EWM Wega 401 M1.02 FKG, Wega 401 M2.20 FKG, Wega 401 M2.40 FKW Operating Instructions Manual
Operating instructions
Welding machine
GB
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
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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.
NOTE
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our
customer service department on +49 2680 181-0.
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other
form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed accepted by the
user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are
observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this reason,
we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation,
improper operation or incorrect usage and maintenance or any actions connected to this in any way.
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
Subject to technical amendments.
Contents
Notes on the use of these operating instructions
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3
1 Contents
1
Contents..................................................................................................................................................3
2 Safety instructions.................................................................................................................................6
2.1 Notes on the use of these operating instructions ..........................................................................6
2.2 Explanation of icons.......................................................................................................................7
2.3 General..........................................................................................................................................8
2.4 Transport and installation ............................................................................................................12
2.4.1 Lifting by crane.............................................................................................................13
2.5 Ambient conditions.......................................................................................................................14
2.5.1 In operation...................................................................................................................14
2.5.2 Transport and storage..................................................................................................14
3 Intended use.........................................................................................................................................15
3.1 Applications..................................................................................................................................15
3.1.1 MIG/MAG standard welding.........................................................................................15
3.2 Documents which also apply .......................................................................................................15
3.2.1 Warranty.......................................................................................................................15
3.2.2 Declaration of Conformity.............................................................................................15
3.2.3 Welding in environments with increased electrical hazards.........................................15
3.2.4 Service documents (spare parts and circuit diagrams)................................................15
4 Machine description – quick overview ..............................................................................................16
4.1 Front view ....................................................................................................................................16
4.2 Rear view.....................................................................................................................................18
4.3 Machine control – Operating elements........................................................................................20
4.3.1 Welding machine control M1.02...................................................................................20
4.3.1.1 Internal operating elements ..........................................................................21
4.3.2 M2.20 welding machine control....................................................................................22
4.3.3 M2.40 welding machine control....................................................................................24
5 Design and function.............................................................................................................................26
5.1 General........................................................................................................................................26
5.2 Transport and installation ............................................................................................................27
5.3 Workpiece lead, general..............................................................................................................27
5.4 Machine cooling...........................................................................................................................27
5.5 Mains connection.........................................................................................................................28
5.5.1 Mains configuration ......................................................................................................28
5.6 Welding torch cooling system......................................................................................................29
5.6.1 General.........................................................................................................................29
5.6.2 List of coolants..............................................................................................................29
5.6.3 Adding coolant..............................................................................................................30
5.7 Welding torch and workpiece line connection .............................................................................31
5.8 Shielding gas supply....................................................................................................................33
5.8.1 Connecting the shielding gas supply............................................................................33
5.8.2 Setting the shielding gas quantity.................................................................................36
5.9 Inserting the wire electrode..........................................................................................................37
5.9.1 Inserting the wire spool ................................................................................................37
5.9.2 Changing the wire feed rollers......................................................................................38
5.9.3 Inching the wire electrode ............................................................................................38
5.9.4 Spool brake setting.......................................................................................................40
5.10 Select welding task......................................................................................................................40
5.10.1 Welding machine control M1.02...................................................................................40
5.10.1.1 Setting the operating point (welding output).................................................40
5.10.1.2 Welding parameter ignition time "tZn" diagram ............................................40
Contents
Notes on the use of these operating instructions
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5.10.2 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.......................................................................43
5.10.2.4 Explanation of symbols.................................................................................43
5.10.2.5 Welding parameter ignition time "tZn" diagram.............................................44
5.10.3 M2.40 welding machine control....................................................................................45
5.10.3.1 Select JOB number (welding task)................................................................45
5.10.3.2 Setting the operating point (welding output). .................................................46
5.10.3.3 Setting the wire correction.............................................................................46
5.10.3.4 Setting the operating mode and runtime parameters....................................47
5.10.3.5 Setting the expert parameters.......................................................................48
5.10.3.6 Explanation of symbols.................................................................................48
5.10.3.7 Welding parameter ignition time "tZn" diagram.............................................49
5.11 MIG/MAG functional sequences / operating modes ....................................................................50
5.11.1 Explanation of signs and functions...............................................................................50
5.11.2 Non-latched operation ..................................................................................................51
5.11.3 4-cycle operation ..........................................................................................................52
5.11.4 Spot welding .................................................................................................................53
5.11.5 Interval..........................................................................................................................54
5.11.6 MIG/MAG automatic cut-out.........................................................................................54
6 Maintenance, care and disposal.........................................................................................................55
6.1 General.........................................................................................................................................55
6.2 Maintenance work, intervals.........................................................................................................55
6.2.1 Daily maintenance tasks...............................................................................................55
6.2.2 Monthly maintenance tasks..........................................................................................55
6.2.3 Annual test (inspection and testing during operation)..................................................55
6.3 Maintenance work........................................................................................................................56
6.4 Disposing of equipment................................................................................................................56
6.4.1 Manufacturer's declaration to the end user..................................................................56
6.5 Meeting the requirements of RoHS..............................................................................................56
7 Rectifying faults....................................................................................................................................57
7.1 Customer checklist.......................................................................................................................57
7.2 Check the machine type setting...................................................................................................58
7.2.1 Setting the machine type..............................................................................................58
7.3 Resetting the control (Reset all)...................................................................................................59
7.4 Vent coolant circuit.......................................................................................................................60
8 Technical data.......................................................................................................................................61
8.1 Wega 401.....................................................................................................................................61
9 Accessories ..........................................................................................................................................62
9.1 Options.........................................................................................................................................62
9.2 General accessories ....................................................................................................................62
9.3 Welding torch cooling system ......................................................................................................62
10 Replaceable parts.................................................................................................................................63
10.1 Wire feed rollers...........................................................................................................................63
10.1.1 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
Contents
Notes on the use of these operating instructions
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Safety instructions
Notes on the use of these operating instructions
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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.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
• The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at the edge of the page.
NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.
Safety instructions
Explanation of icons
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2.2 Explanation of icons
Symbol Description
Press
Do not press
Turn
Switch
0
1
Switch off machine
0
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
Safety instructions
General
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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.
• Do not touch any live parts in or on the machine!
• Connection cables and leads must be free of faults!
• Switching off alone is not sufficient!
• Place welding torch and stick electrode holder on an insulated surf ace!
• The unit should only be opened by specialist staff after the mains plug has been unplugged!
• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!
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.
• Observe the maintenance instructions! (see Maintenance and Testing chapter)
• Unwind welding leads completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if
necessary).
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.
• Appoint only skilled persons for repair work (trained service personnel)!
WARNING
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
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.) according to the relevant
regulations in the country in question!
• Protect persons not involved in the work against arc beams and the risk of glare using
safety curtains!
Safety instructions
General
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WARNING
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressur e
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by weldi ng or cutting!
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent
vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to
the ultraviolet radiation of the arc!
• Ensure that there is sufficient fresh air!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
• Check for fire hazards in the working area!
• Do not carry any easily flammable objects such as matches or lighters.
• Keep appropriate fire extinguishing equipment to hand in the working area!
• Thoroughly remove any residue of flammable substances from the workpiece before
starting welding.
• Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
• Connect welding leads correctly!
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
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 resp ective country.
• Setting up and operating the machine according to IEC 60974-9.
• Check at regular intervals that users are working in a safety-conscious way.
• Regular checks of the machine according to IEC 60974-4.
Safety instructions
General
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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 source s, 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.
Damage to the machine due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage equipment and
electronic devices and cause overheating of components leading to fire.
• Make sure all welding leads are securely connected and check regularly.
• Always ensure a proper and secure electrical connection to the wo rkpiece!
• Set up, attach or suspend all conductive power source components like casing, transport
vehicle and crane frames so they are insulated!
• Do not place any other electronic devices such as drillers or angle grind ers, etc., on the
power source, transport vehicle or crane frames unless they are insulated!
• Always put welding torches and electrode holders on an insulated surface when they are
not in use!
Mains connection
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by ta king current from the mains
network. For some types of machines, connection restrictions or requirement s relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of
the operator, where necessary in consultation with the mains network operator, to ensure that
the machine can be connected.
Safety instructions
General
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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. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas,
including residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the
surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding equipment
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
Safety instructions
Transport and installation
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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.
• Avoid heating the shielding gas cylinder!
CAUTION
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10°
(according to EN 60974-A2).
• Set up and transport the machine on level, solid ground!
• Secure add-on parts using suitable equipment!
• Replace damaged wheels and their fixing elements!
• Fix external wire feed units during transport (avoid uncontrolled rotation)!
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
• Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
Safety instructions
Transport and installation
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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. Lifting principle)!
• Ensure that there is an even load distribution! Only
use ring chains or suspension ropes of the same
length!
• Observe the lifting principle (see Fig.)!
• Remove all accessory components before lifting
(e.g. shielding gas cylinders, tool boxes, wire feed
units, etc.)!
• Avoid jerky movements when raising or lowering!
• Use shackles and load hooks of the appropriate size!
min. 1 mmin.
1
m
75 °
Fig. Lifting principle
Risk of injury due to unsuitable ring screws!
In case of improper use of ring screws or the use of unsuitable ring screws, persons
can be seriously damaged by falling equipment or add-on components!
• The ring screw must be completely screwed in!
• The ring screw must be positioned flat onto and in full contact with the supporting surfaces!
• Check that the ring screws are securely fastened before use and check for any damag e
(corrosion, deformation)!
• Do not use or screw in damaged ring screws!
• Avoid lateral loading of the ring screws!
Safety instructions
Ambient conditions
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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.
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!
2.5.1 In operation
Temperature range of the ambient air:
• -20 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.5.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -25 °C to +55 °C
Relative air humidity
• Up to 90% at 20 °C
Intended use
Applications
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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 us age.
WARNING
Hazards due to improper usage!
Hazards may arise for persons, animals and material objects if the equipment is not
used correctly. No liability is accepted for any damages arising from improper usage!
• The equipment must only be used in line with proper usage and by trained or expert staff!
• Do not modify or convert the equipment improperly!
3.1 Applications
3.1.1 MIG/MAG standard welding
Metal arc welding using a wire electrode whereby gas from an external so urce surrounds the arc and the
molten pool to protect them from the atmosphere.
3.2 Documents which also apply
3.2.1 Warranty
NOTE
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
3.2.2 Declaration of Conformity
The designated machine conforms to EC Directives and standards in terms of its design
and construction:
• EC Low Voltage Directive (2006/95/EC),
• EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly
conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted
conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
3.2.3 Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
3.2.4 Service documents (spare parts and circuit diagrams)
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.
• Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
Machine description – quick overview
Front view
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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
Machine description – quick overview
Front view
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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)
Integrated welding current, shielding gas and torch trigger
12
Machine control
See Machine control – operating elements chapter
13
Welding voltage step switch, final setting
To finally adjust the welding voltage (select the option to roughly preset the welding
voltage first)
14
Welding voltage step switch, presetting
To roughly preset the welding voltage
15
Main switch, machine on/off
16
Collective interference signal light
For error messages, see the "Rectifying faults" chapter
17
Ready for operation signal light
Signal light on when the machine is switched on and ready for operation
18
Quick connect coupling (red)
coolant return
19
Quick connect coupling (blue)
coolant supply
Machine description – quick overview
Rear view
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4.2 Rear view
Figure 4-2
Machine description – quick overview
Rear view
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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 to reset a triggered fuse
11
Button, Automatic cut-out of fan motor
Press to reset tripped circuit breaker
Machine description – quick overview
Machine control – Operating elements
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4.3 Machine control – Operating elements
4.3.1 Welding machine control M1.02
Figure 4-3
Item Symbol Description 0
1
Rotary dial, Wire speed setting
Infinite adjustment of the wire speed.
2
Rotary dial, Spot and interval times
Infinite adjustment of the welding time (0-2s) in "Spots and interval" operating mode
3
"Operating mode" selector switch
Changeover between non-latched, latched, spot, interval
4
Rotary dial, Pause time
Infinite adjustment of the pause time (0–2s) in "Interval" operating mode
5
Ready for operation signal light
Signal light on when the machine is switched on and ready for operation
Machine description – quick overview
Machine control – Operating elements
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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.
Figure 4-4
All details in percent relate to the values stored in the characteristics.
Item Symbol Description 0
1
0
-15
-30
+15
+30
Rotary dial, Wire creep (optional)
+/- 30%
2
Key Button, Wire inching
Currentless wire inching
3
"Gas post-flow time" trimmer
Setting range 0.2-10 s
4
Trimmer, Burn-back
+/- 50%
Machine description – quick overview
Machine control – Operating elements
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4.3.2 M2.20 welding machine control
Figure 4-5
Item Symbol Description 0
1
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".
2 AMP
Current signal light
Lights when the current is shown on the display.
3
Rotary dial, Wire speed/welding parameter setting
Continuous adjustment of the wire speed or welding current and setting of runtime
parameters such as gas post-flows, wire burn-back, etc.
4
"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 5.0 s)
Pulse pause (0.1 s to 2.0 s)
5
Lower display
Display of wire feed speed, welding current and runtime parameters.
Machine description – quick overview
Machine control – Operating elements
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Item Symbol Description 0
6
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 second s. The
button can be pressed again at any time to cancel the process.
7
Button, Wire inching
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.
This ensures a high degree of safety for the welder by preventing accidental ignition of
the arc.
8
Upper, display
Displays welding voltage or person who designated the runtime parameters
9
Signal light, HOLD
Lit: Display shows the last parameters used for welding.
Not lit: Display shows the setpoint values or current values during welding.
10
Signal light, Wire speed
Lights when the wire speed is shown on the display.
Machine description – quick overview
Machine control – Operating elements
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4.3.3 M2.40 welding machine control
Figure 4-6
Item Symbol Description 0
1
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. 3 sec), LED flashes.
2
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".
Signal light, Choke tappings
Depending on the machine design, there are two or three workpiece connection
sockets on the welding machine (choke tappings). The machine displays the
recommended workpiece connection in JOB mode (see relevant images on the
connection sockets).
Choke tapping 1 (hard), workpiece lead connection socket
Choke tapping 2 (medium), workpiece lead connection socket
3
Choke tapping 3 (soft), workpiece lead connection socket
Machine description – quick overview
Machine control – Operating elements
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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 5.0 s)
Pulse pause (0.1 s to 2.0 s)
6
Button, Test welding parameters
Press the button and set the required welding voltage on the step switch at the same
time (the open-circuit voltage will be shown in the upper display; the wire speed,
welding current or panel thickness in the lower display).
7
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 second s. The
button can be pressed again at any time to cancel the process.
8
Button, Wire inching
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.
This ensures a high degree of safety for the welder by preventing accidental ignition of
the arc.
9
Lower display
Display of wire feed speed, welding current, sheet metal thickness, JOB number and
runtime parameters.
10
Upper display
Display of the welding voltage, correction value for the wire speed or parameter
designations for runtime parameters.
11
Signal light, MANUAL
Signal light is on when the machine is not in JOB mode. All parameter settings are
carried out "manually" by the user (JOB 0).
12
Signal light, HOLD
Lit: Display shows the last parameters used for welding.
Not lit: Display shows the setpoint values or current values during welding.
13
Signal light Voltage
On when the welding voltage or open circuit voltage is displayed.
14
Signal light, Wire correction
On when the correction value of the wire speed is being displayed.
Design and function
General
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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. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
CAUTION
Risk of burns on the welding current connection!
If the welding current connections are not locked, connections and leads heat up and
can cause burns, if touched!
• Check the welding current connections every day and lock by turn ing in clockwise direction,
if necessary.
