EWM SATURN MIG 200 User manual

EWM HIGHTEC WELDING GmbH
Dr.-Günter - Henle - Straße 8; D-56271 Mündersbach
Phone: [phone]; Fax: [phone]
Internet: www.ewm.de ; E-mail: [email protected]
Operating Manual
GB
SATURN MIG 200 - 300
SATURN MIG 200 - 300 PROGRAM
for Standard MIG/MAG Welding.
SATURN MIG 200, MIG 200 PROGRAM
SATURN MIG 250, MIG 250 PROGRAM
SATURN MIG 300, MIG 300 PROGRAM
The operating 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 and thus confroms with the
·EU-low voltage guidelines (73/23/EWG)
·EU-EMV- guidelines (89/336/EWG)
(The CE-mark is only required in countries which are members of the European Union).
SUnits may be used in accordance with VDE 0544 (EN 60974-1) in areas where increased
electrical danger exists.
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ã2000 Subject to technical change! Art. Nr.: 099-004305-EWM01 Stand: 28.08.2000

Originaldokument
liegt jedem Gerät bei!
Original document
is enclosed with each machine!
Document original
est joint à toute machine!
EG - Konformitätserklärung
EU - conformity declaration
Déclaration de Conformidité de U.E.
Name des Herstellers:
Name of manufacturer:
Nom du fabricant:
EWM HIGHTEC WELDING GmbH
(nachfolgend EWM genannt)
(In the following called EWM)
(nommé par la suite EWM)
Anschrift des Herstellers:
Address of manufacturer:
Adresse du fabricant:
Dr.- Günter - Henle - Straße 8
D - 56271 Mündersbach –Germany
[email protected]
Hiermit erklären wir, daß das nachstehend
bezeichnete Gerät in seiner Konzeption und
Bauart sowie in der von uns in Verkehr ge-
brachten Ausführung den grundlegenden
Sicherheitsanforderungen der unten genannten
EG- Richtlinien entspricht. Im Falle von
unbefugten Veränderungen, unsachgemäßen
Reparaturen und / oder unerlaubten Umbauten,
die nicht ausdrücklich von EWM autorisiert sind,
verliert diese Erklärung ihre Gültigkeit.
We herewith declare that the machine described
below meets the standard safety regulations of the
EU- guidelines mentionned below in its conception
and construction, as well as in the design put into
circulation by us. In case of unauthorized changes,
improper repairs and / or unauthorized
modifications, which have not been expressly
allowed by EWM, this declaration will lose its
validity.
Par la présente, nous déclarons que la conception
et la construction ainsi que le modéle, mis sur le
marché par nous, de l´appareil décrit ci - dessous
correspondent aux directives fondamentales de
sécurité de la U.E. mentionnées ci- dessous. En cas
de changements non autorisés, de réparations
inadiquates et / ou de modifications prohibeés, qui
n´ont pas été autorisés expressément par EWM,
cette déclaration devientcaduque.
Gerätebezeichnung:
Description of the machine:
Déscription de la machine:
Gerätetyp:
Type of machine:
Type de machine:
Artikelnummer EWM:
Article number:
Numéro d´article
Seriennummer:
Serial number:
Numéro de série:
Optionen:
Options:
Options:
keine
none
aucune
Zutreffende EG - Richtlinien:
Applicable EU - guidelines:
Directives de la U.E. applicables:
EG - Niederspannungsrichtlinie (73/23/EWG)
EU - low voltage guideline
Directive de la U.E. pour basses tensions
EG- EMV- Richtlinie (89/336/EWG)
EU- EMC guideline
U.E.- EMC directive
Angewandte harmonisierte Normen:
Used co-ordinated norms:
Normes harmonisées appliquées:
EN 60974 / IEC 60974 / VDE 0544
EN 50199 / VDE 0544 Teil 206
Hersteller - Unterschrift:
Signature of manufacturer:
Signature du fabricant:
Michael Szczesny , Geschäftsführer
managing director
gérant 05.2000

CONTENTS Page
Contents/1
Safety Instructions ................................................................................................................Safety/1
Instructions for the use of this Operating Manual ...................................................Instructions/1
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
2 Transport and Installation.....................................................................................................2/1
3 Technical Data........................................................................................................................ 3/1
3.1 SATURN - Series ............................................................................................................ 3/1
4 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

