Operating instructions Welding machine Wega 401 M1.02 FKG Wega 401 M2.20 FKG Wega 401 M2.40 FKG Wega 401 M1.02 FKW Wega 401 M2.20 FKW Wega 401 M2.40 FKW 099-005224-EW501 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com 08.11.2011 * *Details for ewm-warranty www.ewm-group.
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.
Contents Notes on the use of these operating instructions 1 Contents 1 Contents.................................................................................................................................................. 3 2 Safety instructions................................................................................................................................. 6 2.1 Notes on the use of these operating instructions ..........................................................................
Contents Notes on the use of these operating instructions 5.10.2 6 7 8 9 10 11 12 4 M2.20 welding machine control ....................................................................................42 5.10.2.1 Setting the operating point (welding output)..................................................42 5.10.2.2 Setting the operating mode and runtime parameters....................................42 5.10.2.3 Setting the expert parameters...............................................................
Contents Notes on the use of these operating instructions 099-005224-EW501 08.11.
Safety instructions Notes on the use of these operating instructions 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.
Safety instructions Explanation of icons 2.2 Explanation of icons Symbol Description Press Do not press Turn Switch 0 0 1 Switch off machine 1 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 099-005224-EW501 08.11.
Safety instructions General 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.
Safety instructions General WARNING Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure when heated. • Move containers with inflammable or explosive liquids away from the working area! • Never heat explosive liquids, dusts or gases by welding or cutting! Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning.
Safety instructions General CAUTION 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.
Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
Safety instructions Transport and installation 2.4 Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! • Place shielding gas cylinders in the holders provided for them and secure with fixing devices.
Safety instructions Transport and installation 2.4.1 Lifting by crane DANGER min .1 m Risk of injury during lifting by crane! When lifting the equipment by crane, serious injuries can be inflicted by falling equipment or add-on units. • Transport on all lifting lugs at the same time (see Fig. Lifting principle)! • Ensure that there is an even load distribution! Only use ring chains or suspension ropes of the same ° 75 length! • Observe the lifting principle (see Fig.
Safety instructions Ambient conditions 2.5 Ambient conditions CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. • Safe operation of the machine must be guaranteed at all times.
Intended use Applications 3 Intended use This machine has been manufactured according to the latest developments in technology and current regulations and standards. It must only be operated in line with the instructions on correct usage. WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly.
Machine description – quick overview Front view 4 Machine description – quick overview 4.1 Front view NOTE Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. Figure 4-1 16 099-005224-EW501 08.11.
Machine description – quick overview Front view Item Symbol Description 0 1 Lifting lug 2 Carrying handle 3 Cooling air inlet 4 Wheels, guide castors 5 Connection socket, workpiece lead "Hard" choke tapping 6 Connection socket, workpiece lead "Medium" choke tapping 7 Connection socket, workpiece lead Choke tapping "soft" 8 Coolant tank 9 Coolant tank cap 10 Automatic cut-out of coolant pump key button press to reset a triggered fuse 11 Central connection for welding torch (Euro) Integ
Machine description – quick overview Rear view 4.2 Rear view Figure 4-2 18 099-005224-EW501 08.11.
Machine description – quick overview Rear view Item Symbol Description 0 1 Wire feed unit cover lock 2 Cover for wire feed unit and operating elements 3 Securing elements for shielding gas cylinder (strap/chain) 4 Wire spool inspection window Check wire supply 5 Cooling air outlet 6 Bracket for shielding gas cylinder 7 Wheels, fixed castors 8 Mains connection cable 9 Connecting nipple G¼, shielding gas connection 10 Key button, automatic cutout Wire feed motor supply voltage fuse press
Machine description – quick overview Machine control – Operating elements 4.3 Machine control – Operating elements 4.3.1 Welding machine control M1.02 Figure 4-3 Item 20 Symbol Description 0 1 Rotary dial, Wire speed setting Infinite adjustment of the wire speed.
Machine description – quick overview Machine control – Operating elements 4.3.1.1 Internal operating elements NOTE The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted (see "Accessories" chapter). • Unlock the right-hand cover on the machine. • Tilt the cover forwards, then remove upwards. There are other operating elements for parameter setting on the machine.
