EWM SATURN MIG 200, SATURN MIG 200 PROGRAM, SATURN MIG 300 PROGRAM, SATURN MIG 250, SATURN MIG 250 PROGRAM Operating Manual

...

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

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).

Units may be used in accordance with VDE 0544 (EN 60974-1) in areas where increased electrical danger exists.

ãã

ã 2000 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 info@ewm.de

Hiermit erklären wir, daß das nachstehend bezeichnete Gerät in seiner Konzeption und Bauart sowie in der von uns in Verkehr gebrachten 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 autorisi ert 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 déclarati on devient caduque.

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 sk in.

•

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

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 shou ld be ser v i ced regu lar l y. (s ee Sect. Mainten ance 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 CO

• 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.

1 About this step switched machine

1/2

1.2 Controls

1.2.1 Control M100

M100 / M110

Standard control M100 “Two-knob operation“ with functions such as steplessly adjustable wire feed speed and pulse- pause 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 internally.

Display unit M110 (Option - can be retro-fitted) in conjunction with the M100 or M201 Two large LED- displays show the welding voltage and welding current during and after welding (HoldFunction).

1 About this step switched machine

1/3

1.2.2 Control Program M201

PROGRAM M201

Comfortable Micro-processor control

„PROGRAM“ M201 with one knob operation and 24 welding programmes for a variety of welding applications which make work easier for the user. The welder simply selects the type of material and gas, the welding wire diameter and the power range on the step switches and the machine is already ready to weld. Tedious

searching for the working point is all done by the control. If the power range is set too high or too low on the step switch - no problem! 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 input feed, gas pre- and post-flow to suit the material selected; increased safety for both machine and user due to automatic shut-down and shortcircuit recognition; steplessly adjustable wire feed rate and wire feed compensation with arc-off feed-in of the wire and gas test; Operating modes: 2- step (latch on/latch off), 4 step (continuous welding), spot welding.

Options and accessories for use with the M201:

Wire compensation on the welding torch or on the remote control, connections for MIG-Push/Pull torch with or without wire feed correction potentiometer.

1 About this step switched machine

1/4

1.3 Range of Applications:

These machines are only for use for MIG / MAG standard welding with short- mixed- and spray- arc using Argon, Mixed gases and CO

• Materials: Low and high alloyed steels, Aluminium- 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 equipment, switchgear and ventilation work,

steelwork and engineering, tacking in production jobs,vehicles and installation work etc.

•

Symbol Units may be used in accordance with VDE 0544 (EN 60974-1) in

where increased electrical danger exists.

2 Transport and Installation

2/1

Transport and Installation

•

The machines may only be transported and operated in an upright position.

•

Before moving, pull out mains plug and place on the mach in e.

•

Secure high-pressure shielding gas cylinder with safety chain to prevent it from toppling

over.

•

Do not roll over hoses or cables.

Place the shielding gas cylinder in the cylinder holder and secure it in place with the securing chain. Maximum permissible cylinder size at internal pressure:

•

200 bar, up to 50 l geometrical volume,

•

300 bar, up to 33 l geometrical volume.

When the current source is moved and positioned, it is only secure against falling to an

angle of 15° (as specified in EN 60974-1). Special attention should be paid to the fact that, when the machine 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 regulations VBG 9, VBG 9a and VGB 15.

Fig. 1:

Crane principle

mind. 60°

mind. 1m

Fig. 2:

Angle of the

suspension ropes

• Lift with the crane at all 4 ring screws simultaneously

(as depicted in Fig. 1).

• Ensure an even distribution of the load to all four

ropes and maintain an angle of at least 60° of the suspension ropes (see Fig. 2).

Use only ring chains or suspension ropes of equal length (at least 1 m).

• Load hook s with se curing cleats and skackles of

corresponding size to DIN 82 101, Form A. Use minimum rated size 0.4.

• Before lifting with a crane, always remove the shielding gas cylinder from the welding

machine.

• Never lift other loads together with the welding machine,

e.g. persons, toolboxes, wire spools etc.

• Avoid jerks when raising and lowering the welding machine.

2 Transport and Installation

2/2

Environmental conditions:

The welding machine can be operated in a location where there is no risk of explosion at

•

an ambient temperature of -10°C (plasma machines 0°C) to +40°C and

•

a relative air humidity up to 50% at 40°C.

•

where the surrounding air is free of unusual amounts of dust, acids, corrosive gases or substances etc., insof ar a s they do not occur durin g w eld in g. Examples of unusual operatin g con d it ion s: Unusual corrosive smoke, vapour, excessive oil vapour, unusual vibrations or jolts, excessive quantities of dust such as grinding dus ts et c., severe weather conditio ns, unus ual cond iti ons near the coast or on board ship.

•

When installing the machine, ensure a free inlet and outlet of air.

The unit is tested to protection class IP23, i.e.:

•

Protection against penetr ation of sol id fore ign bod ie s ∅ > 12mm,

•

Protection against water spray up to an angle of 60° to the vertical.

3 Technical Data

3/1

3.1 Saturn -Series

Saturn - Series

MIG 200 MIG 250 MIG 300

Welding Current Range

30 - 200 A 30 - 250 A 30 - 300 A

Welding Voltage MIG

15 - 24 V 15 - 26,5 V 15 - 29 V

max. Welding Current at 30% Duty Cycle

200 A 250 A 300 A

max. Welding Current at 60% Duty Cycle

140 A 175 A 210 A

max. Welding Current at 100% Duty Cycle

110 A 135 A 165 A

Open Circuit voltage

15 V - 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 12,8 kVA

Frequency

50/60 Hz

Wire-feed speed (compact)

1 m/min- 20 m/min

Work-piece Cable

35 mm

50 mm

Ambient Temperature

-10°C - +40°C

Unit Cooling

Fan

Torch Cooling

Air

Euro central connection

Insulation Class

Protection Type

IP 23

Dimensions without gas cylinders with cylinder holder L/W/H

920 mm / 460 mm / 745 mm

Weight without accessories 93 Kg 102 Kg 112 Kg

4 Description of the System components

4/1

4.1 System Summary

4 Description of the System components

4/2

4.2 The Wel di ng 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 switching

4 Description of the System components

4/3

4.2.1 SATURN 200 - 300 Welding Machine Series (Front- and rearview)

A1 Transport handle B1 Control "PROGRAM" M201 / M100 C1 Main Switch, Machine On/Off

D1 LED for fault display for excess temperature and / or lack of coolant

E1 Welding Current Bush -, Work-piece connection

Choke tapping CO

(hard)

F1 Welding Current Bush -, Work-piece connection

Choke tapping MIX (medium)

G1 Rollers H1 Crane lifting lugs

Option

I1 Welding current and voltage display M110

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)

Remote Control Socket (Option), 19 pole connection for remote control or

control cable from the welding torch

M1 Air inlet opening N1 Turning Roller O1 Safety chain for gas cylinder P1 Support for shielding gas cylinders A2 Gas Connection G 1/4"

A1 Fuse, Control (42V / 4A slow-acting) B1 Mains cable C1 Opening for air outlet D1 Adjustment setting - Gas after-flow E1 Adjustment setting - wire burn-back F1 Button for arc off wire threading G1 polarity switching for cored wire welding (Option)

4 Description of the System components

4/4

4.3 Controls

4.3.1 Control "PROGRAM" M201

Fig.: 4/3 Control "PROGRAM" M201

4 Description of the System components

4/5

4.3.1 Control "PROGRAM" M201

m/min

-10

+10

201

Rotary knob for the stepless setting of:

•

Correction of the wire-feed speed

•

Wire-feed speed 1 - 20 m/min

(Selector switch

set to Manual position)

Signal - Lamp:

Recommended change of switch setting if welding power selection too high "Turn Step switch to the left" (or error message see 6.4)

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)

Rotary knob for the stepless setting of:

•

Spot welding time 0,1 - 4 Seconds

Changeover switch Operating Mode:

•

2- Step Mode,

•

4- Step Mode,

•

Spot Welding.

