Related Manuals for EWM Saturn 301 KGE M1.02
Summary of Contents for EWM Saturn 301 KGE M1.02
- Page 1 Operating instructions Welding machine Saturn 301 KGE (M1.02 / M2.20 / M2.40) Saturn 351 KGE (M1.02 / M2.20 / M2.40) 099-004968-EW501 27.09.2011 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
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Page 2: General Instructions
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents..............................3 2 Safety instructions..........................6 Notes on the use of these operating instructions ................6 Explanation of icons........................7 General ............................8 Transport and installation ......................12 2.4.1 Lifting by crane ......................13 Ambient conditions........................ - Page 4 Wire feed rollers for aluminium wire ................56 10.1.3 Wire feed rollers for cored wire..................56 10.1.4 Conversion sets ......................57 11 Appendix A............................58 11.1 Setting instructions........................58 11.1.1 Saturn 301 ........................58 11.1.2 Saturn 351 ........................59 12 Appendix B............................60 12.1 Overview of EWM branches......................60 099-004968-EW501 27.09.2011...
- Page 5 Contents Notes on the use of these operating instructions 099-004968-EW501 27.09.2011...
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Page 6: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions 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. •... -
Page 7: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine 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... -
Page 8: General
Safety instructions General 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! •... - Page 9 Safety instructions General 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.
- Page 10 Safety instructions General 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 sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...
- Page 11 Safety instructions General 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.
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Page 12: Transport And Installation
Safety instructions Transport and installation 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! •... -
Page 13: Lifting By Crane
Safety instructions Transport and installation 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. -
Page 14: Ambient Conditions
Safety instructions Ambient conditions 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. -
Page 15: Intended Use
Intended use Applications 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 usage. WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Lifting lug Carrying handle Signal light, Functional error On when excess temperature detected Main switch, machine on/off Welding voltage step switch To set the welding voltage Cooling air inlet Connection socket, workpiece lead... -
Page 17: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Wire feed unit cover lock Cover for wire feed unit and operating elements Securing elements for shielding gas cylinder (strap/chain) Bracket for shielding gas cylinder Connecting nipple G¼, shielding gas connection Key button, Automatic cutout Wire feed motor supply voltage fuse (press to reset a triggered fuse) -
Page 18: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements 4.3.1 Welding machine control M1.02 Figure 4-3 Item Symbol Description Rotary dial, Wire speed setting Infinite adjustment of the wire speed. Rotary dial, Spot and interval times Infinite adjustment of the welding time (0-2s) in "Spots and interval"... -
Page 19: Internal Operating Elements
Machine description – quick overview Machine control – Operating elements 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. -
Page 20: Setting The Operating Point (Welding Output)
Machine description – quick overview Machine control – Operating elements 4.3.1.2 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 Action Result... -
Page 21: M2.20 Welding Machine Control
Machine description – quick overview Machine control – Operating elements 4.3.2 M2.20 welding machine control Figure 4-6 Item Symbol Description 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"... - Page 22 Machine description – quick overview Machine control – Operating elements Item Symbol Description 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. The button can be pressed again at any time to cancel the process.
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Page 23: Setting The Operating Point (Welding Output)
Machine description – quick overview Machine control – Operating elements 4.3.2.1 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 Action Result... -
Page 24: Setting The Expert Parameters
Machine description – quick overview Machine control – Operating elements 4.3.2.3 Setting the expert parameters NOTE The parameter values set are preset in the JOB and can be modified if necessary. Operating Action Result element Select expert parameters. The key combination must be pressed within 3 seconds. Select expert parameters: Gas pre-flow time "GvS"... -
Page 25: Welding Parameter Ignition Time "Tzn" Diagram
Machine description – quick overview Machine control – Operating elements 4.3.2.5 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. -
Page 26: M2.40 Welding Machine Control
Machine description – quick overview Machine control – Operating elements 4.3.3 M2.40 welding machine control Figure 4-8 Item Symbol Description 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. - Page 27 Machine description – quick overview Machine control – Operating elements Item Symbol Description 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. "Runtime parameters"...