Risk of injury due to moving parts!
The wire feed units are equipped with moving parts, which can trap hands, hair,
clothing or tools and thus injure persons!
• Do not reach into rotating or moving parts or drive components!
• Keep casing covers closed during operation!
Risk of injury due to welding wire escaping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may
escape in an uncontrolled manner and injure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the
welding torch!
• Remove the pressure rollers from the wire feed unit if no welding torch is fitted!
• Check wire guide at regular intervals!
• Keep all casing covers closed during operation!
Risk from electrical current!
If welding is carried out alternately using different methods and if a welding torch and
an electrode holder remain connected to the machine, the open-circuit/welding voltage
is applied simultaneously on all cables.
• The torch and the electrode holder should therefore always be placed on an in sulated
surface before starting work and during breaks.
Design and function
Transport and installation
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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 fo r the relevant
accessory components.
• Accessory components are detected automatically after the power source is switched on.
Using protective dust caps!
Protective dust caps protect the connection sockets and ther efore the machine against
dirt and damage.
• The protective dust cap must be fitted if there is no accessory component being operated
on that connection.
• The cap must be replaced if faulty or if lost!
5.2 Transport and installation
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.
5.3 Workpiece lead, general
CAUTION
Risk of burns due to incorrect connection of the workpiece lead!
Paint, rust and dirt on the connection restrict the power flow and may lead to stray
welding currents.
Stray welding currents may cause fires and injuries!
• Clean the connections!
• Fix the workpiece lead securely!
• Do not use structural parts of the workpiece as a return lead for the welding current!
• Take care to ensure faultless power connections!
5.4 Machine cooling
To obtain an optimal duty cycle from the power components, the following precautions should be
observed:
• Ensure that the working area is adequately ventilated.
• Do not obstruct the air inlets and outlets of the machine.
• Do not allow metal parts, dust or other objects to get into the machine.
Design and function
Mains connection
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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.
• 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)!
• Mains plug, socket and lead must be checked regularly by an electrician!
• When operating the generator always ensure it is earthed as stated in the operating
instructions. The resulting network has to be suitable for operating devices according to
protection class 1.
5.5.1 Mains configuration
NOTE
The machine may be connected to:
• a three-phase system with four conductors and an earthed neutral conductor
• a three-phase system with three conductors of which any one can be earthed,
e.g. the outer conductor
Figure 5-1
Legend
Item Designation Colour code
L1 Outer conductor 1 black
L2 Outer conductor 2 brown
L3 Outer conductor 3 grey
N Neutral conductor blue
PE Protective conductor green-yellow
CAUTION
Operating voltage - mains voltage!
The operating voltage shown on the rating plate must be consistent with the mains
voltage, in order to avoid damage to the machine!
• For mains fuse protection, please refer to the “Technical data” chapter!
• Insert mains plug of the switched-off machine into the appropriate socket.
Design and function
Welding torch cooling system
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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.
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch (see overview of coolants).
Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure
that the frost protection is adequate to prevent damage to the machine or the accessory
components.
• The coolant must be checked for adequate frost protection with the TYP 1 frost protection
tester (see accessories).
• Replace coolant as necessary if frost protection is inadequate!
NOTE
The disposal of coolant must be carried out according to official regulations and
observing the relevant safety data sheets (German waste code number: 70104)!
• Coolant must not be disposed of together with household waste.
• Coolant must not be discharged into the sewerage system.
• Recommended cleaning agent: water, if necessary with cleaning agent added.
5.6.2 List of coolants
The following coolants may be used (for item nos., please see the Accessories chapter):
Coolant Temperature range
KF 23E (Standard) -10 °C to +40 °C
KF 37E -20 °C to +10 °C
DKF 23E (for plasma machines) 0 °C to +40 °C
Design and function
Welding torch cooling system
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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.
NOTE
After the initial filling, wait for at least one minute when the machine is switched on so
that the tube package is filled with coolant completely and without bubbles.
With frequent changes of torch and during the initial filling process, the cooling unit
tank should be topped up as necessary.
The level of coolant must never fall below the “min” mark.
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".
Design and function
Welding torch and workpiece line connection
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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”).
NOTE
Prepare welding torch according to the welding task in hand (see operating instructions
for the torch).
Figure 5-3
Design and function
Welding torch and workpiece line connection
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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
5
Quick connect coupling (blue)
coolant supply
6
Workpiece
7
Workpiece lead
8
Connection socket, workpiece lead
"Hard" choke tapping
9
Connection socket, workpiece lead
"Medium" choke tapping
10
Connection socket, workpiece lead
Choke tapping "soft"
• Insert the central plug for the welding torch into the central connector and screw togethe r with crown
nut.
• Insert the cable plug of the workpiece lead into the connection socket for workpiece lead 1, 2 or 3
(depending on the application or shielding gas used) and lock by turning to the right.
If fitted:
• Lock connecting nipples of the cooling water tubes into the corresp onding quick connect couplings:
Return line red to quick connect coupling, red (coolant return) and
supply line blue to quick connect coupling, blue (coolant supply).
Design and function
Shielding gas supply
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5.8 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!
• Secure shielding gas cylinders using the standard fastening elemen t s on
the unit (chain/belt)!
• The fastening elements must tightly enclose the shielding gas cylinder!
• Attach the fastening elements within the upper half of the shielding gas
cylinder!
