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Summary of Contents for EWM Saturn drive 41 WE
- Page 1 Operating instructions Wire feed unit Saturn drive 41 WE (M1.02 / M2.20 / M2.40) Saturn drive 41L WE (M1.02 / M2.20 / M2.40) Observe additional system documents! 099-005172-EW501 21.09.2011 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
- Page 2 © EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer.
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Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents..............................3 2 Safety instructions..........................5 Notes on the use of these operating instructions ................5 Explanation of icons........................6 General ............................7 Transport and installation ......................11 Ambient conditions........................12 2.5.1 In operation........................ - Page 4 Wire feed rollers for aluminium wire ................59 10.1.3 Wire feed rollers for cored wire..................59 10.1.4 Conversion sets ......................60 11 Appendix A............................61 11.1 Setting instructions........................61 11.1.1 Saturn 256 DG......................61 11.1.2 Saturn 351 DG......................62 12 Appendix B............................63 12.1 Overview of EWM branches......................63 099-005172-EW501 21.09.2011...
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Page 5: 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 6: 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 7: General
Safety instructions General General DANGER 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. •... - Page 8 Safety instructions General WARNING 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)! •...
- Page 9 Safety instructions General 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.
- Page 10 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 11: 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 12: 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 13: Intended Use
Intended use Applications Intended 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! •... -
Page 14: Documents Which Also Apply
Intended use Documents which also apply 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: •... -
Page 15: Machine Description - Quick Overview
Machine description – quick overview Saturn drive 41L Machine description – quick overview Saturn drive 41L 4.1.1 Front view Figure 4-1 Item Symbol Description Carrying handle Machine control See Machine control – operating elements chapter Wire feed unit cover lock Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger Operating / Connection element not used in this system! -
Page 16: Rear View
Machine description – quick overview Saturn drive 41L 4.1.2 Rear view Figure 4-2 Item Symbol Description 7-pole connection socket Wire feed unit control lead Earth cable connecting (PE) Connection of green-yellow earth cable from the intermediate tube package Connecting thread (G¼") Shielding gas Connector plug, welding current "+"... -
Page 17: Inside View
Machine description – quick overview Saturn drive 41L 4.1.3 Inside view NOTE Control variants • Machines with M1.xx control There are additional control elements inside the machine for function control. • Machines with M2.4x control A "JOB list" label to define the welding tasks is attached to the inside of the casing cover. -
Page 18: Saturn Drive 41
Machine description – quick overview Saturn drive 41 Saturn drive 41 4.2.1 Front view Figure 4-4 Item Symbol Description Carrying handle Machine control See Machine control – operating elements chapter Machine feet Operating / Connection element not used in this system! Operating / Connection element not used in this system! Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger... -
Page 19: Inside View
Machine description – quick overview Saturn drive 41 4.2.2 Inside view NOTE Control variants • Machines with M1.xx control There are additional control elements inside the machine for function control. • Machines with M2.4x control A "JOB list" label to define the welding tasks is attached to the inside of the casing cover. -
Page 20: 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 4-6 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 21: 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). Figure 4-7 All details in percent relate to the values stored in the characteristics. -
Page 22: 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 23: M2.20 Welding Machine Control
Machine description – quick overview Machine control – Operating elements 4.3.2 M2.20 welding machine control Figure 4-9 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 24 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 25: 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 26: 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 27: 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 28: M2.40 Welding Machine Control
Machine description – quick overview Machine control – Operating elements 4.3.3 M2.40 welding machine control Figure 4-11 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 29 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 30: 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 31: 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 32: 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 33: 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 34: 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 35: 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 36: 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 37: Setting Up On Uneven Ground
Design and function Transport and installation 5.2.1 Setting up on uneven ground WARNING Risk of accidents due to improper set-up location! The machines are designed for operation in an upright position! In the event of incorrect setting up of the machine and adjustment of the wire feed retainer, the wire spool can fall out of the machine! •... -
Page 38: Intermediate Tube Package Connection
Design and function Transport and installation 5.2.2 Intermediate tube package connection 5.2.2.1 Saturn drive 41L Figure 5-2 Item Symbol Description Power source Intermediate tube package Intermediate tube package strain relief Connector plug, welding current "+" Welding current connection on wire feed unit Connecting nipple G¼, shielding gas connection Earth cable connecting (PE) Connection of green-yellow earth cable from the intermediate tube package... -
Page 39: Saturn Drive 41
Design and function Transport and installation 5.2.2.2 Saturn drive 41 Figure 5-3 Item Symbol Description Power source Intermediate tube package 7-pole connection socket Wire feed unit control lead Connecting nipple G¼, shielding gas connection Earth cable connecting (PE) Connection of green-yellow earth cable from the intermediate tube package Connector plug, welding current "+"... -
Page 40: Welding Torch Connection
Design and function Welding torch connection Welding torch connection NOTE Fault with 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! Welding torch with plastic core: •... -
Page 41: Saturn Drive 41L
Design and function Welding torch connection 5.3.1 Saturn drive 41L Figure 5-4 Item Symbol Description Welding torch Welding torch hose package Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger • Insert the central plug for the welding torch into the central connector and screw together with crown nut. -
Page 42: Shielding Gas Supply
Design and function Shielding gas supply Shielding gas supply 5.4.1 Gas test • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. • Initiate gas test function on the machine control. •... -
Page 43: Inserting The Wire Electrode
Design and function Inserting the wire electrode Inserting the wire electrode 5.5.1 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 5-6 Item Symbol Description Carrier pin For fixing the wire spool... -
Page 44: Changing The Wire Feed Rollers
Design and function Inserting the wire electrode 5.5.2 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 45: Inching The Wire Electrode
Design and function Inserting the wire electrode 5.5.3 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 46: 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 47: 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). 5.6.1 Explanation of signs and functions Symbol... -
Page 48: Non-Latched Operation
Design and function MIG/MAG functional sequences / operating modes 5.6.2 Non-latched operation Figure 5-10 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 49: Latched Operation
Design and function MIG/MAG functional sequences / operating modes 5.6.3 Latched operation Figure 5-11 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 50: Spot Welding
Design and function MIG/MAG functional sequences / operating modes 5.6.4 Spot welding Figure 5-12 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 51: Interval
Design and function MIG/MAG functional sequences / operating modes 5.6.5 Interval Figure 5-13 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 52: 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 53: 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 54: 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 55: 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 56: 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 57: Technical Data
Technical data Saturn drive 41L Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Saturn drive 41L Supply voltage 42 V AC Max. welding current at 60% DC 550 A Wire feed speed 0.5 m/min to 24 m/min Standard WF roller fitting 0.8 + 1.0 mm (for steel wire) -
Page 58: 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 9.1.1 Saturn drive (M1.02) Type Designation Item no. ON WIRE CREEP POTI Retrofit option, wire creep rotary dial 092-001102-00000 M1.02 9.1.2... -
Page 59: 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 60: 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 61: Setting Instructions
Appendix A Setting instructions Appendix A 11.1 Setting instructions 11.1.1 Saturn 256 DG Saturn 256 SG2/3 SG2/3 Ar82/18 CO 100 AlMg Ar100 CrNi Ar98/2 G3/4 Si1 G3/4 Si1 m/min m/min m/min m/min 12,0 13,5 10,4 18,1 11,6 10,3 10,0 22,2 11,3 13,5 10,2... -
Page 62: 11.1.2 Saturn 351 Dg
Appendix A Setting instructions 11.1.2 Saturn 351 DG 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... -
Page 63: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005172-EW501 21.09.2011...
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