Machine description – quick overview Machine control – Operating elements 4.3.2 M2.20 welding machine control Figure 4-5 Item Symbol Description 0 1 2 3 4 AMP Key button, Operating mode Non-latched Latched MIG spots (parameter selection t1 is carried out using the "Runtime parameters" button, setting on the "Rotary transducer". Interval (parameter selection, t1 = pulse time, t2 = pulse pause, carried out using "Runtime parameter" button, setting on the "Rotary transducer".
Machine description – quick overview Machine control – Operating elements Item Symbol Description 0 6 7 8 9 10 099-005224-EW501 08.11.2011 Button, Gas test The welding voltage and wire feed remain off when testing and setting the gas flow. Pressing the key button once causes shielding gas to flow for approx. 25 seconds. The button can be pressed again at any time to cancel the process. Button, Wire inching For inching the wire electrode when changing the wire spool (speed = 6.0 m/min, constant).
Machine description – quick overview Machine control – Operating elements 4.3.3 M2.40 welding machine control Figure 4-6 Item 1 Symbol Description 0 Button, Welding task / operating point The parameters are set on the rotary transducer Wire speed display (m/min) Welding current display (A) Sheet metal thickness display (mm) 2 3 Display and select the jobs (welding tasks, selection via job list).Change the JOBs by holding down the button (approx. 3 sec), LED flashes.
Machine description – quick overview Machine control – Operating elements Item Symbol Description 0 4 Rotary dial, Wire speed / welding parameter setting Infinite adjustment of the wire speed or welding current, sheet metal thickness, JOB and runtime parameters such as gas post-flows, wire burn-back, etc. 5 "Runtime parameters" button The parameters are set on the rotary transducer Gas post-flow time (0.0 s to 10.0 s) Wire burn-back (-50% to +50%) Spot time / pulse time (0.1 s to 5.
Design and function General 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.
Design and function Transport and installation 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.
Design and function Mains connection 5.5 Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor.
Design and function Welding torch cooling system 5.6 Welding torch cooling system NOTE Only with water-cooled welding machines! 5.6.1 General CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! • Only use the coolant described in this manual (overview of coolants). • Do not mix different coolants. • When changing the coolant, the entire volume of liquid must be changed.
Design and function Welding torch cooling system 5.6.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. Figure 5-2 Item Symbol Description 0 1 Coolant tank cap 2 Coolant filter sieve 3 Coolant tank 4 "Min" mark Minimum coolant level • • • Unscrew and remove the coolant tank sealing cover. Check filter sieve insert for dirt, clean if necessary and reinsert into position. Top up coolant to the filter sieve insert, close sealing cover again.
Design and function Welding torch and workpiece line connection 5.7 Welding torch and workpiece line connection CAUTION Equipment damage due to improperly connected coolant lines! If the coolant lines are not connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. • Connect all coolant lines correctly! • When using a gas-cooled welding torch, add a tube bridge to the coolant circuit (see chapter “Accessories”).
Design and function Welding torch and workpiece line connection Item Symbol Description 0 1 Welding torch 2 Welding torch hose package 3 Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger 4 6 Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply Workpiece 7 Workpiece lead 8 Connection socket, workpiece lead "Hard" choke tapping 9 Connection socket, workpiece lead "Medium" choke tapping 10 Connection soc
Design and function Shielding gas supply 5.8 Shielding gas supply 5.8.
Design and function Shielding gas supply • • Place the shielding gas cylinder into the relevant cylinder bracket. Secure the shielding gas cylinder using a securing chain. Figure 5-4 Item 1 Pressure regulator 2 Shielding gas cylinder 3 Output side of the pressure regulator 4 Cylinder valve • • 34 Symbol Description 0 Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight. Screw gas hose connection crown nut onto the output side of the pressure regulator.
Design and function Shielding gas supply Figure 5-5 Item Symbol Description 0 1 G¼” connecting nipple Shielding gas connection on the pressure regulator. 2 Securing elements for shielding gas cylinder (strap/chain) 3 Bracket for shielding gas cylinder 099-005224-EW501 08.11.
Design and function Shielding gas supply 5.8.2 Setting the shielding gas quantity Welding process MAG welding MIG brazing MIG welding (aluminium) TIG Recommended shielding gas quantity Wire diameter x 11.5 = l/min Wire diameter x 11.5 = l/min Wire diameter x 13.
