EWM Taurus 351-401 Synergic S HP MM FKG Operating Instructions Manual Download Page 33

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Design and function

Notes on the installation of welding current leads

099-005431-EW501

04.02.2016

Use an individual welding lead to the workpiece for each welding machine!

Figure 5-4

Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid
loops!

Always keep leads as short as possible!

Lay any excess cable lengths in meanders.

Figure 5-5

Summary of Contents for Taurus 351-401 Synergic S HP MM FKG

Page 1: ...lding machine Taurus 351 401 Synergic S HP MM FKG Taurus 351 501 Synergic S HP MM FKW 099 005431 EW501 04 02 2016 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For deta...

Page 2: ...accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or not these instructions or the conditions and m...

Page 3: ...ion 27 5 1 General 27 5 2 Installation 28 5 3 Machine cooling 28 5 4 Workpiece lead general 28 5 5 Welding torch cooling system 29 5 5 1 List of coolants 29 5 5 2 Maximal hose package length 29 5 5 3...

Page 4: ...and intermediate drive 72 5 8 12 Expert menu MIG MAG 73 5 8 12 1 Selection 73 5 9 TIG welding 75 5 9 1 Welding torch and workpiece line connection 75 5 9 2 Welding task selection 76 5 9 3 Welding curr...

Page 5: ...lding tasks to the factory settings 110 7 3 1 Resetting a single JOB 110 7 3 2 Resetting all JOBs 111 7 4 Vent coolant circuit 112 8 Technical data 113 8 1 Taurus 351 FKG 113 8 2 Taurus 351 FKW 114 8...

Page 6: ...Contents Notes on the use of these operating instructions 6 099 005431 EW501 04 02 2016...

Page 7: ...e hazard is also highlighted using a symbol in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information i...

Page 8: ...sers must observe Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu 4 s...

Page 9: ...t sensitive to radiation accordingly The correct functioning of pacemakers may be affected obtain advice from a doctor if necessary Do not carry out any unauthorised repairs or modifications To avoid...

Page 10: ...hand in the working area Thoroughly remove any residue of flammable substances from the workpiece before starting welding Only continue work on welded workpieces once they have cooled down Do not all...

Page 11: ...currents Stray welding currents can destroy protective earth conductors damage equipment and electronic devices and cause overheating of components leading to fire Make sure all welding leads are sec...

Page 12: ...ard The 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 foll...

Page 13: ...during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to EN 60974 A2 Set up and transport the machine on level solid ground Secure add on parts using suitable equipme...

Page 14: ...ting eyes always lift all lifting eyes simultaneously When using retrofitted craning frames etc always use at least two lifting points positioned as far apart as possible observe option description Av...

Page 15: ...ties 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 ambie...

Page 16: ...vert the equipment improperly Arc welding machine for standard and pulsed gas shielded metal arc welding with TIG welding and lift arc touch starting or MMA welding as secondary process It may be poss...

Page 17: ...is enclosed with the unit 3 2 3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be used in environments with an increased elect...

Page 18: ...erview Front view 18 099 005431 EW501 04 02 2016 4 Machine description quick overview 4 1 Front view Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines wi...

Page 19: ...MIG MAG cored wire welding Workpiece connection TIG welding Workpiece connection MMA welding Workpiece or electrode holder connection 14 Welding current cable polarity selection Welding current to Eur...

Page 20: ...Machine description quick overview Rear view 20 099 005431 EW501 04 02 2016 4 2 Rear view Figure 4 2...

Page 21: ...s and JOB lists will be located on the inside 4 Wire spool inspection window Check wire supply 5 Cooling air outlet 6 Bracket for shielding gas cylinder 7 Wheels fixed castors 8 PC interface serial D...

Page 22: ...Machine description quick overview Inside view 22 099 005431 EW501 04 02 2016 4 3 Inside view Figure 4 3...

Page 23: ...ew 099 005431 EW501 04 02 2016 23 Item Symbol Description 0 1 Welding torch function changeover switch special welding torch required Changing over programs or JOBs Infinite adjustment of welding perf...

Page 24: ...appendix to these operating instructions 3 Display left Welding current material thickness wire speed hold values 4 Push button parameter selection left power saving mode AMP Welding current Material...

