ESAB MTW 1000 User manual

Brand: ESAB

Model: MTW 1000

Category: Welding System

Type: User manual

ESAB MTW 1000 is a high-performance welding system designed for continuous MIG/MAG welding with exceptional precision and efficiency. Its advanced cooling principle, integrated into the contact tube and external cooling jacket, ensures optimal temperature control for superior weld quality. The contact device seamlessly connects to various wire feed units and systems, enhancing its versatility. With its ability to handle different gas types, wire types, and diameters, the MTW 1000 offers great flexibility for a wide range of welding applications.

0449 066 001 2006--04--10

MTW 1000

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Bruksanvisning

Brugsanvisning

Bruksanvisning

Käyttöohjeet

Instruction manual

Betriebsanweisung

Manuel d’instructions

Gebruiksaanwijzing

Instrucciones de uso

Istruzioni per l’uso

Manual de instruções

Ïäçãßåò ÷ñÞóåùò

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Rätt till ändring av specifi kationer utan avisering förbehålles.

Ret til ændri ng af specifikationer uden varsel forbeholdes.

Rett til å endre spesifi kasjoner uten varsel forbeholdes.

Oikeudet muutoksiin pidätetään.

Rights reserved to alter specifications without notice.

Änderungen vorbehalten.

Sous réserve de modifications sans avis préal able.

Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.

Reservado el derecho de cambiar las especificaciones sin previo aviso.

Ci riserviamo il diritto di variare le specifiche senza preavviso.

Reservamo--nos o direito de alterar as especificações sem aviso prévio.

Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.

SVENSKA 3..............................................

DANSK 13................................................

NORSK 23................................................

SUOMI 33................................................

ENGLISH 43..............................................

DEUTSCH 53.............................................

FRANÇAIS 63.............................................

NEDERLANDS 73.........................................

ESPAÑOL 83..............................................

ITALIANO 93..............................................

PORTUGUÊS 103..........................................

ÅËËÇÍÉÊÁ 113.............................................

ENGLISH

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TOCe

1SAFETY 44...........................................................

2 INTRODUCTION 46...................................................

2.1 General 46..................................................................

2.2 Definitions 46................................................................

2.3 Technical Data 46............................................................

2.4 Main Parts 47................................................................

3 INSTALLATION 48....................................................

3.1 General 48..................................................................

3.2 Connections 48..............................................................

4 OPERATION 49.......................................................

4.1 General 49..................................................................

4.2 Before welding 49............................................................

5 MAINTENANCE 50....................................................

5.1 General 50..................................................................

5.2 As necessary 50.............................................................

5.3 Disassembly 51..............................................................

6 WEAR PARTS 52.....................................................

6.1 Recommendations 52.........................................................

7 ORDERING OF SPARE PARTS 52......................................

SPARE PARTS LIST 125...................................................

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1SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety precautions

must meet the requirements that apply to this type of welding equipment. The following recommen-

dations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well--acquainted with the operation of the welding

equipment. Incorrect operation of the equipment may lead to hazardous situations which can result

in injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding

2. The operator must ensure that:

S no unauthorised person is stationed within the working area of the equipment when it is

started up.

S no--one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from draughts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.

S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close at hand.

S Lubrication and maintenance must not be carried out on the equipment during operation.

WARNING

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR

EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANU--

FACTURER’S HAZARD DATA.

ELECTRIC SHOCK -- Can kill

S Install and earth the welding unit in accordance with applicable standards.

S Do not touch live electrical parts or electrodes with bare skin, wet gloves or

wet clothing.

S Insulate yourself from earth and the workpiece.

S Ensure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

S Keep your head out of the fumes.

S Use ventilation, extraction at the arc, or both, to keep fumes and gases from

your breathing zone and the general area.

ARC RAYS -- Can injure eyes an d burn skin

S Protect your eyes and body. Use the correct welding screen and filter lens

and wear protective clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no

inflammable m aterials nearby.

NOISE -- Excessive noise can damage hearing

S Protect your ears. Use ear defenders or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION

S Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

READ AND UNDERSTAND THE INSTRUCTION MANUAL

BEFORE INSTALLING OR OPERATING.

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2 INTRODUCTION

2.1 General

MTW 1000 is designed for continuous MIG/MAG welding with high requirements for

function and reliability.

The very effective cooling principle is integrated both in the contact tube and in the

external cooling jacket. The coolant passes with a whirling motion through the parts

very close to the contact nozzle and the gas nozzle.

For easy installation the welding cable and the gas and coolant hoses are connected

at the rear of the contact device, which also protects the cables and hoses from

undesired heat and radiation from the welding.

The contact device is available in standard length 300 mm.

The contact device can easily be connected to different wire feed units and wire feed

systems by way of special adapters.

2.2 Definitions

MIG/MAG welding The weld bead is protected by way of shielding gas

during the welding.

