Messer Cutting & Welding K4 Operations Instructions

EWM HIGHTEC WELDING GmbHDr.-Günter- Henle- Straße 8; D-56271 Mündersbach, GermanyPhone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244Internet: www.ewm.d

Safety instructionsS / 5Notes on the use of these operating instructionsThese operating instructions are arranged in chapters.To help you find your wa

1 Technical data1/11.1 WEGA seriesWEGA series MIG 250 MIG 330 MIG 400 MIG 500 MIG 600Setting range for weldingcurrent30-250 A 30-330 A 50-400 A 50-500

1 Technical data1/21.2 WEGA DRIVE 4 WF caseWEGA DRIVE 4Supply voltage42VACWire feed speed1m/min - 20m/minStandard wire-feed roller fitting for steel1.

2 Description of the system components2/12.1 System overview

2 Description of the system components2/22.2 The welding current sources2.2.1 WEGA 250 - 600 welding machine range (front view)A1B1C1D1E1F1G1H1I1J1L1M

2 Description of the system components2/3A1 Carrying handlesB1 "PROGRAM" M200 control (fig. 2/2) or M100 (fig. 2/1)C1 Main switch, machine

2 Description of the system components2/42.2.2 WEGA 250 - 600 welding machine range (rear view)A2B2C2D2E2F2G2H2I2J2K2Fig. 2/3; Rear view (compact des

2 Description of the system components2/52.2.3 WEGA 400 MIG E with electronic choke (front view)A2 Lifting lugsB2 Excess voltage release, fan/water p

2 Description of the system components2/62.2.3 WEGA 400 MIG E with electronic choke (front view)A3B3 Fig. 2/5; Front view (WEGA 400 MIG E with electro

2 Description of the system components2/72.3 Controls2.3.1 “PROGRAM” M200 controlFig.: 2/6 “PROGRAM” M200 control

Originaldokumentliegt jedem Gerät bei!Original documentis enclosed with each machine!Document originalest joint à toute machine!EG - Konformitätserklä

2 Description of the system components2/810m/min2468-102468+1015201510Rotary dial for the infinite adjustment of:• Wire feed speed correction• Wire

2 Description of the system components2/92.3.2 M100 controltt0.511.52sec0sec0sec 2sec1.510.5461018m/min020812141624321Fig.: 2/7 M100 control panel1&qu

2 Description of the system components2/102.4 Voltmeter / ammeter displays2.4.1 M210: digital V / A meter with preset and hold function (optional for

2 Description of the system components2/112.4.2 M110: digital V / A meter with hold function (optional for M100and M200)Fig. 2/9; Control panel of M1

3 Description of M100 / M110 control3/13.1 Description of M100 controlFig. 3/1: M100 control3.1.1 Adjusting the operating pointThe M100 MIG/MAG contro

3 Description of M100 / M110 control3/23.1.2 Selecting the operating modeOperating modechangeover switchThe operating mode can be adjusted to the rele

3 Description of M100 / M110 control3/33.3 Setting other welding parametersThe welding machine and WF case (Fig. 3/2) contain controls to set the foll

3 Description of M100 / M110 control3/43.4 Function sequence in operating modes3.4.1 Explanation of signs and functionsTable :Symbol MeaningPress torc

3 Description of M100 / M110 control3/53.4.2 Non-latched MIG function sequencetItt1. 2.Fig. 3/3 Non-latched MIG1st stepPress and hold torch trigger•

3 Description of M100 / M110 control3/63.4.3 Latched MIG function sequencetttI1.2. 3.4.Fig. 3/4 Latched MIG1st and 2nd stepPress and release torch tri

Table of contents PageContents/1Safety instructions...

3 Description of M100 / M110 control3/73.4.4 MIG spot-welding function sequencetIttFig. 3/5 MIG spotsStart spot weldingPress and hold torch trigger•

3 Description of M100 / M110 control3/83.4.5 MIG interval function sequencetIttFig. 3/6 MIG intervalStart interval weldingPress and hold torch trigger

4 Description of control M200 / M210 (optional)4/14.1 Definition of MIG/MAG welding tasksFig. 4/1: M200 controlThe microprocessor-controlled MIG/MAG “

4 Description of control M200 / M210 (optional)4/24.1.1 MIG/MAG welding task selection and operating point setting(without option M210 / Program, one-

4 Description of control M200 / M210 (optional)4/34.1.2 MIG/MAG welding task selection and operating point setting(without option M210 / Program, manu

4 Description of control M200 / M210 (optional)4/44.3.2 Settings for the electronic choke (WEGA 400 MIG E only)Setting the electronicchoke using switc

4 Description of control M200 / M210 (optional)4/54.4.2.3 Short-circuit in any welding operation (remote ignition)Both LEDs lit with short, fast flash

4 Description of control M200 / M210 (optional)4/64.6 M210 (optional): digital V / A meter with hold and preset functionFig.: 4/2 M210 control panel

4 Description of control M200 / M210 (optional)4/74.6.1 Operating point setting before welding with option M210Prerequisites for the test: Torch trigg

4 Description of control M200 / M210 (optional)4/84.6.2 Welding data display during welding process (actual values)4.6.2.1 Welding current – actual va

Table of contents PageContents/14 Description of controls M200, M210...

