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EWM

HIGHTEC WELDING GmbH

Dr. Günter-Henle-Straße 8 • D-56271 Mündersbach

Fon +49 2680 181-0 • Fax +49 2680 181-244

www.ewm.de

•

[email protected]

Operating instructions

Machines for MIG/MAG welding

WEGA 351, 401, 451, 501, 601

WEGA DRIVE 41, 41L

N. B. These operating instructions must be read before commissioning.

Failure to do so may be dangerous.

Machines may only be operated by personnel who are familiar with the appropriate safety
regulations.

The machines bear the conformity mark and thus comply with the
• EC Low Voltage Directive (2006/95/ EG)
• EC EMC Directive (2004/108/ EG)

In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.

The content of the operating instructions does not constitute grounds for any claims on the part
of the buyer.

The copyright to these operating instructions remains with the manufacturer.
Reprinting, including extracts, only with written approval.

Item No.: 099-004934-EWM01

Revised: 21.07.2009

Содержание WEGA 351

Страница 1: ...appropriate safety regulations The machines bear the conformity mark and thus comply with the EC Low Voltage Directive 2006 95 EG EC EMC Directive 2004 108 EG In compliance with IEC 60974 EN 60974 VD...

Страница 2: ...y and a three year warranty Continual further development and optimisation has made us Germany s market leader in the manufacture of light arc welding machines We have manufacturing training and servi...

Страница 3: ...ields CE EWM HIGHTEC WELDING GMBH D 56271 M NDERSBACH TYP ART SNR PROJ GEPR FT CONTROL Name of Customer company Adress Post code Place Country Stamp Signature of EWM distibutor Date of purchase Name o...

Страница 4: ...30 5 1 Machine control Operating elements 30 5 1 1 Welding machine control M1 02 30 5 1 1 1 Internal operating elements 31 5 1 1 2 Setting the operating point welding output 32 5 1 1 3 Welding parame...

Страница 5: ...or rinse tube package 60 6 9 3 Setting the shielding gas quantity 60 6 10 Inserting the wire electrode 61 6 10 1 Fixing the wire spool retainer pre tension adjustment 61 6 10 2 Spool brake setting 62...

Страница 6: ...ccessories options 76 10 1 General accessories 76 10 2 Options 77 10 3 Wire feed rollers 78 10 3 1 Wire feed rollers for aluminium wire 78 10 3 2 Wire feed rollers for cored wire 78 10 3 3 Conversion...

Страница 7: ...Contents Notes on the use of these operating instructions Item No 099 004934 EWM01 7...

Страница 8: ...edge of the page 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 wit...

Страница 9: ...ns Item No 099 004934 EWM01 9 Instructions and lists detailing step by step actions in given situations can be recognised by bullet points e g Insert the welding current lead socket into the relevant...

Страница 10: ...due to the use of non genuine parts The manufacturer s warranty becomes void if non genuine parts are used Only use system components and options power sources welding torches electrode holders remote...

Страница 11: ...question Protect persons not involved in the work against arc beams and the risk of glare using safety curtains Explosion risk Apparently harmless substances in closed containers may generate excessiv...

Страница 12: ...1 3 10 Set up and transport the machine on level solid ground Secure add on parts using suitable equipment Damage due to supply lines not being disconnected During transport supply lines which have n...

Страница 13: ...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 m i n 1 m 75 Fig Lifting principle Risk of...

Страница 14: ...s Keep the cooling air inlet and outlet clear Observe the minimum distance of 0 5 m from obstacles Installation site The machine must not be operated in the open air and must only be set up and operat...

Страница 15: ...nected power 16 0 kVA 19 2 kVA 23 2 kVA Workpiece lead 50 mm 70 mm 70 mm Recommended generator power 21 5 kVA 26 kVA 32 kVA Cos 0 95 Weight KG 130 kg 145 kg 150 kg Weight KW 150 kg 165 kg 170 kg Weigh...