Page 25: ...ry dial Correction of the arc length from 9 9 V to 9 9 V Selection of welding programs 0 to 15 not possible if accessory components such as program torches are connected 11 Button Parameter selection...

Page 26: ...ction of the arc length 9 9 V to 9 9 V 7 sec Signal light duration of main program PA Setting range 0 1 s to 20 0 s 0 1 s increments Used e g in connection with the super pulse function 8 Signal light...

Page 27: ...he welding current connection If the welding current connections are not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by...

Page 28: ...mponents the following precautions should be observed Ensure that the working area is adequately ventilated Do not obstruct the air inlets and outlets of the machine Do not allow metal parts dust or o...

Page 29: ...protection tester Replace coolant as necessary if frost protection is inadequate The disposal of coolant must be carried out according to official regulations and observing the relevant safety data s...

Page 30: ...the filter sieve insert close sealing cover again After the initial filling wait for at least one minute when the machine is switched on so that the hose package is filled with coolant completely and...

Page 31: ...uctions The resulting network has to be suitable for operating devices according to protection class 1 5 6 1 Mains configuration The machine may be connected to a three phase system with four conducto...

Page 32: ...power sources without HF igniter MIG MAG for as long and as close as possible in parallel Lay the workpiece lead and hose package of power sources with HF igniter TIG for as long as possible in parall...

Page 33: ...04 02 2016 33 Use an individual welding lead to the workpiece for each welding machine Figure 5 4 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Alw...

Page 34: ...shielding gas cylinder Do not attach any element to the shielding gas cylinder valve Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed a...

Page 35: ...securing chain Figure 5 6 Item Symbol Description 0 1 Pressure regulator 2 Shielding gas cylinder 3 Output side of the pressure regulator 4 Cylinder valve Tighten the pressure regulator screw connecti...

Page 36: ...MAG welding Wire diameter x 11 5 l min MIG brazing Wire diameter x 11 5 l min MIG welding aluminium Wire diameter x 13 5 l min 100 argon TIG Gas nozzle diameter in mm corresponds to l min gas through...

Page 37: ...the system starts again from the beginning Figure 5 7 The display shows Nominal values before welding Actual values during welding Hold values after welding MIG MAG Parameter Nominal values Actual val...

Page 38: ...guide tube Operate welding torches with a steel liner with a capillary tube Depending on the wire electrode diameter or type either a steel liner or liner with the correct inner diameter must be inse...

Page 39: ...connection socket MIG MAG welding Workpiece connection 3 Welding torch 4 Welding torch hose package 5 19 pole connection socket analogue For connecting analogue accessory components remote control wel...

Page 40: ...g current lead insert polarity selection into the welding current connection socket and lock Insert the welding torch control cable into the 19 pole connection socket and lock MIG MAG torches with add...

Page 41: ...ome loose from the wire spool holder and fall to the ground causing damage to the machine and injuries Securely fasten the wire spool to the wire spool holder using the knurled nut Before you start wo...

Page 42: ...xing the clamping unit and setting the pressure 4 Clamping unit 5 Wire feed roller see the Wire feed roller overview table Rotate the tommy by 90 clockwise or anti clockwise tommy locks into place Fol...

Page 43: ...code Groove form mm inch Steel Stainless steel Brazing 0 6 023 monochrome light pink V groove 0 8 030 white 0 9 1 0 035 040 blue 1 2 045 red 1 4 052 green 1 6 060 black 2 0 080 grey 2 4 095 brown 2 8...

Page 44: ...intervals Keep all casing covers or protective caps closed during operation Risk of injury due to welding wire escaping from the welding torch The welding wire can escape from the welding torch at hig...

Page 45: ...elding torch outlet A prerequisite for the automatic inching process is the correct preparation of the wire guide especially in the capillary and wire guide tube area The contact pressure has to be ad...

Page 46: ...ol Description 0 1 Allen screw Securing the wire spool retainer and adjustment of the spool brake Tighten the Allen screw 8 mm in the clockwise direction to increase the braking effect Tighten the spo...

