EWM Taurus 335 Synergic S TKM Operating Instructions Manual Download Page 54

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Design and function

MIG/MAG welding

099-005215-EW501

29.06.2011

5.7.13.3

Example, tack welding (non-latched)

Figure 5-26

Basic parameters

Parameter

Meaning / explanation

Setting range

GASstr

Gas pre-flow time

0.0s to 20.0s

GASend:

Gas post-flow time

0.0s to 20s

RUECK

Wire burn-back length

2 to 500

" main program

Parameter

Meaning / explanation

Setting range

Setting the wire speed

5.7.13.4

Example, aluminium tack welding (non-latched special)

END

START

Figure 5-27

Basic parameters

Welding parameter Meaning / explanation

Setting range

GASstr

Gas pre-flow time

0.0s to 20.0s

GASend:

Gas post-flow time

0.0s to 20.0s

RUECK

Wire burn-back length

2 to 500

START

" start program

Welding parameter Meaning / explanation

Setting range

DVstart

Wire speed

0% to 200%

ustart

Arc length correction

-9.9V to +9.9V

tstart Duration

0.0s

20s

" main program

Welding parameter Meaning / explanation

Setting range

Setting the wire speed

END

" end-crater program

Welding parameter Meaning / explanation

Setting range

DVend

Wire speed

0% to 200%

Uend

Arc length correction

-9.9V to +9.9V

tend Duration

0.0s

20s

Summary of Contents for Taurus 335 Synergic S TKM

Page 1: ...nstructions Welding machine GB Taurus 335 Synergic S TKM 099 005215 EW501 29 06 2011 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warranty www ewm...

Page 2: ...ther form of liability regardless of type shall be accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whethe...

Page 3: ...S 16 4 1 1 Front view 16 4 1 2 Rear view 18 4 2 Machine control Operating elements 20 4 2 1 Machine control Concealed operating elements 22 4 2 2 Operating elements in the machine 23 5 Design and func...

Page 4: ...out 59 5 7 16 Standard MIG MAG torch 60 5 7 17 MIG MAG special torches 60 5 7 17 1 Program and Up down operation 60 5 7 18 Remote control 61 5 7 19 Advanced settings 62 5 7 19 1 Selecting changing an...

Page 5: ...6 4 Disposing of equipment 92 6 4 1 Manufacturer s declaration to the end user 92 6 5 Meeting the requirements of RoHS 92 7 Rectifying faults 93 7 1 Customer checklist 93 7 2 Error messages power sour...

Page 6: ...l in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading...

Page 7: ...scription Press Do not press Turn Switch 0 1 Switch off machine 0 1 Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display example wait 4s press Inter...

Page 8: ...s and burns on contact Even low voltages can cause you to get a shock and lead to accidents Do not touch any live parts in or on the machine Connection cables and leads must be free of faults Switchin...

Page 9: ...ith flammable material Connect welding leads correctly Risk of accidents if these safety instructions are not observed Non observance of these safety instructions is potentially fatal Carefully read t...

Page 10: ...suspend all conductive power source components like casing transport vehicle and crane frames so they are insulated Do not place any other electronic devices such as drillers or angle grinders etc on...

Page 11: ...he user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the user must consider the following...

Page 12: ...d by crane or suspended CAUTION Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up Tilt resistance is guaranteed up to...

Page 13: ...s of dust acid corrosive gases or substances may damage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambient...

Page 14: ...om the atmosphere 3 1 2 MIG MAG cored wire welding Welding with cored wire electrodes consisting of a metal casing and a powder core As with MIG MAG standard welding the arc is protected from the atmo...

Page 15: ...ted conversion work not specifically authorised by the manufacturer The original copy of the declaration of conformity is enclosed with the unit 3 2 3 Welding in environments with increased electrical...

Page 16: ...01 29 06 2011 4 Machine description quick overview 4 1 Taurus 335 Synergic S 4 1 1 Front view NOTE The maximum possible machine configuration is given in the text description If necessary the optional...