• Do not attach any element to the shielding gas cylinder valve!
• Observe the instructions from the gas manufacturer and any relevant
regulations concerning the use of compressed air!
• Avoid heating the shielding gas cylinder!
CAUTION
Faults in the shielding gas supply.
An unhindered shielding gas supply from the shielding gas cylinder to the welding
torch is a fundamental requirement for optimum welding results. In addition, a blocked
shielding gas supply may result in the welding torch being destroyed.
• Always re-fit the yellow protective cap when not using the shielding gas connection.
• All shielding gas connections must be gas tight.
NOTE
Before connecting the pressure regulator to the gas cylinder, open the cylinder valve
briefly to expel any dirt.
Design and function
Shielding gas supply
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• 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 0
1
Pressure regulator
2
Shielding gas cylinder
3
Output side of the pressure regulator
4
Cylinder valve
• 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
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35
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
Design and function
Shielding gas supply
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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)
TIG 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 whe re n ecessary:
Shielding gas Factor
75% Ar/25% He 1.14
50% Ar/50% He 1.35
25% Ar/75% He 1.75
100% He 3.16
NOTE
Incorrect shielding gas setting!
If the shielding gas setting is too low or too high, this can introduce air to the weld pool
and may cause pores to form.
• Adjust the shielding gas quantity to suit the welding task!
Design and function
Inserting the wire electrode
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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).
2
1
Figure 5-6
Item Symbol Description 0
1
Carrier pin
For fixing the wire spool
2
Knurled nut
For fixing the wire spool
• Loosen knurled nut from spool holder.
• Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore.
• Fasten wire spool using knurled nut.
CAUTION
Risk of injury due to incorrectly secured wire spool.
If the wire spool is not secured properly, it may come loose from the wire spool holder
and fall to the ground, causing damage to the machine and injuries.
• Securely fasten the wire spool to the wire spool holder using the knurled nut.
• Before you start working, always check the wire spool is secu rely fastened.
Design and function
Inserting the wire electrode
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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.
• Slide new drive rollers into place so that the diameter of the wire used is visible on the dri ve roller.
• Screw the drive rollers in place with knurled screws.
Figure 5-7
5.9.3 Inching the wire electrode
CAUTION
Risk of injury due to welding wire escaping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may
escape in an uncontrolled manner and injure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the
welding torch!
• Remove the pressure rollers from the wire feed unit if no welding torch is fitted!
• Check wire guide at regular intervals!
• Keep all casing covers closed during operation!
CAUTION
Extensive wear due to incorrect contact pressure!
Incorrect contact pressure will cause extensive wear of the wire feed rollers!
• With the adjusting nuts of the pressure units set the contact pressure so that the wire
electrode is conveyed but will still slip through if the wire spool jams.
• Set the contact pressure of the front rollers (in wire feed direction) to a higher value!
Design and function
Inserting the wire electrode
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39
1
2
3
4
5
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).
• Unwind welding wire carefully from the wire spool and insert through the wi re inlet nipple over the drive
roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe.
• Press the clamping element with the pressure roller back downwards and fold the wire units back up
again (wire electrode should be in the groove on the drive roller).
• Set the contact pressure with the adjusting nuts of the pressure unit.
• Press the wire inching button until the wire electrode projects out of the welding torch.
NOTE
The inching speed is infinitely adjustable by simultaneously pressing the wire inching
button and turning the wire speed rotary dial. The display shows the selected inching
speed.
Design and function
Select welding task
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5.9.4 Spool brake setting
1
Figure 5-9
Item Symbol Description 0
1
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
5.10.1.1 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
element
Action Result
Wire speed setting
Welding voltage setting
5.10.1.2 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.
Design and function
Select welding task
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41
Figure 5-10
Legend with an explanation of symbols can be found in the MIG/MAG function sequences /
operating modes chapter.
Design and function
Select welding task
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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
element
Action Result
Wire speed setting
Welding voltage setting
5.10.2.2 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 Result
n x
Select operating mode:
Non-latched
Latched
Spots
Interval
n x
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 2.0 s)
The selected parameter is shown on the display
Set the parameter chosen
Design and function
Select welding task
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43
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
1 x
1 x
2 x
Select expert parameters.
The key combination must be pressed within 3 seconds.
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)
n x
The selected parameter is shown on the display.
Set the parameter chosen.
5.10.2.4 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" - Machine type (type table, see chapter "Rectifying faults")
Design and function
Select welding task
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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
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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 shoul d be set as the JOB number on the
control, as well as welding output via the step switch. This defines the welding task and the system
specifies the optimum wire feed speed for the required operating point after the "Test button" is pressed.
These settings are retained after the machine is switched off. After switching on again, the parameters
previously set can be used to continue welding.
The user has the option to correct the wire feed speed according to the welding task or individual
requirements.
The welding task setting can also be made using the two-dial operation principle, however. To do this, set
the "JOB 0" (manual / no program) from the JOB list, the welding voltage on the step switch, and the wire
speed on the rotary dial. Other parameters are set as described under "Using synergic mode".
Operating
element
Action Result
X x
Select "JOB". When the "JOB" LED lights, press and hold
down the button.
2 sec.
"JOB" LED flashes.
The welder uses the filler material inserted and the connected shielding gas to select the JOB number
according to the "JOB-LIST". The "JOB-LIST" is a sticker fixed near the wire feed drive unit.
