro torch connector
9
10
O-ring
Converting Euro central connection (EC-S) to Euro central connection
Figure 5-44
Crown nut, welding torch central connection (euro)
2
3
Welding current and shielding included.
4
Torch neck spiral
Wire feed tube
7
8
Crown nut
11
Intake nipple
Figure 5-45
Figure 5-46
099-500073-EW501
43
Design and function
Converting Euro centra
25.06.2015
Item
Symbol
Description 0
Cylinder head screw, M3 x 10 mm
Changeable body MTR500W
3
4
CAT torch holder
Hexagon nut, M6
7
8
Shoulder bolt, M6 x 28 mm
11
l connection (EC-S) to Euro central connection
5.6.2 Mounting the welding torch system on the robot
1
2
Shoulder bolt, M8 x 30 mm
Robot
5
6
9
10
• Mount the mounting bracket at the changeable body using the pan head screws M3 x 10 mm.
• Mount the mounting bracket to the CAT torchholder.
Plain washer, M6
Plain washer, M8
Hexagon nut, M8
Mounting bracket
Figure 5-47
44
099-500073-EW501
Maintenance, care and disposal
25.06.2015
CAUTION
Electrical current!
Connect welding torch after performing the maintenance and rinse using the "Gas Test" with
shield gas.
6 Maintenance, care and disposal
The following work must always be carried out with the power source switched off.
Disconnect the welding torch from the connected device, before maintenance.
6.1 Daily maintenance tasks
• Purge the wire guide from the direction of the Euro torch connector with oil- and condensate-free
compressed air or shielding gas.
• Purge the wire guide from the direction of the Euro torch connector with oil- and condensate-free
compressed air or shielding gas.
• Check that coolant connections are tight.
• Check that the welding torch, and where applicable the power source cooling, are functioning
correctly.
• Check the coolant level.
• Check torch, hose package and power connections for exterior damage and replace or have repaired
by specialist st aff as necessary!
• Check the wearing parts in the torch.
• Check that all connections and wearing parts are hand-tight and tighten if necessary.
• Spray the gas nozzle with a splash protection agent.
Daily maintenance tasks
6.2 Monthly maintenance tasks
• Check the coolant container for sludge deposits and check the coolant for cloudiness.
Clean the coolant container if contaminated, and change the coolant.
• If the coolant is dirty, rinse through the welding torch alternately several times with fresh coolant using
the coolant return and supply.
• Check the wire guide.
• Check and clean the welding torch. Deposits in the torch can cause short circuits and have a negative
impact on the welding result, ultimately causing damage to the torch.
• Check that all screw and plug connections and replaceable parts are secured correctly, tighten if
necessary.
099-500073-EW501
45
Maintenance, care and disposal
Maintenance work
25.06.2015
CAUTION
Electric current!
the maintenance work, the entire torch must be returned to the manufacturer
• Observe the local regulations regar d ing disposal!
6.3 Maintenance work
Repairs may only be carried out by authorised specialist staff!
• Do not remove the torch from the hose package!
• Never clamp the torch body in a vice or similar, as this can cause the torch to be irreparably
destroyed!
• If damage occurs to the torch or to the hose package which cannot be corrected as part of
6.4 Disposing of equipment
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and electronic
components, which must be disposed of.
• Do not dispose of in household waste!
6.4.1 Manufacturer's declaration to the end user
• According to European provisions (guideline 2002/96/EG of the European Parliament and the Council
of January, 27th 2003), used electric and electronic equipment may no longer be placed in unsorted
municipal waste. It must be collected separately. The symbol depicting a waste container on wheels
indicates that the equipment must be collected separately.
This machine is to be placed for disposal or recycling in the waste separation systems provided for
this purpose.
• According to German law (law governing the distribution, taking back and environmentally correct
disposal of electric and electronic equipment (ElektroG) from 16.03.2005), used machines are to be
placed in a collection system separate from unsorted municipal waste. The public waste management
utilities (communities) have created collection points at which used equipment from private
households can be disposed of free of charge.
• Information about giving back used equipment or about collections can be obtained from the
respective municipal administration office.
• EWM participates in an approved waste disposal and recycling system and is registered in the Used
Electrical Equipment Register (EAR) under number WEEE DE 57686922.
