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• info@ewm.de Operating instructions Machines for MIG/MAG welding WEGA 351,401,451 WEGA DRIVE 41,41L N. B. These operating instructions must be read before commissioning. Failure to do so may be dangerous. Machines may only be operated by personnel who are familiar with the appropriate safety regulations.
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Congratulations! You have chosen a quality product from EWM HIGHTEC WELDING GmbH. EWM machines provide results of the highest perfection thanks to their PREMIUM quality. Therefore we are happy to provide you with a full 3-year warranty according to our operating instructions.
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Machine and Company Data Please enter the EWM machine data and your company’s data in the appropriate fields. EWM HIGHTEC WELDING GMBH D-56271 MÜNDERSBACH TYP: SNR: ART: PROJ: GEPRÜFT/CONTROL: Name of Customer / company Name of Customer / company Adress...
Transport and installation......................10 2.2.1 Ambient conditions .......................10 Safety rules while lifting........................11 Notes on the use of these operating instructions.................11 3 Technical data............................12 WEGA 351,401,451 ........................12 WEGA DRIVE 41 L ........................13 WEGA DRIVE 41 .........................13 4 Machine description..........................14 WEGA 351,401,451K........................14 4.1.1 Front view ........................14...
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Contents For your safety 5.2.3 Latched operation......................45 5.2.4 Spots..........................46 5.2.5 Interval .......................... 47 5.2.6 MIG/MAG automatic cut-out..................47 6 Commissioning ............................ 48 General ............................48 Area of application – proper usage....................48 Installation ............................ 48 Mains connection ......................... 48 Machine cooling ...........................
Safety instructions For your safety Safety instructions For your safety Observe accident prevention regulations! Ignoring the following safety procedures can be fatal! Proper usage This machine has been manufactured according to the latest developments in technology and current regulations and standards. It is to be operated only for the use for which it was designed (see chapter Commissioning/Area of application).
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Safety instructions For your safety Workpiece, flying sparks and droplets are hot! • Keep children and animals well away from the working area. Their behaviour is unpredictable. • Move containers with inflammable or explosive liquids away from the working area. There is a danger of fire and explosion.
Safety instructions Transport and installation Transport and installation The machines may only be transported and operated in an upright position. Before carrying away or moving, pull out mains plug and place on the machine. When the power source is moved and positioned, it is only tilt resistant up to an angle of 10° (as specified in EN 60974-A2).
Safety instructions Safety rules while lifting Safety rules while lifting Carefully observe the accident prevention regulations VBG 9, VBG 9a and VGB 15. Machines must be connected on the lifting lugs when being lifted by crane (not on the transport bar)! •...
Technical data WEGA 351,401,451 Technical data WEGA 351,401,451 WEGA series Switching steps 24 (2x12) 24 (2x12) Welding current setting range 30 A–350 A 30 A–400 A 30 A–450 A Duty cycle at 40°C ambient temperature 45% DC 60% DC 100% DC Duty cycle at 20°C ambient temperature...
Technical data WEGA DRIVE 41 L WEGA DRIVE 41 L WEGA DRIVE 41 L 42 V AC Supply voltage Max. welding current at 60% DC 500 A Wire-feed speed 0.5 m/min to 24 m/min Standard WF roller fitting 1.0 + 1.2 mm (for steel wire) Drive 4-roller (37mm) Euro-central or Dinse-central...
Machine description WEGA 351,401,451K Machine description WEGA 351,401,451K 4.1.1 Front view Coolant tank and rapid-action closure couplings of coolant supply and return are only fitted in machines with water cooling. Figure 4-1 Item No.: 099-004934-EWM01...
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Rapid-action closure coupling, red (coolant return) Rapid-action closure coupling, blue (coolant supply) Coolant tank Transport bar Cooling air inlet Conveyor rolls, guide castors Lifting lug Conveyor rolls, fixed castors Step switch, "coarse" welding voltage not applicable with WEGA 351 Item No.: 099-004934-EWM01...
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Machine description WEGA 351,401,451K Item Symbol Description "Wire feed unit cover" lock Mains connection lead Safety chain "Automatic cutout" key button Wire feed motor supply voltage fuse (press to reset a triggered fuse) 42V/4A "Automatic cut-out of fan motor" button (press to reset tripped circuit breaker) Connecting nipple G¼, shielding gas connection...
Machine description WEGA 351,401,451D WEGA 351,401,451D 4.2.1 Front view Coolant tank only for machines fitted with water cooling (DW) Figure 4-3 Item No.: 099-004934-EWM01...