Selection switch for setting:

• Setting "manual": Two knob operation

• Welding wire diameter and type of material for Aluminium welding

• Welding wire diameter and type of material for welding Chrome-Nickel

Steels

Changeover switch for selecting type of gas

4 Description of the System components

4/6

4.3.2 Control M100

0.5

1.5

2sec0sec

0sec 2sec

1.5

0.5

m/min

Fig.: 4/4 Operating panel M100

Rotary knob "Wire feed speed"

for stepless selection of the wire feed speed (1 - 20m/min)

0.5

1.5

2sec0sec

Rotary knob "Spot and Pause Time"

for stepless selection of the welding times (0 - 2s) in "SPOT and STITCH " welding modes

Selection switch "Operating Mode"

2- Step; 4- Step; Spot or Stitch

0sec 2sec

1.5

0.5

Rotary knob "Pause Time"

for stepless setting of the pause time (0 - 2s) in "STITCH " welding mode

4 Description of the System components

4/7

4.4 Volt - Ammeter Displays

4.4.1 M110: digital V/A- Meter with Hold- Function (Option for M100 / M201)

Fig.: 4/6; Operating panel digital voltage and current display M110

Digital Welding Current Display

Digital Welding Voltage Display

4.5 The Remote Contr ol (Opti on, only for use with the M201)

Only remote controls which are described in this manual 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 to be supplied with the option „connection possibility remote control and Torch remote control“.

4.5.1 Hand Remote Control (Option)

• Connect remote control to remote control socket (see 4.2).

Rotary knob for the stepless setting of:

•

Correction of the wire-feed speed

•

Wire-feed speed 1 - 20 m/min

(Selector switch

Kap. 4.3.1 set to Manual

position)

Connection plug 19 polig with 5m connectioncable

4 Description of the System components

4/8

4.5.2 Hand Remote Control on the Welding Torch (Option)

in working

4.6 The Interfaces (Option, only with the M201)

4.6.1 Automation Interface(Option, only for the M201)

The welding power source is characterised by a very high standard of safety. This high safety standard is also 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. This is guaranteed when using transformers to VDE 0551.

All the interface contacts described below in this chapter may be exposed to a maximum load of: 100mA +15V/-15V

The following signals are available at the remote control socket:

• Start / Stop - Power Source

• Current is flowing - Signal I > 0

• Pilot voltage for the wire feed speed

5 Steuerungsbeschreibung M100 / M110

5/1

5.1 Description M100 Control

Fig. 5/1: M100 Control

5.1.1 Setting the Working Point

The M100 MIG/MAG control functions on the two-knob operating 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 and the welding wire diameter.

Selection Wire-feed Speed

Turn knob to appropriate

Wire-feed speed

Step Switch Fine step switch for

Setting welding voltage

5 Steuerungsbeschreibung M100 / M110

5/2

5.1.2 Selection of Operating Modes

Operating mode selection switch

The operating modes can be suited to the corresponding welding job

2- Stroke Setting e.g.: Tacking, short weld seams (latch on, latch off)

4- Stroke Setting e.g.: long weld seams

Spot Welding Setting e.g.: Spot Welding Interval Setting e.g.: Tack welding in chassis construction

5.1.3 Choke Tappings

Selection of Choke Tapping 2 Choke Tappings are available for selection to suit the

shielding gas:

Choke Setting 1 "hard" welding choke setting

e.g. for welding with CO

Choke Setting 2 "soft" welding choke setting

e.g. for welding with Mixed gases Argon

5.2 V/ A - Meter with Hold - Function M110 (Option)

5.2.1 Display of actual values during and after welding

The digital VA meter is available as an option for the M100 or M201 controls. The welder is informed of the actual voltage and current values during welding with this display. Further, the last welding data is stored on the screen (Hold- Function).

5 Steuerungsbeschreibung M100 / M110

5/3

5.3 Setting further welding parameters

Operating elements for setting the following welding parameters are in the welding machine or the wire-feed unit (Fig. 5/2).

Fig. 5/2 Setting possibilities in the welding machine or the wire-feed unit

5.3.1 Wire Burn-back

Trimmer Wire Burn-back

steplessly adjustable: 0 - 250 ms

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 the wire is melted into the contact tip. If burn-back is set too low: the welding wire gets stuck in the weld-pool.

5.3.2 Gas after flow time

Trimmer Gas after-flow time

steplessly adjustable: 0,2 - 10 sec.

The gas after flow is intended to ensure that the weld-pool solidifies under a shielding gas atmosphere so no crater porosity is caused.

5.3.3 Feeding in the welding wire

Button arc-off wire threading

The welding wire can be threaded through the hose-pack without voltage and without gas flowing.

5 Steuerungsbeschreibung M100 / M110

5/4

5.3.4 Creep start

Creep start

The wire 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 workpiece at full speed. A reliable, splatter free striking of the arc is made possible.

5 Steuerungsbeschreibung M100 / M110

5/5

5.4 Sequence of functions - Operating modes

5.4.1 Sequence of functions MIG 2-Step

Torch Trigger

pressed

(not) pressed

flowing

(not) flowing

m/min

Gas

Welding Power

1st Stroke 2nd Stroke

Wire-

Creep- feed

Gas-

Post- flow 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 current flows.

• Change over to pre-selected wire feed speed.

2nd Stroke Release torch trigger

• Wire-feed motor stops.

• The arc is switched off after the preset wire burn-back time.

Advantage: Prevents the wire becoming stuck in the weld-pool.

• Gas after-flow time runs.

5 Steuerungsbeschreibung M100 / M110

5/6

5.4.2 Sequence of functions MIG 4-Step

m/min

Torch Trigger

pressed

(not) pressed

flowing

(not) flowing

Gas

Welding Power

1st Stroke 2nd Stroke 3rd Stroke 4th Stroke

Wire-

Creep- feed

Gas-

Post- flow Time

wire- feed

Wire-

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 current flows.

• Change over to pre-selected wire feed speed.

3rd and 4th Strokes Press and release torch trigger

• Wire-feed motor stops.

• The arc is switched off after the preset wire burn-back time.

• Release torch trigger: 4th Stroke, no function

• Gas after-flow time runs.

5 Steuerungsbeschreibung M100 / M110

5/7

5.4.3 Sequence of functions MIG Spot Welding

Weld Time

m/min

Torch Trigger

pressed

(not) pressed

flowing

(not) flowing

Gas

Welding Power

Wire-

Creep- feed

Gas-

Post- flow Time

wire- feed

Wire-

Burn- back

Start Spot Welding Press and hold 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 current flows.

• Change over to pre-selected wire feed speed.

• Wire-feed motor stops after expiry of the preset Spot time.

• The arc is switched off after the preset wire burn-back time.

• Gas after-flow time runs.