4 Description of control M200 / M210 (optional)4/94.6.3 Welding data display (actual values) after welding “Hold function”Signal lightonDisplay unit i

4 Description of control M200 / M210 (optional)4/104.6.5 Error messages on M210 display unit4.6.5.1 Short-circuit fault in welding torch / workpieceSi

4 Description of control M200 / M210 (optional)4/114.8 Other functionsIn the welding machine (fig. 4/3), or with the decompact version in the WF case,

4 Description of control M200 / M210 (optional)4/124.8.3 No-power gas testKey button forgas testThis ensures a high standard of safety for the welder

4 Description of control M200 / M210 (optional)4/134.8.6 Gas pre-flowsThe optimum gas pre-flow time is always specified automatically according to the

4 Description of control M200 / M210 (optional)4/144.9 Function sequence in operating modes4.9.1 Explanation of signs and functionsTable :Symbol Meani

4 Description of control M200 / M210 (optional)4/154.9.2 Non-latched MIG function sequencetItt1. 2.PAFig. 4/5; Non-latched MIG1st stepPress and hold t

4 Description of control M200 / M210 (optional)4/164.9.3 Latched MIG function sequencetttI1. 2. 3. 4.PAFig. 4/6; Latched MIG1st stepPress torch trigge

4 Description of control M200 / M210 (optional)4/174.9.4 MIG spot-welding function sequencetIttFig. 4/7; MIG spotsSpot-welding startsTorch trigger is

5 Quick start for WEGA M200 + M210 PROGRAM5/1Setting the welding task (Program one-dial operation)According to the welding task:Type of gas Adjusting

Table of contents PageContents/15 WEGA M200 + M210 PROGRAM quick start – the fastest way to weld... 5/16 Commissioning...

5 Quick start for WEGA M200 + M210 PROGRAM5/2Operating point setting before welding with M210 (optional)Caution: With the test key button on, there w

6 Commissioning6/16.1 Range of applications:• MIG/MAG welding (only in combination with an additional wire feed unit) forsteel-CrNi ∅ 0.8mm to 1.6mm,

6 Commissioning6/26.4 Cooling the welding machineTo obtain an optimal duty cycle from the power components, the following precautions should beobserve

6 Commissioning6/36.5 Water cooling for welding torches• The cooling of the welding torch is performed by an air-cooled heat exchanger with integrate

6 Commissioning6/4Fig. 1: WEGA series, rear view (decompact)6.7 Connecting the welding torchWe can only guarantee smooth and trouble-free operation of

6 Commissioning6/56.7.3 Connecting the MIG Push/Pull torch (optional)Push / pull torch function description:The most important preconditions for the g

6 Commissioning6/66.8.2 Inching the wire electrodeFig. 5/2: Operating elements inside the welding machine and the WF caseFig. 5/3: Part view of the wi

6 Commissioning6/76.9 Workpiece leadRemove paint, rust and dirt from clamping and welding areas with a wire brush. Attach theworkpiece clip or clamp d

6 Commissioning6/86.10 Shielding gas supply6.10.1 Establishing the gas connectionsPlace the shielding gas cylinder in the cylinder holder and secure i

7 Maintenance and care~/1Under normal operating conditions these welding machines are largely maintenance-free andrequire a minimum of care. However,

Safety instructionsS / 1For Your SafetyObserve accident prevention regulations.Ignoring the following safety procedures can be fatal.Designed useThis

7 Maintenance and care~/27.2.3 Measurement of insulation resistanceDisconnect the machine from the mains. Pull out the mains plug!Open the machine and

8 Operating problems, causes and remedies8/18.1 Customer checklistAll machines are subjected to strict manufacturing and final inspection procedures.