• In addition to this, returns are also possible throughout Europe via EWM sales partners.
6.5 Meeting the requirements of RoHS
We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the
46
RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU).
099-500073-EW501
25.06.2015
Legend
Symbol
Description
Remedy
7 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.
7.1 Checklist for rectifying faults
The correct machine equipment for the material and process gas in use is a fundamental
requirement for perfect operatio n !
Rectifying faults
Checklist for rectifying faults
Fault/Cause
Welding torch overheated
Insufficient coolant flow
Check coolant level and refill if necessary
Eliminate kinks in conduit system (hose packages)
Vent coolant circuit
Loose welding current connections
Tighten power connections on the torch and/or on the workpiece
Tighten contact tip correctly
Overload
Check and correct welding current setting
Use a more powerful welding torch
Functional error with the welding torch op erating elements
Connection problems
Make control lead connections and check that they are fitted correctly.
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
Halting wire feeding
Check the counter pressure setting of the wire feed roller
Check the torch neck equipment such as contact tip and wire feed
Kinked hose packages
Extend and lay out the torch hose package
Incompatible parameter settings
Check settings and correct if necessary
099-500073-EW501
47
Rectifying faults
Checklist for rectifying faults
25.06.2015
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
Incompatible parameter settings
Check settings and correct if necessary
Check shielding gas setting and replace shielding gas cylinder if necessary
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
Condensation (hydrogen) in the gas tube
Purge hose package with gas or replace
Coolant in the torch neck or wire feed.
Tighten the crown nut at the torch neck.
Purge hose package with gas or replace
Splashes in the gas nozzle
Gas distributor out of order or missing
Lock the o-rings
48
099-500073-EW501
25.06.2015
7.2 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".
To vent the cooling system always us e the b lue coolant connection, which is lo cated as deep as
possible inside the system (close to the cool ant tank)!
Rectifying faults
Vent coolant circuit
099-500073-EW501
Figure 7-1
49
Technical data
MTR500W, MTR500W PP
25.06.2015
Electrodes' polarity
Normally negative
Guide type
Machine-operated
Voltage type
DC direct voltage
Voltage measurement
141 V (peak value)
Shielding gas
CO2 and mixtures
Duty c ycle
100%
Maximum welding current M21
500 A
Maximum welding current CO2
550 A
Wire diameter
0,8 – 1,6 mm
Ambient temperature
-10 °C to +40 °C
Protection rating for the machi n e
connections (EN 60529)
Tube package length
1,5 m / 3,2 m / 4,2 m / 5,2 m
Torch cooling
Coolant mixture
Cooling capacity
min 800 W
Maxmum coolant pressure
3,5 bar
Flow rate of coolant
1.0 l/min
Gas flow
10-20 l/min
Coolant connection
Connector nipple NW 5
Air-blast hose
G 3/8" (spigot nut)
Control line
10-wire
Weight
1.2 kg
Connection
Euro-ZA / EC-S
Constructed to standard
EN 60974-7
8 Technical data
8.1 MTR500W, MTR500W PP
Performance specifications and guarantee only in connection with original spare and
replacement parts!
IP3X
50
099-500073-EW501
General
25.06.2015
CAUTION
machine is switched off.
The welding torch shown is an example only. Depending on the type used, torches may vary.
Item
Symbol
Description 0
Gas nozzle
Welding spatter guard
3
Torch neck 45°
7
9 Replaceable parts
9.1 General
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!
• Only insert and lock accessory components into the relevant connection socket when the
Replaceable parts
1
2
Contact tip
4
Contact tip holder
5
6
Torch neck spiral
Steel liner
8
Liner
Figure 9-1
099-500073-EW501
51
Replaceable parts
General
25.06.2015
Type
Designation
Item no.
