EWM MT551W Series User manual

Operating instructions
EN welding torch
MT301W
MT451W
MT551W
MT301W...X
MT451W...X
MT551W...X
099-500058-EW501 Observe additional system documents! 04.08.2016
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the site of operation.
• Safety and warning labels at the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to the state of the art and any regulations and
standards applicable. It may be operated, serviced and repaired by trained personnel only.
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.................................................................................................................................5
2.1Notes on the use of these operating instructions ..........................................................................5
2.1.1Explanation of icons .......................................................................................................6
2.2General..........................................................................................................................................7
2.3Transport........................................................................................................................................9
2.4Scope of delivery ...........................................................................................................................9
2.4.1Ambient conditions.........................................................................................................9
2.4.1.1In operation.....................................................................................................9
2.4.1.2Transport and storage.....................................................................................9
3Intended use.........................................................................................................................................10
3.1General........................................................................................................................................10
3.2Documents which also apply.......................................................................................................10
3.2.1Warranty.......................................................................................................................10
3.2.2Declaration of Conformity.............................................................................................10
3.2.3Service documents (spare parts) .................................................................................10
4Product description – quick reference ..............................................................................................11
4.1Product variants...........................................................................................................................11
4.2Standard welding torch................................................................................................................12
4.3Function torch..............................................................................................................................13
4.3.1Operating elements......................................................................................................14
4.3.2Operating elements for up/down welding torch............................................................14
4.3.3Operating elements 2 for up/down welding torch.........................................................15
4.3.4Operating elements for PC1 welding torch ..................................................................16
4.3.4.1Welding data display.....................................................................................17
4.3.5Operating elements for PC2 welding torch ..................................................................18
4.3.5.1Welding data display.....................................................................................19
4.3.6Euro torch connector with control cable.......................................................................20
4.3.7Euro torch connector without control cable..................................................................20
4.4Fume extraction torch..................................................................................................................21
4.4.1Fume extraction torch Euro torch connector................................................................22
4.5Equipment recommendations......................................................................................................23
5Design and function.............................................................................................................................24
5.1General........................................................................................................................................24
5.2Welding torch cooling system......................................................................................................25
5.2.1Approved coolants overview ........................................................................................25
5.2.2Maximal hose package length......................................................................................25
5.3Configure welding torch...............................................................................................................26
5.3.1Turning the torch neck..................................................................................................27
5.3.2Changing the torch neck ..............................................................................................27
5.4Adjusting the welding machine Euro torch connector..................................................................29
5.4.1Preparation work on the euro torch connector to connect welding torches with
plastic liners..................................................................................................................29
5.4.2Preparation work on the central connector to connect welding torches with spiral
guides...........................................................................................................................29
5.5Assemble the wire guide..............................................................................................................29
5.5.1Combined liner .............................................................................................................30
5.5.2Guide spiral ..................................................................................................................33
6Maintenance, care and disposal.........................................................................................................36
6.1Maintenance work, intervals........................................................................................................36
6.1.1Daily maintenance tasks ..............................................................................................36
6.1.2Monthly maintenance tasks..........................................................................................36
6.2Maintenance work........................................................................................................................36
6.3Disposing of equipment ...............................................................................................................37
6.3.1Manufacturer's declaration to the end user..................................................................37

Contents
Notes on the use of these operating instructions
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6.4Meeting the requirements of RoHS..............................................................................................37
7Rectifying faults....................................................................................................................................38
7.1Checklist for rectifying faults ........................................................................................................38
7.2Functional check PC1X – PC2X ..................................................................................................40
7.3Vent coolant circuit.......................................................................................................................41
8Technical data.......................................................................................................................................42
8.1MT 301 / 451 / 551.......................................................................................................................42
9Replaceable parts.................................................................................................................................43
9.1MT301W.......................................................................................................................................43
9.2MT451W.......................................................................................................................................45
9.3MT551W.......................................................................................................................................47
9.4MT301W F ...................................................................................................................................49
9.5MT451W F ...................................................................................................................................50
10Circuit diagrams...................................................................................................................................52
10.1MT U/D.........................................................................................................................................52
10.2MT U/DX.......................................................................................................................................53
10.3MT 2U/D.......................................................................................................................................54
10.4MT 2U/DX ....................................................................................................................................55
10.5MT PC1........................................................................................................................................56
10.6MT PC1X......................................................................................................................................57
10.7MT PC2........................................................................................................................................58
10.8MT PC2X......................................................................................................................................59
11Appendix A............................................................................................................................................60
11.1Overview of EWM branches.........................................................................................................60

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.
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
Notes on the use of these operating instructions
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2.1.1 Explanation of icons
Symbol Description Symbol Description
Indicates technical aspects which the
user must observe. Activate and release/tap/tip
l
0
Switch off machine Release/do not activate
l
0
Switch on machine Press and hold
switch
Wrong Turn
Correct Numerical value – adjustable
Menu entry Signal light lights up in green
Navigating the menu Signal light flashes green
Exit menu Signal light lights up in red
4s
Time representation (e.g.: wait
4 s/activate) Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use