Stop Spot Welding

1. Spot welding ends when the preset spot time is over.

2. It can be stopped sooner by releasing the torch trigger.

Release torch trigger: Spot welding can be started again.

5 Steuerungsbeschreibung M100 / M110

5/8

5.4.4 Sequence of functions MIG Interval

Wire

Creep- feed

Wire

Creep- feed

m/min

Weld Time

Weld Time Weld TimePause Time Pause Time

Torch Trigger

pressed

(not) pressed

flowing

(not) flowing

Gas

Welding Power

Wire-

Creep- feed

Gas-

Post- flow Time

wire- feed

Wire-

Burn- back

Start Interval Welding Press and hold 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 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-back time.

• After the preset Pause time has elapsed the welding cycle starts again with wire creep feed.

This welding process (Interval) will continue to be repeated until the torch . trigger is released!

Stop Interval Welding Release torch trigger during welding phase:

• Release torch trigger.

• Wire-feed motor stops.

• Arc is switched off after the preset wire burn-back time.

• Gas after-flow time runs.

Release torch trigger during pause phase:

• Release torch trigger.

• Gas after-flow time runs.

6 Description of M201 control

6/1

6.1 Description of MIG/MAG Welding jobs

manuell

1-20 m/min1-20

m/min

0.6

1.2

1.0

0.8

0.6

0.8

1.0

1.2

CrNi

100% CO2SG100% CO2

SG/CrNi

90-100% Ar

SG/CrNi

90-100%

AlMg

100% Ar

AlMg

100% Ar

AlSi

100% Ar

AlSi

100%

Al99

100% Ar

Al99

100% Ar

SG/CrNi

80-90% Ar

SG/CrNi

80-90% Ar

PROGRAM

0.1

4sec

m/min

-10

+10

201

GEN-A3GENTITLEGENTITLE0201GEN-POSGEN-SUMCANONIICANONII1.01.0EDITMISO1:11

M201

Fig. 6/1: M201 Control

The 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 the welding wire diameter as well as

the welding power, using the step switch. This defines the welding task and when the torch trigger is pressed the control system gives the wire feed speed for the optimum working point. The user has the possibility of correcting the wire feed speed according to the welding task or to individual requirements.

Correction of the wire feed speed may be done:

• on the PROGRAM M201 control,

• on the re mote control (Option)

• or on the welding torch with rotary knob (Option).

6 Description of M201 control

6/2

6.1.1 MIG/MAG- welding jobs and setting the working point (without option M210 / operating mode Programme, one-knob operation)

Selection switch gas type

Selection switch for the various types of gas

Selection switch welding wire diameter / type of material

Selection switch for setting the:

• Welding wire 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)

Step switch

„fine“

For setting the welding power in fine steps

m/min

-10

+10

201

Rotary knob Rotary knob for setting the:

1. Wire feed speed correction (outer scale) in Programme operating mode (one knob operation)

2. Wire feed speed 1- 20m/min (inner scale) in manual operating mode (two knob operation)

6 Description of M201 control

6/3

6.1.2 MIG/MAG- welding jobs and setting the working point (operating mode manual, two knob operation)

Two knob operation as with conventional MIG/MAG welding units is possible with the M201 control.

Selection switch welding wire diameter / type of material

Switch selection to the "manual" two knob operating mode setting.

Step Switch Select welding voltage Step switch "Coarse "

For setting the welding voltage in coarse steps

Step switch "Fine"

For setting the welding voltage in fine steps

m/min

-10

+10

201

Rotary knob Wire feed speed

Knob for setting the Wire feed speed

1- 20 m/min

6.2 Selection of operating mode 2- Stroke, 4- Stroke, Spot welding

Operating mode selector 2- Stroke setting e.g.: Tack welding, short weld seams

4- Stroke setting e.g.: long weld seams Spot welding setting e.g.: spot welding

6.3 Selection of the Choke Tapping

Selection Choke Tapping

2 Choke tappings are available depending upon the

shielding gas used:

Choke setting 1 "hard" welding choke connection

e.g. for welding under CO

Choke setting 2 " soft" welding choke connection

e.g. for welding under Mixed gases and Argon

6 Description of M201 control

6/4

6.4 Signal lamps for error messages

These signal lamps show the user operating errors or faults in the welding torch or in the machine.

6.4.1 Error message “too much/ too little” welding power pre-selected

If the welding power pre-selected on the step switch is too high or too low for the welding wire diameter, the type of material and the gas type chosen the corresponding warning lamp lights up.

Errors are only reported once the torch trigger has been pressed ! It is still possible to weld despite the error message!

Signal lamp Step switch

Signal lamp lights:

Welding power too high Set step switch lower

Signal lamp Step switch

Signal lamp lights:

Welding power too low Set step switch higher

6.4.2 Error message “No programme 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.

Welding is not possible!

For selected welding parameter combination

Signal lamps

no programme is available

flash simultaneously

6.4.2.1 Short-circuit when the machine is switched on

Both LEDs light brightly and blink briefly. "Welding is impossible". Remove the torch from the workpiece. LEDs no longer blink.

6.4.2.2 Short-circuit at the first welding operation

Both LEDs blink briefly and rapidly, "welding is impossible". When the torch trigger is pressed, both LEDs light blink 6x in succession alternately.

6.4.2.3 Short-circuit in any welding operation (contact ignition)

Both LEDs blink briefly and rapidly. However, the machine can weld normally. (The values from the previous welding operations are accepted.) The LEDs extinguish as soon as the torch trigger is pressed.

6 Description of M201 control

6/5

6.5 Correcting the wire feed speed

6.5.1 Correcting the wire feed speed with the remote control (Option)

Setting the correction of the wire feed speed (one knob operation) or the wire feed speed (Operating mode manual, two knob operation) can be carried out independently of the settings on the control.

6.5.2 Correcting the wire feed speed with the remote control on the welding torch (Option)

•

Connect the welding torch with potentiometer to the central connection on the 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 operation) can be carried out independently of the settings on the control.

6.6 M110 (Option) digital V / A - Meter with Hold - Function

6.6.1 Display of actual welding data during and after welding

The digital V/A meter M110 is available as an option for the M100 and M201 controls. With this display the Welder is kept informed of the actual current values for voltage and current during welding. What is more, the last values for welding voltage and current measured are stored in the display (Hold- Function).

6 Description of M201 control

6/6

6.7 Further Functions

Operating elements to adjust the following welding parameters can be found in the welding machine (Fig. 6/3), or, with the decentralised version, in the wire-feed unit.

Fig. 6/3; Adjustment possibilities in the welding machine

6.7.1 Wire Burn-back

Trimmer Wire burn-back time

-100% +100

The time is automatically pre-set to the optimum value to correspond with the wire-feed speed and the welding parameters (0%), it may, however be changed by about

± 100 % with the trimmer.

Setting Instructions:

6.7.2 Gas after-flow time

Trimmer Gas after-flow time

The gas after flow is intended to ensure that the weld-pool solidifies under a shielding gas atmosphere so no crater porosity is caused. The time is automatically pre-set to the optimum value to correspond with the material / gas combination (0%), it may, however be changed by about ± 50 % with the trimmer.

6 Description of M201 control

6/7

6.7.3 Feeding in the welding wire

Button arc-off wire threading

The welding wire can be threaded through the hose-pack without voltage and without gas flowing.