Page 17: ...accessory components remote control welding torch control lead etc 12 Connection socket welding current MIG MAG cored wire welding Workpiece connection TIG welding Workpiece connection MMA welding Wor...

Page 18: ...Machine description quick overview Taurus 335 Synergic S 18 099 005215 EW501 29 06 2011 4 1 2 Rear view Figure 4 2...

Page 19: ...ltage supply 4 8 pole connection socket Cooling unit control lead 5 digital 7 pole connection socket digital For connecting digital accessory components documentation interface robot interface or remo...

Page 20: ...l Operating elements 20 099 005215 EW501 29 06 2011 4 2 Machine control Operating elements sec sec sec sec sec sec DYN sec sec Super puls HOLD AMP VOLT PROG m min DYN S Wire Gas Material JOB LIST M 3...

Page 21: ...ry dial For setting the welding performance for selecting the JOB welding task and for setting other welding parameters 5 Select operating mode button Non latched Latched Signal light lights up in gre...

Page 22: ...e 0 0 s to 20 0 s 0 1 s increments 6 Signal light main program PA Wire speed WF min to WF max Correction of the arc length 9 9 V to 9 9 V 7 DYN Signal light dynamics Setting range 40 to 40 8 sec Signa...

Page 23: ...Inching the Wire Electrode chapter 19 Gas test rinse button Gas test For setting the shielding gas quantity Rinse For rinsing longer tube packages See also Shielding Gas Supply chapter 4 2 2 Operatin...

Page 24: ...feed units are equipped with moving parts which can trap hands hair clothing or tools and thus injure persons Do not reach into rotating or moving parts or drive components Keep casing covers closed d...

Page 25: ...NG Risk of accident due to improper transport of machines that may not be lifted Do not lift or suspend the machine The machine can fall down and cause injuries The handles and brackets are suitable f...

Page 26: ...orking area is adequately ventilated Do not obstruct the air inlets and outlets of the machine Do not allow metal parts dust or other objects to get into the machine 5 4 Workpiece lead general CAUTION...

Page 27: ...ctions The resulting network has to be suitable for operating devices according to protection class 1 5 5 1 Mains configuration NOTE The machine may be connected to a three phase system with four cond...

Page 28: ...ling unit 2 1 3 Figure 5 3 Item Symbol Description 0 1 4 pole connection socket Cooling unit voltage supply 2 8 pole connection socket Cooling unit control lead 3 Cooling module Insert and lock the 8...

Page 29: ...s steel Use a plastic core to weld or braze soft high alloy wire electrodes or aluminium materials Preparation for connecting welding torches with a plastic core Push forward the capillary tube on the...

Page 30: ...ts polarity selection for MIG MAG welding 5 Standard applications Connection for welding current connection socket welding current connection socket 6 MIG MAG welding Workpiece connection 7 Workpiece...

Page 31: ...current 7 Workpiece Insert the central plug for the welding torch into the central connector and screw together with crown nut Insert the plug on the workpiece lead into the welding current connectio...

Page 32: ...accessories are required when using standardised basket coils DIN 8559 2 1 Figure 5 6 Item Symbol Description 0 1 Carrier pin For fixing the wire spool 2 Knurled nut For fixing the wire spool Loosen...

Page 33: ...injury due to welding wire escaping from the welding torch The welding wire can escape from the welding torch at high speed and cause bodily injury including injuries to the face and eyes Never direc...

Page 34: ...nwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe Pres...

Page 35: ...ten the Allen screw 8 mm in the clockwise direction to increase the braking effect NOTE Do not jam the wire spool Tighten the spool brake until the wire spool no longer turns when the wire feed motor...

Page 36: ...enu on the control or using the PC300 NET welding parameter software 5 7 7 Welding task selection 5 7 7 1 Basic welding parameters Select JOB welding task using the JOB list On decompact welding syste...