CONTENTS Page
Contents/2
5 Description of M100 / M110 Controls................................................................................... 5/1
5.1 Description M100 Control................................................................................................. 5/1
5.1.1 Setting the Working Point.................................................................................... 5/1
5.1.2 Selection of Operating Modes ............................................................................. 5/2
5.1.3 Choke Tappings .................................................................................................. 5/2
5.2 V / A - Meter with Hold - Function M110 (Option) ............................................................ 5/2
5.2.1 Display actual values during and after welding.................................................... 5/2
5.3 Setting further welding parameters ................................................................................... 5/3
5.3.1 Wire burn-back .................................................................................................... 5/3
5.3.2 Gas after-flow time ..............................................................................................5/3
5.3.3 Feeding in the wire .............................................................................................. 5/3
5.3.4 Creep start........................................................................................................... 5/4
5.4 Sequence of functions - operating modes........................................................................ 5/5
5.4.1 Sequence of functions 2-step.............................................................................. 5/5
5.4.2 Sequence of functions 4-step.............................................................................. 5/6
5.4.3 Sequence of functions spot welding.................................................................... 5/7
5.4.4 Sequence of functions Interval ............................................................................ 5/8
6 Description of M201, M210 Controls.................................................................................... 6/1
6.1 Definition of MIG/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 working point
(without option M210 / operating mode manual, two-knob operation)................. 6/3
6.2 Selection of the operating mode 2-stroke, 4-stroke, Spot welding................................... 6/3
6.3 Selection of the choke tapping ......................................................................................... 6/3
6.4 Signal lamps for error messages...................................................................................... 6/4
6.4.1 Error message too much/ too little welding power pre-selected.......................... 6/4
6.4.2 Error message “No programme available“ .......................................................... 6/4
6.4.2.1 Short-circuit when the machine is switched on .................................... 6/4
6.4.2.2 Short-circuit at the first welding operation............................................ 6/4
6.4.2.3 Short-circuit in any welding operation (contact ignition)....................... 6/4
6.5 Correcting the wire feed speed ........................................................................................ 6/5
6.5.1 Correcting the wire feed speed with remote control (Option) .............................. 6/5
6.5.2 Correcting the wire feed speed with remote control on the welding torch
(Option)................................................................................................................ 6/5

CONTENTS Page
Contents/3
6.6. M110 (Option) digital V / A - Meter with Hold Function .................................................... 6/5
6.6.1 Display of actual welding data during and after welding...................................... 6/5
6.7 Further Functions ............................................................................................................ 6/6
6.7.1 Wire burn-back .................................................................................................... 6/6
6.7.2 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........................................................................................ 6/8
6.8 Sequence of functions in operating modes ...................................................................... 6/9
6.8.1 Sequence of functions 2-Stroke........................................................................... 6/9
6.8.2 Sequence of functions 4-Stroke......................................................................... 6/10
6.8.3 Sequence of functions Spot welding.................................................................. 6/11
7 Summary Manual .................................................................................................................. 7/1

CONTENTS Page
Contents/4
8 Commissioning...................................................................................................................... 8/1
8.1 Setting up the Welding Machine....................................................................................... 8/1
8.2 Mains Connection............................................................................................................. 8/1
8.2.1 Reconnecting the mains voltage 400/415V at the control transformer................ 8/1
8.3 Cooling the Welding Machine........................................................................................... 8/2
8.4 Welding Torch Connections ............................................................................................. 8/2
8.4.1 MIG- Welding Torch ............................................................................................8/2
8.4.2 MIG- Welding Torch with adjustment knob for wire-feed correction
(Option, in preparation)........................................................................................ 8/2
8.4.3 Connection of 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
8.6.1 Changing the welding current polarity (option for cored wire welding)................ 8/5
8.7 Shielding gas supply.........................................................................................................8/6
8.7.1 Fitting the gas connections.................................................................................. 8/6
8.7.2 Shielding gas settings.......................................................................................... 8/6
9 Setting instructions ............................................................................................................... 8/6
10 Maintenance and Care......................................................................................................... 10/1
11 Operating Faults, Causes and Cures................................................................................. 11/1
11.1Customer Checklist ........................................................................................................ 11/1
12. Spare Parts List ................................................................................................................... 12/1
13. Accessories, Options (in preparation) ................................................................................ 13/1
14. Circuit diagrams .................................................................................................................. 14/1

Safety instructions
Safety/1
For Your Safety:
Warning: Observe accident prevention regulations!
Ignoring the following safety procedures can be fatal.
•Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves.
•Protect eyes and face with protective visor.
Electric shocks can be fatal
•The machine may only be connected to correctly earthed sockets.
•Only operate with intact connection lead including protective conductor and safety plug.
•An improperly repaired plug or damaged mains cable insulation can cause electric shocks.
•The machine may only be opened by qualified and authorised personnel.
•Before opening, pull out the mains plug. Switching off is not sufficient. Wait for 2 minutes
until capacitors are discharged.
•Always put down welding torch, stick electrode holder in an insulated condition.
Even touching low voltages can cause you to jump and lead to accidents, so:
•Secure yourself from falls before working on platforms or scaffolding.
•When welding, operate handle earth tongs, torch and workpiece properly, not in ways for
which they are not intended. Do not touch live parts with bare skin.
•When welding, operate handle earth tongs, torch and workpiece properly, not in ways for
which 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 breathe in smoke and gases.
•Ensure that there is sufficient fresh air.
•Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can
be converted into poisonous phosgene by ultraviolet radiation.
Workpiece, flying sparks and droplets are hot
•Keep children and animals well away from the working area. Their behaviour is unpredictable.
•Move containers with inflammable or explosive liquids away from the working area.
There is a danger of fire and explosion.
•Never heat explosive liquids, dust or gases by welding or cutting. There is also a danger of
explosions when apparently harmless substances develop high pressures in enclosed
containers by heating.
Take care to avoid fire hazards
•Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when
parts are glowing or hot slag is present.
•A constant check must be kept on whether fire hazards have been created in the working area.
•Highly inflammable objects, such as matches and cigarette lighters for example, must not be
carried in trouser pockets.
•You must ensure that fire extinguishing equipment - appropriate to the welding process - is
available close to the welding work area and that easy access is possible.

