EWM Wega 401 FDG User manual

Operating instructions
Welding machine
Wega 401, 501 FDG
Wega 401, 501, 601 FDW
099-004934-EW501
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13.06.2013
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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 [phone].
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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1Contents
1Contents..................................................................................................................................................3
2Safety instructions.................................................................................................................................5
2.1 Notes on the use of these operating instructions ..........................................................................5
2.2 Explanation of icons.......................................................................................................................6
2.3 General..........................................................................................................................................7
2.4 Transport and installation ............................................................................................................11
2.4.1 Lifting by crane.............................................................................................................12
2.4.2 Ambient conditions.......................................................................................................13
2.4.2.1 In operation...................................................................................................13
2.4.2.2 Transport and storage...................................................................................13
3Intended use.........................................................................................................................................14
3.1 Applications..................................................................................................................................14
3.1.1 MIG/MAG standard welding.........................................................................................14
3.2 Use and operation solely with the following machines................................................................14
3.3 Documents which also apply.......................................................................................................15
3.3.1 Warranty.......................................................................................................................15
3.3.2 Declaration of Conformity.............................................................................................15
3.3.3 Welding in environments with increased electrical hazards.........................................15
3.3.4 Service documents (spare parts and circuit diagrams)................................................15
3.3.5 Calibration/Validation ...................................................................................................15
4Machine description –quick overview ..............................................................................................16
4.1 Wega 401.....................................................................................................................................16
4.1.1 Front view.....................................................................................................................16
4.1.2 Rear view......................................................................................................................18
4.2 Wega 501, 601.............................................................................................................................20
4.2.1 Front view.....................................................................................................................20
4.2.2 Rear view......................................................................................................................22
5Design and function.............................................................................................................................24
5.1 General........................................................................................................................................24
5.2 Installation....................................................................................................................................25
5.3 Machine cooling...........................................................................................................................25
5.4 Workpiece lead, general..............................................................................................................25
5.5 Welding torch cooling system......................................................................................................26
5.5.1 General.........................................................................................................................26
5.5.2 List of coolants..............................................................................................................26
5.5.3 Adding coolant..............................................................................................................27
5.6 Mains connection.........................................................................................................................28
5.6.1 Mains configuration ......................................................................................................28
5.7 Intermediate hose package connection.......................................................................................29
5.7.1 Wega 401.....................................................................................................................29
5.7.2 Wega 501, 601.............................................................................................................30
5.8 Shielding gas supply (shielding gas cylinder for welding machine).............................................31
5.8.1 Connection ...................................................................................................................32
5.9 Connection for workpiece lead ....................................................................................................33
5.9.1 Wega 401.....................................................................................................................33
5.9.2 Wega 501, 601.............................................................................................................34
6Maintenance, care and disposal.........................................................................................................35
6.1 General........................................................................................................................................35
6.2 Maintenance work, intervals........................................................................................................35
6.2.1 Daily maintenance tasks ..............................................................................................35
6.2.1.1 Visual inspection...........................................................................................35
6.2.1.2 Functional test...............................................................................................35
6.2.2 Monthly maintenance tasks..........................................................................................36
6.2.2.1 Visual inspection...........................................................................................36
6.2.2.2 Functional test...............................................................................................36
6.2.3 Annual test (inspection and testing during operation)..................................................36

Contents
Notes on the use of these operating instructions
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6.3 Maintenance work........................................................................................................................36
6.4 Disposing of equipment................................................................................................................37
6.4.1 Manufacturer's declaration to the end user..................................................................37
6.5 Meeting the requirements of RoHS..............................................................................................37
7Rectifying faults....................................................................................................................................38
7.1 Checklist for rectifying faults........................................................................................................38
7.2 Vent coolant circuit.......................................................................................................................39
8Technical data.......................................................................................................................................40
8.1 Wega 401 FDG............................................................................................................................40
8.2 Wega 401 FDW............................................................................................................................41
8.3 Wega 501 FDG............................................................................................................................42
8.4 Wega 501, 601 FDW....................................................................................................................43
9Accessories ..........................................................................................................................................44
9.1 System components.....................................................................................................................44
9.2 General accessories ....................................................................................................................44
9.3 Options.........................................................................................................................................45
9.3.1 Wega 401 .....................................................................................................................45
9.3.2 Wega 501, 601 .............................................................................................................45
10 Appendix A............................................................................................................................................46
10.1 Setting instructions.......................................................................................................................46
11 Appendix B............................................................................................................................................49
11.1 Overview of EWM branches.........................................................................................................49