Design and function Inserting the wire electrode 5.9 Inserting the wire electrode 5.9.1 Inserting the wire spool NOTE Standard D300 wire spool holder can be used. Adapters (see accessories) are required when using standardised basket coils (DIN 8559). 1 2 Figure 5-6 Item Symbol Description 0 Carrier pin For fixing the wire spool Knurled nut For fixing the wire spool 1 2 • Loosen knurled nut from spool holder.
Design and function Inserting the wire electrode 5.9.2 Changing the wire feed rollers NOTE Unsatisfactory welding results due to faulty wire feeding! Wire feed rollers must be suitable for the diameter of the wire and the material. • Check the roller label to verify that the rollers are suitable for the wire diameter. Turn or change if necessary! • use V-groove rollers with for steel wires and other hard wires, • use U-groove rollers for aluminium wires and other soft, alloyed wires.
Design and function Inserting the wire electrode 1 2 3 5 4 Figure 5-8 Item Symbol Description 0 1 Pressure units 2 Clamping units 3 Wire feed nipple 4 Guide tube 5 Capillary tube or plastic core with support tube, depending on the torch equipment • Extend and lay out the torch hose package. • Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards).
Design and function Select welding task 5.9.4 Spool brake setting 1 Figure 5-9 Item 1 • Symbol Description 0 Allen screw Securing the wire spool retainer and adjustment of the spool brake Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect. NOTE Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation! 5.10 Select welding task 5.10.1 Welding machine control M1.02 5.10.1.
Design and function Select welding task Figure 5-10 Legend with an explanation of symbols can be found in the MIG/MAG function sequences / operating modes chapter. 099-005224-EW501 08.11.
Design and function Select welding task 5.10.2 M2.20 welding machine control 5.10.2.1 Setting the operating point (welding output) This control works according to the twin-knob operation principle. To set the operating point, only the wire speed and the welding voltage need to be set according to the material and the electrode diameter. Operating Action Result element Wire speed setting Welding voltage setting 5.10.2.
Design and function Select welding task 5.10.2.3 Setting the expert parameters NOTE The parameter values set are preset in the JOB and can be modified if necessary. Operating element Action Result 1x Select expert parameters. The key combination must be pressed within 3 seconds. 1x 2x nx Select expert parameters: Gas pre-flow time "GvS" (0 s to 10 s) Wire creep speed "On" 0.5 – 24 m/min Ignition time "tZn" (0 ms to 500 ms) The selected parameter is shown on the display. Set the parameter chosen. 5.
Design and function Select welding task 5.10.2.5 Welding parameter ignition time "tZn" diagram NOTE In the ignition time, the wire feed continues to run at creep speed after the arc is ignited; the ignition behaviour is improved with the optimum setting. The process described below is always used if there is a pause between welding processes of not less than 1.5 seconds. Figure 5-11 Legend with an explanation of symbols can be found in the MIG/MAG function sequences / operating modes chapter.
Design and function Select welding task 5.10.3 M2.40 welding machine control 5.10.3.1 Select JOB number (welding task) This microprocessor-controlled control works according to the one-dial operation principle. Only the gas type, material type and wire electrode diameter should be set as the JOB number on the control, as well as welding output via the step switch.
Design and function Select welding task 5.10.3.2 Setting the operating point (welding output) NOTE The operating point setting in JOB "0" (manual) is carried out as described in the chapter of the same name for control M2.4x. The following settings are therefore only intended for work in JOBs 1-24.
Design and function Select welding task 5.10.3.4 Setting the operating mode and runtime parameters NOTE The parameter values set are preset in the JOB and can be modified if necessary. Operating element Action nx nx Result Select operating mode: Non-latched Latched Spots Interval Select welding parameter: Set gas post-flow time "GnS" (0.0 s to 10.0 s) Set wire burn-back time "drb" (-50% to 50%) Spot/interval time "t1" (0.1 s to 5.0 s) Interval/pause "t2" (0.1 s to 2.
Design and function Select welding task 5.10.3.5 Setting the expert parameters NOTE The parameter values set are preset in the JOB and can be modified if necessary. Operating element Action Result 1x Select expert parameters. The key combination must be pressed within 3 seconds. 1x 2x nx Select expert parameters: Gas pre-flow time "GvS" (0 s to 10 s) Wire creep speed "On" 0.5 – 24 m/min Ignition time "tZn" (0 ms to 500 ms) The selected parameter is shown on the display. Set the parameter chosen. 5.
