EWM SATURN MIG 200 Operating Manual Download

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SATURN 250-300 (M100)

Summary of Contents for SATURN MIG 200

Page 1: ...manual must be read before using the machine It can be dangerous to ignore this The machine may only be used by personnel who are familiar with appropriate regulations This machine bears the CE mark a...

Page 2: ...unauthorized changes improper repairs and or unauthorized modifications which have not been expressly allowed by EWM this declaration will lose its validity Par la pr sente nous d clarons que la conc...

Page 3: ...tion of the System components 4 1 4 1 System Summary 4 1 4 2 The Welding Power Source 4 2 4 2 1 SATURN 200 300 Welding Machine Series Front and rearview 4 2 4 3 Controls 4 4 4 3 1 Control PROGRAM M201...

Page 4: ...IG MAG welding jobs 6 1 6 1 1 MIG MAG Welding Jobs and setting of the working point without option M210 operating mode programme one knob operation 6 2 6 1 2 MIG MAG Welding Jobs and setting of the wo...

Page 5: ...7 2 Gas after flow time 6 6 6 7 3 Feeding in the wire electrode 6 7 6 7 4 Creep start 6 7 6 7 5 Gas pre flow 6 8 6 7 6 Ignition control 6 8 6 7 7 Forced shut down 6 8 6 7 8 Short circuit monitoring 6...

Page 6: ...MIG Push Pull Torch Option 8 3 8 5 Installing the Welding Wire 8 3 8 5 1 Insertion of the wire spool 8 3 8 5 2 Inching the wire electrode 8 4 8 5 3 Setting the spool brake 8 4 8 6 Workpiece Cable 8 5...

Page 7: ...ich they are not intended Do not touch live parts with bare skin Never use torches or earth cables with damaged insulation Smoke and gases can lead to breathing difficulties and poisoning Do not breat...

Page 8: ...by the welding machine or by the high voltage pulses of the ignition unit As laid down in Electromagnetic Compatibility Standard EN 50199 the machines are intended f use in industrial areas if they a...

Page 9: ...ved by the user Warning Applies to working and operating procedures which must be followed precisely to avoid damaging or destroying the machine Caution Applies to working and operating procedures whi...

Page 10: ...Finishing thanks to low splatter welding in both short and spray arc range when using Argon Mixed gases and CO2 Easy to use thanks to the ergonomic construction of the machine and the clear layout of...

Page 11: ...time and the operating modes 2 step latch welding 4 step continuous welding spot welding and tacking Gas after flow and wire burn back time as well as arc off wire threading and gas test can be set i...

Page 12: ...oblem Signal lamps show one should select a higher or lower range Further functions Intelligent ignition management for reliable and low splatter arc striking automatic matching of wire burn back wire...

Page 13: ...um and Nickel based alloys Copper and its alloys Solid wire and cored wire electrodes Applications Production and repair welding in metalworking industries and trade maintenance of agricultural equipm...

Page 14: ...chine is moved additional danger results from obstacles on the floor as these can cause additional tilting moments Safety rules for crane transport Carefully observe the accident prevention regulation...

Page 15: ...s etc insofar as they do not occur during welding Examples of unusual operating conditions Unusual corrosive smoke vapour excessive oil vapour unusual vibrations or jolts excessive quantities of dust...

Page 16: ...36 V 15 5 V 37 5 V 15 5 V 41 V Mains fuses slow acting 3 x 16 A 3 x 16 A 3 x 20 A Switch Steps 12 15 Load cycle time 10 min Mains Voltage 3 x 400 V 415V bei 50 60Hz max Connected Power 7 1 kVA 9 6 kVA...

Page 17: ...4 Description of the System components 4 1 4 1 System Summary...

Page 18: ...Description of the System components 4 2 4 2 The Welding Power Source 4 2 1 SATURN 200 300 Welding Machine Series Front and rearview Fig 4 1 Front View Fig 4 2 Rear View In the Unit polarity switchin...

Page 19: ...lay M110 1 12 11 10 9 8 6 5 4 3 2 J1 Step Switch Fine setting for welding voltage M100 or power M201 MIG 200 250 12 Steps MIG 300 15 Steps K1 Welding Torch Connection Euro central connection L1 Remote...

Page 20: ...4 Description of the System components 4 4 4 3 Controls 4 3 1 Control PROGRAM M201 Fig 4 3 Control PROGRAM M201...

Page 21: ...left or error message see 6 4 3 Signal Lamp Recommended change of switch setting if welding power selection too low Turn Step switch to the right or error message see 6 4 4 Rotary knob for the steples...

