EWM Saturn 301 FKG Operating Instructions Manual Download Page 56

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Replaceable parts

Wire feed rollers

099-004968-EW501

13.09.2021

10.1.4 Conversion kit

Type

Designation

Item no.

URUE VERZ>UNVERZ FE/AL

Conversion kit, 37mm, 4-roller drive on non-toothed

rollers (steel/aluminium)

092-000845-00000

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

Conversion kit, 37mm, 4-roller drive for aluminium 092-000847-00000

URUE AL 4ZR4R 2,4+3,2

Conversion kit, 37mm, 4-roller drive for aluminium 092-000868-00000

URUE ROE 2DR4R

0,8/0,9+0,8/0,9

Conversion kit, 37mm, 4-roller drive for cored wire 092-000830-00000

URUE ROE 2DR4R

1,0/1,2+1,4/1,6

Conversion kit, 37mm, 4-roller drive for cored wire 092-000831-00000

URUE ROE 2DR4R

1,4/1,6+2,0/2,4

Conversion kit, 37mm, 4-roller drive for cored wire 092-000832-00000

URUE ROE 2DR4R 2,8+3,2

Conversion kit, 37mm, 4-roller drive for cored wire 092-000833-00000

Figure 10-1

Summary of Contents for Saturn 301 FKG

Page 1: ...Operating instructions EN Welding machine Saturn 301 FKG M1 02 M2 20 M2 40 Saturn 351 FKG M1 02 M2 20 M2 40 099 004968 EW501 Observe additional system documents 13 09 2021...

Page 2: ...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 ac...

Page 3: ...ng parameter ignition time tZn diagram 23 4 3 3 M2 40 welding machine control 24 4 3 3 1 Welding task selection 26 4 3 3 2 Setting the operating point welding output 27 4 3 3 3 Setting the wire correc...

Page 4: ...Disposing of equipment 48 7 Rectifying faults 49 7 1 Checklist for rectifying faults 49 7 2 Check the machine type setting 50 7 2 1 Setting the machine type 50 7 3 Resetting the control Reset all 51 8...

Page 5: ...Contents Notes on using these operating instructions 099 004968 EW501 13 09 2021 5...

Page 6: ...s and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning sym bol The hazard is also highlighted using a symbol in the page margin CAUTION Working or ope...

Page 7: ...tch off machine Release Switch on machine Press and hold Switch Incorrect Invalid Turn Correct Valid Numerical value adjustable Input Signal light lights up in green Navigation Signal light flashes gr...

Page 8: ...cal specialist may interconnect the sources as per standard IEC 60974 9 2010 Installa tion and use and German Accident Prevention Regulation BVG D1 formerly VBG 15 or country specific regulations Befo...

Page 9: ...temperatures of 100 C or higher and arcing and work on live components Hearing protection against harming noise Explosion risk Apparently harmless substances in closed containers may generate excessi...

Page 10: ...s 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 use...

Page 11: ...placement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the ma chine is switched off Requirements for connection to the public...

Page 12: ...on or connection points can heat up significantly during operation water cooled version When opening the coolant circuit escaping coolant may cause scalding Open the coolant circuit only when the powe...

Page 13: ...in its design and construction to the EU directives listed in the decla ration The product comes with a relevant declaration of conformity in the original The manufacturer recommends carrying out the...

Page 14: ...Machine description quick overview Front view side view from the right 14 099 004968 EW501 13 09 2021 4 Machine description quick overview 4 1 Front view side view from the right Figure 4 1...

Page 15: ...pping 6 Slide latch lock for the protective cap 7 Protective cap Cover for the wire feed mechanism and other operating elements Depending on the machine series additional stickers with information on...

Page 16: ...Machine description quick overview Rear view interior view from the right 16 099 004968 EW501 13 09 2021 4 2 Rear view interior view from the right Figure 4 2...