6.7.4 Creep start

Fig. 6/3; Screen print M201 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 changed at a later time at the rear of the M200 controller (inside the machine) at trimmer P3 (completely left = -25%, completely right = +25%;works setting middle position). The changed wire feed speed is active after renewed pressing of the torch trigger.

6 Description of M201 control

6/8

6.7.5 Gas preflow

The gas pre-flow time is set automatically to the optimum value for the type of material and gas selected.

6.7.6 Ignition Management

The arc striking process is monitored and optimised to suit the prevailing conditions. This leads to consistent, reproducible arc striking characteristics under the widest variety of applications.

6.7.7 Forced Shut-down

The forced shut-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 function also helps to prevent accidents (both for the user and the machine). If a short-circuit between the welding wire electrode and the workpiece or anything at the same electrical potential as the workpiece occurs when welding or using the welding machine the gas, wirefeed and welding voltage are switched off in fractions of a second. The short-circuit is also displayed as an error message. (see 6.6.5.1+6.6.5.2).

6 Description of M201 control

6/9

6.8 Sequence of functions - Operating modes

.8.1 Sequence of functions MIG 2-Step

m/min

Wire

Creep- feed

Torch Trigger

pressed

(not) pressed

flowing

(not) flowing

Gas

Welding Power

1st Stroke 2nd Stroke

Gas

Pre- flow Time

Gas-

Post- flow Time

wire- feed

Wire-

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 wire hits the workpiece, welding current flows.

• Change over to pre-selected wire-feed speed.

2nd Stroke Release torch trigger

• Wire-feed motor stops.

• The arc is switched off after the preset wire burn-back time.

Advantage: Prevents the wire becoming stuck in the weld-pool.

• Gas after-flow time runs.

6 Description of M201 control

6/10

6.8.2 Sequence of functions MIG 4-Step

m/min

Wire

Creep- feed

Torch Trigger

pressed

(not) pressed

flowing

(not) flowing

Gas

Welding Power

1st Stroke 2nd Stroke 3rd Stroke 4th Stroke

Gas

Pre- flow Time

Gas-

Post- flow Time

wire- feed

Wire-

Burn- back

Fig. 6/5; Sequence of functions MIG 4- Stroke

1st Step Press and hold 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 to pre-selected wire feed speed.

2nd Stroke Release torch trigger

If welding is interrupted for more than 3 sec., the wire-feed, welding voltage and gas are switched off!

3rd Stroke Press torch trigger (has no effect)

4th Stroke Release torch trigger

• Wire-feed motor stops.

• The arc is switched off after the preset wire burn-back time.

• Gas after-flow time runs.

6 Description of M201 control

6/11

6.8.3 Sequence of functions MIG Spot Welding

Weld Time

m/min

Wire

Creep- feed

Torch Trigger

pressed

(not) pressed

flowing

(not) flowing

Gas

Welding Power

Gas

Pre- flow Time

Gas-

Post- flow Time

wire- feed

Wire-

Burn- back

Fig. 6/6; Sequence of functions MIG Spot Welding

Start Spot Welding Press and hold torch 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 wire-feed speed.

• Wire-feed motor stops after expiry of the preset Spot time.

• The arc is switched off after the preset wire burn-back time.

• Gas after-flow time runs.

Stop Spot Welding

1. Spot welding ends when the preset spot time is over.

2. It can be stopped sooner by releasing the torch trigger.

Release torch trigger: Spot welding can be started again.

7 Short Operating Manual SATURN M201 PROGRAM

7/1

Setting the welding task (One-knob operation programme)

entsprechend der Schweißaufgabe:

Gas type Set type of gas

Wire diameter/ Material type

Set switch to type of material with the corresponding wire diameter

Welding power in fine steps Setting the welding power in fine steps

Operating mode selection switch

2 stroke setting

4 stroke setting

Spot welding

Setting the operating mode

Signal lamp lights: Welding power too high

Switch the selection switch lower

Signal lamp lights: Welding power too low

Switch the selection switch higher

m/min

-10

+10

201

The optimum wire feed speed is automatically pre-set on pressing the torch trigger This can be corrected with the potentiometer

Setting the wire feed speed correction (outside scale)

Setting the welding parameters (Two knob operation manual)

Welding wire diameter/ Type of material

Set the selector switch to „manual“ two knob operation

Welding voltage in fine steps Setting the welding voltage in fine

steps

Setting the wire feed speed Setting the wire feed speed

(Welding voltage) 1-20 m/min(inner scale)

8 Commissioning

8/1

8.1 Setting up the Welding Machine

Pay attention to the safety instructions “ For your safety” on the first page!

•

Set up the machine so that there is enough room to adjust the operating elements.

•

Take care that the unit is installed in a stabile position and appropriately secured to prevent it rolling away.

8.2 Mains Connection

An appropriate mains plug must be connected to the power lead of the machine! The connection must be carried out by a qualified electrician according to the applicable regulations The phase sequence is free and has no influence on the direction of rotation of the fan!

The operating voltage shown on the data plate must correspond to the mains supply voltage!

For mains fuses please refer to the technical data (Chapter 3)!

•

Plug the switched off unit into the appropriate socket.

8.2.1 Reconnecting the mains voltage 400/415V at the control 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 reconnected from "A" to "B".

- Mains voltage 400V Cable "C" must be reconnected from "B" to "A".

• Connect the earthing cable to the side panel and screw tight.

Those machines that are delivered to countries with other mains voltages than standard ones, are marked with the following stickers: a) Indications of mains voltage: see at the end of the mains cable b) Mains voltage connected ex works: see at the back

side of the machine, above the data plate!

Netzanschlußspannung

Mains voltage

400V

c) Sticker with special mains voltages, needed for

the marking by yourselves are enclosed with the operation manual.

After reclamping to 415 V, the

• sticker c) has to be sticked upon sticker b) and

• sticker a) has to be removed from the end of the cable.

230V 230V 400V 400V 415V 415V 460V 460V 500V 500V ___V ___V

460V 500V

400 415

(Art-No. of the sticker please see chapter Accessories.

8 Commissioning

8/2

8.3 Cool i ng the Welding Machine

To achieve the optimum duty cycle from the power components, pay attention to the following conditions:

•

Ensure that the workplace is adequately ventilated,

•

The air inlets and outlets of the machine must be unobstructed,

•

Metal particles, dust or other fine bodies may not gain access to the unit.

8.4 Welding Torch Connections

We can only guarantee the perfect function of our machines when they are used with our range of welding torches.

8.4.1 MIG- Welding 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 central connection!

Preparing the welding torch for the welding task:

• Shorten the Teflon liner and the push on guide tube just enough that the gap to the drive rollers

is as short as possible.

The Teflon liner and the guide tube may not be deformed!

• Debur the Teflon guide tube and liner cleanly!

Connecting the welding torch:

• Insert the welding torch in the welding machine central connection and screw tight with the cap

nut.

8.4.2 MIG- Welding Torch with adjustment knob for wire-feed correction

in working

8 Commissioning

8/3

8.4.3 Connection of the MIG Push/Pull- Torch (Option)

Description of function, Push / Pull Torch:

An essential prerequisite for high welding economy and weld seam quality is an unimpaired welding wire feed. This is particularly problematic with:

•

The use of long hose-packs,

•

Welding wires which do not slide easily,

•

Welding wires with low resistance to kinking,

•

the need for particularly smooth wire-feed speeds. In such cases an additional feed assistance within the welding torch gives drastic improvements over purely push wire-feed units.. In addition to the pushing wire-feed rollers (PUSH) in the power source or the wire-feed unit, an additional pulling drive (PULL) is used in the torch. A current regulator synchronises the two wire-feed motors.