CONTACT TIP M8 CUCRZR
D0.8
Contact tip
094-005409-00000
D0.9
D1.0
SD M8X30 1,2MM CUCRZR
Contact tip
094-013113-00000
CONTACT TIP M8 CUCRZR
D1,4
Contact tip
094-005411-00000
D1,6
D2,0
CTH 500W M8
Nozzle holder, M8
094-009896-00500
GASNOZZ NW15,5 15.5MM
72.5MM
Gas nozzle, bottle-shape
094-010220-00500
75.5mm
SPLS 500W HD
Splash protection, high-temperature-resistant
094-013862-00000
0.8-1.2mm
LST RED EWM RT 3605.00m
0.8-1.2mm
Steel liner, red
094-012655-00500
3603.20m 1.4-1.6mm
3605.00m 1.4-1.6mm
Steel liner, blue
0/22DG
NLS 0/22° 1,4-1,6MM
L=195MM
BSLblue liner for steel 0°/22°
094-016522-00500
35/45DG
1.6mm
35/45DG
0/22DG
NLB AL 195mm 1.2-1.6mm
ROB TS
Brass liner for aluminium 0°/22°
094-016526-00000
ROB TS
ROB TS
CONTACT TIP M8 CUCRZR
CONTACT TIP M8 CUCRZR
CONTACT TIP M8 CUCRZR
CONTACT TIP M8 CUCRZR
RGN 500W S3 K15/-1.1
LST RED EWM RT 3603.20m
LST BLUE EWM RT
Contact tip 094-005410-00000
Contact tip 094-005225-00000
Contact tip 094-005412-00000
Contact tip 094-005413-00000
Gas nozzle, bottle-shape 094-016512-00500
Steel liner 094-011627-00500
Steel liner 094-010579-00500
LST BLUE EWM RT
NLS RED 195mm 1.0-1.2mm
NLS RED 217mm 1.0-1.2mm
NLS BLUE 217mm 1.2-
NLB AL 195mm 0.8-1.0mm
NLB AL 217mm 0.8-1.0mm
NLB AL 217mm 1.2-1.6mm
094-012640-00500
Liner BSLred for steel, 0°/22° 094-016521-00500
Liner BSLred for steel, 35°/45° 094-016523-00500
BSLblue liner for steel 35°/45° 094-016524-00500
Brass liner for aluminium 0°/22° 094-016525-00000
Brass liner for aluminium 35°/45° 094-016527-00000
Brass liner for aluminium 35°/45° 094-016528-00000
52
099-500073-EW501
25.06.2015
Item
Symbol
Description 0
1
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
Drive roll for aluminium (U-groove)
094-010188-00500
WFR U-GROOVE 1.6
Drive roll for aluminium (U-groove)
094-016545-00500
WFR V-GROOVE 0.8
Drive roll, universal (V-groove)
094-016546-00500
WFR V-GROOVE 0.9
Drive roll, universal (V-groove)
094-016547-00500
WFROLL UNI V 1.0
Drive roll, universal (V-groove)
094-010194-00500
WFROLL UNI V 1.2
Drive roll, universal (V-groove)
094-010195-00500
WFROLL UNI V 1.4
Drive roll, universal (V-groove)
094-010196-00500
WFROLL UNI V 1.6
Drive roll for aluminium (U-groove)
094-010197-00500
9.2 Wire feed rollers
Drive roller
Figure 9-2
Replaceable parts
Wire feed rollers
099-500073-EW501
53
Accessories
Wire feed rollers
25.06.2015
Type
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
Y=45
RTN 500W 45DG
Torch neck EWM RT 45°
094-016507-00500
1.50
TBROB RT-PP W I=17.1:1
2.20
EWM RT-PP W hose package
094-016535-00503
3.20
4.20
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
ALU
S ALU
10 Accessories
BH WH W500 22° X=239
TBROB RT-PP W I=17.1:1
TBROB RT-PP W I=17.1:1
TBROB RT-PP W I=17.1:1
SP ROB RT-PP W 1,3M EC-S
SP ROB RT-PP W 4,20M EC-
Torch neck 094-021366-00000
EWM RT-PP W hose package 094-016535-00501
EWM RT-PP W hose package 094-016535-00505
EWM RT-PP W hose package 094-016535-00506
Hose package, water cooled 094-021368-00001
Hose package, water cooled 094-021368-00000
54
099-500073-EW501
Circuit diagram
25.06.2015
11 Circuit diagram
The circuit diagrams are only intended for authorised service personnel!
11.1 MTR500W, MTR500W PP
MTR500W, MTR500W PP
099-500073-EW501
Figure 11-1
55
Appendix A
Overview of EWM branches
25.06.2015
12 Appendix A
12.1 Overview of EWM branches
56
099-500073-EW501
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