2.3 Technical Data

Gas type Mix/Ar CO

Welding current at:

100% duty cycle 1000 A 1000 A

Gas flow: 12--30 l/min 12--25 l/min

Wire type and diameter:

Non--/ low--alloy steel 1.0--1.6 mm 1.0--1.6 mm

Stainless steel 1.0--1.6 mm

Cored wire 1.0--2.4 mm 1.0--2.4 mm

Aluminium 1.0--2.0 mm

Necessary cooling at max welding data:

(1 cooling unit)

Max. temperature, coolant 60_C 60_C

Max. working pressure, coolant 6.0 bar 6.0 bar

Min. flow, coolant 16.0 l / min 16.0 l / min

Min. working pressure, coolant 3.5 bar 3.5 bar

Necessary cooling at max welding data:

(2 cooling units)

Max. temperature, coolant 60_C 60_C

Max. working pressure, coolant 6.0 bar 6.0 bar

Min. flow, coolant (Contact tube) 6.5 l/ min 6.5 l/ min

Min. flow, coolant (Cooling jacket) 9.5 l/ min 9.5 l/ min

Min. working pressure, coolant 2.25 bar 2.25 bar

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2.4 Main Parts

1. Gas nozzle

2. Spatter shield

3. Centre sleeve

4. Allen screw

5. Insulating tube

6. O--ring

7. Insulating sleeve

8. Contact tube

9. Wire guide set

10. Contact nozzle

11. Cooling jacket

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3 INSTALLATION

3.1 General

The installation must be executed by a professional.

3.2 Connections

Alternative 1 Alternative 2

1. Gas

2. Cooling coil

3. Cooling unit

4. Cooling unit (Cooling jacket)

5. Cooling unit (Contact tube)

Alternative1(1coolingunit)

A distributing pipe branching the water to the respective cooling coil (2) is fitted to the

supply line. On the return line a collecting pipe is fitted leading the water back to the

cooling unit (3).

Alternative2(2coolingunits)

The two cooling units (4, 5 ) are to be fitted to respective cooling coil (2).

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4 OPERATION

4.1 General

General safety regulations for the handling of the equipment can be found on

page 44. Read through before you start using the equipment!

4.2 Before welding

S Make sure the water cooling functions.

S Make sure the spatter shield is not damaged or missing.

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5 MAINTENANCE

5.1 General

Note:

All warranty undertakings given by the supplier cease to apply if the customer

attempts to rectify any faults on the machine during the warranty period.

5.2 As necessary

S Clean the contact nozzle, the gas nozzle and the spatter shield of welding

spatter.

Let the gas nozzle cool off before it is dismantled (about 30 sec.).

Do not use a tool when dismantling the gas nozzle.

Lubricate the thread of the nozzle using for example a copper--based paste.

To avoid the gas nozzle getting caught we recommend you to inject weld spray

into the nozzle. Use ESAB’s weld spray (order no. 0760 025 500).

N.B.

The spatter shield protects the centre sleeve being burnt through by the heat

and radiation from the welding.

Check the condition of the spatter shield often and replace as necessary.

Do not weld if the spatter shield of the contact nozzle is missing or in bad

condition.

S Check the condition of the wear insert and blow it clean using compressed air.

Select a contact nozzle of the correct dimension according to the wire, see the

table on page 52.

S Check the contact nozzle and replace if deformed or worn.

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5.3 Disassembly

S Unscrew the Allen screw (4) from the clamp.

S Remove the insulating tube (5) from the screw hole.

S Screw out the the gas nozzle (1) and withdraw the spatter shield (2).

S Clean the front part of the contact tube of welding spatter.

S Withdraw the contact tube (8) through the insulating sleeve (7) and the clamp by

turning the contact tube and drawing it backwards.

Disassemble the insulating sleeve (7) in the same way.

S Push out the centre sleeve (3) forwards from the end of the clamp by way of a

20 mm round bar, some 400 mm of length.

S Fit the contact device in reverse order.

N.B. Check the o--rings (6) and replace as necessary.

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6WEARPARTS

6.1 Recommendations

Wire Ø Wire material Contact nozzle* Wire guide insert Ref.

table

mm Fe Ss Cw Al Marking Bore

Order no. Steel Teflon Brass Poin t

1.0 X X X W1.0 1.2 0457625005 X A

1.0 X W1.0 1.2 0457625005 X B

1.2 X X X W1.2 1.4 0457625006 X A

1.2 X W1.2 1.5 0457625007 X B

1.4 X X X W1.4 1.6 0457625008 X A

1.6 X X X W1.6 1.8 0457625009 X A

1.6 X W1.6 1.8 0457625009 X B

1.6 X X X W1.6 2.1 0457625010 X A

1.6 X W1.6 2.1 0457625010 X B

2.0 X X W2.0 2.4 0457625011 X D

2.0 X W2.0 2.4 0457625011 X C

2.4 X X W2.4 2.8 0457625012 X D

2.4 X W2.4 2.8 0457625012 X C

*) When setting welding data, please select a contact nozzle specified in the table. If

the wire binds in the contact nozzle when welding with high welding data, please

select a contact nozzle of greater bore diameter.

Poin t Wire guide insert Wire Ø

Order number:

A Steel spiral (L=210) 1.0--1.6 0457454001

Steel spiral (L=260) 1.0--1.6 0457454002

Steel spiral (L=310) 1.0--1.6 0457454003

B Teflon insert 1.0--1.6 0457619001

(To be cut to desired length on assembly.)

