EWM Wega 401 M1.02 FKG Operating Instructions Manual Download Page 64

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Replaceable parts

Wire feed rollers

099-005224-EW501

08.11.2011

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

Summary of Contents for Wega 401 M1.02 FKG

Page 1: ...2 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 ew...

Page 2: ...ther 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 whethe...

Page 3: ...nts 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...

Page 4: ...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 ma...

Page 5: ...Contents Notes on the use of these operating instructions 099 005224 EW501 08 11 2011 5...

Page 6: ...l 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...

Page 7: ...scription 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 Inter...

Page 8: ...pment 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 av...

Page 9: ...s 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 w...

Page 10: ...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 grinders etc on...

Page 11: ...he 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...

Page 12: ...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 equipme...

Page 13: ...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 m i n 1 m m i n 1 m 75 Fig Lifting principle R...

Page 14: ...s 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...

Page 15: ...f 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 sh...

Page 16: ...view Front view 16 099 005224 EW501 08 11 2011 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...

Page 17: ...ing 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 adju...

Page 18: ...Machine description quick overview Rear view 18 099 005224 EW501 08 11 2011 4 2 Rear view Figure 4 2...

Page 19: ...ing 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 nip...

Page 20: ...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 Changeove...

Page 21: ...itted 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...

Page 22: ...t 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 Continuo...

Page 23: ...r 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 h...

Page 24: ...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 carr...

Page 25: ...o flow for approx 25 seconds 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 constan...

Page 26: ...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 d...

Page 27: ...ite 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...

Page 28: ...ctions 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 cond...

Page 29: ...on 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 fros...

Page 30: ...e 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 a...

Page 31: ...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 ga...

Page 32: ...g 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 toge...

Page 33: ...nder 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 th...

Page 34: ...elding 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 press...

Page 35: ...y 099 005224 EW501 08 11 2011 35 Figure 5 5 Item Symbol Description 0 1 G connecting nipple Shielding gas connection on the pressure regulator 2 Securing elements for shielding gas cylinder strap chai...

Page 36: ...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 where necessary...

Page 37: ...ed 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...

Page 38: ...ng 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 uncon...

Page 39: ...wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe Press the clamping element with the pressu...

Page 40: ...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 weldi...

Page 41: ...Design and function Select welding task 099 005224 EW501 08 11 2011 41 Figure 5 10 Legend with an explanation of symbols can be found in the MIG MAG function sequences operating modes chapter...

Page 42: ...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 mo...

Page 43: ...y 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 i...

Page 44: ...eed 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...

Page 45: ...elding 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...

Page 46: ...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 Wi...

Page 47: ...OB 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...

Page 48: ...y 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 i...

Page 49: ...c 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...

Page 50: ...n 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...

Page 51: ...ding gas is expelled gas pre flows Wire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Changeover to the pre selected wire s...

Page 52: ...feed motor runs at creep speed Arc ignites when the wire electrode makes contact with the workpiece welding current flows Changeover to the pre selected wire speed after the set ignition time tZn Step...

Page 53: ...ows 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 elapse...

Page 54: ...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...

Page 55: ...d 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 W...

Page 56: ...pean 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 unsorted municipal waste It must...

Page 57: ...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 spo...

Page 58: ...rrect 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 Settin...

Page 59: ...g 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...

Page 60: ...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...

Page 61: ...t 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 gen...

Page 62: ...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 AK3...

Page 63: ...92 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...

Page 64: ...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 R...

Page 65: ...Appendix A Recommended settings 099 005224 EW501 08 11 2011 65 11 Appendix A 11 1 Recommended settings Figure 11 1...

Page 66: ...Appendix B Overview of EWM branches 66 099 005224 EW501 08 11 2011 12 Appendix B 12 1 Overview of EWM branches...

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