Page 17: ...nts for shielding gas cylinder strap chain 2 Cooling air outlet 3 Bracket for shielding gas cylinder 4 Carrying handle 5 Operating elements see 4 3 1 1 chapter 6 Wire feed unit 7 Wire spool holder 8 C...

Page 18: ...gnal light on when the machine is switched on and ready for operation 2 Rotary dial Wire speed setting Infinite adjustment of the wire speed 3 Rotary dial Spot and interval times Infinite adjustment o...

Page 19: ...etting on the machine Figure 4 4 All details in percent relate to the values stored in the characteristics Item Symbol Description 0 1 Rotary dial Wire creep optional 30 2 Gas post flow time trimmer S...

Page 20: ...e last parameters used for welding Not lit Display shows the setpoint values or current values during welding 3 Signal light Wire speed Lights when the wire speed is shown on the display 4 AMP Current...

Page 21: ...operating mode and runtime parameters The parameters are pre set in the control but can be adjusted individually If there is no user action within 5 seconds during the setting process the control int...

Page 22: ...0 s to 10 s Wire creep speed On 0 5 24 m min Ignition time tZn 0 ms to 500 ms The selected parameter is shown on the display Set the parameter chosen 4 3 2 4 Explanation of symbols Symbol Meaning GnS...

Page 23: ...e arc striking is positively affected by the adjustable ignition time After the arc striking the wire feeder continues operating in wire creep speed for the set ignition time This behaviour occurs whe...

Page 24: ...t in JOB mode All parameter settings are car ried out manually by the user JOB 0 4 Signal light HOLD Lit Display shows the last parameters used for welding Not lit Display shows the setpoint values or...

Page 25: ...vant images on the connection sockets Choke tapping 1 hard workpiece lead connection socket Choke tapping 2 medium workpiece lead connection socket Choke tapping 3 soft workpiece lead connection socke...

Page 26: ...et can be used to continue welding The user has the option to correct the wire feed speed according to the welding task or individual require ments The welding task setting can also be made using the...

Page 27: ...orkpiece inductance er ror etc To correct the error press TEST again If the operating mode has already been selected all the necessary settings will have been activated and welding can be started 4 3...

Page 28: ...ard display Operating ele ment Action Result 1 x Select expert parameters The combination of button must be pressed within 3 seconds 1 x 2 x n x Select expert parameters Gas pre flow time GvS 0 s to 1...

Page 29: ...e arc striking is positively affected by the adjustable ignition time After the arc striking the wire feeder continues operating in wire creep speed for the set ignition time This behaviour occurs whe...

Page 30: ...set up the complete wire guide system from the wire spool to the welding torch Check wire guide at regular intervals Keep all casing covers or protective caps closed during operation Read and observe...

Page 31: ...bserve the regulations regarding occupational safety and accident prevention for the respective country Craning principle Risk of injury due to unsuitable lifting eye In case of improper use of liftin...

Page 32: ...the limits the cylinders may tip at an angle of up to 10 according to IEC 60974 2 and people may be injured as a result Use shielding gas cylinders with a maximum geometric volume of 33 l at a fillin...

Page 33: ...for the application on the pressure regulator Press the gas test key button briefly The shielding gas will then flow for approx 25 sec Pressing the key button again briefly will pause the test If the...

Page 34: ...ith HF igniter TIG for as long as pos sible in parallel with a distance of 20 cm to avoid HF sparkover Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences A...

Page 35: ...heck that all welding current connections are firmly secured and electrical connections are in perfect condition Set up attach or suspend all conductive power source components such as casing trans po...

Page 36: ...ns plug socket and lead must be checked by a qualified electrician on a regular basis When operating the generator always ensure it is earthed as stipulated in the operating in structions The network...

Page 37: ...et workpiece lead Hard choke tapping 3 Connection socket workpiece lead Medium choke tapping 4 Welding torch 5 Welding torch connection Euro torch connector Welding current shielding gas and torch tri...