Страница 16: ...cuit voltage 16 5 49 5 V 16 5 57 5 V Mains voltage tolerances 3 x 400V 15 Frequency 50 60Hz Mains fuse safety fuse slow blow 3x32A Max connected power 27 5 kVA 36 7 kVA Workpiece lead 95 mm2 95 mm2 Re...

Страница 17: ...ent temperature 20 C to 40 C Dimensions L x W x H mm 690 x 300 x 410 Weight approx 18 kg Constructed to standards IEC 60974 1 5 10 3 4 WEGA DRIVE 41 WEGA DRIVE 41 Supply voltage 42 V AC Max welding cu...

Страница 18: ...Machine description WEGA 351 401 451K 18 Item No 099 004934 EWM01 4 Machine description 4 1 WEGA 351 401 451K 4 1 1 Front view Figure 4 1...

Страница 19: ...Connection socket workpiece lead Hard choke tapping 7 Connection socket workpiece lead Medium choke tapping 8 Connection socket workpiece lead Choke tapping soft 9 Key button automatic cut out of coo...

Страница 20: ...Machine description WEGA 351 401 451K 20 Item No 099 004934 EWM01 4 1 2 Rear view Figure 4 2...

Страница 21: ...ins connection lead 3 Safety chain 4 42V 4A Key button automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse 5 Button Automatic cut out of fan motor Press to reset tripp...

Страница 22: ...Machine description WEGA 351 401 451 501 601 D 22 Item No 099 004934 EWM01 4 2 WEGA 351 401 451 501 601 D 4 2 1 Front view Figure 4 3...

Страница 23: ...nnection socket workpiece lead Medium choke tapping 9 Connection socket workpiece lead Choke tapping soft 10 Conveyor rolls fixed castors 11 Conveyor rolls guide castors 12 Cooling air inlet 13 Signal...

Страница 24: ...Machine description WEGA 351 401 451 501 601 D 24 Item No 099 004934 EWM01 4 2 2 Rear view 6 6 7 7 4 4 3 3 2 2 1 1 10 10 5 5 9 9 14 11 11 12 12 8 8 13 Figure 4 4...

Страница 25: ...reset tripped circuit breaker 5 Earth cable connecting nipple Connection of green yellow earth cable from the intermediate tube package 6 Rapid action closure coupling red coolant return 7 Rapid actio...

Страница 26: ...and therefore have the appropriate sticker attached Figure 4 5 Item Symbol Description 0 1 Machine control See Machine control operating elements chapter 2 Wire feed unit cover lock 3 Label Wire feed...

Страница 27: ...able connecting nipple Connection of green yellow earth cable from the intermediate tube package 3 Connecting nipple G shielding gas connection 4 Connector plug welding current Welding current connect...

Страница 28: ...ng the cap 3 Label Wire feed parts subject to wear 4 Damper support for the cover 5 Carrying handle 6 Machine control See Machine control operating elements chapter 7 Spool holder 8 Rubber feet 9 Cent...

Страница 29: ...sticker attached Figure 4 8 Item Symbol Description 0 1 Spool holder 2 Sticker JOB List 3 Wire delivery unit 4 Connecting nipple G shielding gas connection 5 7 pole connection socket Wire feed unit co...

Страница 30: ...wire speed 2 0sec 5 10 20sec 2 5 t1 Rotary dial Spot and interval times Infinite adjustment of the welding time 0 20s in Spots and interval operating mode 3 Operating mode selector switch Changeover...

Страница 31: ...ne it is essential that the cover is fitted back into position afterwards Unlock the right hand cover on the machine Tilt the cover forwards then remove upwards There are other operating elements for...

Страница 32: ...de diameter Operating element Action Result Wire speed setting Welding voltage setting 5 1 1 3 Welding parameter ignition time tZn diagram NOTE In the ignition time the wire feed continues to run at c...