All standard Push/Pull- torches with Euro central connections 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 knob on the control is deactivated.)

Prerequisites for the connection of a Push/Pull Torch:

•

The welding machine must be prepared for the connection of this torch (Option).

•

The welding torch socket must be wired to correspond with the torch used.

8.5 I nstal ling the Welding Wire

To achieve optimum wire-feed, it is essential to use wire-feed rollers which suit the diameter of the welding wire used and the type of material (Change if necessary)!

8.5.1 Insertion of the Wire Spool

Standard hub spools D300 can be used. For use of the standardised basket spools (DIN 8559) an adapter is needed (see Accessories).

Fig. 5/1: Hub Spool

• Undo knurled nut D1 from the spool hub.

• Fix the welding wire spool on the hub in such a way that the carrier pin A1 locates in the hole in

the spool

• Tighten the wire spool with the knurled nut D1.

8 Commissioning

8/4

8.5.2 Inching the wire electrode

Fig. 5/2: Operating elements inside the welding machine and the WF case

Fig. 5/3: Part view of the wire feed

•

Lay out the torch hose package in an extended position

• Loosen the knurled nuts A2 on the wire feed and swivel them outwards at the sides.

The clamping elements B2 with the counter-rollers swivel upwards automatically.

• Unwind the wire electrode in a clockwise direction from the wire spool D2 and insert it through the

wire inlet nipple E2, the grooves in the drive rollers and the guide tube into the capillary tube 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 set the counter-pressure back upwards.

The pressing force must be adjusted with the knurled nuts such that the wire electrode is conveyed but slips when the wire spool jams!

• Press the wire inching button until the wire electrode projects from the welding torch.

Danger of injury! When inching the wire, never point the torch at persons or animals!

8.5.3 Setting the Spool Brake

Only tighten the spool brake so far that the wire spool no longer free-wheels when the torch trigger is released!

• Tighten the hexagonal inner bolt

C1 in the wire spool whilst holding the nut B1 still.

8 Commissioning

8/5

8.6 Workpiece Cable

Remove paint, rust and dirt from the clamping or welding location with a wire brush! Fix the earthing clamp or tongs close to the weld location! Assembly aids, pipes, rails etc.. may not be used as a return lead unless theyare part of the job itself! A perfect current flow must be ensured on welding benches and jigs!

Torch and hosepack and the workpiece cable should never be rolled up in a spiral! Operation whilst rolled our straight avoids voltage drops through 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 the right.

8.6.1 Changing the welding current polarity (option for cored wire welding)

The polarity of the welding current potentials (welding torch/workpiece) can be changed inside the machine by rewiring the welding leads.

Fig. 5/3: Changing the polarity of welding current leads

Switch off the welding machine. Withdraw the mains plug from the socket.

• Remove the plastic caps of the screw fasteners,

• unscrew the welding current leads,

• exchange the leads and screw back into place,

• replace the plastic caps.

8 Commissioning

8/6

8.7 Shi elding Gas Supply

8.7.1 Fitting the gas connections

Place the shielding gas cylinders in the their support and secure them with the chain against accidents!

No impurities may be allowed to get into the shielding gas lines as these could cause blockages. Open the cylinder valve briefly before connecting the pressure regulatorto blow out any dirt present. All shielding gas connections must be made gas-tight!

•

Install the pressure regulator onto the gas cylinder.

•

Screw the gas hose to the regulator on the gas cylinder with the G ¼“ connection.

•

Screw the gas hose to the rear of the welding machine with the G ¼“ connection

(Chapter 4.: F2).

8.7.2 Shielding gas settings

As standard, a gas flow limitation nozzle for a gas flow of. 0 - 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 gas settings: Too little shielding gas: incomplete gas shield, the intruding air causes porosity in the weld

seam.

Too much shielding gas: turbulence can arise allowing air to intrude and cause porosity,

in the weld seam.

• Open the cylinder valve slowly.

• Open the pressure regulator.

• Switch the power source on with the "ON/OFF" switch.

• Select "2-Stroke" operating mode.

• Release the knurled nut on the wire-feed and swing up the tensioner with the counter roller.

The welding wire may not be fed any more!

• Press and hold the torch trigger, the shielding gas flows.

Do not touch the welding wire! Open circuit voltage!

• Adjust shielding gas quantity on the pressure regulator to suit the application (see setting

instructions).

9 Setting Instructions

in working

10 Maintenance and Care

10/1

These welding machines require very little maintenance. However, depending upon the amount of dust occurring, the unit should be cleaned as described below and visually checked at least every 4

- 6 months.

In so doing, the unit must be reliably isolated from the mains power supply.

PULL OUT THE MAINS PLUG!

(Switching off or pulling out a fuse does not give adequate isolation protection)

- Remove both side walls.

- Tighten all screw and crimped connections and visually check the unit.

- Scorched areas should be checked and corrected by a specialist..

- Replace any faulty power leads.

Treat the individual components as follows:

Power Source

out with oil and water free compressed air depending upon the amount of dust present.

Electronics, Printed Circuit Boards

The electronic components may not be blow clean with compressed air but should be cleaned off with a vacuum cleaner.

Torch with Hosepack

Protect thehosepack from hot components. Blow out or replace the wire guide spiral or the Teflon liner. No great increase in the hole through the contact nozzle is permissible. Replace with new in good time.

Drive Rollers

These rollers are subject to normal wear. If the counter-roller brings the correct pressure the welding wire must be fed smoothly. If the counter-rollers and the drive rollers touch with wire in then the drive rollers should be replaced (watch for possible undersized welding wire).

Coolant (KF 23E-10) and Check of the Cooling Unit

The coolant level in the UK 500 must be checked at regular intervals.

As soon as the fluid level falls by more than ¼ of the tank contents it must be topped up with more coolant. Further, the coolant container should be regularly cleaned from dirt particles (by blowing out or vacuuming) to ensure an optimum cooling of the welding torch.

Repairs

Repair and maintenance work may only be performed by qualified personnel. In all service matters, always consult your dealer. Return deliveries of defective equipment subject to warranty may only be made through your dealer. When replacing 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 must be quoted. If repair or maintenance work is carried out on this machine by personnel who are not trained and authorised to undertake such work, the right to claim under the warranty lapses.

Die im Kapitel

"Wartung und Pflege" aufgeführten Hinweise, Richtlinien und Normen wurden

grundlegend überarbeitet und sind aus diesem G

rund nicht mehr gültig!

Die relevanten Hinweise, Richtlinien und Normen finden Sie in den

beiliegenden

Ergänzungsblättern "Allgemeine Hinweise zu 3 Jahre G

arantie", Art. Nr.: 099-000GAR-EWMxx.

Sollten die Dokumente nicht vorliegen, können diese über den autorisierten Fachhändler

angefordert werden!

Außerachtlassung kann lebensgefährlich sein!

The instructions, guidelines and standards given in the "Maintenance and Care" chapter have

been completely revised and are therefore no longer valid!

The relevant instructions, guidelines and standards can be found in the enclosed supplements

"General notes on the 3 year warranty",item no.: 099-000GAR-EWMxx.

If these documents are missing, they can be reque

sted from your authorised specialist dealer!