Design and function Select welding task 5.10.3.7 Welding parameter ignition time "tZn" diagram NOTE In the ignition time, the wire feed continues to run at creep speed after the arc is ignited; the ignition behaviour is improved with the optimum setting. The factory setting is that the ignition time is already optimally preset for various materials. The process described below is always used if there is a pause between welding processes of not less than 1.5 seconds.
Design and function MIG/MAG functional sequences / operating modes 5.11 MIG/MAG functional sequences / operating modes NOTE There are optimum pre-sets for welding parameters such as gas pre-flow and burn back, etc. for numerous applications (although these can also be changed if required). 5.11.
Design and function MIG/MAG functional sequences / operating modes 5.11.2 Non-latched operation Figure 5-14 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. • Changeover to the pre-selected wire speed after the set ignition time (tZn). Step 2 • Release torch trigger. • WF motor stops.
Design and function MIG/MAG functional sequences / operating modes 5.11.3 4-cycle operation Figure 5-15 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". • Arc ignites when the wire electrode makes contact with the workpiece; welding current flows. • Changeover to the pre-selected wire speed after the set ignition time (tZn). Step 2 • Release torch trigger (no effect). Step 3 • Press torch trigger (no effect).
Design and function MIG/MAG functional sequences / operating modes 5.11.4 Spot welding Figure 5-16 1. Start • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. • Changeover to the pre-selected wire speed after the set ignition time (tZn). • The WF stops after the set spot welding time elapses.
Design and function MIG/MAG functional sequences / operating modes 5.11.5 Interval Figure 5-17 1. Start • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire-feed motor runs at "creep-start speed". • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. • Changeover to the pre-selected wire speed after the set ignition time (tZn). • The wire feed stops after the pulse time expires.
Maintenance, care and disposal General 6 Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! • Wait for 4 minutes until the capacitors have discharged! 6.
Maintenance, care and disposal Maintenance work 6.3 Maintenance work 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.
Rectifying faults Customer checklist 7 Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer. 7.
Rectifying faults Check the machine type setting 7.2 Check the machine type setting NOTE Only with the M2.xx machine control. After switching on, the machine type that has been set is displayed for a short time, denoted as "tyP". If the machine type displayed does not match the machine, you have to correct this setting. „tyP 00“ „tyP d00“ „tyP 01“ „tyP r01“ „tyP 02“ „tyP d02“ „tyP d03” „tyP d04” 7.2.1 Saturn 251 Saturn 256 Saturn 301 Mira 301 (M2.
Rectifying faults Resetting the control (Reset all) 7.3 Resetting the control (Reset all) NOTE M2.xx control The first action should always be to check and if necessary correct the machine type setting. All user settings will be overwritten with factory settings and must therefore be checked afterwards, or set up again! After resetting the machine control to the factory settings, it is essential that the machine type used is checked and reset if necessary.
Rectifying faults Vent coolant circuit 7.4 Vent coolant circuit NOTE If there is less coolant in the coolant tank than the minimum required you may need to vent the coolant circuit. In this case the welding machine will automatically shut down the coolant pump and signal an error, see chapter "Rectifying faults". To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! 60 099-005224-EW501 08.11.
Technical data Wega 401 8 Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! 8.1 Wega 401 Wega Switching steps Setting range for welding current Setting range for welding voltage Duty cycle (25 °C) 401 FKG Duty cycle (40 °C) Open circuit voltage Mains connection lead Mains voltage (tolerances) Frequency Mains fuse (safety fuse, slow-blow) Max.
Accessories Options 9 Accessories NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. 9.1 Options Type ON Filter W ON LB Wheels 160x40MM ON Holder Gas Bottle <50L ON Tool Box ON Hose/FR Mount ON Drahteinschleich Poti M1.02 9.2 Designation Adapter for K300 basket coil Manometer pressure regulator Gas hose Pilot static tube Pilot static tube Machine plug Item no.
Replaceable parts Wire feed rollers 10 Replaceable parts 10.1 Wire feed rollers CAUTION 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. 10.1.
Replaceable parts Wire feed rollers 10.1.
Appendix A Recommended settings 11 Appendix A 11.1 Recommended settings Figure 11-1 099-005224-EW501 08.11.
Appendix B Overview of EWM branches 12 Appendix B 12.1 Overview of EWM branches 66 099-005224-EW501 08.11.