Safety instructions
Safety/2
Take care to avoid fire hazards
•Containers in which fuels or lubricants have been present must be thoroughly cleaned before
welding begins. It is not sufficient simply for the receptacle to be empty.
•After a workpiece has been welded, it must only be touched or brought into contact with
inflammable material when it has cooled down sufficiently.
•Loose welding connections can completely destroy protective conductor systems of interior
installations and cause fires. Before beginning welding work, ensure that the handle earth
tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical
connection from the workpiece to the power source.
Noise exceeding 70 dBA can cause permanent hearing damage
•Wear suitable earmuffs or plugs.
•Ensure that other people who spend time in the working area are not inconvenienced by the
noise.
Secure gas cylinder
•Place shielding gas cylinders in the holders provided for them and secure with safety chains.
•Take care when handling cylinders; do not throw or heat, guard against them toppling over!
•When moving by crane, take off the gas cylinder from the welding machine.
Caution: Interference by electric and electromagnetic fields can be caused 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 are operated e.g. in residential environments problems can occur
ensuring electromagnetic compatibility.
•The functioning of heart pacemakers can be adversely affected when you are standing near th
e
welding machine.
•Malfunctioning of electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the
welding location is possible.
•Other mains supply leads, trip leads, signal and telecommunications leads above, under and
near the welding device may be subject to interference.
Warning: Electromagnetic interference must be reduced to such a level that it no longer
constitutes interference.
Possible reduction measures:
•Welding equipment should be serviced regularly. (see Sect. Maintenance and care)
•Welding leads should be as short as possible and run closely together on or near to the
ground.
•Selective shielding of other leads and equipment in the environment can reduce radiation
Caution: Repairs and modifications may only be carried out by authorised, trained,
specialist personnel.
The warranty becomes null and void in the event of unauthorised interference.
Our operating instructions will provide you with an introduction into the safe use of the
machine.
Therefore please read them closely and only start work when you are familiar with them.

Notes on the use of these operating instructions
Instructions/1
These operating instructions are arranged in Sections.
To help you find your way around more quickly, in the margins you will occasionally see, in addition
to sub-headings, icons referring to particularly important passages of text which are graded as
follows depending on their importance:
(Note): Applies to technical peculiarities which must be observed 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 which must be followed
precisely to avoid endangering people and includes the „Warning“ symbol.
Instructions and lists detailing step-by-step actions in given situations can be recognised
by bullet points, e.g.:
•Insert plug of welding current lead into socket (Sect. 5, G2) and lock.
Meaning of the diagram descriptions:
e.g. (C1) means: Item C / Figure 1 in the respective Section
e.g. (Sect. 3, C1) means: in Section 3 Item C / Figure 1

1 About this step switched machine
1/1
Congratulations !
The SATURN- Series machines are known for their excellent arc striking and welding
characteristics, ergonomic, robust construction and excellent price/performance relationship.
They can be used everywhere from the simplest welding tasks right up to high-tech applications in
industry and trade thanks to their various control concepts.
1.1 The advantages of these MIG/MAG - Welding Machines:
•Perfect Ignition thanks to the optimum welding choke with tappings for the various types of
and Welding material, the fine step welding voltage adjustment, the wire burn-back and
Characteristics large wire feed rollers for reliable wire feed.
•Minimum 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 the
operating elements.
•Mobile with large turning and fixed wheels, 4 lifting lugs for unrestricted crane
operations and protection to IP23 for outdoor operations as well as a low
centre of gravity for high resistance to tipping.
•Robust with a solid sheet-steel housing ideal for the tough world of industry and trade.
•Easy to Service thanks to the clear layout of the modules in the machine.
•Universal Applications thanks to simple polarity switching for cored wire welding (Option).
•Reliable thanks to temperature gauges in the transformer and rectifier.
•Flexible thanks to the wide range of accessories and options such as, for example,:
remote control for wire compensation, Push/Pull- torch, etc.