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EWM Saturn 301 KGE M1.02, Operating Instructions Manual

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EWM Saturn 301 KGE M1.02 Operating Instructions Manual Download Page 1

 

 

 

 

 

Operating instructions 

 

 
 
 

 

 

 

 

 

Welding machine 

 

 

 

 

GB

 

Saturn 301 KGE (M1.02 / M2.20 / M2.40) 
Saturn 351 KGE (M1.02 / M2.20 / M2.40) 

 
 

 

099-004968-EW501 

27.09.2011

 
 

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Summary of Contents for Saturn 301 KGE M1.02

Page 1: ...machine GB 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 Details for...

Page 2: ...ther form of liability regardless of type shall be accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whethe...

Page 3: ...ng point welding output 20 4 3 1 3 Welding parameter ignition time tZn diagram 20 4 3 2 M2 20 welding machine control 21 4 3 2 1 Setting the operating point welding output 23 4 3 2 2 Setting the opera...

Page 4: ...nce tasks 49 6 2 3 Annual test inspection and testing during operation 49 6 3 Maintenance work 50 6 4 Disposing of equipment 50 6 4 1 Manufacturer s declaration to the end user 50 6 5 Meeting the requ...

Page 5: ...Contents Notes on the use of these operating instructions 099 004968 EW501 27 09 2011 5...

Page 6: ...l in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading...

Page 7: ...scription Press Do not press Turn Switch 0 1 Switch off machine 0 1 Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display example wait 4s press Inter...

Page 8: ...pment sensitive to radiation accordingly The correct functioning of pacemakers may be affected obtain advice from a doctor if necessary Do not carry out any unauthorised repairs or modifications To av...

Page 9: ...s or lighters Keep appropriate fire extinguishing equipment to hand in the working area Thoroughly remove any residue of flammable substances from the workpiece before starting welding Only continue w...

Page 10: ...suspend all conductive power source components like casing transport vehicle and crane frames so they are insulated Do not place any other electronic devices such as drillers or angle grinders etc on...

Page 11: ...he user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the user must consider the following...

Page 12: ...during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to EN 60974 A2 Set up and transport the machine on level solid ground Secure add on parts using suitable equipme...

Page 13: ...shielding gas cylinders tool boxes wire feed units etc Avoid jerky movements when raising or lowering Use shackles and load hooks of the appropriate size m i n 1 m m i n 1 m 75 Fig Lifting principle R...

Page 14: ...s of dust acid corrosive gases or substances may damage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambient...

Page 15: ...f Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction EC Low Voltage Directive 2006 95 EC EC EMC Directive 2004 108 EC This declaration sh...

Page 16: ...erature detected 4 Main switch machine on off 5 Welding voltage step switch To set the welding voltage 6 Cooling air inlet 7 Connection socket workpiece lead Hard choke tapping 8 Connection socket wor...

Page 17: ...unit cover lock 2 Cover for wire feed unit and operating elements 3 Securing elements for shielding gas cylinder strap chain 4 Bracket for shielding gas cylinder 5 Connecting nipple G shielding gas c...

Page 18: ...Infinite adjustment of the wire speed 2 Rotary dial Spot and interval times Infinite adjustment of the welding time 0 2s in Spots and interval operating mode 3 Operating mode selector switch Changeove...

Page 19: ...itted see Accessories chapter Unlock the right hand cover on the machine Tilt the cover forwards then remove upwards There are other operating elements for parameter setting on the machine Figure 4 4...

Page 20: ...lectrode diameter Operating element Action Result Wire speed setting Welding voltage setting 4 3 1 3 Welding parameter ignition time tZn diagram NOTE In the ignition time the wire feed continues to ru...

Page 21: ...t using Runtime parameter button setting on the Rotary transducer 2 AMP Current signal light Lights when the current is shown on the display 3 Rotary dial Wire speed welding parameter setting Continuo...

Page 22: ...r inching the wire electrode when changing the wire spool speed 6 0 m min constant The welding wire is inched into the tube package with the current off and without gas being expelled This ensures a h...

Page 23: ...erating element Action Result Wire speed setting Welding voltage setting 4 3 2 2 Setting the operating mode and runtime parameters NOTE The parameter values set are preset in the JOB and can be modifi...

Page 24: ...rameters The key combination must be pressed within 3 seconds Select expert parameters Gas pre flow time GvS 0 s to 10 s Wire creep speed On 0 5 24 m min Ignition time tZn 0 ms to 500 ms n x The selec...

Page 25: ...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 b...

Page 26: ...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 carr...

Page 27: ...o flow for approx 25 seconds The button can be pressed again at any time to cancel the process 8 Button Wire inching For inching the wire electrode when changing the wire spool speed 6 0 m min constan...

Page 28: ...ing task or individual requirements The welding task setting can also be made using the two dial operation principle however To do this set the JOB 0 manual no program from the JOB list the welding vo...

Page 29: ...ire speed using the welding current Hold down the TEST button and at the same time set the operating point on the step switch The display shows the required parameters and the open circuit voltage If...

Page 30: ...reset in the JOB and can be modified if necessary Operating element Action Result n x Select operating mode Non latched Latched Spots Interval n x Select welding parameter Set gas post flow time GnS 0...

