EWM TH AMT User manual

Operating instructions
EN Welding machines and accessories
TH AMT
Torch holder
099-019400-EW501 Observe additional system documents! 25.02.2016
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General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
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 extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change, errors excepted.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2Safety instructions.................................................................................................................................4
2.1Notes on the use of these operating instructions ..........................................................................4
2.2Explanation of icons.......................................................................................................................5
2.3General..........................................................................................................................................6
2.4Transport and installation ..............................................................................................................6
2.4.1Ambient conditions.........................................................................................................7
2.4.1.1In operation.....................................................................................................7
2.4.1.2Transport and storage.....................................................................................7
3Intended use...........................................................................................................................................8
3.1General..........................................................................................................................................8
3.2Use and operation solely with the following machines..................................................................8
3.3Documents which also apply.........................................................................................................9
3.3.1Warranty.........................................................................................................................9
3.3.2Declaration of Conformity...............................................................................................9
3.3.3Service documents (spare parts) ...................................................................................9
4Machine description – quick overview ..............................................................................................10
4.1TH AMT........................................................................................................................................10
5Design and function.............................................................................................................................11
5.1General........................................................................................................................................11
5.2Parts list.......................................................................................................................................12
5.3Assembly .....................................................................................................................................13
5.4Set up tool coordinate system .....................................................................................................15
5.5Secure tool coordinate system ....................................................................................................16
6Maintenance, care and disposal.........................................................................................................19
6.1General........................................................................................................................................19
6.2Maintenance work, intervals........................................................................................................20
6.2.1Daily maintenance tasks ..............................................................................................20
6.2.1.1Visual inspection...........................................................................................20
6.2.2Monthly maintenance tasks..........................................................................................20
6.2.2.1Visual inspection...........................................................................................20
6.3Disposing of equipment ...............................................................................................................20
6.3.1Manufacturer's declaration to the end user..................................................................20
6.4Meeting the requirements of RoHS .............................................................................................20
7Rectifying faults ...................................................................................................................................21
7.1Checklist for rectifying faults........................................................................................................21
8Technical data ......................................................................................................................................22
8.1TH AMT........................................................................................................................................22
9Appendix A ...........................................................................................................................................23
9.1Overview of EWM branches ........................................................................................................23

Safety instructions
Notes on the use of these operating instructions
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2 Safety instructions
2.1 Notes on the use of 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.
• 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
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
• 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
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
• 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
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at the edge of the page.
Special technical points which users must 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.

Safety instructions
Explanation of icons
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2.2 Explanation of icons
Symbol Description
Special technical points which users must observe.
Correct
Wrong
Press
Do not press
Press and keep pressed
Turn
Switch
Switch off machine
Switch on machine
ENTER enter the menu
NAVIGATION Navigating in the menu
EXIT Exit 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
l
0
l
0

Safety instructions
General
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2.3 General
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!
• Inform persons in the working area that they must comply with the regulations!
Validity of the document!
This document is valid only in combination with the operating instructions for the
product being used!
• Read and observe the operating instructions for all system components, especially the
safety instructions!
CAUTION
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.
• Regular checks of the machine according to IEC 60974-4.
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
machine is switched off.
2.4 Transport and installation
CAUTION
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
• Disconnect supply lines!

Safety instructions
Transport and installation
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2.4.1 Ambient conditions
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
2.4.1.1 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
2.4.1.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -10 °C to +55 °C
Relative air humidity
• Up to 70% at 20 °C

Intended use
General
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3 Intended use
3.1 General
WARNING
Hazards due to improper usage!
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!
• Do not modify or convert the equipment improperly!
The TH AMT torch holder is used to mount the welding torch to the robot.
3.2 Use and operation solely with the following machines
• AMT 301
• AMT 451
• AMT 551

Intended use
Documents which also apply
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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
The designated machine conforms to EC Directives and standards in terms of its design
and construction:
• EC Low Voltage Directive (2006/95/EC),
• EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly
conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted
conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
3.3.3 Service documents (spare parts)
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Spare parts can be obtained from the relevant authorised dealer.

Machine description – quick overview
TH AMT
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4 Machine description – quick overview
4.1 TH AMT
Figure 4-1
Item Symbol Description 0
1 Clamping bracket
2 Welding torch clamping range
3 Torch holder
4 Robot mounting bore

Design and function
General
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5 Design and function
5.1 General
WARNING
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
• Follow safety instructions on the opening pages of the operating instructions.
• Commissioning may only be carried out by persons who have the relevant expertise of
working with arc welding machines!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
Faulty assembly!
If system components are not carefully plugged in or not completely connected, they
may detach during moving and cause severe injury.
• Always completely plug in, connect or engage system components.
CAUTION
Risk of injury due to electrical current and compressed air!
Only carry out the following tasks once the power source is securely switched off and
there is no compressed air in the system!
• Switch off the welding machine!
• Cut off the compressed air supply at the source!
• Disconnect all mains plugs!