Page 37: ...min Figure 5 10 Display Setting selection Dynamics setting 40 Arc harder and narrower 40 Arc softer and wider 5 7 7 4 Superpulses m min Figure 5 11 Display Setting selection Selects super pulses Switc...

Page 38: ...ng selection menu wire burn back Set wire burn back Parameter setting setting range 0 to 499 Wire back burn set too high large drops developing on the wire electrode result in poor ignition properties...

Page 39: ...ay between AMP Welding current Material thickness Wire speed Application example Aluminium is to be welded Material AlMg Gas Ar 100 Wire diameter 1 2 mm The correct wire speed is not known and is to b...

Page 40: ...ual machines and their functions 5 7 9 MIG MAG welding data display To the left and right of the control displays are the Parameter selection buttons They are used to select welding parameters to be d...

Page 41: ...cross sections are adequate Fully unroll welding current cables torche tube packages and if applicable intermediate tube packages Avoid loops Use welding torches preferably water cooled that are suita...

Page 42: ...also be changed if required 5 7 12 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I We...

Page 43: ...g gas is expelled gas pre flows Wire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Change over to pre selected wire speed S...

Page 44: ...speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters change at the sp...

Page 45: ...re flows Wire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART for the time tstart Slope to main pro...

Page 46: ...gnites after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART spot time starts Slope to main program PA After the set spot time elapses slope goes to...

Page 47: ...tact with the workpiece welding current is flowing start program PSTART for the time tstart Slope on main program PA Start the super pulse function beginning with main program PA The welding parameter...

Page 48: ...ed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Change over to pre selected WF speed main program PA Step 2 Release torch trigg...

Page 49: ...ntact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduce...

Page 50: ...after the set time tSTART elapses and at the latest when the torch trigger is released Tapping1 can be used to change over to the reduced main program PB Repeated tapping will switch back to the main...

Page 51: ...current is flowing start program PSTART for the time tstart Step 2 Release torch trigger Slope on main program PA Start the super pulse function beginning with main program PA The welding parameters c...

Page 52: ...n program PA continuous welding Reduced main program PB targeted heat reduction End program PEND minimisation of end craters via targeted heat reduction The programs include the parameters wire speed...

Page 53: ...rom PSTART to PA 0 0s to 20 0s 5 PA Wire speed absolute 0 1 m min to 40 m min 6 Dynamics 40 to 40 7 Duration spot time and superpulse 0 01s to 20 0s 8 PB Wire speed relative Arc length correction rela...

Page 54: ...t I PA PEND PSTART Figure 5 27 Basic parameters Welding parameter Meaning explanation Setting range GASstr Gas pre flow time 0 0s to 20 0s GASend Gas post flow time 0 0s to 20 0s RUECK Wire burn back...

Page 55: ...ing explanation Setting range DVstart Wire speed 0 to 200 ustart Arc length correction 9 9V to 9 9V tstart Duration 0 0s to 20s PA main program Welding parameter Meaning explanation Setting range Sett...

Page 56: ...start Arc length correction 9 9V to 9 9V tstart Duration 0 0s to 20s PA main program Welding parameter Meaning explanation Setting range tS1 Slope duration from PSTART to PA 0 0s to 20s DV3 Setting th...

Page 57: ...elding parameters for the main programs using the following components Program changeover Program Operating mode Welding process Superpulse Wire speed Voltage correction Dynamics P0 Yes 1 Yes 2 M3 71...

Page 58: ...A3 PA3 PA4 PA5 Figure 5 31 Example 3 Aluminium welding of different sheet metal thicknesses non latched or latched special PA0 PA1 PA8 PA9 t I Figure 5 32 NOTE Up to 16 programs PA0 to PA15 can be def...

Page 59: ...t arc length correction Display example 0 8 V correction Setting range 9 9 V to 9 9 V 1 x Select Dynamic program sequence parameter LED DYN is on sec sec sec sec sec sec DYN sec sec Super puls m min S...

Page 60: ...ing special torches can be used together with this welding machine UP DOWN welding torch with one rocker for setting the wire speed or to change up to 10 weldingprograms POWERCONTROL 1 welding torch w...

