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CONTENTS

Page

Contents/1

Safety Instructions ................................................................................................................Safety/1

Instructions for the use of this Operating Manual ...................................................Instructions/1

About this step switched machine....................................................................................... 1/1

1.1 The advantages of these MIG/MAG- Welding Machines ................................................. 1/1

1.2 Controls ............................................................................................................................ 1/2

1.2.1

Control M100 ....................................................................................................... 1/2

1.2.2

Control Program M201 ........................................................................................ 1/3

1.3 Range of Applications....................................................................................................... 1/4

Transport and Installation..................................................................................................... 2/1

Technical Data........................................................................................................................ 3/1

3.1 SATURN - Series ............................................................................................................ 3/1

Description 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 ................................................................................. 4/4

4.3.2

Control M100 ....................................................................................................... 4/6

4.4 Volt-/ Ammeter Display..................................................................................................... 4/7

4.4.1

M110: digital V / A - Meter with Hold - Function

(Option for M100+M201) ..................................................................................... 4/7

4.5 The Remote Control (Option only with the M201) ............................................................ 4/7

4.5.1

Hand Remote Control RM (Option only with the M201)

...................................... 4/7

4.5.2

Remote Control On the welding torch (Option only with the M201) .................... 4/8

4.6 The Interfaces(Option, only with the M201) ..................................................................... 4/8

4.6.1

Automation Interface (Option) ............................................................................. 4/8

Содержание SATURN MIG 200

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 54: ......

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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