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Page 28: Select Job Number (Welding Task)
Machine description – quick overview Machine control – Operating elements 4.3.3.1 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 should be set as the JOB number on the control, as well as welding output via the step switch. -
Page 29: Setting The Operating Point (Welding Output)
Machine description – quick overview Machine control – Operating elements 4.3.3.2 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. -
Page 30: Setting The Operating Mode And Runtime Parameters
Machine description – quick overview Machine control – Operating elements 4.3.3.4 Setting the operating mode and runtime parameters NOTE The parameter values set are preset in the JOB and can be modified if necessary. Operating Action Result element Select operating mode: Non-latched Latched Spots... -
Page 31: Setting The Expert Parameters
Machine description – quick overview Machine control – Operating elements 4.3.3.5 Setting the expert parameters NOTE The parameter values set are preset in the JOB and can be modified if necessary. Operating Action Result element Select expert parameters. The key combination must be pressed within 3 seconds. Select expert parameters: Gas pre-flow time "GvS"... -
Page 32: Welding Parameter Ignition Time "Tzn" Diagram
Machine description – quick overview Machine control – Operating elements 4.3.3.7 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. -
Page 33: Design And Function
Design and function General Design and function 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! •... -
Page 34: Transport And Installation
Design and function Transport and installation 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. •... -
Page 35: Mains Connection
Design and function Mains connection 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)! -
Page 36: Welding Torch And Workpiece Line Connection
Design and function Welding torch and workpiece line connection Welding torch and workpiece line connection Figure 5-2 Item Symbol Description Connection socket, workpiece lead "Hard" choke tapping Connection socket, workpiece lead "Medium" choke tapping Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger •... -
Page 37: Shielding Gas Supply
Design and function Shielding gas supply Shielding gas supply 5.7.1 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! •... - Page 38 Design and function Shielding gas supply Figure 5-3 Item Symbol Description G¼” connecting nipple Shielding gas connection on the pressure regulator. Securing elements for shielding gas cylinder (strap/chain) Bracket for shielding gas cylinder Cylinder valve Output side of the pressure regulator Pressure regulator Shielding gas cylinder •...
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Page 39: Setting The Shielding Gas Quantity
Design and function Shielding gas supply 5.7.2 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) 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 40: Inserting The Wire Electrode
Design and function Inserting the wire electrode Inserting the wire electrode 5.8.1 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). Figure 5-4 Item Symbol Description Carrier pin For fixing the wire spool... -
Page 41: Changing The Wire Feed Rollers
Design and function Inserting the wire electrode 5.8.2 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! •... -
Page 42: Inching The Wire Electrode
Design and function Inserting the wire electrode 5.8.3 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! •... -
Page 43: Spool Brake Setting
Design and function Inserting the wire electrode • Extend and lay out the torch tube 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 wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe. -
Page 44: Mig/Mag Functional Sequences / Operating Modes
Design and function MIG/MAG functional sequences / operating modes 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). 5.9.1 Explanation of signs and functions Symbol... -
Page 45: Non-Latched Operation
Design and function MIG/MAG functional sequences / operating modes 5.9.2 Non-latched operation Figure 5-8 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 current flows. •... -
Page 46: Latched Operation
Design and function MIG/MAG functional sequences / operating modes 5.9.3 Latched operation Figure 5-9 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; welding current flows. •... -
Page 47: Spot Welding
Design and function MIG/MAG functional sequences / operating modes 5.9.4 Spot welding Figure 5-10 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 current flows. •... -
Page 48: Interval
Design and function MIG/MAG functional sequences / operating modes 5.9.5 Interval Figure 5-11 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. •... -
Page 49: Maintenance, Care And Disposal
Maintenance, care and disposal General 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! •... -
Page 50: Maintenance Work
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. •... -
Page 51: Rectifying Faults
Rectifying faults Customer checklist 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 your authorised dealer. -
Page 52: Check The Machine Type Setting
Rectifying faults Check the machine type setting 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. -
Page 53: Resetting The Control (Reset All)
Rectifying faults Resetting the control (Reset all) 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. -
Page 54: Technical Data
Technical data Saturn 301, 351 KG Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Saturn 301, 351 KG Saturn 301 KG 351 KG Switching steps Setting range for welding 30 A to 300 A 30 A to 350 A current Max. -
Page 55: Accessories
Accessories Options Accessories NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Options Type Designation Item no. ON FILTER S Retrofit option, dirt filter for air inlet 092-002090-00000 ON FSB WHEELS S Retrofit option for locking brake for machine wheels 092-002109-00000 ON HOSE/FR MOUNT Optional holder for tubes and remote control for... -
Page 56: Replaceable Parts
Replaceable parts Wire feed rollers 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 sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •... -
Page 57: 10.1.4 Conversion Sets
Replaceable parts Wire feed rollers 10.1.4 Conversion sets Type Designation Item no. URUE VERZ>UNVERZ FE/AL Conversion kit, 37mm, 4-roller drive on non-toothed 092-000845-00000 rollers (steel/aluminium) 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... -
Page 58: Setting Instructions
Appendix A Setting instructions Appendix A 11.1 Setting instructions 11.1.1 Saturn 301 SATURN 301 SG2/3 G3/4 Si1 CO SG2/3 G3/4 Si1 Ar 82/18 CrNi Ar 98/2 AlMg Ar 100 m/min m/min m/min m/min 10,8 10,5 10,1 13,8 12,3 12,0 10,3 13,7 15,5 14,0... -
Page 59: Saturn 351
Appendix A Setting instructions 11.1.2 Saturn 351 SATURN 351 SG2/3 G3/4 Si1 Ar 82/18 SG2/3 G3/4 Si1 CO CrNi Ar 98/2 AlMg Ar 100 m/min m/min m/min m/min 10,6 11,3 12,8 11,4 14,2 15,5 14,0 12,3 15,5 17,4 10,9 15,7 10,4 23,2 10,6... -
Page 60: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-004968-EW501 27.09.2011...
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