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Summary of Contents for EWM Wega 401 M1.02 FKG
- Page 1 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 08.11.2011 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
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Page 2: General Instructions
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents..............................3 2 Safety instructions..........................6 Notes on the use of these operating instructions ................6 Explanation of icons........................7 General ............................8 Transport and installation ......................12 2.4.1 Lifting by crane ......................13 Ambient conditions........................ - Page 4 Wire feed rollers for steel wire ..................63 10.1.2 Wire feed rollers for aluminium wire ................63 10.1.3 Wire feed rollers for cored wire..................63 10.1.4 Conversion sets ......................64 11 Appendix A............................65 11.1 Recommended settings .......................65 12 Appendix B............................66 12.1 Overview of EWM branches......................66 099-005224-EW501 08.11.2011...
- Page 5 Contents Notes on the use of these operating instructions 099-005224-EW501 08.11.2011...
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Page 6: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions 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. •... -
Page 7: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine 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... -
Page 8: General
Safety instructions General 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! •... - Page 9 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.
- Page 10 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! •...
- Page 11 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.
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Page 12: Transport And Installation
Safety instructions Transport and installation 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! •... -
Page 13: Lifting By Crane
Safety instructions Transport and installation 2.4.1 Lifting by crane DANGER 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. -
Page 14: Ambient Conditions
Safety instructions Ambient conditions 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. -
Page 15: Intended Use
Intended use Applications 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. -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view NOTE Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. Figure 4-1 099-005224-EW501 08.11.2011... - Page 17 Machine description – quick overview Front view Item Symbol Description Lifting lug Carrying handle Cooling air inlet Wheels, guide castors Connection socket, workpiece lead "Hard" choke tapping Connection socket, workpiece lead "Medium" choke tapping Connection socket, workpiece lead Choke tapping "soft" Coolant tank Coolant tank cap Automatic cut-out of coolant pump key button...
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Page 18: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 099-005224-EW501 08.11.2011... - Page 19 Machine description – quick overview Rear view Item Symbol Description Wire feed unit cover lock Cover for wire feed unit and operating elements Securing elements for shielding gas cylinder (strap/chain) Wire spool inspection window Check wire supply Cooling air outlet Bracket for shielding gas cylinder Wheels, fixed castors Mains connection cable...
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Page 20: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements 4.3.1 Welding machine control M1.02 Figure 4-3 Item Symbol Description Rotary dial, Wire speed setting Infinite adjustment of the wire speed. Rotary dial, Spot and interval times Infinite adjustment of the welding time (0-2s) in "Spots and interval"... -
Page 21: Internal Operating Elements
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. -
Page 22: M2.20 Welding Machine Control
Machine description – quick overview Machine control – Operating elements 4.3.2 M2.20 welding machine control Figure 4-5 Item Symbol Description 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"... - Page 23 Machine description – quick overview Machine control – Operating elements Item Symbol Description 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.
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Page 24: M2.40 Welding Machine Control
Machine description – quick overview Machine control – Operating elements 4.3.3 M2.40 welding machine control Figure 4-6 Item Symbol Description 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) Display and select the jobs (welding tasks, selection via job list).Change the JOBs by holding down the button (approx. - Page 25 Machine description – quick overview Machine control – Operating elements Item Symbol Description 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. "Runtime parameters"...
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Page 26: Design And Function
Design and function General Design and function 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! •... -
Page 27: Transport And Installation
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. •... -
Page 28: Mains Connection
Design and function Mains connection 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. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations (any phase sequence for three-phase machines)! -
Page 29: Welding Torch Cooling System
Design and function Welding torch cooling system 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! •... -
Page 30: Adding Coolant
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 Coolant tank cap Coolant filter sieve Coolant tank "Min" mark Minimum coolant level •... -
Page 31: Welding Torch And Workpiece Line Connection
Design and function Welding torch and workpiece line connection 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. - Page 32 Design and function Welding torch and workpiece line connection Item Symbol Description Welding torch Welding torch hose package Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply Workpiece Workpiece lead...
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Page 33: Shielding Gas Supply
Design and function Shielding gas supply Shielding gas supply 5.8.1 Connecting the shielding gas supply WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! •... - Page 34 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 Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve •...
- Page 35 Design and function Shielding gas supply Figure 5-5 Item Symbol Description G¼” connecting nipple Shielding gas connection on the pressure regulator. Securing elements for shielding gas cylinder (strap/chain) Bracket for shielding gas cylinder 099-005224-EW501 08.11.2011...