Page 61: ...re directly dependent on the configuration of the respective welding machine or wire feed unit The settings are defined by changeover switches or by setting special parameters dependent on the control...

Page 62: ...1 HOLD AM P VOLT PROG m min m min Figure 5 34 NOTE ENTER Enter the menu Switch off machine at the main switch Press and hold the left parameter selection button and switch the machine on again at the...

Page 63: ...ff Ex works 1 correction operation on Main program PA flashing Program changeover with standard torch 0 no program changeover Ex works 1 special latched 2 specific latched special n cycle active Lat a...

Page 64: ...works 1 program selection possible 5 7 19 2 Reset to factory settings NOTE All special parameters saved by the user will be overwritten by the factory settings Displays Operating element Action Result...

Page 65: ...ge up down setting and up down symbol Program limit P4 Program selection can be limited with the special parameter P4 The setting is adopted for all JOBs Program selection depends on the position of t...

Page 66: ...be carried out with these values To allow the welder also to perform wire and voltage correction in program mode the correction mode must be switched on and limit values for wire and voltage must be...

Page 67: ...ess button and hold down for approx 4 s Left Current limit value of the wire feed speed correction VOLT PROG 4 s Right Current limit value of the voltage correction m min Set limit value for the wire...

Page 68: ...elapsed The program then switches automatically to absolute program 4 Accessory components such as remote controls or special torches may not be connected Program switching at the wire feed unit contr...

Page 69: ...sec can switch to other programs Programs PA1 to PA9 are possible 3rd cycle Press and hold torch trigger Slope to end program PEND from PAN The program can be stopped at any time by pressing the torc...

Page 70: ...with key switches optional see Key switches chapter must be configured as masters P10 1 The wire feed configured as the master is active after the welding machine is switched on There are no other fun...

Page 71: ...nfigure special parameter P12 to P12 2 or P12 1 Operating element Action Result Display JOB LIST 1 x Select JOB list m min Select the source JOB Wait for around 3 seconds until the JOB has been transf...

Page 72: ...to set the welding parameters manually Selection of JOB 0 can be prevented via the key switch or with the block program 0 parameter P2 See List of special parameters chapter Key switch position 0 or...

Page 73: ...nterference Appoint only skilled persons for repair work trained service personnel CAUTION Test Before re commissioning it is essential that an inspection and test during operation is carried out conf...

Page 74: ...e central connector torch enables polarity selection 5 TIG Connection socket for welding current Connection socket welding current 6 TIG welding Workpiece connection 7 Workpiece Insert the central plu...

Page 75: ...ipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant return and supply line blue to quick connect coupling blue coolan...

Page 76: ...sing the Wire speed rotary dial Operating element Action Result Displays m min Welding current is set Setpoint setting 5 8 4 TIG arc ignition 5 8 4 1 Liftarc ignition a b c Figure 5 40 The arc is igni...

Page 77: ...ns and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I Welding output Gas pre flows Gas post flows Non latched Sp...

Page 78: ...on latched t t I 1 2 PA PEND PSTART Figure 5 42 Selection Select non latched special mode Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows The arc is ignited using liftarc W...

Page 79: ...ed operating mode Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows The arc is ignited using liftarc Welding current flows with pre selected setting Step 2 Release torch trig...

Page 80: ...gram PA is given at the earliest after the set time tSTART elapses and at the latest when the torch trigger is released Tapping can be used to switch to the reduced main program PB Repeated tapping wi...

Page 81: ...reduced main program Welding current 1 to 100 8 Duration reduced main program 0 01 s to 20 0 s 9 Slope duration from PA to PEND 0 s to 20 s 10 PEND end program Welding current 1 to 100 11 Duration en...

Page 82: ...selection plug Retainer for the polarity selection plug in MMA mode or for transport 5 Electrode holder Insert cable plug of the electrode holder into either the or welding current connection socket a...