Set JOB number (0-24).
1 x
Confirm selection.
CrNi
Ar98/2
Ar82/18
AlMg
Ar100
AlSi
Ar100
Al99
Manuell / no program
Ar100
%
Gas
0,8
1
9
13
17
21
0
1,0
2
10
14
18
22
1,2
3
11
15
19
23
1,6
Job-Nr.
4
12
16
20
24
Material
5678
SG2/3
G3/4 Si1
CO 100
2
Massivdraht / Solid Wire
Massivdraht / Solid Wire
Wire
094-010488-00500
Figure 5-12
Design and function
Select welding task
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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.
Operating
element
Action Result
n x
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" button and at the same time set the operating
point on the step switch.
The display shows the required parameters and the open circuit
voltage.
If the "Volt" and "Wire feed correction" diodes are flashing, this indicates
an error (e.g. short circuit between torch and workpiece, inductivity
error, etc). To correct the error, press "TEST" again.
If the operating mode has already been selected, all the necessary settings will have been
activated and welding can be started.
5.10.3.3 Setting the wire correction
The wire speed (arc length) can be modified using the wire correction if required.
Operating
element
Action Result
Set the wire correction value
Design and function
Select welding task
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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 Result
n x
Select operating mode:
Non-latched
Latched
Spots
Interval
n x
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 2.0 s)
The selected parameter is shown on the display
Set the parameter chosen
Design and function
Select welding task
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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
1 x
1 x
2 x
Select expert parameters.
The key combination must be pressed within 3 seconds.
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)
n x
The selected parameter is shown on the display.
Set the parameter chosen.
5.10.3.6 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" - Machine type (type table, see chapter "Rectifying faults")
Design and function
Select welding task
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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.
Figure 5-13
Legend with an explanation of symbols can be found in the MIG/MAG function sequences /
operating modes chapter.
Design and function
MIG/MAG functional sequences / operating modes
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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
Press torch trigger
Release torch trigger
Tap torch trigger (press briefly and release)
Shielding gas flowing
I
Welding output
Wire electrode is being conveyed
Wire creep
Wire burn-back
Gas pre-flows
Gas post-flows
Non-latched
Latched
t
Time
t1
Spot time
t2
Interval pause
tZn
Ignition time
Design and function
MIG/MAG functional sequences / operating modes
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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 curre nt flows.
• Changeover to the pre-selected wire speed after the set ignition time (tZn).
Step 2
• Release torch trigger.
• WF motor stops.
• Arc is extinguished after the pre-selected wire burn-back time elapses.
• Gas post-flow time elapses.
Design and function
MIG/MAG functional sequences / operating modes
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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; weldin g 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).
Step 4
• Release torch trigger.
• WF motor stops.
• Arc is extinguished after the pre-selected wire burn-back time elapses.
• Gas post-flow time elapses.
Design and function
MIG/MAG functional sequences / operating modes
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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 curre nt flows.
• Changeover to the pre-selected wire speed after the set ignition time (tZn).
• The WF stops after the set spot welding time elapses.
• Arc is extinguished after the pre-selected wire burn-back time elapses.
• Gas post-flow time elapses.
2. End
• Release torch trigger.
NOTE
When the torch trigger is released, the welding process is also interrupted even before
the spot time elapses.
With fast tacking (time between two welding process under approx. 1.5 seconds) the gas
pre-flow, the creep process and also the ignition time (tZn) are not required.
Design and function
MIG/MAG functional sequences / operating modes
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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.
• Arc is extinguished after the wire burn-back time elapses.
• The process is repeated after the pause time elapses.
2. End
• Release torch trigger.
• Wire feed stops.
• Arc is extinguished after the wire burn-back time elapses.
• Gas post-flow time elapses.
NOTE
When the torch trigger is released, the welding process is also interrupted even before
the spot time elapses.
With fast tacking (time between two welding process under approx. 1.5 seconds) the gas
pre-flow, the creep process and also the ignition time (tZn) are not required.
5.11.6 MIG/MAG automatic cut-out
NOTE
The welding machine ends the ignition process or the welding process with an
• Ignition fault (no welding current flows within 5 s after the start signal).
• Arc interruption (arc is intrerupted for longer than 2 s).
Maintenance, care and disposal
General
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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!
6.1 General
When used in the specified environmental conditions and under normal operating condition s, this
machine is largely maintenance-free and requires a minimum of care.
There are some points, which should be observed, to guarantee fault-free operation of your welding
machine. Among these are regular cleaning and checking as descri bed below, depending on the pollution
level of the environment and the length of time the unit is in use.
6.2 Maintenance work, intervals
6.2.1 Daily maintenance tasks
• Check correct mounting of the wire spool.
• Mains supply lead and its strain relief
• Welding current cables (check that they are fitted correctly and secured)
• Gas tubes and their switching equipment (solenoid valve)
• Gas cylinder securing elements
• Operating, message, safety and adjustment devices (Functional test)
• Other, general condition
6.2.2 Monthly maintenance tasks
• Casing damage (front, rear and side walls)
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
• Selector switches, command devices, emergency stop devices, voltage re ducing devices, message
and control lamps
• Check coolant tubes and their connections for impurities
• Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
6.2.3 Annual test (inspection and testing during operation)
NOTE
The welding machine may only be tested by competent, capable personsl.