Page 38: ...r intervals Keep all casing covers or protective caps closed during operation 5 1 10 1 Inserting the wire spool CAUTION Risk of injury due to incorrectly secured wire spool If the wire spool is not se...

Page 39: ...er hard wires Use driven rolls with U groove for aluminium wires and other soft alloyed wires Use driven rolls with knurled U groove for flux cored wires Slide new drive rollers into place so that the...

Page 40: ...et nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe Press the clamping element with the pressure roller back downwards and fold the wire...

Page 41: ...stops but without it jamming during operation 5 1 11 Operating modes functional sequences There are optimum pre sets for welding parameters such as gas pre flow and burn back etc for numerous applicat...

Page 42: ...rupted for longer than 2 s 5 1 11 3 Non latched mode Figure 5 14 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 w...

Page 43: ...runs at creep speed Arc ignites when the wire electrode makes contact with the workpiece welding current flows Changeover to the pre selected wire speed after the set ignition time tZn Step 2 Release...

Page 44: ...angeover to the pre selected wire speed after the set ignition time tZn The WF stops after the set spot welding time elapses Arc is extinguished after the pre selected wire burn back time elapses Gas...

Page 45: ...ignition time tZn The wire feed stops after the pulse time expires Arc is extinguished after the wire burn back time elapses The process is repeated after the pause time elapses 2 End Release torch tr...

Page 46: ...ce matters always consult the dealer who supplied the machine Return deliveries of defective equipment subject to warranty may only be made through your dealer When replacing parts use only original s...

Page 47: ...rollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks Visual inspection Casing damage front rear and side walls Wheels and their securing elements Transport ele...

Page 48: ...r on wheels indicates that the equipment must be collected separately This machine has to be disposed of or recycled in accordance with the waste separation systems in use According to German law law...

Page 49: ...Welding wire is touching electrically conductive casing parts check wire guide has the welding wire sprung off the wire spool Check for a correct mounting of the welding lead Fit the feeder clamp of...

Page 50: ...ckage Wire guide core or spiral is dirty or worn Clean core or spiral replace kinked or worn cores 7 2 Check the machine type setting After switching on the machine type that has been set is displayed...

Page 51: ...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...

Page 52: ...antity Shielding gas cylinder 10 l to 33 l 2 6 gal to 7 3 gal max Filling pressure Shielding gas cylinder 300 bar 30 MPa Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambie...

Page 53: ...al max Filling pressure Shielding gas cylinder 300 bar 30 MPa Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 25 C to 40 C Machine cooling Torch cooling F...

Page 54: ...trofit option for locking brake for machine wheels 092 002109 00000 ON Drahteinschleich Poti M1 02 Retrofit option wire creep rotary dial 092 001102 00000 GH 2X1 4 2M Gas hose 094 000010 00001 A V EN1...

Page 55: ...ressure rollers smooth 37mm 092 000844 00000 10 1 2 Wire feed rollers for aluminium wire Type Designation Item no AL 4ZR4R 0 8 1 0 Twin rollers 37 mm for aluminium 092 000869 00000 AL 4ZR4R 1 0 1 2 Tw...

Page 56: ...092 000846 00000 URUE AL 4ZR4R 1 2 1 6 Conversion kit 37mm 4 roller drive for aluminium 092 000847 00000 URUE AL 4ZR4R 2 4 3 2 Conversion kit 37mm 4 roller drive for aluminium 092 000868 00000 URUE R...

Page 57: ...Appendix Setting instructions 099 004968 EW501 13 09 2021 57 11 Appendix 11 1 Setting instructions 11 1 1 Saturn 301 Figure 11 1...

Page 58: ...Appendix Setting instructions 58 099 004968 EW501 13 09 2021 11 1 2 Saturn 351 Figure 11 2...

Page 59: ...Appendix Searching for a dealer 099 004968 EW501 13 09 2021 59 11 2 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide...

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