Safety instructions
General
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2.2 General
WARNING
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low
voltages can cause a shock and lead to accidents.
• Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
• Always place torches and electrode holders on an insulated surface!
• Wear the full personal protective equipment (depending on the application)!
• The machine may only be opened by qualified personnel!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during
welding, there is a risk of flames.
• Be watchful of potential sources of fire in the working area!
• Do not carry any easily inflammable objects, e.g. matches or lighters.
• Ensure suitable fire extinguishers are available in the working area!
• Thoroughly remove any residue of flammable materials from the workpiece prior to starting
to weld.
• Only further process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!
Risk of injury due to radiation or heat!
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
safety curtains!
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!

Safety instructions
General
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CAUTION
Electromagnetic fields!
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 6.1 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
necessary).
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
Trained personnel!
Commissioning is reserved for persons who have the relevant expertise of working with arc
welding machines.
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!
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.
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.

Safety instructions
Transport
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2.3 Transport
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!
2.4 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.
2.4.1 Ambient conditions
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:
• -25 °C to +55 °C
Relative air humidity
• Up to 90% at 20 °C

Intended use
General
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3 Intended use
3.1 General
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. 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 its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
Welding torch for arc welding machines for GMAW.
3.2 Documents which also apply
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
The labelled machine complies with the following EC directives in terms of its design and
construction:
• Low Voltage Directive (LVD) 2014/35/EC
• Electromagnetic Compatibility Directive (EMC) 2014/30/EC
• Restriction of Hazardous Substance (RoHS) 2011/65/EC
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which
have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the
specific declaration of conformity is included with every product.
3.2.3 Service documents (spare parts)
WARNING
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.

Product description – quick reference
Product variants
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4 Product description – quick reference
4.1 Product variants
Version Functions Performance class
W Water-cooled
You use the torch trigger to switch the welding process on and
off. Interchangeable contact tip holder.
MT301, MT451, MT551
S Short torch neck MT301, MT451, MT551
L Extended torch neck MT451, MT551
C Interchangeable torch neck
The welding torch can be equipped with a torch neck angled
at 45°, 36° and 22°. The torch neck can be turned to the
desired position.
MT301, MT451
F Fume extraction torch
The fume extraction torch features an extraction unit. The
extraction capacity can be infinitely adjusted using a slider.
MT301, MT451
U/D Up/down torch
The welding power (welding current/wire feed speed) or the
program number can be adjusted on the welding torch.
MT301, MT451, MT551
2U/D 2 up/down torch
The welding power (welding current/wire feed speed) and the
voltage correction or the JOB number and program number
can be adjusted on the welding torch.
MT301, MT451, MT551
PC1 POWERCONTROL1 welding torch
The welding power (welding current/wire feed speed) or the
program number can be adjusted on the welding torch. Values
and changes are shown on the welding torch display.
MT301, MT451, MT551
PC2 POWERCONTROL2 welding torch
The welding power (welding current/wire feed speed) and the
voltage correction or the JOB number and program number
can be adjusted on the welding torch. Values and changes
are shown on the welding torch display.
MT301, MT451, MT551
X X technology (Multimatrix)
Welding torch with X technology – MT function torch without
separate control cable
MT301, MT451, MT551
The extended functions for welding torches MT301W…X, MT451W…X and MT551W…X are only
available if the welding torches on EWM machines are connected to the following control:
M3.70-A Phoenix Expert
M3.71-A Phoenix Progress
M3.72-A Alpha Q Progress
M3.76-A Taurus Synergic S
M3.7X-A drive 4X HP
M3.7X-B drive 4X LP

Product description – quick reference
Standard welding torch
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4.2 Standard welding torch
4
3
2 1
5
Figure 4-1
Item Symbol Description 0
1Gas nozzle
2 Torch neck 45°
3 Torch trigger
4 Grip plate
5 Welding torch hose package

Product description – quick reference
Function torch
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4.3 Function torch
4
5
6
3 2 1
Figure 4-2
Item Symbol Description 0
1Gas nozzle
2 Torch neck 45°
3 Operating elements
4 Grip plate
5 Torch trigger
6 Welding torch hose package

Product description – quick reference
Function torch
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4.3.1 Operating elements
Programm
Up / Down
Programm
Up / Down
Figure 4-3
• Switch the"Program or up/down mode“ changeover switch at the welding machine to the up/down or
program mode position (see chapter "Design and function").
The 'Program or up/down function' changeover switch may look different on your machine. Use
the operating instructions for your power source to operate the switch.
4.3.2 Operating elements for up/down welding torch
U/D
X
21 21
Figure 4-4
Item Symbol Description 0
1 "A -" button (Program mode)
Decrease program number
"A -" button (Up/Down mode)
Reduce welding performance (welding current/wire-feed speed)
2 "A +" button (Program mode)
Increase program number
"A +" button (Up/Down mode)
Increase welding performance (welding current/wire-feed speed)

