Operating instructions Wire feed unit GB Wega drive 41 WE (M1.02 / M2.20 / M2.40) Wega drive 41L WE (M1.02 / M2.20 / M2.40) Observe additional system documents! Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com 26.09.2011 * *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 5.3 6 7 8 9 10 11 12 4 Welding torch connection.............................................................................................................40 5.3.1 Wega drive 41L.............................................................................................................41 5.3.1.1 Wega drive 41 ...............................................................................................42 5.4 Shielding gas supply ..........
Contents Notes on the use of these operating instructions 099-004965-EW501 26.09.
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 099-004965-EW501 26.09.
Safety instructions General 2.3 General DANGER 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.
Safety instructions General 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.
Safety instructions General 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.
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 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 Wega drive 41L 4 Machine description – quick overview 4.1 Wega drive 41L 4.1.
Machine description – quick overview Wega drive 41L 4.1.
Machine description – quick overview Wega drive 41L 4.1.3 Inside view NOTE Control variants • Machines with M1.xx control There are additional control elements inside the machine for function control. • Machines with M2.4x control A "JOB list" label to define the welding tasks is attached to the inside of the casing cover.
Machine description – quick overview Wega drive 41 4.2 Wega drive 41 4.2.
Machine description – quick overview Wega drive 41 4.2.2 Inside view NOTE Control variants • Machines with M1.xx control There are additional control elements inside the machine for function control. • Machines with M2.4x control A "JOB list" label to define the welding tasks is attached to the inside of the casing cover.
Machine description – quick overview Machine control – Operating elements 4.3 Machine control – Operating elements 4.3.1 Welding machine control M1.02 Figure 4-6 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). Figure 4-7 All details in percent relate to the values stored in the characteristics.
Machine description – quick overview Machine control – Operating elements 4.3.1.2 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 4.3.1.
Machine description – quick overview Machine control – Operating elements 4.3.2 M2.20 welding machine control Figure 4-9 Item Symbol Description 0 1 2 AMP 3 4 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 6 7 8 9 10 24 Symbol Description 0 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 4.3.2.1 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 4.3.2.
Machine description – quick overview Machine control – Operating elements 4.3.2.3 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.
Machine description – quick overview Machine control – Operating elements 4.3.2.5 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.
Machine description – quick overview Machine control – Operating elements 4.3.3 M2.40 welding machine control Figure 4-11 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.
Machine description – quick overview Machine control – Operating elements 4.3.3.1 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.
Machine description – quick overview Machine control – Operating elements 4.3.3.2 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.
Machine description – quick overview Machine control – Operating elements 4.3.3.4 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.
Machine description – quick overview Machine control – Operating elements 4.3.3.5 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.
Machine description – quick overview Machine control – Operating elements 4.3.3.7 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 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 Transport and installation 5.2.1 Setting up on uneven ground WARNING Risk of accidents due to improper set-up location! The machines are designed for operation in an upright position! In the event of incorrect setting up of the machine and adjustment of the wire feed retainer, the wire spool can fall out of the machine! • Machines may only be assembled by trained specialist staff! • Only assemble and operate machines in the recommended positions.
Design and function Transport and installation 5.2.2 Intermediate tube package connection 5.2.2.
Design and function Transport and installation 5.2.2.
Design and function Welding torch connection 5.3 Welding torch 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 connection 5.3.1 Wega drive 41L Figure 5-4 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 Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply 5 • • Insert the central plug for the welding torch into the central connector and screw together with crown nut.
Design and function Welding torch connection 5.3.1.1 Wega drive 41 Figure 5-5 Item 1 Welding torch 2 Welding torch hose package 3 Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger 4 Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply 5 • • 42 Symbol Description 0 Insert the central plug for the welding torch into the central connector and screw together with crown nut.
Design and function Shielding gas supply 5.4 Shielding gas supply 5.4.1 Gas test • • • • • • Slowly open the gas cylinder valve. Open the pressure regulator. Switch on the power source at the main switch. Initiate gas test function on the machine control. Set the relevant gas quantity for the application on the pressure regulator. Trigger gas test function at the machine control inside the machine (wire feed unit with M1.xx) or at the operating panel (wire feed unit with M2.xx).
Design and function Inserting the wire electrode 5.5 Inserting the wire electrode 5.5.1 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 1 2 Symbol Description 0 Carrier pin For fixing the wire spool Knurled nut For fixing the wire spool • Loosen knurled nut from spool holder.
Design and function Inserting the wire electrode 5.5.2 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 5.5.
Design and function Inserting the wire electrode • Extend and lay out the torch tube package. • Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards). Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe.
Design and function MIG/MAG functional sequences / operating modes 5.6 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). 5.6.
Design and function MIG/MAG functional sequences / operating modes 5.6.2 Non-latched operation Figure 5-10 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 5.6.3 Latched operation Figure 5-11 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 5.6.4 Spot welding Figure 5-12 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 5.6.5 Interval Figure 5-13 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". 58 099-004965-EW501 26.09.
Technical data Wega drive 41L 8 Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! 8.1 Wega drive 41L Supply voltage Max. welding current at 60% DC Wire feed speed Standard WF roller fitting Drive Torch connection Protection classification 0.5 m/min to 24 m/min 0.8 + 1.
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 9.1.1 Wega drive 41/41 L (M1.02) Type ON WIRE CREEP POTI M1.02 9.1.
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 11-1 099-004965-EW501 26.09.
Appendix A Recommended settings SG2/3 G3/4 Si1 mm 0,8 1,0 1,5 2,0 3,0 4,0 5,0 6,0 8,0 10,0 12,0 14,0 16,0 20,0 mm m/min 0,8 1,0 0,8 1,0 1,2 0,8 1,0 1,2 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 1,0 1,2 1,6 1,0 1,2 1,6 1,0 1,2 1,6 1,0 1,2 1,6 1,1 1,0 1,3 1,2 0,7 5,8 3,2 1,8 6,8 3,7 2,4 1,6 8,9 5,4 3,5 1,9 11,6 6,9 3,9 2,4 15,2 8,8 4,8 2,6 16,9 9,7 5,2 2,7 20,9 10,4 6,8 3,0 23,3 16,4 8,6 4,4 20,9 10,5 6,1 22,5 15,8 7,2 23,8 22
Appendix A Recommended settings WEGA 601 SG2/3 G3/4 Si1 CO2 100 SG2/3 G3/4 Si1 Ar 82/18 mm 0,8 1,0 1,5 2,0 3,0 4,0 5,0 6,0 8,0 10,0 12,0 14,0 16,0 20,0 mm 0,8 1,0 0,8 1,0 1,2 0,8 1,0 1,2 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 0,8 1,0 1,2 1,6 1,0 1,2 1,6 1,0 1,2 1,6 1,0 1,2 1,6 1,0 1,2 1,6 m/min 2,1 2,0 2,1 2,0 1,4 5,7 3,2 1,7 6,7 3,7 2,3 1,5 9,1 5,3 3,4 1,9 12,3 7,3 3,8 2,4 13,9 9,0 4,6 2,6 16,8 9,7 5,5 2,8 21,0 10,5 6,5 3,1 23,2 16,2
Appendix B Overview of EWM branches 12 Appendix B 12.1 Overview of EWM branches 66 099-004965-EW501 26.09.