Page 31: ...rameters The key combination must be pressed within 3 seconds Select expert parameters Gas pre flow time GvS 0 s to 10 s Wire creep speed On 0 5 24 m min Ignition time tZn 0 ms to 500 ms n x The selec...

Page 32: ...ed 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 The process desc...

Page 33: ...feed units are equipped with moving parts which can trap hands hair clothing or tools and thus injure persons Do not reach into rotating or moving parts or drive components Keep casing covers closed d...

Page 34: ...ite 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...

Page 35: ...ctions The resulting network has to be suitable for operating devices according to protection class 1 5 5 1 Mains configuration NOTE The machine may be connected to a three phase system with four cond...

Page 36: ...Connection socket workpiece lead Medium choke tapping 3 Central connection for welding torch Euro Integrated welding current shielding gas and torch trigger Insert central plug of the welding torch in...

Page 37: ...nder Do not attach any element to the shielding gas cylinder valve Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air Avoid heating th...

Page 38: ...nder strap chain 3 Bracket for shielding gas cylinder 4 Cylinder valve 5 Output side of the pressure regulator 6 Pressure regulator 7 Shielding gas cylinder Place the shielding gas cylinder into the r...

Page 39: ...TIG 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: ...ed nut For fixing the wire spool Loosen knurled nut from spool holder Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore Fasten wire spool using knurled nut...

Page 41: ...e wire and the material Check the roller label to verify that the rollers are suitable for the wire diameter Turn or change if necessary use V groove rollers with for steel wires and other hard wires...

Page 42: ...re guide system from the wire spool to the welding torch Remove the pressure rollers from the wire feed unit if no welding torch is fitted Check wire guide at regular intervals Keep all casing covers...

Page 43: ...re unit Press the wire inching button until the wire electrode projects out of the welding torch CAUTION Extensive wear due to incorrect contact pressure Incorrect contact pressure will cause extensiv...

Page 44: ...n back etc for numerous applications although these can also be changed if required 5 9 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger...

Page 45: ...ing 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 Changeover to the pre selected wire sp...

Page 46: ...eed motor 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...

Page 47: ...ws Changeover 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...

Page 48: ...elapses The process is repeated after the pause time elapses 2 End Release torch trigger Wire feed stops Arc is extinguished after the wire burn back time elapses Gas post flow time elapses NOTE When...

Page 49: ...d valve Gas cylinder securing elements Operating message safety and adjustment devices Functional test Other general condition 6 2 2 Monthly maintenance tasks Casing damage front rear and side walls W...

Page 50: ...pean provisions guideline 2002 96 EG of the European Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must...

Page 51: ...nching wire electrodes chapter Check settings and correct if necessary a Worn wire rolls Check and replace if necessary a Wire feed motor without supply voltage automatic cutout triggered by overloadi...

Page 52: ...rrect this setting tyP 00 Saturn 251 tyP d00 Saturn 256 tyP 01 Saturn 301 tyP r01 Mira 301 M2 xx tyP 02 Saturn 351 tyP d02 Wega 351 Saturn 351 DG tyP d03 Wega 401 451 tyP d04 Wega 501 601 7 2 1 Settin...

Page 53: ...g 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...

Page 54: ...2 V 15 5 V to 37 5 V Mains connection lead H07RN F4G2 5 Mains voltage tolerances 3 x 400 V 15 to 15 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 25 A Max connected load 12 8 kVA 16 kVA Reco...

Page 55: ...ke for machine wheels 092 002109 00000 ON HOSE FR MOUNT Optional holder for tubes and remote control for machines without star handle 092 002116 00000 ON WIRE CREEP POTI M1 02 Retrofit option wire cre...

Page 56: ...92 000841 00000 FE 2DR4R 1 0 1 2 Drive rollers 37 mm steel 092 000842 00000 FE 2DR4R 1 2 1 6 Drive rollers 37 mm steel 092 000843 00000 FE AL 2GR4R Pressure rollers smooth 37mm 092 000844 00000 10 1 2...

Page 57: ...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 58: ...0 9 2 1 0 8 8 0 10 2 8 7 0 10 1 11 1 0 10 2 16 1 0 9 2 1 2 6 0 0 9 2 5 1 0 10 2 8 4 0 10 2 10 4 0 8 2 1 6 3 5 0 9 2 2 3 0 9 2 4 3 0 10 2 9 6 0 8 2 6 0 0 8 16 6 0 12 2 11 9 0 12 2 15 3 0 10 2 17 7 0 9...

Page 59: ...0 10 1 10 9 0 11 2 15 7 0 10 2 1 2 4 9 0 8 2 5 4 0 11 2 5 4 0 9 1 10 4 0 9 2 1 6 2 4 0 7 1 3 2 0 12 2 3 8 0 9 1 9 1 0 8 2 6 0 0 8 23 2 0 16 2 10 6 0 12 2 20 5 0 13 2 19 2 0 11 2 1 0 6 2 0 9 2 7 7 0 1...

Page 60: ...Appendix B Overview of EWM branches 60 099 004968 EW501 27 09 2011 12 Appendix B 12 1 Overview of EWM branches...

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