Страница 33: ...ignition of the arc 2 Button Gas test The welding voltage and wire feed remain off when testing and setting the gas flow Pressing the key button once causes shielding gas to flow for approx 25 seconds...

Страница 34: ...on the Rotary transducer 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 7 Puls...

Страница 35: ...g element Action Result Wire speed setting Welding voltage setting 5 1 2 2 Setting the operating mode and runtime parameters NOTE The parameter values set are preset in the JOB and can be modified if...

Страница 36: ...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 1 2 4 Welding parameter ignition time tZn diagram NOT...

Страница 37: ...or the welder by preventing accidental ignition of the arc 2 Button Gas test The welding voltage and wire feed remain off when testing and setting the gas flow Pressing the key button once causes shie...

Страница 38: ...ulse time 0 1 s to 5 0 s 7 Pulse pause 0 1 s to 2 0 s 8 Display Top Display of the welding voltage correction value for the wire speed or parameter designations for runtime parameters 9 Display Down D...

Страница 39: ...ers 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...

Страница 40: ...eed 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 Vo...

Страница 41: ...in the JOB and can be modified if necessary Operating element Action Result Select operating mode Non latched Latched Spots n x Interval Select welding parameter Set gas post flow time GnS 0 0 s to 1...

Страница 42: ...e tZn 0 ms to 500 ms n x The selected parameter is shown on the display Set the parameter chosen 5 1 3 6 Welding parameter ignition time tZn diagram NOTE In the ignition time the wire feed continues t...

Страница 43: ...the welding machine rES is shown briefly on the display 5 1 3 8 Check the machine type setting NOTE When first switching on after resetting to the factory settings the machine type is displayed under...

Страница 44: ...s 44 Item No 099 004934 EWM01 5 1 3 10 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 M...

Страница 45: ...ree burn etc for numerous applications although these can also be changed if required 5 2 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigge...

Страница 46: ...lding 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...

Страница 47: ...e 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 St...

Страница 48: ...flows Changeover to the pre selected wire speed after the set ignition time tZn The WF stops after the set spot time elapses Arc is extinguished after the pre selected wire burn back time elapses Gas...

Страница 49: ...e 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 Whe...

Страница 50: ...nection sockets and therefore 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 i...

Страница 51: ...ust be checked regularly by an electrician 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...

Страница 52: ...olant 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 C...

Страница 53: ...ith the wire guide On delivery the central connector Euro is fitted with a capillary tube for welding torches with spiral guides Conversion is necessary if a welding torch with a plastic core is used...

Страница 54: ...Commissioning Welding torch and workpiece line connection 54 Item No 099 004934 EWM01 Figure 6 2...

Страница 55: ...Medium choke tapping 6 Connection socket workpiece lead Choke tapping soft Insert central plug of the welding torch into the central connector and screw together with crown nut Insert the cable plug o...

Страница 56: ...Welding current connection on wire feed unit 4 Rapid action closure coupling blue coolant supply 5 Rapid action closure coupling red coolant return 6 Intermediate tube package strain relief 7 Earth ca...

Страница 57: ...t and secure with crown nut the plug can only be inserted into the connection socket in one position Connect crown nut of the shielding gas line to the G connecting nipple Screw the eyelet of the eart...

Страница 58: ...ermediate tube package strain relief and lock by turning to the right Insert the plug on the welding current lead into the connection socket and lock Lock connecting nipples of the cooling water tubes...

Страница 59: ...re reducer 7 Shielding gas cylinder Before connecting the pressure reducer to the gas cylinder open the cylinder valve briefly to blow out any dirt Place the shielding gas cylinder into the relevant c...

Страница 60: ...he pressure reducer Press button Gas flows for a maximum of 25 seconds or until button is pressed again 6 9 3 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG...

Страница 61: ...spool brake Figure 6 6 Item Symbol Description 0 1 Securing and braking unit 2 Allen screw Securing the wire spool retainer and adjustment of the spool brake 3 Wire spool retainer Loosen the hexagonal...