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Machine description WEGA 351,401,451D Item Symbol Description Wire feed unit Lifting lug Transport bar Main switch, machine on/off Step switch, welding voltage "coarse" Step switch, welding voltage Connection socket, workpiece lead "Hard" choke tapping Connection socket, workpiece lead "Medium" choke tapping Connection socket, workpiece lead Choke tapping "soft"...
Machine description WEGA 351,401,451D 4.2.2 Rear view Rapid-action closure couplings in coolant supply and return lines only fitted in machines with water cooling (DW) Figure 4-4 Item No.: 099-004934-EWM01...
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Machine description WEGA 351,401,451D Item Symbol Description "Automatic cutout" key button Wire feed motor supply voltage fuse (press to reset a triggered fuse) 42V/4A "Automatic cut-out of fan motor" button (press to reset tripped circuit breaker) 7-pole connection socket •...
Machine description WEGA DRIVE 41 L WEGA DRIVE 41 L 4.3.1 Front view Internal operating elements for gas test, current test and wire inching are only present in machines with M1.02 (& M1.01) control. In machines with M2.20 and M2.40 control, these operating elements are integrated into the machine control.
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Machine description WEGA DRIVE 41 L Item Symbol Description Control / Operating elements (see chapter Function specification) "Wire feed unit cover" lock Label "Wire feed parts subject to wear" Carrying handle with integrated lifting lug Spool holder Operating elements (see chapter Function specification) Wire delivery unit Rubber feet Euro-central connector (welding torch connection)
Machine description WEGA DRIVE 41 L 4.3.2 Rear view Figure 4-6 Item Symbol Description 7-pole connection socket • Wire feed unit control lead Earth cable connecting nipple Connection of green-yellow earth cable from the intermediate tube package Connecting nipple G¼, shielding gas connection Connector plug, welding current "+"...
Machine description WEGA DRIVE 41 WEGA DRIVE 41 4.4.1 Front view Figure 4-7 Item Symbol Description Slide latch, lock for the protective cap Recessed grip for opening the cap Label "Wire feed parts subject to wear" Damper/support for the cover Carrying handle Control / Operating elements (see chapter Function specification) Spool holder...
Machine description WEGA DRIVE 41 4.4.2 Inside view Internal operating elements for gas test, current test and wire inching are only present in machines with M1.02 (& M1.01) control. In machines with M2.20 and M2.40 control, these operating elements are integrated into the machine control.
Functional characteristics Machine control – Operating elements Functional characteristics Machine control – Operating elements 5.1.1 M1.01 welding machine control Figure 5-1 Item Symbol Description "Wire speed setting" rotary dial Infinite adjustment of the wire speed. Dial for "Spot and interval times" Infinite adjustment of the welding time (0-2 s) in "Spots and interval"...
Functional characteristics Machine control – Operating elements 5.1.1.1 Internal operating elements In decompact machines in combination with M1.02 (& M1.01), the internal operating elements are located in the wire feed unit. (see the chapter "Machine description" ) For the following processes the cover must be removed; to protect the machine it is essential that the cover is fitted back into position afterwards.
Functional characteristics Machine control – Operating elements 5.1.2 Welding machine control M1.02 M 1.02 8 9 10 m/min 0sec 0sec 2sec 2sec Figure 5-3 Item Symbol Description "Wire speed setting" rotary dial Infinite adjustment of the wire speed. Dial for "Spot and interval times" Infinite adjustment of the welding time (0-2 s) in "Spots and interval"...
Functional characteristics Machine control – Operating elements 5.1.2.1 Internal operating elements In decompact machines in combination with M1.02 (& M1.01), the internal operating elements are located in the wire feed unit. (see the chapter "Machine description" ) For the following processes the cover must be removed; to protect the machine it is essential that the cover is fitted back into position afterwards.
Functional characteristics Machine control – Operating elements 5.1.2.3 Welding parameter ignition time "tZn" diagram 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.
Functional characteristics Machine control – Operating elements 5.1.3 M2.20 welding machine control Figure 5-6 Item Symbol Description "Wire inching" button For inching the wire electrode when changing the wire spool (speed = 6.0 m/min, constant). The welding wire is inched into the tube package with the current off and without gas being expelled.
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Functional characteristics Machine control – Operating elements Item Symbol Description "Operating mode" key button 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"...
Functional characteristics Machine control – Operating elements 5.1.4 Selecting MIG/MAG welding tasks 5.1.4.1 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...