8 Operating problems, causes and remedies8/2Fault Possible cause RemedyMalfunction of feedor gas valveFault in the electronics Replace electronicsChec

9 Ersatzteilliste/Spare Parts List9/1

9 Ersatzteilliste/Spare Parts List9/2Fig. 9/1a Vorderseite dekompakt / Front view, decompactFig. 9/1b Vorderseite kompakt / Front view compact

9 Ersatzteilliste/Spare Parts List9/3Item Designation: Description250A -400A 500A -600AA1 Drehknopf Rotary knob074-0000315-00000for A1 Drehknopfdeckel

9 Ersatzteilliste/Spare Parts List9/4Fig. 9/2a Rückseite dekompakt / Rear view, decompactFig. 9/2b Rückseite kompakt / Rear view compact

9 Ersatzteilliste/Spare Parts List9/5Item Designation: Description250A -400A 500A -600AA2 Sicherungskette Securing chain094-000178-00000B2 Bockrolle F

9 Ersatzteilliste/Spare Parts List9/6Fig. 9/3a linke Seite dekompakt / Left side, decompactFig. 9/3b linke Seite kompakt / Left side, compact

9 Ersatzteilliste/Spare Parts List9/7Item Designation:Description:A3 RelaisplatineRelay PCB040-000510-00000B3 SchützRelay094-000591-00000 094-000590-0

Safety instructionsS / 2 Smoke and gases can lead to breathing difficulties and poisoning.· Do not breathe in smoke and gases.· Ensure that there i

9 Ersatzteilliste/Spare Parts List9/8Fig. 9/4a rechte Seite dekompakt / Right side, decompactFig. 9/4b rechte Seite kompakt / Right side, compact

9 Ersatzteilliste/Spare Parts List9/9Item Designation: Description250A-400A500A-600AA4 Wärmetauscher Heat exchanger094-002585-00004 094-003341-00000B4

9 Ersatzteilliste/Spare Parts List9/10WEGA 400 MIG “E” M110 with electronic chokeA6B6Fig. 9/5a Vorderseite / Front viewC6D6E6F6Fig. 9/5b, linke Seite

9 Ersatzteilliste/Spare Parts List9/11Item Designation: Description400 MIG DW „E“ M110A6 Drehknopf Rotary dial094-001815-00000B6 Anschlußbuchse Connec

9 Ersatzteilliste/Spare Parts List9/12Fig. 9/6a Drahtvorschubkoffer / Wire feed caseFig. 9/6b Drahtvorschubkoffer / Wire feed case

9 Ersatzteilliste/Spare Parts List9/13Item Designation:DescriptionA5 Drehknopf Rotary dial074-000234-00000for A5 Drehknopfdeckel Rotary dial cap074-00

9 Ersatzteilliste/Spare Parts List9/14Fig. 9/7a Explosionszeichnung Drahtvorschubeinheit 4-Rollenantrieb / Exploded view of 4-roll drive wire feed uni

9 Ersatzteilliste/Spare Parts List9/15Item Designation:Description1 Vier Rollen BasisstückFour roll feed plate 094-006257-000002 Schraube M6x14Screw M

9 Ersatzteilliste/Spare Parts List9/1632 4 Zwillingsrollen AL 2,4+3,24 twin rolls AL 2.4+3.2 092-000870-0000033 2 AR Röhrchendraht 0,8/0,9+0,8/0,92 DR

10 Accessories10/110.1 MIG welding torch10.1.1 MIG potentiometer torchDesignation / description Item No.:Optional remote control connection option, po

Safety instructionsS / 3 Interference by electrical and electromagnetic fields is possible e.g. from the weldingmachine or from the high-voltage puls

11 Schaltplan / Circuit diagrams11/111.1 WEGA 330 - 600 compact (M100)

11 Schaltplan / Circuit diagrams11/211.2 WEGA 330 - 600 compact (M100/110)

11 Schaltplan / Circuit diagrams11/311.3 WEGA 330 - 600 compact (M200)

11 Schaltplan / Circuit diagrams11/411.4 WEGA 330 - 600 compact (M200/110)

11 Schaltplan / Circuit diagrams11/511.5 WEGA 330 - 600 compact (M200/M210)

11 Schaltplan / Circuit diagrams11/611.6 WEGA 330 - 600 decompact

11 Schaltplan / Circuit diagrams11/711.7 WEGA 330 - 600 decompact (M110)

11 Schaltplan / Circuit diagrams11/811.8 WEGA 330 - 600 decompact (M210)

11 Schaltplan / Circuit diagrams11/911.9 WEGA 400 E M110)

11 Schaltplan / Circuit diagrams11/1011.10 WEGA DRIVE 4 (M100)

Safety instructionsS / 4Safety rules for crane transportCarefully observe the accident prevention regulations VBG 9, VBG 9a and VGB 15.Fig. 1:Crane pr

11 Schaltplan / Circuit diagrams11/1111.11 WEGA DRIVE 4 (M200)