Page 22: ...b Wire feed speed for stepless selection of the wire feed speed 1 20m min 2 t 0 5 1 1 5 2sec 0sec Rotary knob Spot and Pause Time for stepless selection of the welding times 0 2s in SPOT and STITCH we...

Page 23: ...l may be connected Remote controls may only be plugged in or unplugged when the unit is switched off The welding machine automatically recognises the remote control when switched on The machine have t...

Page 24: ...so retained when the machine is used with peripheral equipment for mechanised welding if this peripheral equipment also meets the same criteria especially with respect to insulation and power supply T...

Page 25: ...ting principle i e to determine his working point the operator must only enter the required Wire feed speed on the control and the Welding Voltage on the step switches corresponding to the material an...

Page 26: ...election of Choke Tapping 2 Choke Tappings are available for selection to suit the shielding gas 1 Choke Setting 1 hard welding choke setting e g for welding with CO2 2 Choke Setting 2 soft welding ch...

Page 27: ...h the formation of large globes on the end of the welding wire causes poor arc striking performance or the wire is melted into the contact tip If burn back is set too low the welding wire gets stuck i...

Page 28: ...creep feed rate is a percentage of the preset wire feed rate As standard this is factory set to 50 e g Wire feed speed 10m min Creep speed 5 m min Advantage The welding wire does not hit the workpiec...

Page 29: ...low Time wire feed Wire Burn back 1st Step Press and hold torch trigger Shielding gas flows out Wire feed motor runs at Creep speed The arc strikes once the welding wire hits the workpiece welding cur...

Page 30: ...Burn back 1st and 2nd Strokes Press and release torch trigger Shielding gas flows out of torch Wire feed motor runs at Creep speed The arc strikes once the welding wire hits the workpiece welding cur...

Page 31: ...ows out of torch Wire feed motor runs at Creep speed The arc strikes once the welding wire hits the workpiece welding current flows Change over to pre selected wire feed speed Wire feed motor stops af...

Page 32: ...its the workpiece welding current flows Change over to pre selected wire feed speed The wire feed motor stops after the preset Pulse time has elapsed Arc is switched off after the preset wire burn bac...

Page 33: ...he microprocessor controlled MIG MAG control PROGRAM M201 works on the one knob operating principle i e To define his working point the user must only pre set the type of gas the type of material and...

Page 34: ...diameter and material for Aluminium Al Welding wire diameter and material for high alloyed steels CrNi or low alloyed steels SG Setting manual Two knob operation no preselected programme 1 12 11 10 9...

Page 35: ...itch Fine For setting the welding voltage in fine steps 0 m min 2 4 6 8 10 2 4 6 8 10 15 20 1 5 10 Rotary knob Wire feed speed Knob for setting the Wire feed speed 1 20 m min 6 2 Selection of operatin...

Page 36: ...amme available If no programme is available in the M201 control for the selected welding parameter combination welding wire diameter type of material and gas then the lamps flash simultaneously Weldin...

Page 37: ...he welding machine Plug the torch control cable into the remote control socket Setting the correction of the wire feed speed one knob operation or the wire feed speed Operating mode manual two knob op...

Page 38: ...however be changed by about 100 with the trimmer Setting Instructions If burn back is set too high the formation of large globes on the end of the welding wire causes poor arc striking performance or...

Page 39: ...control The wire creep speed depends on the welding task on the material type of gas and wire diameter and is determined by characteristic curves Observe Fig 6 3 The value for wire creep can be change...

Page 40: ...hut down function helps to prevent accidents Whenever welding is interrupted for more than 3 seconds the wire feed the welding voltage and the gas are switched off 6 7 8 Short circuit monitoring This...

Page 41: ...re Burn back Fig 6 4 Sequence of functions MIG 2 Stroke 1st Step Press and hold torch trigger Shielding gas flows out Gas pre flow Wire feed motor runs at Creep speed The arc strikes once the welding...

Page 42: ...torch trigger until the arc is struck Shielding gas flows out of torch Wire feed motor runs at Creep speed The arc strikes once the welding wire hits the workpiece welding current flows Change over t...

Page 43: ...trigger Shielding gas flows out of torch gas pre flow Wire feed motor runs at Creep speed The arc strikes once the welding wire hits the workpiece welding current flows Change over to pre selected wir...

Page 44: ...r too high Switch the selection switch lower Signal lamp lights Welding power too low Switch the selection switch higher 0 m min 2 4 6 8 10 2 4 6 8 10 15 20 1 5 10 The optimum wire feed speed is autom...