Functional characteristics Machine control – Operating elements 5.1.4.3 Setting the expert parameters The parameter values set are preset in the JOB and can be modified if necessary. Operating Action Result element Select expert parameters. The key combination must be pressed within 3 seconds. Select expert parameters: Gas pre-flow time "GvS"...
Functional characteristics Machine control – Operating elements 5.1.5 M2.40 welding machine control Figure 5-8 Item Symbol Description "Wire inching" button For inching the wire electrode when changing the wire spool (speed = 6.0 m/min, constant). The welding wire is inched into the tube package with the current off and without gas being expelled.
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Functional characteristics Machine control – Operating elements Item Symbol Description "Wire speed / welding parameter setting" rotary dial 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. "Operating mode"...
Functional characteristics Machine control – Operating elements 5.1.6 Selecting MIG/MAG welding tasks 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.
Functional characteristics Machine control – Operating elements 5.1.6.2 Setting the operating point (welding output) Operating Action Result element Select the parameter via which the welding output is to be set: Using the panel thickness Using the wire speed Using the welding current Hold down the "TEST"...
Functional characteristics Machine control – Operating elements 5.1.6.5 Setting the expert parameters The parameter values set are preset in the JOB and can be modified if necessary. Operating Action Result element Select expert parameters. The key combination must be pressed within 3 seconds. Select expert parameters: Gas pre-flow time "GvS"...
If an incorrect machine type is shown, it must be reset. „tyP 00“ SATURN 251 „tyP 01“ SATURN 301 „tyP 02“ SATURN 351 „tyP d02“ WEGA 351 / SATURN 351 DG „tyP d03” WEGA 401/451 „tyP d04” WEGA 551/651 5.1.7.3 Setting the machine type Operating...
Functional characteristics Machine control – Operating elements 5.1.7.4 Display, explanation of symbols Symbol Meaning "GnS" - Gas post-flows "drb" - Wire burn-back "t1" - Spot time "t2" - Interval time "GvS" - Gas pre-flows "On" - Wire creep "tZn" - Ignition time "tyP"...
Functional characteristics MIG/MAG functional sequences / operating modes MIG/MAG functional sequences / operating modes The following applies during the wire creep phase: If there is no welding current flowing after 5 seconds (factory setting), the ignition process is cancelled (ignition error). The following applies during the welding phase: If the arc is broken during the welding process and is not re-ignited within 5 seconds (factory setting), there is an automatic cut-out.
Functional characteristics MIG/MAG functional sequences / operating modes 5.2.2 Non-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 after the wire electrode makes contact with the workpiece; welding current flows. •...
Functional characteristics MIG/MAG functional sequences / operating modes 5.2.3 Latched operation Figure 5-12 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". In machines with control M2.40, the torch trigger can be released and step 2 begins. Cancel option: Press the torch trigger again and release.
Functional characteristics MIG/MAG functional sequences / operating modes 5.2.4 Spots Figure 5-13 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. •...
Functional characteristics MIG/MAG functional sequences / operating modes 5.2.5 Interval Figure 5-14 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. •...
Commissioning General Commissioning In machines of the KGE/KGI and DG series, there is no connection of the coolant hoses as described in the following text. The commissioning corresponds otherwise with the machines illustrated (incl. water cooling). General Warning – Risk from electrical current! Follow the safety instructions on the opening pages entitled “For your safety”.
Commissioning Adding coolant Adding coolant The unit is supplied ex works with a minimum level of coolant. The level of coolant must never fall below the "min" mark on the tank. The sieve must always be inserted in the filling pipe before filling. Mixing with other liquids or the use of other coolants voids our manufacturer's guarantee.
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Commissioning Welding torch and workpiece line connection With compact machines, the connection of the welding torch is made on the machine itself; with decompact machines, on the wire feed. In all variants, the workpiece lead is connected directly to the power source. Figure 6-1 Item No.: 099-004934-EWM01...
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Commissioning Welding torch and workpiece line connection Item Symbol Description Euro-central connector (welding torch connection) Welding current, shielding gas and torch trigger included Rapid-action closure coupling, red (coolant return) Rapid-action closure coupling, blue (coolant supply) Connection socket, workpiece lead "Hard" choke tapping Connection socket, workpiece lead "Medium"...
Commissioning Welding torch and workpiece line connection 6.8.1 Intermediate tube package connection The following section of the document applies only to decompact welding machines. 6.8.1.1 Wire feed unit Figure 6-2 Item Symbol Description 7-pole connection socket • Wire feed unit control lead Connecting nipple G¼, shielding gas connection Connector plug, welding current "+"...