C Teflon insert 2.0--2.4 0457619002

(To be cut to desired length on assembly.)

D Brass tube (L=208) 2.0--2.4 0457620001

Brass tube (L=258) 2.0--2.4 0457620002

Brass tube (L=308) 2.0--2.4 0457620003

7 ORDERING OF SPARE PARTS

Spare parts are ordered through your nearest ESAB representative, see back cover.

When ordering spare parts, please state machine type and number as well as desig-

nation and spare part number as shown in the spare parts list on page 125.

This will simp lify dispatch and ensure you get the right part.

ESAB AB

SE--695 81 LAXÅ

SWEDEN

Phone +46 584 81 000

www.esab.com

051118

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H

Vienna--Liesing

Tel: +43 1 888 25 11

Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V.

Brussels

Tel: +32 2 745 11 00

Fax: +32 2 745 11 28

THE CZECH REPUBLIC

ESAB V AMBERK s.r.o.

Prague

Tel: +420 2 819 40 885

Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB

Copenhagen--Valby

Tel:+4536300111

Fax:+4536304003

FINLAND

ESAB Oy

Helsinki

Tel: +358 9 547 761

Fax: +358 9 547 77 71

FRANCE

ESAB France S.A.

Cergy Pontoise

Tel:+33130755500

Fax:+33130755524

GERMANY

ESAB GmbH

Solingen

Tel: +49 212 298 0

Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd

Waltham Cross

Tel: +44 1992 76 85 15

Fax: +44 1992 71 58 03

ESAB Automation Ltd

Andover

Tel: +44 1264 33 22 33

Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft

Budapest

Tel:+3612044182

Fax:+3612044186

ITALY

ESAB Saldatura S.p.A.

Mesero (Mi)

Tel:+3902979681

Fax:+390297289181

THE NETHERLANDS

ESAB Nederland B.V.

Utrecht

Tel: +31 30 2485 377

Fax: +31 30 2485 260

NORWAY

AS ESAB

Larvik

Tel:+4733121000

Fax:+4733115203

POLAND

ESAB Sp.zo.o.

Katowice

Tel: +48 32 351 11 00

Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda

Lisbon

Tel: +351 8 310 960

Fax: +351 1 859 1277

SLOVAKIA

ESAB Slovakia s.r.o.

Bratislava

Tel:+421744882426

Fax:+421744888741

SPAIN

ESAB Ibérica S.A.

Alcalá de Henares (MADRID)

Tel: +34 91 878 3600

Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB

Gothenburg

Tel:+4631509500

Fax:+4631509222

ESAB international AB

Gothenburg

Tel:+4631509000

Fax:+4631509360

SWITZERLAND

ESAB AG

Dietikon

Tel: +41 1 741 25 25

Fax: +41 1 740 30 55

North and South America

ARGENTINA

CONARCO

Buenos Aires

Tel: +54 11 4 753 4039

Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A.

Contagem--MG

Tel: +55 31 2191 4333

Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc.

Missisauga, Ontario

Tel: +1 905 670 02 20

Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A.

Monterrey

Tel: +52 8 350 5959

Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products

Florence, SC

Tel: +1 843 669 44 11

Fax: +1 843 664 57 48

Asia/Pacific

CHINA

Shanghai ESAB A/P

Shanghai

Tel: +86 21 5308 9922

Fax: +86 21 6566 6622

INDIA

ESAB India Ltd

Calcutta

Tel: +91 33 478 45 17

Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama

Jakarta

Tel: +62 21 460 0188

Fax: +62 21 461 2929

JAPAN

ESAB Japan

Tokyo

Tel: +81 3 5296 7371

Fax: +81 3 5296 8080

MALAYSIA

ESAB (Malaysia) Snd Bhd

Selangor

Tel: +60 3 8027 9869

Fax: +60 3 8027 4754

SINGAPORE

ESAB Asia/Pacific Pte Ltd

Singapore

Tel: +65 6861 43 22

Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation

Kyungnam

Tel: +82 55 269 8170

Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE

Dubai

Tel: +971 4 887 21 11

Fax: +971 4 887 22 63

Representative offices

BULGARIA

ESAB Representative Of fice

Sofia

Tel/Fax: +359 2 974 42 88

EGYPT

ESAB Egypt

Dokki--Cairo

Tel: +20 2 390 96 69

Fax: +20 2 393 32 13

ROMANIA

ESAB Representative Of fice

Bucharest

Tel/Fax: +40 1 322 36 74

RUSSIA

LLC ESAB

Moscow

Tel: +7 095 543 9281

Fax: +7 095 543 9280

LLC ESAB

St Petersburg

Tel: +7 812 336 7080

Fax: +7 812 336 7060

Distributors

For addresses and phone

numbers to our distributors in

other countries, please visit our

home page

www.esab.com

ESAB MTW 1000 User manual

Brand: ESAB

Model: MTW 1000

Category: Welding System

Type: User manual

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ESAB MTW 1000 User manual

ESAB MTW 1000 User manual

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