A capable person is one who, because of his training, knowledge and experience, is
able to recognise the dangers that can occur while testing welding power sources as
well as possible subsequent damage and who is able to implement the required safety
procedures.
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition
to the regulations on testing given here, the relevant local laws and regulations must also be observed.
Maintenance, care and disposal
Maintenance work
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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.
• Appoint only skilled persons for repair work (trained service personnel)!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service matters, always consult the dealer who supplied the
machine. Return deliveries of defective equipment subject to warranty may only be made through your
dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the
machine type, serial number and item number of the machine, as well as the type designation and item
number of the spare part.
6.4 Disposing of equipment
NOTE
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and
electronic components, which must be disposed of.
• Do not dispose of in household waste!
• Observe the local regulations regarding disposal!
6.4.1 Manufacturer's declaration to the end user
• According to European provisions (guideline 2002/96/EG of the European Parliament and the Council
of January, 27th 2003), used electric and electronic equipment may no longer be placed in u nsorted
municipal waste. It must be collected separately. The symbol depicting a waste container on wheels
indicates that the equipment must be collected separately.
This machine is to be placed for disposal or recycling in the waste separation system s provided for this
purpose.
• According to German law (law governing the distribution, taking b ack and environmentally correct
disposal of electric and electronic equipment (ElektroG) from 16.03.2005), used machines are to be
placed in a collection system separate from unsorted municipal waste. The public wa ste management
utilities (communities) have created collection points at which used equipment from private households
can be disposed of free of charge.
• 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.
• In addition to this, returns are also possible throughout Europe via EWM sales partners.
6.5 Meeting the requirements of RoHS
We, EWM HIGHTEC Welding GmbH Mündersbach, hereby co nfirm that all products supplied by us which
are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).
Rectifying faults
Customer checklist
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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 you r autho rised
dealer.
7.1 Customer checklist
Collective interference signal light illuminates
a Excess temperature, welding machine
# Allow the machine to cool down whilst still switched on
a Welding current monitoring device triggered (stray welding currents flowing across the protective
earth). The error must be reset by switching the machine off and on again.
# Welding wire is touching electrically conductive casing parts (check wire guide, has the welding
wire sprung off the wire spool?).
# Check for a correct mounting of the welding lead. Fit the feeder clamp of the welding lead as
close as possible to the arc.
Coolant error/no coolant flowing
a Insufficient coolant flow
# Check coolant level and refill if necessary
a Air in the coolant circuit
# see chapter "Vent coolant circuit"
Wire feed problems
a Contact tip blocked
# Clean, spray with anti-spatter spray and replace if necessary
a Setting the spool brake (see "Setting the spool brake" chapter)
# Check settings and correct if necessary
a Setting pressure units (see "Inching wire electrodes" chapter)
# Check settings and correct if necessary
a Worn wire rolls
# Check and replace if necessary
a Wire feed motor without supply voltage (automatic cutout triggered by overloading)
# Reset triggered fuse (rear of the power source) by pressing the ke y button
a Kinked hose packages
# Extend and lay out the torch hose package
a Wire guide core or spiral is dirty or worn
# Clean core or spiral; replace kinked or worn cores
Functional errors
a Machine control without displaying the signal lights after switching on
# Phase failure > check mains connection (fuses)
a No welding performance
# Phase failure > check mains connection (fuses)
a Various parameters cannot be set
# Entry level is blocked, disable access lock (see chapter entitled "Lock welding parameters
against unauthorised access")
a Connection problems
# Make control lead connections and check that they are fitted correctly.
a Loose welding current connections
# Tighten power connections on the torch and/or on the workpiece
# Tighten contact tip/collet correctly
Rectifying faults
Check the machine type setting
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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“ Saturn 251
„tyP d00“ Saturn 256
„tyP 01“ Saturn 301
„tyP r01“ Mira 301 (M2.xx)
„tyP 02“ Saturn 351
„tyP d02“ Wega 351, Saturn 351 DG
„tyP d03” Wega 401,451
„tyP d04” Wega 501,601
7.2.1 Setting the machine type
Operating
element
Action Result
1 x
Switch off the welding machine.
+
Press and hold both buttons.
1 x
Switch on the welding machine, "Anl" is shown on the display.
m/min
Whilst "Anl" is being displayed, set the machine type:
0 Saturn 251 KGE
1 Saturn 301 KGE
2 Saturn 351 KGE
3 decompact (DK), all; Wega, all
7 Mira 301 KGE
Rectifying faults
Resetting the control (Reset all)
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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.
Operating
element
Action Result
1 x
Switch off the welding machine.
+
t2
t1
Press and hold both buttons.
1 x
Switch on the welding machine, "rES" is shown briefly on the display.
Rectifying faults
Vent coolant circuit
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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)!
Technical data
Wega 401
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8 Technical data
NOTE
Performance specifications and guarantee only in connection with original spare and
replacement parts!