Product description – quick reference
Function torch
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4.3.3 Operating elements 2 for up/down welding torch
2U/D
X
4
43 3
2
21 1
Figure 4-5
Item Symbol Description 0
1 "A +" button (Program mode)
Increase program number
"A +" button (Up/Down mode)
Increase welding performance (welding current/wire-feed speed)
2 "A -" button (Program mode)
Decrease program number
"A -" button (Up/Down mode)
Reduce welding performance (welding current/wire-feed speed)
3 "B +" button (program mode)
Increase JOB number
"B +" button (up/down mode)
Welding voltage correction, increase value
4 "B -" button (program mode)
Decrease JOB number
"B -" button (up/down mode)
Welding voltage correction, decrease value

Product description – quick reference
Function torch
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4.3.4 Operating elements for PC1 welding torch
A A
1
Pc 1
X
3 3
1 1
2 2
Figure 4-6
Item Symbol Description 0
1 Three-figure display
Display of welding parameters > see 4.3.4.1 chapter.
2 "A +" button (Program mode)
Increase program number
"A +" button (Up/Down mode)
Increase welding performance (welding current/wire-feed speed)
3 "A -" button (Program mode)
Decrease program number
"A -" button (Up/Down mode)
Reduce welding performance (welding current/wire-feed speed)

Product description – quick reference
Function torch
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4.3.4.1 Welding data display
The signal lamps in the lower part of the torch display indicate the welding parameters currently selected.
The corresponding parameter value is shown on the three-digit display.
After the welding machine is switched on, the active JOB number is shown on the display for approx. 3
seconds. The display then switches to the setpoint value for the welding current or wire speed.
In up/down mode, the corresponding parameter value is shown on the display for parameter changes. If
this parameter is not changed for approx. 5 seconds, the display switches back to the values specified by
the machine control.
A
32
1
Figure 4-7
Item Symbol Description 0
1 Three-figure display
Display of welding parameters > see 4.3.4.1 chapter.
2 A Welding current display signal lamp
3 Wire speed display signal lamp
Example displays for welding parameters in the welding data display
Welding parameters Display
Welding current
A
Wire speed
A
Programs
A

Product description – quick reference
Function torch
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4.3.5 Operating elements for PC2 welding torch
AV Job AV Job
PC2
X
4 4
1 1
5 5
3 3
2 2
Figure 4-8
Item Symbol Description 0
1 Three-figure display
Display of welding parameters > see 4.3.4.1 chapter.
2 "B +" button (program mode)
Increase JOB number
"B +" button (up/down mode)
Welding voltage correction, increase value
3 "A +" button (Program mode)
Increase program number
"A +" button (Up/Down mode)
Increase welding performance (welding current/wire-feed speed)
4 "A -" button (Program mode)
Decrease program number
"A -" button (Up/Down mode)
Reduce welding performance (welding current/wire-feed speed)
5 "B -" button (program mode)
Decrease JOB number
"B -" button (up/down mode)
Welding voltage correction, decrease value

Product description – quick reference
Function torch
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4.3.5.1 Welding data display
The signal lamps in the lower part of the torch display indicate the welding parameters currently selected.
The corresponding parameter value is shown on the three-digit display.
After the welding machine is switched on, the active JOB number is shown on the display for approx. 3
seconds. The display then switches to the setpoint value for the welding current or wire speed.
In up/down mode, the corresponding parameter value is shown on the display for parameter changes. If
this parameter is not changed for approx. 5 seconds, the display switches back to the values specified by
the machine control.
V
A
JOB
432
1
5
Figure 4-9
Item Symbol Description 0
1 Three-figure display
Display of welding parameters > see 4.3.5.1 chapter.
2 A Welding current display signal lamp
3 Wire speed display signal lamp
4 V Voltage correction display signal lamp
5 JOB JOB number display signal lamp
Example displays for welding parameters in the welding data display
Welding parameters Display
Welding current
Wire speed
Voltage correction
Programs
JOB number
V
A
JOB
V
A
JOB
V
A
JOB
V
A
JOB
V
A
JOB

Product description – quick reference
Function torch
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4.3.6 Euro torch connector with control cable
3
4
5
1
2
Figure 4-10
Item Symbol Description 0
1 Anti-kink spring
2 Euro central connection
3 Control cable plug
With function torches only
4 Quick connect coupling, blue (coolant supply)
5 Quick connect coupling, red (coolant return)
4.3.7 Euro torch connector without control cable
3
4
1
2
Figure 4-11
Item Symbol Description 0
1 Anti-kink spring
2 Euro central connection
Welding current, shielding gas and torch trigger included
3 Quick connect coupling, blue (coolant supply)
4 Quick connect coupling, red (coolant return)