Страница 62: ...brake Tighten the Allen screw 8 mm in the clockwise direction to increase the braking effect NOTE Do not jam the wire spool Tighten the spool brake until the wire spool no longer turns when the wire...

Страница 63: ...accessories are required when using standardised basket coils DIN 8559 Figure 6 8 Item Symbol Description 0 1 Carrier pin For fixing the wire spool 2 Knurled nut For fixing the wire spool Loosen knur...

Страница 64: ...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 Nut rollers with for steel wires and other hard wires use...

Страница 65: ...out clamping units and counter pressure rollers will automatically flip upwards Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves...

Страница 66: ...perience 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 In the ev...

Страница 67: ...ard but is also specific to arc welding equipment NOTE The former term of repetition test has been replaced due to a change in the corresponding standard with Inspection and testing during operation I...

Страница 68: ...lding current sockets The voltmeter must display mean values and have an internal resistance 1 M In the case of step switch controlled devices set the maximum output voltage step switch Adjust the pot...

Страница 69: ...nductor current 5 mA 2 Leakage current from the welding sockets separately to PE 10 mA 7 3 7 Measurement of protective conductor resistance Measure between the plug earthed contact and accessible live...

Страница 70: ...g an order please quote the type designation and item number as well as the type serial number and item number of the relevant equipment We hereby confirm that the servicing and maintenance instructio...

Страница 71: ...rately This machine is to be placed for disposal or recycling in the waste separation systems provided for this purpose According to German law law governing the distribution taking back and environme...

Страница 72: ...ll additional parts used by EWM but manufactured by other companies e g motors pumps fans torches etc Non reproducible software errors and parts subject to mechanical ageing are excluded from the warr...

Страница 73: ...remote control remote control extension cable coolant etc The warranty does not apply to products that are damaged due to accidents misuse improper operation incorrect installation use of force disre...

Страница 74: ...Rule of thumb Wire diameter 10 flow in l min Gas cylinder empty Change Electrode is projecting too far forwards Move torch closer to weld seam Air current Shield welding area Poor wire quality Use hi...

Страница 75: ...ng machine rES is shown briefly on the display 9 3 Check the machine type setting NOTE When first switching on after resetting to the factory settings the machine type is displayed under the designati...

Страница 76: ...EZA MIG welding torch gas cooled 094 013428 00000 WK50QMM 4M KL Workpiece cable clamp 092 000003 00000 WEGA 351 DG MT300G 3M EZA MIG welding torch gas cooled 094 013428 00000 WK50QMM 4M KL Workpiece c...

Страница 77: ...ntermediate hose package water 094 000407 00001 ZWIPA 95QMM MIG W 10M Intermediate hose package water 094 000407 00002 10 2 Options Type Designation Item no ON RMSDDV1 Optional wheel assembly retrofit...

Страница 78: ...4 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...

Страница 79: ...11 9 T2 10 2 0V 3 230V 1 2 4A F2 R ckseite 1 2 4A F3 1 2 Gasgek hlt 4 T 3 Wassergek hlt 3 4 Druckw chter F8 7 0VAC 10 0VAC 13 230VAC 14 230VAC 16 0VAC 17 0VAC 18 230VAC 1 T 2 T schwarz rot 2 Rollen A...

Страница 80: ...1 2 3 4 5 6 7 8 9 10 11 12 A2 X5 Gas NC Gas IGR0 NC NC NC Iist Iist IGR0 NC NC 1 2 PE Y1 Gas 1 PE2 PE S2 S3 Temp 105 C 8 6 4 2 16 14 15 11 9 T2 10 2 0V 1 2 4A F2 R ckseite 1 T 2 T 1 2 4A F3 1 2 Gasge...