Not observing these instruc

tions can be potentially fatal!

Les consignes, directives et normes indiquées au chapitre « Maintenance et entretien » ont été

mises à jour et ne sont donc plus valables !

Vous trouverez les consignes, directives et normes applica

bles dans les additifs « Consignes

généra

les relatives

à la garantie de 3 an

s », à l´article : 099-000GAR-EWMxx.

Si vous ne possédez pas les documents, vous pouvez vous les procurer auprès de votre

revendeur autorisé !

Le non-respect des consignes peut représenter un danger de mort !

Le istruzioni, direttive e norme presenti nel capitolo „

Manutenzion

e e cura” sono state

completamente riviste e per questo motivo non sono più valide!

Le istruzioni, direttive e norme rilevanti le trovate nell'aggiornamento qui allegato “Is

truzioni

generali sui 3 anni di

garanzia”, Nr. Art.: 099-000GAR-EWMxx.

Se i documenti non fossero disponibili, possono

essere richiesti al rivenditore autorizzato!

L'inosservanza delle istruzioni può comportare pericolo di vita!

11 Operating Faults, Causes and Cures

11/1

11.1 Customer Checklist

All machines are subjected to very strict production and final testing. If something should not function correctly despite this, please refer to the following table. If none of the suggested cures clears the problem then please contact an authorised agency.

Problem Possible Cause What to do

The welding wire does not feed

Splatter is blocking the contact tip orifice

The wire-feed rollers are slipping

The wire-feed motor is not turning

A kink in the wire 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 drive rollers with new ones. Wire is jammed, check its passage.

Check fuse F1 on WK 5 (see spare parts list)

Undo the contact tip and cut off the distorted wire

Loosen brake

Replace it

The wire forms loops

1.2.Liner or tip blocked Hose pack bent too tightly

Clean or replace Ensure a basically straight hosepack

The welding wire feedrate is uneven

Blocked or damaged wire guide spiral

The brake on the wire spool is set too tightly

Contact tip has too small a hole

Clean or replace

Loosen wire spool brake

Use the right contact tip

11 Operating Faults, Causes and Cures

11/2

Problem Possible Cause What to do

The weld seam is porous

Too little or too much gas

Gas cylinder is empty Unsuitable gas quality or

inadequate purity Excessive protrusion of welding

wire Draft effects or wind influence

Gas nozzle blocked by splatter Wrong wire quality or wire

surface is dirty

Very dirty surface of the workpiece

Wire diameter x 10 is gas flow in l/min

Replace the cylinder Use a different gas

Reduce the gap from torch to weld seam

Reduce the air flow by shielding the welding area

clean or replace the gas nozzle Use a wire of the quality prescribed

for MIG/MAG welding. Store wires in clean conditions

Clean the base metal

9.10Local overheating of the workpiece

Sucking in of “wrong“ 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 strong splatter

1.2.Weld blow occurring

No gas

Find a better place to connect the workpiece lead by trial and error

Set the gas flow to correspond to the application

Unit will not switchon1.2.No mains power

Fault in power source

Check mains fuses and replace if necessary

Correct fault

No welding current 1.2.Poor contact on the workpiece

lead Over-temperature

Check connection and positioning

Allow the unit to cool down

Lack of water 1.2.Too little water

Leak in water circuit

Top up coolant Fix the leak and top up water

Malfunction of feed or gas valve

Electronic fault Change the electronics

Check connections

Unit does not weld the values set on P2

Remote control or robot is connected

Disconnect remote control or have display show remote control values

12 Ersatzteilliste/Spare Parts List

12/1

12 Ersatzteilliste/Spare Parts List

12/2

Abb. 12/1: Vorderseite/front view

Abb. 12/2: Rückseite/rear view

12 Ersatzteilliste/Spare Parts List

12/3

Pos. Bezeichnung: Description SATURN

A1 Leiterplatte M100 PCB M100 040-000509-00000 B1 Seitenwand links side panel left 094-002661-00007 C1 Netzschalter Ein/Aus mains on/off switch 094-002680-00000 D1 LED - Anzeige LED - display 094-002752-00000 E1 Anschlußbuchse connection socket 074-000232-00000

F1 Lenkrolle turning rollers 094-000181-00000 G1 Seitenwand rechts side panel right 094-002660-00007 H1 Eurozentralanschluß welding torch connection 094-000347-00000

zu H1 Isolierflansch insulation housing 094-005221-00000 zu H1 Madenschraube headless setscrew 094-005222-00000 zu H1

Kapillarrohr bis

ÆÆ

Æ 1,6mm capillary tube ÆÆÆÆ 1,6mm

094-002559-00000

zu H1

Kapillarrohr

ÆÆ

Æ 2,0 u. 2,4mm capillary tube ÆÆÆÆ 2,0 a. 2,4mm

094-001607-00000

I1 Stufenschalter step switch

094-001990-00000

SATURN 200 SATURN 250

I1 Stufenschalter step switch 094-002611-00000

SATURN300

zu I1 Drehknopf switch knob 094-001815-00000

J1 Anschlußbuchse (Option) 19-

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 Drehknopf Pfeilscheibe switch knob arrow indicator 074-000315-00002

M1 Folie Bedieneinheit M201 foil control panel M201 094-002834-00001 N1 Drehknopf switch knob 074-000234-00000

zu N1 Drehknopfdeckel switch knob cap 074-000234-00001 zu N1 Drehknopf Pfeilscheibe switch knob arrow indicator 074-000234-00002

O1 Leiterplatte M201 PCB M201 040-000511-00001 P1 Leiterplatte M110 (Option) PCB M110 (option) 040-000512-00000 Q1 Gehäusedeckel housing cover 094-002309-00003 R1 Kranösen crane lifting lugs 094-000209-00000 A2 Sicherheitskette safety chain 094-000178-00000 B2 Bockrolle rollers 094-000179-00000 C2 Netzkabel mains cable 092-000659-00000 D2 Kabelverschraubung cable inlet 094-000208-00000

zu D2 Gegenmutter lock nut 024-000207-00001

E2 Gasventil gas valve 094-000472-00000

F2 Sicherungshalter Mutter fuse holder with nut 094-000001-00000

zu F2 Sicherungskappe fuse cap 094-000001-00001 zu F2 Sicherung 3,15 A träge fuse 3,15A träge 094-002832-00000

12 Ersatzteilliste/Spare Parts List

12/4

Abb. 12/3: rechte Seite/right side

Abb. 12/4 linke Seite/left side

12 Ersatzteilliste/Spare Parts List

12/5

Pos. Bezeichnung: Description SATURN

A3 Drehknopf switch knob 094-000997-00000

zu A3 Potentiometer potentiometer 044-001782-00000

B3 Klebefolie Adhesive film 094-006024-00000 C3 Antrieb Drahtvorschub

(Einzelteile siehe Abb. 12/5)

Wire feed (individual parts see Fig. 12/5)

094-002753-00000

D3 Motor Drahtvorschub wire feed motor 094-004274-00000

C3/D3

Vorschub komplett (Antrieb + Motor)

wire feed complete (Wire feed + motor)

092-000909-00000

E3 Polaritätsumschalter (Option) polarity switch (option) 092-000689-00001

zu E3 Isolierstützpunkt 074-000537-00000

F3 Spulendorn coil pin 094-000346-00000 H3 Tast er key switch 044-001116-00000

I3 Trimmer trimmer 040-000186-00000

A4 Versorgungstrafo supply transformer 094-002417-00004 B4 Shunt shunt 074-000034-00000 C4 Haupttransformator incl.