Page 83: ...Result Display JOB LIST 1 x Select JOB number input comes on m min Set the JOB number The machine adopts the required setting after approx 3 seconds 5 9 3 Welding current setting The welding current i...

Page 84: ...ks in spite of the Arcforce device the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating Check the welding current setting and...

Page 85: ...s in the holders provided for them and secure with fixing devices Avoid heating the shielding gas cylinder CAUTION Faults in the shielding gas supply An unhindered shielding gas supply from the shield...

Page 86: ...n gas hose on pressure regulator to be gas tight 5 10 2 Gas test Slowly open the gas cylinder valve Open the pressure regulator Switch on the power source at the main switch Initiate gas test function...

Page 87: ...pores to form Adjust the shielding gas quantity to suit the welding task 5 11 Interfaces CAUTION Damage due to the use of non genuine parts The manufacturer s warranty becomes void if non genuine par...

Page 88: ...er 1 must be unplugged on PCB M320 1 in the welding machine Contact open welding current off F Output 0 V Reference potential G P Output I 0 Power relay contact galvanically isolated max 15 V 100 mA H...

Page 89: ...ctly Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission The PC may be destroyed due to high frequency ignition pulses Interface SECINT X10USB must be co...

Page 90: ...ng parameters on the machine the control input can be locked with the aid of a key switch In key switch position 1 all functions and parameters can be set without restriction In key switch position 0...

Page 91: ...securing elements Operating message safety and adjustment devices Functional test Other general condition 6 2 2 Monthly maintenance tasks Casing damage front rear and side walls Wheels and their secu...

Page 92: ...pean provisions guideline 2002 96 EG of the European Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must...

Page 93: ...nching wire electrodes chapter Check settings and correct if necessary a Worn wire rolls Check and replace if necessary a Wire feed motor without supply voltage automatic cutout triggered by overloadi...

Page 94: ...olant level Top up the coolant Leak in the coolant circuit rectify the leak and top up the coolant Coolant pump is not working check excess current release on air cooling unit Err 5 x Error WF unit WF...

Page 95: ...customised welding parameters that are stored will be replaced by the factory settings 7 3 1 Resetting a single JOB JOB LIST JOB LIST m min Figure 7 1 Display Setting selection Reset to factory settin...

Page 96: ...r 3 sec 7 4 General operating problems 7 4 1 Interface for mechanised welding WARNING No function of the external shut down devices emergency stop switch If the emergency stop circuit has been realise...

Page 97: ...on 10 min 60 DC 6 min welding 4 min pause Open circuit voltage 79 V Mains voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 16 A Mains connection lead H07RN...

Page 98: ...000914 00000 GS25L G1 4 SW 17 Pilot static tube 094 001100 00000 5POLE CEE 16A M Machine plug 094 000712 00000 9 2 Remote control connection cable Type Designation Item no R10 19POL Remote control 09...

Page 99: ...Net welding parameter software set incl cable and SECINT X10 USB interface 090 008265 00000 WELDQAS1 Station Stationary welding data monitoring and docu set for one welding machine 090 008215 00000 WE...

Page 100: ...000849 00000 AL 4ZR4R 2 4 3 2 Twin rollers 37 mm for aluminium 092 000870 00000 10 1 3 Wire feed rollers for cored wire Type Designation Item no ROE 2DR4R 0 8 0 9 0 8 0 9 Drive rollers 37 mm cored wi...

Page 101: ...Replaceable parts Wire feed rollers 099 005215 EW501 29 06 2011 101 Figure 10 1...

Page 102: ...olid Wire 1 34 98 42 106 190 189 188 131 130 129 126 187 127 128 3 35 99 43 107 254 179 4 36 100 44 108 255 180 5 37 101 45 109 256 181 6 8 9 10 CuSi L ten Brazing CuAl L ten Brazing 114 115 116 117 1...

Page 103: ...Appendix B Overview of EWM branches 099 005215 EW501 29 06 2011 103 12 Appendix B 12 1 Overview of EWM branches...

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