Страница 81: ...T T 1 1 1 M1 M4 L fter 1 1 1 nur bei 500 600A Anlagen M7 M8 L fter 15 42V 14 0V K A LED gr n H2 L1 L1 Xx 1 L2 L2 L3 L3 PE PE S1 U V L2 L1 K1 1 1 K1 1 3 K1 1 5 1 5 3 4 6 2 K1 1 PE 1 PE K1 1 1 K1 1 3 V...

Страница 82: ...42VAC Sch tz US 18VAC 18VAC 0VAC NC 1 2 3 4 5 6 7 X5 Y1 Gas 1 2 PE X4 1 2 T T T T S4 T 3 4 S5 T 3 4 Ringkern n Wdg 1 PE_Dyn R ckseite Frontseite Innenblech Innenblech Gastest Einf deln 1 T PE_Dyn 1 P...

Страница 83: ...6 1 CS2 CS1 RD1 WR1 5V CLK1 0V1 Drehg A Drehg A nb 10V Uref OE NC NC X6 15V X1 16 X1 15 X1 14 X1 13 X1 12 X1 11 X1 10 X1 9 X1 8 X1 7 X1 6 X1 5 X1 4 X1 3 X1 2 X1 1 CS2 CS1 RD1 WR1 5V CLK1 0V1 Drehg A D...

Страница 84: ...he event of unau thorised modifications improperly con ducted repairs non observance of the deadlines for the repetition test and or non permitted conversion work not specifically authorised by EWM Pa...

Страница 85: ...0 7 2 5 6 0 10 1 10 9 0 11 2 15 7 0 10 2 1 2 4 9 0 8 2 5 4 0 11 2 5 4 0 9 1 10 4 0 9 2 1 6 2 4 0 7 1 3 2 0 12 2 3 8 0 9 1 9 1 0 8 2 6 0 0 8 23 2 0 16 2 10 6 0 12 2 20 5 0 13 2 19 2 0 11 2 1 0 6 2 0 9...

Страница 86: ...9 4 2 7 3 11 2 2 7 2 9 9 2 2 1 16 6 2 3 3 1 2 8 2 2 7 3 4 4 2 3 1 5 9 1 12 1 11 2 2 2 3 1 6 3 6 2 2 2 4 1 2 6 1 3 0 1 11 1 7 3 2 2 3 6 0 0 8 21 2 2 10 2 12 8 2 7 2 13 5 2 5 2 19 0 2 5 3 1 0 13 4 2 10...

Страница 87: ...9 5 2 7 3 10 6 2 6 2 9 9 2 1 1 16 3 2 2 3 1 2 8 4 2 7 3 4 7 2 3 1 5 8 1 11 1 11 1 2 1 3 1 6 3 5 2 1 2 4 2 2 6 1 3 0 1 10 1 7 3 2 1 3 6 0 0 8 21 4 2 10 2 13 2 2 7 2 13 1 2 4 2 18 6 2 4 3 1 0 13 5 2 10...

Страница 88: ...2 10 3 1 0 8 8 2 2 2 7 9 3 4 3 8 8 2 8 3 12 1 2 6 3 1 2 4 8 2 7 3 4 7 3 2 2 7 3 2 10 3 9 2 2 3 3 1 6 2 6 2 6 3 2 7 2 11 2 3 0 2 5 2 6 6 2 5 3 6 0 0 8 16 9 3 3 3 13 1 3 4 3 12 6 2 9 3 18 7 2 12 3 1 0 9...

Страница 89: ...16 6 2 6 3 1 0 9 0 2 9 2 8 0 3 1 3 9 3 2 5 3 12 0 2 2 3 1 2 4 6 2 3 3 4 7 2 11 3 7 4 2 7 3 9 2 1 11 3 1 6 2 6 2 2 3 2 5 2 7 2 3 0 2 1 2 6 5 2 1 3 6 0 0 8 16 8 2 12 3 13 3 3 1 3 12 9 2 6 3 19 0 2 9 3 1...

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