Page 47: ...r You can adjust additional parameters in the control configuration menu or using the PC300 NET welding parameter software if required See 11 1 JOB List chapter 5 8 4 Welding task selection 5 8 4 1 Ba...

Page 48: ...s a multitude of possibilities For example to enable the welding of vertical up welds without the Christmas tree technique when selecting program 1 the relevant superPuls variant depending on the mate...

Page 49: ...Display Setting selection menu burn back Set burn back Parameter setting setting range 0 to 499 Back burn set too high large drops developing on the wire electrode result in poor ignition properties...

Page 50: ...he welding current material thickness or wire speed Operating element Action Result n x Switching the display between Welding current Material thickness Wire speed Application example Aluminium is to...

Page 51: ...ssory components for operating point setting The operating point can also be set with various accessory components such as remote controls special torches PC software robot and industrial bus interfac...

Page 52: ...12 0 255 9 5 256 7 0 Ar 80 90 189 17 0 179 12 0 180 9 5 181 6 0 CrNi Ar 91 99 251 12 0 252 12 0 253 6 0 You can make use of these properties after selecting the forceArc process As with pulse arc weld...

Page 53: ...ot formation and secure sidewall fusion Un alloyed and low alloy steels Manual and automated applications rootArc welding up to Wire mm 0 6 0 8 0 9 1 1 2 1 6 Material Gas JOB JOB JOB JOB JOB JOB Steel...

Page 54: ...so be changed if required 5 8 6 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 Weldin...

Page 55: ...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 56: ...c 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 specified t...

Page 57: ...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 program PA Step...

Page 58: ...e 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 end program PEND Wi...

Page 59: ...orkpiece 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 parameters change at the...

Page 60: ...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 trigger no ef...

Page 61: ...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 62: ...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 program PA St...

Page 63: ...g 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 change at the spec...

Page 64: ...rt of the seam Main 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 para...

Page 65: ...Duration spot time and superpulse 0 01s to 20 0s 7 8 PB Wire speed relative Arc length correction relative 1 to 200 9 9V to 9 9V 8 9 Duration 0 01s to 20 0s 9 1 0 Slope duration from PA to PEND 0 0s t...

Page 66: ...cial Figure 5 32 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 50...

Page 67: ...tion 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 Setting the wir...

Page 68: ...tion 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 the wire speed 0 to 200 t2 Duration 0 1s to 20s tS3 Sl...

Page 69: ...wing components Program switching JOB switching Program Operating mode superPuls Wire speed Voltage correction Dynamics M3 7x Wire feeder control Yes Yes P0 Yes Yes Yes P1 15 Yes R20 Remote control Ye...

Page 70: ...igure 5 36 Example 3 Aluminium welding of different sheet metal thicknesses non latched or latched special Figure 5 37 Up to 16 programs PA0 to PA15 can be defined An operating point wire speed arc le...

Page 71: ...1 n x Select program sequence parameter Main program PA LED is on Set wire speed Absolute value Set arc length correction Display example 0 8 V correction Setting range 9 9 V to 9 9 V 1 x Select Dyna...

Page 72: ...orch function changeover switch special welding torch required Changing over programs or JOBs Infinite adjustment of welding performance 5 8 11 2 Switching between Push Pull and intermediate drive DAN...

Page 73: ...r setting 5 8 12 1 Selection ENTER Enter the menu Keep the welding parameters push button pressed for 3 s NAVIGATION Navigate the menu Select parameters by pressing the welding parameters push button...

Page 74: ...he torch trigger in the main program see the special parameters description 1 No JOB dependent program limit 2 9 JOB dependent program limit for max selectable programs For machine versions with pulse...

Page 75: ...ty selection TIG Connection socket for welding current 7 Quick connect coupling red coolant return 8 Quick connect coupling blue coolant supply Insert the central plug for the welding torch into the c...

Page 76: ...s set Setpoint setting 5 9 4 TIG arc ignition 5 9 4 1 Liftarc ignition Figure 5 41 The arc is ignited on contact with the workpiece a Carefully place the torch gas nozzle and tungsten electrode tip on...

Page 77: ...ymbol 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 Special non latched...

Page 78: ...cial non latched Figure 5 43 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 Welding gas flows wi...