Stufenschalter

transformer 032-000110-00003

SATURN 200

C4 Haupttransformator incl.

Stufenschalter

transformer 032-000111-00007

SATURN 250

Haupttransformator incl. Stufenschalter

transformer 032-000113-00005

SATURN 300

D4 Gleichrichter rectifier 060-005B40-0004K E4 Lüfter fan 074-000015-00000

F4 Drossel choke 032-000115-00004 G4 Sättigungswandler saturation transducer 044-000967-00001

J4 Schütz relay 094-000592-00000 H4 Anschlußbuchse connection socket 040-000521-00000

I4 Steuertrafo M201 control transformer M201 044-002266-00000

12 Ersatzteilliste/Spare Parts List

12/6

Abb. 12/5 a: Explosionszeichnung Drahtvorschubeinheit 2-Rollenantrieb /

exploded view wire feed 2-rolls drive

Abb.12/5b: Ersatzrollen Aluminium / spare part rolls aluminium

Abb.12/5c: Ersatzrollen Fülldraht / spare part rolls cored wire

12 Ersatzteilliste/Spare Parts List

12/7

Pos. Bezeichnung: Description 1 Zwei Rollen Basisstück Feed plate fiter with inlet/outlet holders

094-006283-00000

2 Halter Andruckeinrichtung

Holder pressure device 094-006284-00000

3 Innensechskantschrau be

Allen screw 094-006265-00000

4 A ndruckeinrichtun g mit Skala

Pressure device with scale 094-006285-00000

5 Splint Andruckeinrichtung

Locating pin pressure device 094-006286-00000

6 Achsenwelle Andruckarm

Axle shaft pressure arm 094-006287-00000

7 Mutter M6

Nut M6 094-006288-00000

8 Sicherungsschraube Antriebsrolle

Retaining screw feed roll 094-006263-00000

9 Andruckarm links

Pressure arm left hand 094-006260-00000

10 Abstandsrolle groß

Spacer large 094-005402-00000

11 Achse Andruckarm

Axle pressure arm 094-006261-00000

13 Abstandsrolle klein

Spacer small 094-006280-00000

14 Rändelschraube

Knurled fixing screw 094-006262-00000

15 Unterlegscheibe

washer 094-002556-00000

16 Drahteinlaufnippel 0,6mm-1,6mm Draht

Inlet guide 0,6mm-1,6mm wire 094-002088-00000

17 Drahteinlaufnippel 1,6mm-3,2mm Draht

Inlet guide 1,6mm-3,2mm wire 094-000740-00000

18 Drahteinlaufnippel mit Dra ht f ührungsrohr blau

Innendurchmesser 2,0mm

Inlet guide with wire guide tube blue i.d. 2,0mm 094-006275-00000

19 Drahteinlaufnippel mit Dra ht f ührungsrohr rot

Innendurchmesser 2,5mm

Inlet guide with wire guide tube red i.d. 2,5mm 094-006276-00000

20 Drahteinlaufnippel mit weichem Führungsrohr

rot Innendurchm. 2,5mm

Inlet guide with soft liner tube red i.d. 2,5mm 094-006277-00000

21 Schraube M6x11

Screw M6x11 094-002558-00000

22 Aufnahme Antriebsrolle

Adaptor feed roll 094-005234-00000

24 Rändelschraube Antriebsrolle

Knurled screw feed roll 094-002557-00000

25 Sicherungskit

Safety guard kit 094-005706-00000

Antriebsarm links komplett

Pressure arm left complete 094-006282-00000

26 Hauptantriebszahnrad

Main gear drive 094-005233-00000

27 Aufnahme Antriebsrolle

Gear adaptor feed-pressure roll 094-005232-00000

23 1 AR 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-Standard

1 DR steel 0,9+1,2; steel-standard 094-003221-00000

23 1 AR Stahl 1,0+1,2; Stahl-Standard

1 DR steel 1,0+1,2; steel-standard 094-003219-00000

23 1 AR Stahl 1,2+1,6; Stahl-Standard

1 DR steel 1,2+1,6; steel-standard 094-003220-00000

12 Gegendruckrolle glatt; Stahl

Counterpressure rolls plane; steel 094-005231-00000

28 2 Zwillingsrollen AL 0,8+1,0

2 twin rolls AL 0,8+1,0 092-000873-00000

28 2 Zwillingsrollen AL 1,0+1,2

2 twin rolls AL 1,0+1,2 092-000828-00000

28 2 Zwillingsrollen AL 1,2+1,6

2 twin rolls AL 1,2+1,6 092-000829-00000

28 2 Zwillingsrollen AL 2,4+3,2

2 twin rolls AL 2,4+3,2 092-000874-00000

29 1 AR Röhrchendraht 0,8/0,9+0,8/0,9

1 DR cored wire 0,8/0,9+0,8/0,9 094-003229-00000

29 1 AR Röhrchendraht 1,0/1,2+1,4/1,6

1 DR cored wire 1,0/1,2+1,4/1,6 094-003233-00000

29 1 AR Röhrchendraht 1,4/1,6+2,0/2,4

1 DR cored wire 1,4/1,6+2,0/2,4 094-003234-00000

29 1 AR Röhrchendraht 2,8+3,2

1 DR cored wire 2,8+3,2 094-003230-00000

30 Gegendruckrolle randiert Röhrchendraht

Counterpressure rolls knurled cored wire 094-005319-00000

o.Abb. Umrüstung verzahnt > unverzahnt

Conversion geared > ungeared 092-000825-00000

12/5b Umrüstset 2 Z-Rollen Aluminium 0,8+1,0

Conversion kit 2 T-rolls AL 0,8+1,0 092-000871-00000

12/5b Umrüstset 2 Z-Rollen Aluminium 1,0+1,2

Conversion kit 2 T-rolls AL 1,0+1,2 092-000826-00000

12/5b Umrüstset 2 Z-Rollen Aluminium 1,2+1,6

Conversion kit 2 T-rolls AL 1,2+1,6 092-000827-00000

12/5b Umrüstset 2 Z-Rollen Aluminium 2,4+3,2

Conversion kit 2 T-rolls AL 2,4+3,2 092-000872-00000

12/5c Umrüstset 1 AR Röhr 0,8/0,9-0,8/0,9

Conversion kit DR cored w. 0,8/0,9+0,8/0,9 092-000820-00000

12/5c Umrüstset 1 AR Röhr 1,0/1,2+1,4/1,6

Conversion kit DR cored w. 1,0/1,2+1,4/1,6 092-008210-00000

12/5c Umrüstset 1 AR Röhr 1,4/1,6+2,0/2,4

Conversion kit DR cored w. 1,4/1,6+2,0/2,4 092-000822-00000

12/5c Umrüstset 1 AR Röhr 2,8+3,2

Conversion kit DR cored w. 2,8+3,2 092-000823-00000

AR = Antriebsrolle; DR = Drive rolls; AL = Aluminium

12 Ersatzteilliste/Spare Parts List

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 Fülldraht / spare part rolls cored wire

