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Summary of Contents for EWM Saturn 256 DG
- Page 1 Operating instructions Machines for MIG/MAG welding Saturn 256 DG Observe additional system documents! 099-005167-EW501 29.06.2010 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
Inhaltsverzeichnis Inhaltsverzeichnis 1 Inhaltsverzeichnis ..........................3 2 Safety instructions..........................6 Notes on the use of these operating instructions ................6 Explanation of icons........................7 General ............................8 Transport and installation ......................11 Ambient conditions........................12 2.5.1 In operation........................12 2.5.2 Transport and storage ....................12 3 Intended use ............................ - Page 4 7.2.1 Check the machine type setting ...................26 Setting the machine type......................26 7.3.1 Reset via machine control ....................27 8 Technical data............................28 Saturn 256 DG ..........................28 9 Accessories, options ...........................29 General accessories ........................29 10 Appendix A............................30 10.1 Setting instructions........................30 11 Appendix B............................31 11.1 Overview of EWM branches......................31...
- Page 5 Inhaltsverzeichnis 099-005167-EW501 29.06.2010...
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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 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. •...
- Page 10 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.
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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 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 14: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description 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 "Hard"... -
Page 15: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Key button, automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse 42V/4A Changeover switch for welding current polarity (welding voltage display) Depending on the polarity selected on the welding torch (standard MIG or cored wire welding) it is necessary to set this status on the machine to ensure the welding voltage is displayed correctly. -
Page 16: Design And Function
Design and function General Design and function NOTE Observe documentation of other system components when connecting! General DANGER 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. •... -
Page 17: Installation
Design and function 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 18: 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 19: Intermediate Tube Package Connection
Design and function Mains connection 5.5.2 Intermediate tube package connection Figure 5-2 Item Symbol Description Wire feed unit Intermediate tube package Intermediate tube package strain relief Connector plug, welding current "+" Welding current connection on wire feed unit Earth cable connecting (PE) Connection of green-yellow earth cable from the intermediate tube package 7-pole connection socket Wire feed unit control lead... -
Page 20: Shielding Gas Supply
Design and function Shielding gas supply Shielding gas supply 5.6.1 Connecting the shielding gas supply DANGER Risk of injury caused by shielding gas cylinders toppling over! Shielding gas cylinders may topple over and cause serious injury if not adequately secured! •... - Page 21 Design and function Shielding gas supply Figure 5-3 Item Symbol Description Pressure reducer Shielding gas cylinder Output side of the pressure reducer Cylinder valve • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. •...
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Page 22: Connection For Workpiece Lead
Design and function Connection for workpiece lead Connection for workpiece lead Figure 5-4 Item Symbol Description Workpiece Connection socket, workpiece lead Choke tapping "soft" Connection socket, workpiece lead "Hard" choke tapping • Insert cable plug on the workpiece lead into the connection socket for workpiece lead 1 or 2 (depending on the application or shielding gas used) and lock by turning to the right. -
Page 23: 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 24: Repair 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 25: 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 26: Machine Faults (Error Messages)
Rectifying faults Machine faults (error messages) Machine faults (error messages) NOTE Only with the M2.4x machine control. Error message Possible cause Remedy Pol. (M2.41) The selected welding current polarity Set the changeover switch for the welding does not match the machine current polarity (welding voltage display) on configuration the rear of the machine's power source to... -
Page 27: Reset Via Machine Control
Rectifying faults Setting the machine type 7.3.1 Reset via machine control NOTE M2.40 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 28: Technical Data
Technical data Saturn 256 DG Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Saturn 256 DG Switching steps Welding current setting range 30 A - 250 A Duty cycle at 25°C ambient temperature... -
Page 29: Accessories, Options
Accessories, options General accessories Accessories, options General accessories Type Designation Item no. AK300 Adapter for K300 basket coil 094-001803-00001 G1 2M G1/4 R 2M Gas hose 094-000010-00001 GS16L G1/4" SW 17 Pilot static tube 094-000914-00000 GS25L G1/4" SW 17 Pilot static tube 094-001100-00000 WK50QMM 4M KL Workpiece cable, clamp... -
Page 30: Setting Instructions
Appendix A Setting instructions Appendix A 10.1 Setting instructions 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 13,0 14,0 24,0 13,5... -
Page 31: Overview Of Ewm Branches
420 412 358-551 www.ewm-group.com/cz · info.cz@ewm-group.com Tel: · Fax: +49 5384 90798-0 www.ewm-group.com/handel · nl-nord@ewm-group.com EWM HIGHTEC WELDING SALES s.r.o. EWM HIGHTEC WELDING UK Ltd. Unit B Coopies Way Prodejní a poradenské centrum Tyr š ova 2106 Coopies Lane Industrial Estate Morpeth ·...
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