EWM MTR500W PP User manual

Operating instructions
MIG/MAG welding torch
MTR500W
MTR500W PP
099-500073-EW501 Observe additional system documents! 25.06.2015
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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
1Contents..................................................................................................................................................3
2Safety instructions.................................................................................................................................5
2.1 Notes on the use of these operating instructions ..........................................................................5
2.2 Explanation of icons.......................................................................................................................6
2.3 General ..........................................................................................................................................7
2.4 Transport........................................................................................................................................9
2.5 Scope of delivery ...........................................................................................................................9
2.6Ambient conditions.........................................................................................................................9
2.6.1 In operation.....................................................................................................................9
2.6.2 Transport and storage....................................................................................................9
3Intended 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
4Machine 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
5Design 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
5.5.2.1Changing the wire feed rollers......................................................................36
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
6Maintenance, 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
7Rectifying faults ...................................................................................................................................47
7.1 Checklist for rectifying faults........................................................................................................47
7.2 Vent coolant circuit.......................................................................................................................49
8Technical data ......................................................................................................................................50
8.1 MTR500W, MTR500W PP...........................................................................................................50

Contents
Notes on the use of these operating instructions
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9Replaceable 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

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
ENTERENTER
ENTER (enter the menu)
NAVIGATION
NAVIGATION (Navigating in the menu)
EXIT
EXIT (Exit the menu)
4 s
Time display (example: wait 4s/press)
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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2.3 General
DANGER
Electric shock!
Welding machines use high voltages which can result in potentially
fatal electric shocks
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 holder on an insulated surface!
• The unit should only be opened by specialist staff after the mains plug has been
unplugged!
• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!
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 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
necessary).
Validity of this document!
This document describes an accessory and is only valid in combination with the
operating instructions for the power source being used (welding machine)!
• Read the operating instructions, in particular the safety instructions for the power source
(welding machine)!
WARNING
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
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!
• Connect welding leads correctly!

Safety instructions
General
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WARNING
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!
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!
CAUTION
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!
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.
Trained personnel!
Commissioning is reserved for persons who have the relevant expertise of working with
arc welding machines.

Safety instructions
Transport
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2.4 Transport
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!
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.
2.6 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)!
2.6.1 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

Intended use
General
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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
workpiece.
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!
3.2 Applications
3.2.1 MIG/MAG standard welding
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.
3.2.2 MIG/MAG pulse welding
Welding process for optimum welding results when joining stainless steel and aluminium thanks to
controlled drop transfer and targeted, adapted heat input.
3.2.3 MIG/MAG cored wire welding
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).

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
MTR500W
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4 Machine description – quick overview
The welding torch shown is an example only. Depending on the type used, torches may vary.
4.1 MTR500W
Figure 4-1
Item
Symbol
Description 0
1Gas nozzle
2
Torch neck 45°
3 Changeable body MTR500W
4
Sealing lips
5
Adapter

Machine description –
quick overview
MTR500W PP
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4.2 MTR500W PP
Figure 4-2
Item
Symbol
Description 0
1
Gas nozzle
2 Torch neck 45°
3
Changeable body MTR500W PP
4
Sealing lips
5
Cap
6 Adapter

Machine description
– quick overview
Welding torch connection
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4.3 Welding torch connection
4.3.1 Euro central connection
Figure 4-3
Item
Symbol
Description 0
1
Euro central connection
Welding current and shielding included.
2 Quick connect coupling, blue (coolant supply)
3
Control lead cable plug
4
Quick connect coupling, red (coolant return)
5
Air-blast hose

Machine description –
quick overview
Welding torch connection
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4.3.2 Euro central connection (EC-S)
Figure 4-4
Item
Symbol
Description 0
1
Welding torch central connector (EC-S)
Integrated welding current and shielding.
2
Quick connect coupling, blue (coolant supply)
3
Control lead cable plug
4
Quick connect coupling, red (coolant return)
5
Air-blast hose

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!
CAUTION
Insulate the arc welder from welding voltage!
Not all active parts of the welding current circuit can be shielded from direct contact. To
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!
• Always place torches and electrode holders on an insulated surface!
Risk of burns on the welding current connection!
If the welding current connections are not locked, connections and leads heat up and
can cause burns, if touched!
• Check the welding current connections every day and lock by turning in clockwise direction,
if necessary.
Risk of injury due to moving parts!
The wire feeders are equipped with moving parts, which can trap hands, hair, clothing
or tools and thus injure persons!
• Do not reach into rotating or moving parts or drive components!
• Keep casing covers or protective caps closed during operation!
Risk of injury due to welding wire escaping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may
escape in an uncontrolled manner and injure 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!
• Keep all casing covers or protective caps closed during operation!
Risk from electrical current!
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
surface before starting work and during breaks.

Design and function
General
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CAUTION
Damage due to incorrect connection!
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.
• Accessory components are detected automatically after the power source is switched on.
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 operated
on that connection.
• The cap must be replaced if faulty or if lost!

Design and function
Welding torch
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5.2 Welding torch
CAUTION
Equipment damage due to improperly connected coolant pipes!
If the coolant pipes are not properly connected or a gas-cooled welding torch is used,
the coolant circuit is interrupted 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 -
See 10 Accessories chapter.
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.
• Operate welding torches with a steel liner > with a capillary tube.
Depending on the wire electrode diameter 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 electrodes (steel).
• 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 connector 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
Item
Symbol
Description 0

Design and function
Welding torch
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Item
Symbol
Description 0
1
Welding torch
2
Welding torch hose package
3
19-pole connection socket (analogue)
Connection socket for analogue control signals (collision protection, etc.)
4 AIR G ¼" connecting nipple
Compressed air for torch nozzle cleaning
5
Quick connect coupling (red)
coolant return
6
Quick connect coupling (blue)
coolant supply
7
Welding torch connection (Euro or EC-S)
Welding current and shielding integrated.
• 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!

Design and function
Configure welding torch
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5.3 Configure welding torch
WARNING
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!
• Allow the welding torch to cool down before carrying out any maintenance work!
CAUTION
Risk of injuries due to hot coolant water!
Removing the coolant sleeve opens the coolant 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.
• Flush the welding torch with gas following any maintenance works.
Figure 5-2
Item
Symbol
Description 0
1
Gas nozzle
2 Welding spatter guard
3
Contact tip
4
Contact tip holder
5
Torch neck 45°
6
O-ring
7
Equipment kit
CAUTION
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.
• Check and if necessary replace all O-rings when converting the torch!