Safety instructions
Notes on the use of these operating instructions
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2Safety 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
Switch off machine
Switch on machine
ENTERENTER
ENTER (enter the menu)
NAVIGATION
NAVIGATION (Navigating in the menu)
EXIT
EXIT (Exit the menu)
4 s
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 surface!
•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 pressure
when heated.
•Move containers with inflammable or explosive liquids away from the working area!
•Never heat explosive liquids, dusts or gases by welding or cutting!
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. 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!
Danger when coupling multiple power sources!
Coupling multiple power sources in parallel or in series has to be carried out by
qualified personnel and in accordance with the manufacturer's guidelines. Before
bringing the power sources into service for arc welding operations, a test has to verify
that they cannot exceed the maximum allowed open circuit voltage.
•Connection of the machine may be carried out by qualified personnel only!
•When decommissioning individual power sources, all mains and welding current leads have
to be safely disconnected from the welding system as a whole. (danger due to inverse
voltages)!
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!

Safety instructions
General
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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 respective 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.
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
•Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of
products!
•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 workpiece!
•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 grinders, 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 taking current from the mains
network. For some types of machines, connection restrictions or requirements 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!
Fig. Lifting principle
Risk of injury due to unsuitable lifting eye!
In case of improper use of lifting eyes or the use of unsuitable lifting eyes, persons can
be seriously damaged by falling equipment or add-on components!
•The lifting eye must be completely screwed in!
•The lifting eye must be positioned flat onto and in full contact with the supporting surfaces!
•Check that the lifting eyes are securely fastened before use and check for any damage
(corrosion, deformation)!
•Do not use or screw in damaged lifting eyes!
•Avoid lateral loading of the lifting eyes!

Safety instructions
Transport and installation
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2.4.2 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!
2.4.2.1 In operation
Temperature range of the ambient air:
•-25 °C to +40 °C
Relative air humidity:
•Up to 50% at 40 °C
•Up to 90% at 20 °C
2.4.2.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
•-30 °C to +55 °C
Relative air humidity
•Up to 90% at 20 °C

Intended use
Applications
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3Intended use
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 source surrounds the arc and the
molten pool to protect them from the atmosphere.
3.2 Use and operation solely with the following machines
NOTE
A suitable wire feed unit (system component) is required in order to operate the welding
machine!
Wega drive 41
Wega drive 41L
Wega 401


Wega 501


Wega 601



Intended use
Documents which also apply
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3.3 Documents which also apply
3.3.1 Warranty
NOTE
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
3.3.2 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.
3.3.3 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.
3.3.4 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.
3.3.5 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months

Machine description –quick overview
Wega 401
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4Machine description – quick overview
4.1 Wega 401
NOTE
Coolant tank and quick connect coupling of coolant supply and return are only fitted in
machines with water cooling.
4.1.1 Front view
Figure 4-1

Machine description –quick overview
Wega 401
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Item
Symbol
Description 0
1
Lifting lug
2
Main switch, machine on/off
3
Welding voltage step switch, presetting
To roughly preset the welding voltage
4
Welding voltage step switch, final setting
To finally adjust the welding voltage (select the option to roughly preset the welding
voltage first)
5
Signal light, Functional error
On when excess temperature detected
6
Carrying handle
7
Cooling air inlet
8
Automatic cut-out of coolant pump key button
press to reset a triggered fuse
9
Coolant tank cap
10
Coolant tank
11
Connection socket, workpiece lead
"Hard" choke tapping
12
Connection socket, workpiece lead
"Medium" choke tapping
13
Connection socket, workpiece lead
Choke tapping "soft"
14
Wheels, guide castors
15
Wheels, fixed castors

Machine description –quick overview
Wega 401
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4.1.2 Rear view
Figure 4-2

Machine description –quick overview
Wega 401
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Item
Symbol
Description 0
1
Intermediate hose package strain relief
2
Key button, automatic cutout
Wire feed motor supply voltage fuse
press to reset a triggered fuse
3
7-pole connection socket
Wire feed unit control lead
4
Mains connection cable
5
Button, Automatic cut-out of fan motor
Press to reset tripped circuit breaker
6
Quick connect coupling (red)
coolant return
7
Quick connect coupling (blue)
coolant supply
8
Earth cable connecting (PE)
Connection of green-yellow earth cable from the intermediate tube package
9
Connector plug, welding current "+"
Welding current connection on wire feed unit
10
Cooling air outlet
11
Bracket for shielding gas cylinder

Machine description –quick overview
Wega 501, 601
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4.2 Wega 501, 601
NOTE
Coolant tank and quick connect coupling of coolant supply and return are only fitted in
machines with water cooling.
4.2.1 Front view
Figure 4-3