8.1 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
400 A (70%) Duty cycle (25 °C)
300 A (100%)
400 A (60%) Duty cycle (40 °C)
300 A (100%)
Open circuit voltage 15.5 V to 45 V
Mains connection lead H07RN-F4G4
Mains voltage (tolerances) 3 x 400 V (+/- 15%)
Frequency 50/60 Hz
Mains fuse
(safety fuse, slow-blow)
3 x 25 A
Max. connected load 19.2 kVA
Recommended generator power 26 kVA
Welding lead 70 mm²
cosϕ
0.95
Cooling capacity at 1 l/min - 1200 W
Tank capacity (max.) - 9 l
Flow rate (max.) - 5 l/min
Outlet pressure (max.) - 3.5 bar
Weight DW 145 kg 185 kg
Dimensions L x W x H in mm 1100 x 550 x 940
Insulation class/protection
classification
H/IP 23
Ambient temperature -20 °C to +40 °C
Machine/torch cooling Fan/gas Fan/water
EMC class A
Constructed to standard IEC 60974-1, -5, -10
/
IEC 60974-1, -2, -5, -10
/
Accessories
Options
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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 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 092-002151-00000
ON Tool Box Retrofit option tool box 092-002138-00000
ON Hose/FR Mount Optional holder for tubes and remote control for
machines without pivot support
092-002116-00000
ON Drahteinschleich Poti
M1.02
Retrofit option, wire creep rotary dial 092-001102-00000
9.2 General accessories
Type Designation Item no.
AK300 Adapter for K300 basket coil 094-001803-00001
DM1 32L/MIN Manometer pressure regulator 094-000009-00000
GH 2X1/4'' 2M Gas hose 094-000010-00001
GS16L G1/4" SW 17 Pilot static tube 094-000914-00000
GS25L G1/4" SW 17 Pilot static tube 094-001100-00000
5POLE/CEE/32A/M Machine plug 094-000207-00000
9.3 Welding torch cooling system
Type Designation Item no.
KF 23E-10 Coolant (-10 °C), 9.3 l 094-000530-0000 0
KF 23E-200 Coolant (-10 °C), 200 litres 094-000530-00001
KF 37E-10 Coolant (-20 °C), 9.3 l 094-006256-0000 0
KF 37E-200 Coolant (-20 °C), 200 l 094-006256-00001
TYP 1 Frost protection tester 094-014499-00000
HOSE BRIDGE Tube bridge 092-007843-00000
Replaceable parts
Wire feed rollers
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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 source s, 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.
10.1.1 Wire feed rollers for steel wire
Type Designation Item no.
FE 2DR4R 0,6+0,8 Drive rollers, 37 mm, steel 092-000839-00000
FE 2DR4R 0,8+1,0 Drive rollers, 37 mm, steel 092-000840-00000
FE 2DR4R 0,9+1,2 Drive rollers, 37 mm, steel 092-000841-00000
FE 2DR4R 1,0+1,2 Drive rollers, 37 mm, steel 092-000842-00000
FE 2DR4R 1,2+1,6 Drive rollers, 37 mm, steel 092-000843-00000
FE/AL 2GR4R Pressure rollers, smooth, 37mm 092-000844-00000
10.1.2 Wire feed rollers for aluminium wire
Type Designation Item no.
AL 4ZR4R 0,8+1,0 Twin rollers, 37 mm, for aluminium 092-000869-00000
AL 4ZR4R 1,0+1,2 Twin rollers, 37 mm, for aluminium 092-000848-00000
AL 4ZR4R 1,2+1,6 Twin rollers, 37 mm, for aluminium 092-000849-00000
AL 4ZR4R 2,4+3,2 Twin rollers, 37 mm, for aluminium 092-000870-00000
10.1.3 Wire feed rollers for cored wire
Type Designation Item no.
ROE 2DR4R 0,8/0,9+0,8/0,9 Drive rollers, 37 mm, cored wire 092-000834-00000
ROE 2DR4R 1,0/1,2+1,4/1,6 Drive rollers, 37 mm, cored wire 092-000835-00000
ROE 2DR4R 1,4/1,6+2,0/2,4 Drive rollers, 37 mm, cored wire 092-000836-00000
ROE 2DR4R 2,8+3,2 Drive rollers, 37 mm, cored wire 092-000837-00000
ROE 2GR4R Pressure rollers, knurled, 37mm 092-000838-00000
Replaceable parts
Wire feed rollers
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10.1.4 Conversion sets
Type Designation Item no.
URUE VERZ>UNVERZ FE/AL
4R
Conversion kit, 37mm, 4-roller drive on non-toothed
rollers (steel/aluminium)
092-000845-00000
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 Conversion kit, 37mm, 4-roller drive for aluminium 092-000847-00000
URUE AL 4ZR4R 2,4+3,2 Conversion kit, 37mm, 4-roller drive for aluminium 092-000868-00000
URUE ROE 2DR4R
0,8/0,9+0,8/0,9
Conversion kit, 37mm, 4-roller drive for cored wire 092-000830-00000
URUE ROE 2DR4R
1,0/1,2+1,4/1,6
Conversion kit, 37mm, 4-roller drive for cored wire 092-000831-00000
URUE ROE 2DR4R
1,4/1,6+2,0/2,4
Conversion kit, 37mm, 4-roller drive for cored wire 092-000832-00000
URUE ROE 2DR4R 2,8+3,2 Conversion kit, 37mm, 4-roller drive for cored wire 092-000833-00000
Figure 10-1
Appendix A
Recommended settings
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11 Appendix A
11.1 Recommended settings
Figure 11-1
Appendix B
Overview of EWM branches
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12 Appendix B
12.1 Overview of EWM branches
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