12 Ersatzteilliste/Spare Parts List

12/9

Pos. Bezeichnung: Description 1 Vier Rollen Basisstück

Four roll feed plate 094-006257-00000

2 Schraube M6x14

Screw M6x14 094-006258-00000

3 Andruckarm rechts

Pressure arm right hand 094-006259-00000

3A Andruckarm links

Pressure arm left hand 094-006260-00000

4 Achsenwelle mit gerändeltem Kopf

Axle shaft with knurled head 094-006261-00000

5Rändelschraube Achsenwelle

Knurled fixing screw axle shaft 094-006262-00000

6 Sicherungsschraube Antriebsrolle

Retaining screw feed roll 094-006263-00000

7Rändelschraube Antriebsrolle

Knurled screw feed roll 094-002557-00000

8 Achsenwelle Andruckarm

Axle shaft pressure arm

094-006264-00000

Innensechskantschraube

Allen screw 094-006265-00000

10 Feder Andruckarm

Spring pressure arm auto-lift 094-006266-00000

Abstandsrohr Andruckarm

Spacer tube pressure arm auto-lift 094-006267-00000

12 Aufnahme Antriebsrollen

Gear adaptor feed-pressure roll 094-005232-00000

13 Achsenwelle

Axle shaft gear adaptor-feed roll 094-006268-00000

14 Unterlegscheibe

Washer 094-002556-00000

15 Andruckeinrichtung mit Skala

Pressure device with scale 094-006269-00000

16 Splint Andruckeinrichtung

Locating pin pressure device 094-006270-00000

17 Aufnahmehalter Drahtführungshülse

Adaptor block holder intermediate guide 094-006271-00000

18 Innensechskantschraube

Allen screw adaptor body M6x12 094-006272-00000

19 Drahtführungshülse 0,8mm-2,0mm Draht

Intermediate guide 0,8mm-2,0mm wire 094-006273-00000

20 Drahtführungshülse 1,6mm-3,2mm Draht

Intermediate guide 1,6mm-3,2mm wire 094-006274-00000

21 Drahteinl aufnippel 0,6mm-1,6mm Draht

Inlet guide 0,6mm-1,6mm wire 094-002088-00000

22 Drahteinl aufnippel 1,6mm-3,2mm Draht

Inlet guide 1,6mm-3,2mm wire 094-002740-00000

23 Drahteinlaufnippel mit Drahtführungsrohr blau

Innendurchmesser 2,0mm

Inlet guide with wire guide tube blue i.d. 2,0mm 094-006275-00000

24 Drahteinlaufnippel mit Drahtführungsrohr

Innendurchmesser 2,5mm

Inlet guide with wire guide tube ref i.d. 2,5mm 094-006276-00000

25 Drahteinlaufnippel mit weichem

Führungsrohr rot Innendurchm. 2,5mm

Inlet guide with soft liner tube red i.d. 2,5mm 094-006277-00000

26 Hauptantriebszahnrad

Main gear drive 094-005233-00000

28 Sicherungskit

Guard safety kit 094-006279-00000

29 Abstandsrollen groß

Spacer 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 hand complete 094-006282-00000

27 2 AR Stahl 0,6+0,8; Stahl-Standard

2 DR steel 0,6+0,8; steel-standard 092-000839-00000

27 2 AR Stahl; 0,8+1,0; Stahl-Standard

2 DR steel 0,8+1,0; steel-standard 092-000840-00000

27 2 AR Stahl; 0,9+1,2; Stahl-Standard

2 DR steel 0,9+1,2; steel-standard 092-000841-00000

27 2 AR Stahl; 1,0+1,2; Stahl-Standard

2 DR steel 1,0+1,2; steel-standard 092-000842-00000

27 2 AR Stahl; 1,2+1,6; Stahl-Standard

2 DR steel 1,2+1,6; steel-standard 092-000843-00000

30 2 Gegendruckrollen glatt; S tahl

2 counterpressure rolls plane; steel 092-000844-00000

32 4 Zwillingsrollen AL 0,8+1,0

4 twin rolls AL 0,8+1,0 092-000869-00000

32 4 Zwillingsrollen AL 1,0+1,2

4 twin rolls AL 1,0+1,2 092-000848-00000

32 4 Zwillingsrollen AL 1,2+1,6

4 twin rolls AL 1,2+1,6 092-000849-00000

32 4 Zwillingsrollen AL 2,4+3,2

4 twin rolls AL 2,4+3,2 092-000870-00000

33 2 AR Röhrchendraht 0,8/0,9+0,8/0,9

2 DR cored wire 0,8/0,9+0,8/0,9 092-000834-00000

33 2 AR Röhrchendraht 1,0/1,2+1,4/1,6

2 DR cored wire 1,0/1,2+1,4/1,6 092-000835-00000

33 2 AR Röhrchendraht 1,4/1,6+2,0/2,4

2 DR cored wire 1,4/1,6+2,0/2,4 092-000836-00000

33 2 AR Röhrchendraht 2,8+3,2

2 DR cored wire 2,8+3,2 092-000837-00000

34 2 Gegendruckrollen randiert Röhrchendraht

2 counterpressure rolls knurled cored wire 092-000838-00000

o.Abb. Umrüstung verzahnt>unverzahnt, Stahl/Alu

Conversion geared>ungeared, Steel/Alu 092-000845-00000

12/6b Umrüstset 4 Z-Rollen AL 0,8+1,0 Opt. Alu

Conversion kit 4 T-rolls AL 0,8+1,0 092-000867-00000

12/6b Umrüstset 4 Z-Rollen AL 1,0+1,2 Opt. Alu

Conversion kit 4 T-rolls AL 1,0+1,2 092-000846-00000

12/6b Umrüstset 4 Z-Rollen AL 1,2+1,6 Opt. Alu

Conversion kit 4 T-rolls AL 1,2+1,6 092-000847-00000

12/6b Umrüstset 4 Z-Rollen AL 2,4+3,2 Opt. Alu

Conversion kit 4 T-rolls AL 2,4+3,2 092-000868-00000

12/6c Umrüstset 2 AR Röhr 0,8/0,9+0,8/0,9 Opt.-Röhr

Conversion kit 2 DR cored wire 0,8/0,9+0,8/0,9 092-000830-00000

12/6c Umrüstset 2 AR Röhr 1,0/1,2+1,4/1,6 Opt.-Röhr

Conversion kit 2 DR cored wire 1,0/1,2+1,4/1,6 092-000831-00000

12/6c Umrüstset 2 AR Röhr 1,4/1,6+2,0/2,4 Opt.-Röhr

Conversion kit 2 DR cored wire 1,4/1,6+2,0/2,4 092-000832-00000

12/6c Umrüstset 2 AR Röhr 2,8+3,2 Opt.-Röhr

Conversion kit 2 DR cored wire 2,8+3,2 092-000833-00000

AR = Antriebsrolle; DR = Drive rolls; AL = Aluminium

13 Accessories

13/1

13.1 Work-piece cables

Description Version Part. No.:

WK35QMM - 4M/Z

Work-piece cable 35 mm

, 4m, Clamp

092-000008-00000

WK50QMM - 4M/Z

Work-piece cable 50 mm

, 4m, Clamp

092-000003-00000

13.2 General

Description Version Part. No.:

RM RM remote control 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 steel 094-000071-00000 H5F Welder’s gloves 5 Fingers 094-000070-00000 KS1 Welding helmet 094-000011-00000 AK300 Adapter for basket spool K300 094-001803-00001 GMMB1 Gas flow-meter (on the torch) 094-000074-00000

Adhesive foil KLF „Kabel-400V“ 094-007249-00000