Page 79: ...ting 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 trigger no e...

Page 80: ...en 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 will switch back...

Page 81: ...A 0 s to 20 s 5 PA main program Welding current absolute 5 A to 550 A 6 Duration PA 0 01 s to 20 0 s 7 PB reduced main program Welding current 1 to 100 8 Duration reduced main program 0 01 s to 20 0 s...

Page 82: ...ated surface 5 10 1 Connecting the electrode holder and workpiece lead Figure 5 47 Item Symbol Description 0 1 Workpiece 2 Electrode holder 3 Connection socket welding current 4 Connection socket weld...

Page 83: ...e machine adopts the required setting after approx 3 seconds 5 10 3 Welding current setting The welding current is normally set using the Wire speed rotary dial Operating element Action Result Display...

Page 84: ...ectrode from annealing If the electrode sticks in spite of the Arcforce device the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overhe...

Page 85: ...lease note the relevant documentation of the accessory components 5 12 Interfaces for automation DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage...

Page 86: ...ification 0 V 10 V wire feed speed E Output Reference potential 0 V F S Input Welding power start stop S1 G Input Control voltage specification 0 V 10 V arc length correction P Input Activation of con...

Page 87: ...documentation of for example welding voltage and current wire speed and motor current WELDQAS welding data monitoring and documentation system Network compatible welding data monitoring and documentat...

Page 88: ...ibility in optimising their requirements These settings are not configured directly on the machine control since a regular setting of the parameters is generally not required The number of selectable...

Page 89: ...ion button switch machine off and on again ENTER EXIT NAVIGATION l 0 AMP Hold Prog VOLT kW Figure 5 52 Display Setting selection Ramp time for wire inching 0 normal inching 10s ramp time 1 fast inchin...

Page 90: ...can be selected using PowerControl 2 torches Lower limit 129 Ex works Upper limit remote JOB changeover JOB range of the POWERCONTROL2 torch Upper limit 169 Ex works HOLD function 0 HOLD values are no...

Page 91: ...0 type B Program settings for relative programs 0 Combined setting of relative programs possible ex works 1 Individual setting of relative programs possible ex works Correction or nominal voltage disp...

Page 92: ...ion changeover switch see Machine description Programs can only be switched when the changeover switch is in the program position Programs can be switched by means of a connected remote control or spe...

Page 93: ...am can only 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 volta...

Page 94: ...gram number 4 s Press button and hold down for approx 4 s Left Current limit value of the wire feed speed correction Right Current limit value of the voltage correction Set limit value for the wire fe...

Page 95: ...time has 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...

Page 96: ...latest when the torch trigger is released Tapping pressing briefly and releasing within 0 3 sec can switch to other programs Programs PA1 to PA9 are possible 3rd cycle Press and hold torch trigger Slo...

Page 97: ...es optional See 5 14 Protecting welding parameters from unauthorised access chapter must be configured as masters P10 1 The wire feed configured as the master is active after the welding machine is sw...

Page 98: ...arameter P14 to the upper limit of the target JOBs Set Program or Up Down function changeover switch to Program position JOBs can be changed over in the specified range using the accessory component C...

Page 99: ...P12 1 Enable block JOB mode special parameter P16 1 Change to block JOB mode by selecting one of the special JOBs 129 130 or 131 Simultaneous operation with interfaces such as RINT X12 BUSINT X11 DVI...

Page 100: ...e MIG MAG standard welding pulse arc welding at the wire feed unit control or the welding machine control P18 0 Program 0 To select the operating mode and welding type at the wire feed unit Program 1...

Page 101: ...ex works Adjustment may only be carried out by authorised service personnel basic setting 1 Program settings for relative programs P23 The start down slope and end program relative programs can be se...

Page 102: ...rotary knob EXIT Exit the menu Press the parameter selection right push button switch machine off and on again ENTER EXIT NAVIGATION l 0 l 0 Prog VOLT kW M3 7x B D LP M3 7x A C HP Figure 5 56 Display...

Page 103: ...lding torch With other hose package lengths it is necessary to carry out a voltage correction to optimise welding properties The voltage correction value can be set close to zero by means of realignin...