Page 45: ...l transformer Fig Control transformer Remove the left side panel of the welding machine disconnect the earthing cable Connect cable C for the required mains voltage Mains voltage 415V Cable C must be...

Page 46: ...Torch Welding torch with guide spiral The capillary tube must be in place in the central connection Welding torch with guide spiral e g with Teflon guide No capillary tube may be present in the centra...

Page 47: ...ions such as for example Binzel Dinse Autogen Ritter and TB can be connected Welding torch with one setting knob The wire feed correction can be made using the setting knob on the torch The adjustment...

Page 48: ...and teflon core with the guide tube C2 Press the clamping elements B2 with the counter rollers back downwards wire electrode must lie in the groove of the drive roller Swivel the knurled nuts A2 which...

Page 49: ...so called induction losses and a negative alteration of the welding characteristics Plug the workpiece lead in one of the power sockets choke tapping points Chapter 4 E1 F1 and lock it by turning to...

Page 50: ...16 l min is installed For applications such as Aluminium where a greater gas flow rate is needed a gas flow limitation nozzle for 0 32 l min see Accessories should be fitted Results of wrong shielding...

Page 51: ...placing parts use only original spare parts When ordering spare parts the machine type serial number and item number of the machine as well as the type description and item number of the spare part mu...

Page 52: ...e prevents it going through the contact tip The brake on the wire spool is set too tightly Torch faulty Clean the contact tip and spray with anti splatter Check the counter roller Replace worn out dri...

Page 53: ...g air in the gas line Wherever several short passes are welded the job must be given a chance to cool down before welding is continued Check the gas line for sealing Deal with any leaks Unusually stro...

Page 54: ......

Page 55: ...12 Ersatzteilliste Spare Parts List 12 1...

Page 56: ...12 Ersatzteilliste Spare Parts List 12 2 Abb 12 1 Vorderseite front view Abb 12 2 R ckseite rear view...

Page 57: ...polig connection socket opt 094 003064 00000 K1 Transportgriff transport handle 094 000212 00000 L1 Drehknopf switch knob 074 000315 00000 zu L1 Drehknopfdeckel switch knob cap 074 000315 00001 zu L1...

Page 58: ...12 Ersatzteilliste Spare Parts List 12 4 Abb 12 3 rechte Seite right side Abb 12 4 linke Seite left side...

Page 59: ...7 00000 F3 Spulendorn coil pin 094 000346 00000 H3 Taster key switch 044 001116 00000 I3 Trimmer trimmer 040 000186 00000 A4 Versorgungstrafo supply transformer 094 002417 00004 B4 Shunt shunt 074 000...

Page 60: ...12 5 a Explosionszeichnung Drahtvorschubeinheit 2 Rollenantrieb exploded view wire feed 2 rolls drive 27 28 26 Abb 12 5b Ersatzrollen Aluminium spare part rolls aluminium 29 30 27 26 Abb 12 5c Ersatz...

Page 61: ...Stahl 0 6 0 8 Stahl Standard 1 DR steel 0 6 0 8 steel standard 094 003217 00000 23 1 AR Stahl 0 8 1 0 Stahl Standard 1 DR steel 0 8 1 0 steel standard 094 003218 00000 23 1 AR Stahl 0 9 1 2 Stahl Stan...

Page 62: ...st 12 8 Abb 12 6a Explosionszeichnung Drahtvorschubeinheit 4 Rollenantrieb exploded view wire feed 4 rolls drive Abb 12 6b Ersatzrollen Aluminium spare part rolls aluminium Abb 12 6c Ersatzrollen F ll...

Page 63: ...acer large 094 005402 00000 31 Abstandsrollen klein Spacer small 094 006280 00000 Andruckarm rechts komplett Pressure arm right complete 094 006281 00000 Andruckarm links komplett Pressure arm left ha...

Page 64: ...ntrol wire feed correction 5m 090 008063 00000 DM1 Pressure regulator with gauge 28 30l min 094 000009 00000 EG1000 Replacement glasses 1000h 90x110mm 094 000073 00000 DBV2A Wire brush for stainless s...

Page 65: ...14 Schaltpl ne Circuit diagrams 14 1 SATURN 250 300 M100...

Page 66: ...14 Schaltpl ne Circuit diagrams 14 2 SATURN 250 300 M100 M110...

Page 67: ...14 Schaltpl ne Circuit diagrams 14 3 SATURN 250 300 M200...

Page 68: ...14 Schaltpl ne Circuit diagrams 14 4 SATURN 250 300 M200 M110...

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EWM SATURN MIG 200, Operating Manual

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