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Page 36: Setting The Shielding Gas Quantity
Design and function Shielding gas supply 5.8.2 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11.5 = l/min MIG brazing Wire diameter x 11.5 = l/min MIG welding (aluminium) Wire diameter x 13.5 = l/min (100 % argon) Gas nozzle diameter in mm corresponds to l/min gas throughput Helium-rich gas mixtures require a higher gas volume! The table below can be used to correct the gas volume calculated where necessary:... -
Page 37: Inserting The Wire Electrode
Design and function Inserting the wire electrode 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). Figure 5-6 Item Symbol Description Carrier pin For fixing the wire spool... -
Page 38: Changing The Wire Feed Rollers
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! •... - Page 39 Design and function Inserting the wire electrode Figure 5-8 Item Symbol Description Pressure units Clamping units Wire feed nipple Guide tube Capillary tube or plastic core with support tube, depending on the torch equipment • Extend and lay out the torch hose package. •...
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Page 40: Spool Brake Setting
Design and function Select welding task 5.9.4 Spool brake setting Figure 5-9 Item Symbol Description 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! - Page 41 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 08.11.2011...
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Page 42: M2.20 Welding Machine Control
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... -
Page 43: Setting The Expert Parameters
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 Action Result element Select expert parameters. The key combination must be pressed within 3 seconds. Select expert parameters: Gas pre-flow time "GvS"... -
Page 44: Welding Parameter Ignition Time "Tzn" Diagram
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. -
Page 45: M2.40 Welding Machine Control
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. -
Page 46: Setting The Operating Point (Welding Output)
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. -
Page 47: Setting The Operating Mode And Runtime Parameters
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 Action Result element Select operating mode: Non-latched Latched Spots Interval Select welding parameter: Set gas post-flow time "GnS"... -
Page 48: Setting The Expert Parameters
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 Action Result element Select expert parameters. The key combination must be pressed within 3 seconds. Select expert parameters: Gas pre-flow time "GvS"... -
Page 49: Welding Parameter Ignition Time "Tzn" Diagram
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. -
Page 50: Mig/Mag Functional Sequences / Operating Modes
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). 5.11.1 Explanation of signs and functions Symbol Meaning... -
Page 51: Non-Latched Operation
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. •... -
Page 52: 4-Cycle Operation
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. •... -
Page 53: Spot Welding
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. •... -
Page 54: Interval
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. •... -
Page 55: Maintenance, Care And Disposal
Maintenance, care and disposal General 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! •... -
Page 56: Maintenance Work
Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • 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. •... -
Page 57: Rectifying Faults
Rectifying faults Customer checklist 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. -
Page 58: Check The Machine Type Setting
Rectifying faults Check the machine type setting 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. -
Page 59: Resetting The Control (Reset All)
Rectifying faults Resetting the control (Reset all) 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. -
Page 60: Vent Coolant Circuit
Rectifying faults Vent coolant circuit 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". -
Page 61: Technical Data
Technical data Wega 401 Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Wega 401 Wega 401 FKG 401 FKW Switching steps 24 (2 x 12) Setting range for welding current 30 A to 400 A Setting range for welding voltage 15.5 V to 34.0 V Duty cycle (25 °C) -
Page 62: Accessories
Accessories Options Accessories NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Options Type Designation Item no. ON Filter W Retrofit option contamination filter for air inlet 092-002091-00000 ON LB Wheels 160x40MM Retrofit option for locking brake for machine wheels 092-002110-00000 ON Holder Gas Bottle <50L Retrofit option holding plate for gas bottle <50 L... -
Page 63: Replaceable Parts
Replaceable parts Wire feed rollers 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! •... -
Page 64: Conversion Sets
Replaceable parts Wire feed rollers 10.1.4 Conversion sets Type Designation Item no. URUE VERZ>UNVERZ FE/AL Conversion kit, 37mm, 4-roller drive on non-toothed 092-000845-00000 rollers (steel/aluminium) URUE AL 4ZR4R 0,8+1,0 Conversion kit, 37mm, 4-roller drive for aluminium 092-000867-00000 URUE AL 4ZR4R 1,0+1,2 Conversion kit, 37mm, 4-roller drive for aluminium 092-000846-00000 URUE AL 4ZR4R 1,2+1,6... -
Page 65: Recommended Settings
Appendix A Recommended settings Appendix A 11.1 Recommended settings Figure 11-1 099-005224-EW501 08.11.2011... -
Page 66: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005224-EW501 08.11.2011...
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