Page 104: ...ight pressure put the welding torch in place with the contact tip on a clean purged location on the workpiece and then press the torch trigger for approx 2 seconds A short circuit current will flow br...

Page 105: ...se quote the machine type serial number and item number of the machine as well as the type designation and item number of the spare part 6 1 General When used in the specified environmental conditions...

Page 106: ...ich must be disposed of Do not dispose of in household waste Observe the local regulations regarding disposal 6 3 1 Manufacturer s declaration to the end user According to European provisions guidelin...

Page 107: ...rake See 5 8 2 5 Spool brake setting chapter Check settings and correct if necessary Setting pressure units See 5 8 2 4 Inching the wire electrode chapter Check settings and correct if necessary Worn...

Page 108: ...not issuing a signal M3 51 defective inform Service Error 6 gas x Shielding gas error Check shielding gas supply for machines with shielding gas monitoring Error 7 Se Vol x Secondary excess voltage In...

Page 109: ...The error message will disappear once the error has been rectified b The error message can be reset by pressing a key button Welding machine control Key button RC1 RC2 Expert CarExpert Progress M3 11...

Page 110: ...mised welding parameters that are stored will be replaced by the factory settings 7 3 1 Resetting a single JOB EXIT RESET ENTER 3 s 3 s 3 s Figure 7 1 Display Setting selection RESET to factory settin...

Page 111: ...11 7 3 2 Resetting all JOBs JOBs 1 128 and 170 256 will be reset Custom JOBs 129 169 are maintained ENTER 3 s EXIT RESET 3 s 3 s Figure 7 2 Display Setting selection RESET to factory settings The RESE...

Page 112: ...nt circuit Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling To vent the cooling system always use the blue coolant connection which i...

Page 113: ...quency 50 60 Hz Mains fuse safety fuse slow blow 3 x 25 A Mains connection lead H07RN F4G6 Maximum connected load 13 9 kVA 10 9 kVA 15 0 kVA Recommended generator rating 20 3 kVA cos efficiency 0 99 9...

Page 114: ...VA cos efficiency 0 99 90 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine welding torch cooling Fan gas or water Cooling capacity at 1 l min 1500 W Max flow...

Page 115: ...Mains connection lead H07RN F4G6 Maximum connected load 17 2 kVA 13 2 kVA 18 2 kVA Recommended generator rating 24 6 kVA cos efficiency 0 99 90 Insulation class protection classification H IP 23 Ambi...

Page 116: ...VA cos efficiency 0 99 90 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine welding torch cooling Fan gas or water Cooling capacity at 1 l min 1500 W Max flow...

Page 117: ...6 kVA cos efficiency 0 99 90 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine welding torch cooling Fan gas or water Cooling capacity at 1 l min 1500 W Max...

Page 118: ...e control all welding machine functions can be set directly at the workplace 090 008776 00000 FRV 7POL 0 5 m Extension connecting cable 092 000201 00004 FRV 7POL 1 m Extension connecting cable 092 000...

Page 119: ...ntrol 092 002910 00000 ON Filter T P Retrofit option contamination filter for air inlet 092 002092 00000 ON Tool Box Retrofit option tool box 092 002138 00000 9 4 Computer communication Type Designati...

Page 120: ...azing 092 002770 00008 FE 4R 1 0 MM 0 04 INCH BLUE Drive roll set 37 mm 4 rolls V groove for steel stainless steel and brazing 092 002770 00010 FE 4R 1 2 MM 0 045 INCH RED Drive roll set 37 mm 4 rolls...

Page 121: ...nurled for flux cored wire 092 002848 00008 FUEL 4R 1 0 MM 0 04 INCH BLUE ORANGE Drive roll set 37 mm 4 rolls V groove knurled for flux cored wire 092 002848 00010 FUEL 4R 1 2 MM 0 045 INCH RED ORANGE...

Page 122: ...Appendix A JOB List 122 099 005431 EW501 04 02 2016 11 Appendix A 11 1 JOB List Figure 11 1...

Page 123: ...Appendix B Overview of EWM branches 099 005431 EW501 04 02 2016 123 12 Appendix B 12 1 Overview of EWM branches...

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