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EWM SATURN MIG 200 - User Manual

EWM SATURN MIG 200
68 pages
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EWM HIGHTEC WELDING GmbH
Dr.-Günter - Henle - Straße 8; D-56271 Mündersbach
Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244
Internet:
www.ewm.de ; E-mail: info@ewm.de
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).
S
Units may be used in accordance with VDE 0544 (EN 60974-1) in areas where increased
electrical danger exists.
ã
ãã
ã 2000 Subject to technical change! Art. Nr.: 099-004305-EWM01 Stand: 28.08.2000

Table of Contents

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Summary

Safety Instructions

General Safety Precautions

Covers warnings for electrical, fume, fire, and hot material hazards.

Noise, Gas Cylinder, and Interference Safety

Addresses hearing protection, secure gas cylinder handling, and electromagnetic interference.

Repair and Maintenance Safety Warnings

Highlights risks of unauthorized repairs and warranty voidance.

Notes on Using the Operating Instructions

Instructional Symbols and Warning Notations

Explains warning symbols, notes, cautions, and diagram notations used in the manual.

About the Switched Machine

Machine Advantages and Features

Details the benefits and key features of the MIG/MAG welding machines.

Control Interfaces Overview

Introduces the M100 and M201 control panels and their basic functions.

Machine Applications

Outlines the suitable materials, processes, and applications for the welding machines.

Transport and Installation

Safe Transport Procedures

Provides guidelines for machine transport, including crane lifting safety.

Environmental Operating Conditions

Specifies acceptable temperature, humidity, and air quality for machine operation.

Technical Data

Saturn Series Specifications

Lists detailed technical specifications for the Saturn welding machine series.

System Components Description

System Overview Diagram

Presents a high-level view of the welding system's main components and connections.

Welding Power Source Details

Illustrates and labels the front and rear views of the welding power source unit.

Control Panel Layouts

Details the design and elements of the M100, M201, and M110 control panels.

Optional Displays and Remote Controls

Describes optional V/A meters, hand remote controls, and torch remotes.

Interface Connections

Provides information on interface ports for automation and external control.

M100 Control Operation

M100 Control Overview and Settings

Details the M100 control layout and basic working point setting procedures.

M100 Operating Modes and Choke Tappings

Explains selection of operating modes and choke tapping functions.

M100 Optional V;A Meter Functionality

Describes the features and operation of the optional M110 digital V/A meter.

M100 Advanced Welding Parameters

Covers adjustment of parameters like wire burn-back, gas after-flow, and creep start.

M100 Operating Mode Sequences

MIG 2-Step Sequence

Details the sequence of operations for the 2-Step MIG welding process.

MIG 4-Step Sequence

Details the sequence of operations for the 4-Step MIG welding process.

MIG Spot Welding Sequence

Explains the operational sequence for MIG spot welding.

MIG Interval Welding Sequence

Details the sequence of operations for MIG interval welding.

M201 Control Operation

M201 Welding Job Setup

Guides users on setting up MIG/MAG welding jobs using the M201 control.

M201 Welding Job Configuration (One-Knob)

Explains setting welding tasks and parameters in M201's one-knob mode.

M201 Manual Operation and Mode Selection

Covers manual two-knob operation, mode selection, and choke tapping.

M201 Error Indicators and Troubleshooting

Explains signal lamps for errors, including short-circuit and program availability.

M201 Wire Feed Speed Correction

Provides instructions for correcting wire feed speed using various controls.

M201 M110 Display and Advanced Functions

Details the M110 display and advanced functions like burn-back and gas preflow.

M201 Operational Safety Features

Covers safety functions like forced shut-down and short-circuit monitoring.

M201 Operating Mode Sequences

MIG 2-Step Sequence

Details the sequence of operations for the M201's 2-Step MIG welding process.

MIG 4-Step Sequence

Details the sequence of operations for the M201's 4-Step MIG welding process.

MIG Spot Welding Sequence

Explains the operational sequence for M201 MIG spot welding.

Short Operating Manual: M201 PROGRAM

Setting Welding Tasks (One-Knob Operation)

Guides setting welding tasks using the M201's one-knob programme feature.

Setting Welding Parameters (Two-Knob Operation)

Guides setting welding parameters using the M201's two-knob manual mode.

Commissioning the Welding Machine

Machine Setup and Mains Connection

Instructions for positioning, securing, and connecting the machine to the mains power.

Torch, Wire, and Gas Installation

Covers connecting welding torches, installing wire, and setting up gas supply.

Wire Feed and Spool Brake Adjustment

Details inching the wire electrode and adjusting the spool brake tension.

Workpiece Cable and Polarity Setup

Instructions for connecting the workpiece cable and changing welding current polarity.

Shielding Gas Supply Setup and Settings

Guides fitting gas connections and setting the correct shielding gas flow.

Maintenance and Care

Electronic Component Cleaning

Instructions for cleaning electronic components using a vacuum cleaner.

Coolant System Checks

Information regarding coolant levels and checks for the welding torch system.

Operating Faults, Causes, and Cures

Customer Troubleshooting Checklist

A guide for diagnosing and resolving common welding machine problems.

Spare Parts List

Accessories

Work-piece Cables

Lists available work-piece cables with specifications and part numbers.

General Accessories

Lists general accessories like remote controls, regulators, and safety gear.

Circuit Diagrams

SATURN 250-300 (M100)

Provides the circuit diagram for the SATURN 250-300 with M100 control.

SATURN 250-300 (M100;M110)

Presents the circuit diagram for SATURN 250-300 with M100/M110 controls.

SATURN 250-300 (M200)

Displays the circuit diagram for the SATURN 250-300 with M200 control.

SATURN 250-300 (M200;M110)

Shows the circuit diagram for SATURN 250-300 with M200/M110 controls.

EWM SATURN MIG 200 Specifications

General IconGeneral
Welding processMIG/MAG
Input Voltage230 V
Mains frequency50/60 Hz
Welding Current Range30 - 200 A
Output Current Range30 - 200 A
Open Circuit Voltage53 V
Weight13.7 kg
Dimensions485 x 220 x 380 mm
Protection classIP23
Mains Voltage230 V
Power SupplySingle-phase
Wire Diameter0.6 – 1.0 mm
Wire Diameter Range0.6 – 1.0 mm

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