Commissioning Welding torch and workpiece line connection 6.8.1.2 Welding machine Figure 6-3 Item Symbol Description 7-pole connection socket • Wire feed unit control lead Rapid-action closure coupling, red (coolant return) Rapid-action closure coupling, blue (coolant supply) Connector plug, welding current "+" Welding current connection on wire feed unit Earth cable connecting nipple Connection of green-yellow earth cable from the intermediate tube package...
Commissioning Shielding gas supply Shielding gas supply 6.9.1 Connecting the shielding gas supply With compact machines, the shielding gas connection is made on the machine itself; with decompact machines, on the intermediate tube package of the wire feed (see "Intermediate tube package connection").
Commissioning Shielding gas supply 6.9.2 Gas test or "rinse tube package" For machines with M2.40 or M2.20 control, the gas test is carried out by pressing the appropriate button on the control; for machines with M1.01 control, the gas test is made on the internal operating elements (see "Machine description") of the compact welding machine or on the internal operating elements of the wire feed.
Commissioning Inserting the wire electrode 6.10 Inserting the wire electrode The removal of the welding power source cover is only done with compact machines; with decompact machines, the wire spool is inserted into the wire feed unit. With decompact machines, open the casing of the wire feed by unlocking and opening the cover to an upwards position.
Commissioning Inserting the wire electrode 6.10.3 Inserting the wire spool The pretensioning of the pin reel shall be checked before each wire spool replacement and before the adjustment of the spool brake, see chapter on fixing of the pin reel (adjustment of the pretensioning)! Standard D300 pin reels can be used.
Commissioning Inserting the wire electrode 6.10.5 Inching the wire electrode Figure 6-8 Item Symbol Description Pressure units Clamping units Wire inlet nipple Guide tube Capillary tube or Teflon core • Extend and lay out the torch tube package. • Unfasten pressure units and fold out (clamping units and counter-pressure rollers will automatically flip upwards).
Commissioning Inserting the wire electrode 6.10.6 Spool brake setting The pretensioning of the pin reel shall be checked before each wire spool replacement and before the adjustment of the spool brake, see chapter on fixing of the pin reel (adjustment of the pretensioning)! Figure 6-9 Item...
DIN EN 61010-1 Appendix A – Measuring Circuit A1. You as the user are tasked with ensuring that your EWM machines conform to the standard E VDE 0544-207 and are tested with the relevant test equipment and measuring devices given above.
Maintenance and care Repetition test 7.3.1 Test intervals and scope A quarterly partial test and an annual extensive test are to be carried out. The extensive test must also be carried out each time that repairs are made; in the case of heavy use, the period can be reduced (e.g. to 6 months when used at construction sites).
Maintenance and care Repetition test 7.3.5 Measurement of insulation resistance The mains switch must be on before the insulation in the interior of the machine through to the transformer can be checked. If a mains contactor is fitted, this should be bridged or the measurement must be carried out on both sides.
Returns of defective equipment subject to warranty may only be made through your EWM sales partner. In the event of problems or queries, please contact the EWM Service Department directly (+49 (0) 2680 181 0). Use only original spare parts and replacement parts when servicing. When placing an order, please quote the type designation and item number, as well as the type, serial number and item number of the relevant equipment.
Your administrative office will be pleased to inform you of the options. EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922.
(such as circuit boards, ignition units) Manufacturer/supplier warranty on: • all additional parts used by EWM, but manufactured by other companies (e.g. motors, pumps, fans, torches, etc.) Non-reproducible software errors and parts subject to mechanical aging are excluded from the warranty (e.g.
Furthermore, it is not valid in the case of unauthorised changes, repairs or modifications. In addition, a claim for warranty does not exist in the case of partially or completely dismantled products and interventions by persons who are not authorised by EWM, as well as in the case of normal wear.
Operating problems, causes and remedies Customer checklist Operating problems, causes and remedies M2.40 control The first action should always be to check and if necessary correct the machine type setting (chapters “Function specification”, “Reset to factory settings”) Customer checklist Error Possible cause Remedy No wire feed...
Umbauten, die nicht ausdrücklich von authorised by EWM. bées n’ayant pas été autorisés expressé- EWM autorisiert sind, verliert diese ment par EWM, cette déclaration devient Erklärung ihre Gültigkeit. caduque. Gerätebezeichnung: Description of the machine: Déscription de la machine: Gerätetyp:...
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