Design and function
Parts list
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5.2 Parts list
Check for completion before conversion (see item list).
Item0Quantity Description 0
1 2 Cylinder head screw, M6 x 25
2 1
Hexagon nut, M6
3 1
M6 plain washer
4 1 M6 shoulder screw
5 1 Hexagon nut, M8
6 1 M8 plain washer
7 1 M8 shoulder screw
8 1
Torch holder
9 1 Clamping bracket

Design and function
Assembly
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5.3 Assembly
Figure 5-1
Item Symbol Description 0
1 Hexagon nut, M8
2 M8 plain washer
3 Torch holder
4 Mounting bracket RSA
5 M8 shoulder screw
• Install the torch holder to the support RSA using 1 M8 shoulder screw, M8 plain washer and M8
hexagonal nut each.
Figure 5-2
Item Symbol Description 0
1 Torch holder
2 Clamping bracket
3 Cylinder head screw, M6 x 45
• Remove the M6 x 25 mm cylinder head screw and clamping bracket from the torch holder.

Design and function
Assembly
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The illustration serves as an example only.
Figure 5-3
Item Symbol Description 0
1 Cylinder head screw, M6 x 45
2 Clamping bracket
3Welding torch
4 Torch holder
• Attach the torch to the torch holder.

Design and function
Set up tool coordinate system
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5.4 Set up tool coordinate system
Figure 5-4
Item Symbol Description 0
1 Hexagon nut, M8
2 Torch holder
• Loosen M8 hexagonal nut and swivel the torch holder until the tool coordinate system is set up.
• Once the tool coordinate system is set up, secure with an M8 hexagonal nut.

Design and function
Secure tool coordinate system
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5.5 Secure tool coordinate system
Figure 5-5
Item Symbol Description 0
1 Torch holder
2 Mounting bracket RSA
3 Twist drill with 5.8-mm diameter
• Align a twist drill with a diameter of 5.8 mm to the existing bore in the support RSA and drill through
support and torch holder.
• Chamfer the bore outer edges

Design and function
Secure tool coordinate system
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Figure 5-6
Item Symbol Description 0
1 Torch holder
2 Mounting bracket RSA
3 6H7 hand reamer
• Ream the 5.8-mm bore in the support RSA and torch holder using a 6H7 hand reamer to achieve a
hole fit of 6H7.

Design and function
Secure tool coordinate system
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Figure 5-7
Item Symbol Description 0
1
M6 nut
2
M6 plain washer
3 Torch holder
4 Mounting bracket RSA
5 M6 shoulder screw
• Install support RSA and torch holder using 1 M6 shoulder screw, M6 plain washer and M6 nut each.

Maintenance, care and disposal
General
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6 Maintenance, care and disposal
DANGER
Improper maintenance and testing
The equipment may only be cleaned, repaired or tested by specialist, skilled persons! A
skilled person is one who, due to training, knowledge and experience, is able to
recognise the dangers that can occur during testing of this equipment as well as
possible subsequent damage and who is able to implement the required safety
procedures.
• Complete all tests given in the chapter below!
• Only put the equipment back into operation following a successful test.
WARNING
Mains voltage!
All mains and supply lines on the machine being tested must be disconnected before
cleaning or testing.
• Disconnect all mains and supply lines.
CAUTION
Risk of injury due to electrical current and compressed air!
Only carry out the following tasks once the power source is securely switched off and
there is no compressed air in the system!
• Switch off the welding machine!
• Cut off the compressed air supply at the source!
• Disconnect all mains plugs!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service matters, always consult the dealer who supplied the
machine. Return deliveries of defective equipment subject to warranty may only be made through your
dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the
machine type, serial number and item number of the machine, as well as the type designation and item
number of the spare part.
6.1 General
Under the specified ambient conditions and normal working conditions, this machine is essentially
maintenance-free and requires just a minimum of care.
There are a few points which must be observed in order to ensure correct operation.
This includes regular cleaning and checking as described below, depending on the pollution level of the
environment and the length of time the machine is in use.

Maintenance, care and disposal
Maintenance work, intervals
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6.2 Maintenance work, intervals
6.2.1 Daily maintenance tasks
CAUTION
Cleaning!
The machine may become damaged if cleaned with liquids! Removing residues using
compressed air may disturb chips and result in eye damage!
• Do not use any liquids for cleaning!
• Use a small brush or suitable cleaning tool to remove residues!
• Check that all connections and wearing parts are hand-tight and tighten if necessary.
• Check that all screw and plug connections and replaceable parts are secured correctly, tighten if
necessary.
6.2.1.1 Visual inspection
• Other, general condition
6.2.2 Monthly maintenance tasks
6.2.2.1 Visual inspection
• Remove any spatter.
• Clean surface
6.3 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!
• Observe the local regulations regarding disposal!
6.3.1 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.
6.4 Meeting the requirements of RoHS
We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the
RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU).