EWM Taurus 351 Basic FKG Operating Instructions Manual Download Page 5

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Contents

Notes on the use of these operating instructions

099-005425-EW501

14.07.2016

Summary of Contents for Taurus 351 Basic FKG

Page 1: ...aurus 351 Basic FKG Taurus 401 Basic FKG Taurus 351 Basic FKW Taurus 401 Basic FKW Taurus 501 Basic FKW 099 005425 EW501 14 07 2016 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group com ...

Page 2: ...service department on 49 2680 181 0 A list of authorised sales partners can be found at www ewm group com Liability relating to the operation of this equipment is restricted solely to the function of the equipment No other 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...

Page 3: ...m 23 5 1 5 1 Approved coolants overview 23 5 1 5 2 Maximal hose package length 23 5 1 5 3 Adding coolant 24 5 1 6 Notes on the installation of welding current leads 25 5 1 7 Stray welding currents 26 5 1 8 Mains connection 27 5 1 8 1 Mains configuration 27 5 1 9 Shielding gas supply shielding gas cylinder for welding machine 28 5 1 9 1 Pressure regulator connection 28 5 1 9 2 Shielding gas hose co...

Page 4: ...sual inspection 58 6 3 1 2 Functional test 58 6 3 2 Monthly maintenance tasks 58 6 3 2 1 Visual inspection 58 6 3 2 2 Functional test 58 6 3 3 Annual test inspection and testing during operation 59 6 4 Disposing of equipment 59 6 4 1 Manufacturer s declaration to the end user 59 6 5 Meeting the requirements of RoHS 59 7 Rectifying faults 60 7 1 Checklist for rectifying faults 60 7 2 Error messages...

Page 5: ...Contents Notes on the use of these operating instructions 099 005425 EW501 14 07 2016 5 ...

Page 6: ...y observed to prevent serious and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning symbol The 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 includes the CAUTION keyword in its heading with a general ...

Page 7: ...ch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Correct Numerical value adjustable Menu entry Signal light lights up in green Navigating the menu Signal light flashes green Exit menu Signal light lights up in red Time representation e g wait 4 s activate Signal light flashes red Interruption in the menu display other setting options possible Tool not required do n...

Page 8: ...tective equipment depending on the application The machine may only be opened by qualified personnel Hazard when interconnecting multiple power sources If a number of power sources are to be connected in parallel or in series only a technical specialist may interconnect the sources as per standard IEC 60974 9 2010 Installation and use and German Accident Prevention Regulation BVG D1 formerly VBG 1...

Page 9: ...sparks results in burns Use welding shield or welding helmet with the appropriate safety level depending on the application Wear dry protective clothing e g welding shield gloves etc according to the relevant regulations in the country in question Protect persons not involved in the work against arc beams and the risk of glare using safety curtains WARNING Explosion risk Apparently harmless substa...

Page 10: ...ent by workers at work The regulations applicable to occupational safety and accident prevention in the country concerned Setting up and operating the machine as per IEC 60974 9 Brief the user on safety conscious work practices on a regular basis Regularly inspect the machine as per IEC 60974 4 The manufacturer s warranty becomes void if non genuine parts are used Only use system components and op...

Page 11: ...l areas connected to the low voltage public mains network Setting up and operating When operating arc welding systems in some cases electro magnetic interference can occur although all of the welding machines comply with the emission limits specified in the standard The user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compat...

Page 12: ...g damaged itself during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to IEC 60974 1 Set up and transport the machine on level solid ground Secure add on parts using suitable equipment The units are designed for operation in an upright position Operation in non permissible positions can cause equipment damage Only transport and operate in an upright position Acce...

Page 13: ...Directive LVD Electromagnetic Compatibility Directive EMC Restriction of Hazardous Substance RoHS In case of unauthorised changes improper repairs non compliance with specified deadlines for Arc Welding Equipment Inspection and Testing during Operation and or prohibited modifications which have not been explicitly authorised by EWM this declaration shall be voided An original document of the speci...

Page 14: ...verview Front view 14 099 005425 EW501 14 07 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 with water cooling Figure 4 1 ...

Page 15: ... MIG MAG welding workpiece connection MIG MAG cored wire welding welding current connection for the welding torch MMA welding electrode holder connection 13 Connection socket welding current MIG MAG welding welding current connection for the welding torch MIG MAG cored wire welding workpiece connection MMA welding workpiece connection 14 Welding current cable polarity selection Welding current to ...

Page 16: ...Machine description quick overview Rear view 16 099 005425 EW501 14 07 2016 4 2 Rear view Figure 4 2 ...

Page 17: ...nal stickers with information on the replacement parts 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 D sub connection socket 9 pole With this machine series for maintenance purposes only specialist staff 9 Connecting nipple G shielding gas connection 10 Key button Autom...

Page 18: ...Machine description quick overview Inside view 18 099 005425 EW501 14 07 2016 4 3 Inside view Figure 4 3 Item Symbol Description 0 1 Wire spool holder 2 Wire feed unit ...

Page 19: ... J3 Air arc gouging 2 Display left Welding current wire feed speed 3 Status displays AMP Welding current display signal light Wire feed speed display signal light 4 Display welding process J1 MIG MAG welding J2 MMA welding J3 Gouging 5 Welding parameter setting rotary dial For setting the welding performance for selecting the JOB welding task and for setting other welding parameters 6 Select opera...

Page 20: ...ltage 9 Push button parameter selection right power saving mode VOLT Welding voltage kW Welding power display Gas flow rate option Enter power saving mode by pressing the push button for long interval 10 Display right Welding voltage welding performance motor current wire feed mechanism during wire inching shielding gas flow rate option 11 Push button gas test rinse hose package see 5 1 9 4 chapte...

Page 21: ...eeder remote control etc Properly close and lock all casing covers and protective caps before lifting by crane Use the correct number of hoisting equipment of the right size in the correct position Observe craning principle see figure For machines with lifting eyes always lift all lifting eyes simultaneously When using retrofitted craning frames etc always use at least two lifting points positione...

Page 22: ...o 90 at 20 C 5 1 2 2 Transport and storage Storage in an enclosed space temperature range of the ambient air 30 C to 70 C Relative air humidity Up to 90 at 20 C 5 1 3 Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Keep the cooling air inlet and outlet clear Observe the minimum distance of 0 5 m from obstacles 5 1 4...

Page 23: ...verview of coolants Do not mix different coolants When changing the coolant the entire volume of liquid must be changed Dispose of the coolant in accordance with local regulations and the material safety data sheets German waste code number 70104 May not be disposed of in household waste Prevent entry into sewers Absorb with liquid binding material sand gravel acid binding agents universal binding...

Page 24: ...oolant to 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 without bubbles With frequent changes of torch and during the initial filling process the cooling unit tank should be topped up as necessary The level of coolant must never fall below the mi...

Page 25: ... 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 parallel with a distance of 20 cm to avoid HF sparkover Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences Always keep leads as short as possible For optimum welding results max 30 m welding lead intermediate hose...

Page 26: ...ors damage machines and electronic devices and cause overheating of components leading to fire Check that all welding current connections are firmly secured and electrical connections are in perfect condition Set up attach or suspend all conductive power source components such as casing transport vehicles and crane frames so they are insulated Do not place any other electronic devices such as dril...

Page 27: ...checked by an electrician on a regular basis When operating the generator always ensure it is earthed as stipulated in the operating instructions The network created must be suitable for operating machines according to protection class I 5 1 8 1 Mains configuration The machine may be connected to a three phase system with four conductors and an earthed neutral conductor a three phase system with t...

Page 28: ...s supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch being destroyed Always re fit the yellow protective cap when not using the shielding gas connection All shielding gas connections must be gas tight 5 1 9 1 Pressure regulator connection Figure 5 7 Item Symb...

Page 29: ...installation 099 005425 EW501 14 07 2016 29 5 1 9 2 Shielding gas hose connection Figure 5 8 Item Symbol Description 0 1 Connecting nipple G shielding gas connection Connect crown nut of the shielding gas line to the G connecting nipple ...

Page 30: ...n is generally found near a wire feeder Shielding gas flows for around 25 seconds or until the button is pressed again If the shielding gas setting is too low or too high this can introduce air to the weld pool and may cause pores to form Adjust the shielding gas quantity to suit the welding task Setting instructions Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11...

Page 31: ...an be used to switch the display between welding voltage welding performance and gas flow rate option What is shown on the displays depends among other things on the selected welding procedure and the machine state welding power saving mode machine error MIG MAG welding Parameter Nominal values Actual values Hold values Welding current Wire feed speed Welding voltage Welding performance MMA weldin...

Page 32: ...g 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 inserted in the torch Recommendation Use a steel liner when welding hard unalloyed wire electrodes steel Use a chrome nickel liner when welding hard high alloy wire electrodes CrNi Use a liner to weld or braze soft wire electrodes...

Page 33: ... 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 welding torch control lead etc 6 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and torch trigger integrated 7 Welding current cable polarity selection Welding curr...

Page 34: ...ng 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 additional control cables only Where applicable Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant re...

Page 35: ...g in an unpredictable manner Welding wire can be conveyed at very high speeds and if conveyed incorrectly may escape in an uncontrolled manner and injure persons Before mains connection set up the complete wire guide system from the wire spool to the welding torch Check wire guide at regular intervals Keep all casing covers or protective caps closed during operation 5 3 2 1 Open the protective fla...

Page 36: ...tly fasten the wire spool to the wire spool support Before you start working always check the wire spool is securely fastened Standard D300 wire spool holder can be used Adapters see 9 chapter are required when using standardised basket coils DIN 8559 Figure 5 12 Item Symbol Description 0 1 Carrier pin For fixing the wire spool 2 Knurled nut For fixing the wire spool Loosen knurled nut from spool ...

Page 37: ...ixing 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 Fold the closure brackets outwards by 90 Unfasten pressure units and fold out clamping units and pressure rollers will automatically flip upwards Remove the wire feed rollers from the roller support Sel...

Page 38: ...MM EFEED see 10 chapter Wire feed roller overview table Material Diameter Colour 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 8 110 Light green 3 2 125 purple Aluminium 0 8 030 bichrome white yellow U groove 0 9 1 0 035 040 blue 1 2 045 red 1 6 06...

Page 39: ...still slip through if the wire spool jams Set the contact pressure of the front rollers in wire feed direction to a higher value The inching speed is infinitely adjustable by simultaneously pressing the wire inching push button and turning the wire speed rotary knob The left display shows the wire feed speed selected the right display shows the current motor current of the wire feed mechanism Figu...

Page 40: ...be found on a sticker near the wire drive Version 1 left hand mounting Version 2 right hand mounting Figure 5 15 Automatic inching stop Touch the welding torch against the workpiece during inching Inching of the welding wire will stop as soon it touches the workpiece 5 3 2 5 Spool brake setting Figure 5 16 Item Symbol Description 0 1 Allen screw Securing the wire spool retainer and adjustment of t...

Page 41: ... The operating point setting can also be made with the accessory components R11 RG11 remote control Up Down torch with two rockers 2 U D You will find an overview of accessory components in the Accessories chapter See the operating instructions for the machine in question for a more detailed description of the individual machines and their functions see 9 chapter ...

Page 42: ...rease value harder arc Decrease value softer arc Gas pre flow time Gas post flow time Correct wire burn back If too high a value is set a large ball will form at the tip of the wire electrode bad re ignition or the wire electrode sticks to the contact tip If too low a value is set the wire electrode sticks to the weld pool Increase value increase wire burn back Decrease value decrease wire burn ba...

Page 43: ...on of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I Welding output Wire electrode is being conveyed Wire creep Wire burn back Gas pre flows Gas post flows Non latched Latched t Time PSTART Ignition program PA Main program PEND End program ...

Page 44: ...ng 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 Step 2 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses ...

Page 45: ...A Step 2 Release torch trigger no effect Step 3 Press torch trigger no effect Step 4 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses 5 3 6 Standard MIG MAG torch The MIG welding torch trigger is essentially used to start and stop the welding process Operating elements Functions Torch trigger Start stop welding 5 ...

Page 46: ...isk of being crushed or burnt When replacing spent or new stick electrodes Switch off machine at the main switch Wear appropriate safety gloves Use insulated tongs to remove spent stick electrodes or to move welded workpieces and Always put the electrode holder down on an insulated surface ...

Page 47: ...t welding current 4 Connection socket welding current Insert cable plug of the electrode holder into either the or welding current connection socket and lock by turning to the right Insert cable plug of the workpiece lead into either the or welding current connection socket and lock by turning to the right Polarity depends on the instructions from the electrode manufacturer given on the electrode ...

Page 48: ...e improves the ignition of the stick electrodes using an increased ignition current a Hotstart time b Hotstart current I Welding current t Time Figure 5 24 5 4 5 Antistick Anti stick prevents the electrode 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 overheat...

Page 49: ...molten metal is blown out with compressed air Special electrode holders with a compressed air connection and carbon electrodes are required for gouging Figure 5 26 Item Symbol Description 0 1 Workpiece 2 Connection socket welding current 3 Gouging torch 4 Connection socket welding current Insert the gouging torch cable plug into the welding current connection socket and lock in place by turning to...

Page 50: ...Design and function MMA welding 50 099 005425 EW501 14 07 2016 5 4 7 Welding task selection Figure 5 27 ...

Page 51: ...lexibility 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 special parameters can deviate between the machine controls used in the welding system also see the relevant standard operating instructions If required the special parameters can be reset to the f...

Page 52: ... tapping start Ex works 1 latched tapping start possible Support for wire feeders with voltage sensing 0 Function switched off 1 Function switched on ex works Remote control encoding Frc 0 Automatic remote control detection ex works 2 Remote control encoding for accessory components with a single rotary knob only 9 Remote control encoding for accessory components with a single pair of buttons or a...

Page 53: ...tly increased to a ramp function to 6 0 m min The ramp time can be set between two ranges During wire inching the speed can be changed by means of the welding parameter setting rotary dial Changing the speed has no effect on the ramp time Latched special latched tap start P9 In latched tap start operating mode it is possible to switch straight to the second step by tapping the torch trigger it is ...

Page 54: ... or change the parameters by turning the Welding voltage rotary knob EXIT Exit the menu Press the Push button parameter selection right push button switch machine off and on again Enter Exit l 0 l 0 Figure 5 30 Display Setting selection Lead resistance 1 Lead resistance for the first welding circuit 0 mΩ 60 mΩ 8 mΩ ex works Only qualified service personnel may change the parameters Time controlled...

Page 55: ...any operating element e g tapping the torch trigger deactivates power saving mode and the machine is ready for welding again 5 7 3 Aligning the cable resistance The resistance value of the cables can be set directly or be aligned by the power source In the delivery status the cable resistance of the power source is set to 8 mOhm This value corresponds to a grounding cable of 5 m an intermediate ho...

Page 56: ...setting rotary knob Parameter rL1 must be adjusted for all machine combinations 3 Alignment measurement Applying slight 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 briefly which is used to determine and display the cable resistance The value can be be...

Page 57: ... who is able to implement the required safety procedures In the event of failure of any one of the following tests the machine must not be operated again until it has been repaired and a new test has been carried out Repair and maintenance work may only be performed by qualified authorised personnel otherwise the right to claim under warranty is void In all service matters always consult the deale...

Page 58: ... Wheels and their securing elements Transport elements strap lifting lugs handle Other general condition 6 3 1 2 Functional test Operating message safety and adjustment devices Functional test Welding current cables check that they are fitted correctly and secured Gas tubes and their switching equipment solenoid valve Gas cylinder securing elements Check correct mounting of the wire spool Check th...

Page 59: ... 4th 2021 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be collected separately The symbol depicting a waste container on wheels indicates that the equipment must be collected separately This machine is to be placed for disposal or recycling in the waste separation systems provided for this purpose According to German law law governing the distr...

Page 60: ...blocked Clean spray with anti spatter spray and replace if necessary Setting the spool brake see 5 3 2 5 chapter Check settings and correct if necessary Setting pressure units see 5 3 2 4 chapter Check settings and correct if necessary Worn wire rolls Check and replace if necessary Wire feed motor without supply voltage automatic cutout triggered by overloading Reset triggered fuse rear of the pow...

Page 61: ... defective inform Service 6 x Shielding gas error Check shielding gas supply for machines with shielding gas monitoring 7 x Secondary overvoltage Inverter error inform Service 8 x Earth fault between welding wire and earth line Separate the connection between welding wire and casing or an earthed object 9 x Fast cut out Triggered by BUSINT X11 or RINT X12 Rectify error on robot 10 x Arc interrupti...

Page 62: ...message will disappear once the error has been rectified b The error message can be reset by pressing a push button Welding machine control Push button RC1 RC2 Expert Expert 2 0 CarExpert Progress M3 11 alpha Q Concept Basic Basic S Synergic Synergic S Progress M3 71 Picomig 305 not possible c The error message can only be reset by switching the machine off and on again The shielding gas error Err...

Page 63: ...ding parameter calibration When differentiating between the welding parameters set on the wire feed unit remote control and those shown on the welding machine they can be calibrated easily with this function NAVIGATION C B A C C B C B C B C B B A A C C C C A A A EXIT ENTER l 0 Figure 7 1 ...

Page 64: ...ant 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 is located as deep as possible inside the system close to the coolant tank Figure 7 2 ...

Page 65: ...fuse safety fuse slow blow 3 x 25 A Mains connection lead H07RN F4G6 Max connected load 13 9 kVA 15 0 kVA Recommended generator rating 20 3 kVA cos efficiency 0 99 90 Ambient temperature 25 C to 40 C Machine cooling torch cooling Fan AF gas Workpiece lead 70 mm Insulation class protection classification H IP 23 EMC class A Safety identification Other standards used IEC 60974 1 5 10 Wire spool diam...

Page 66: ...07RN F4G6 Max connected load 17 2 kVA 18 2 kVA Recommended generator rating 24 6 kVA cos efficiency 0 99 90 Ambient temperature 25 C to 40 C Machine cooling torch cooling Fan AF gas Workpiece lead 70 mm Insulation class protection classification H IP 23 EMC class A Safety identification Other standards used IEC 60974 1 5 10 Wire spool diameter Standardized wire spools up to 300 mm Wire feed speed ...

Page 67: ... 0 99 90 Ambient temperature 25 C to 40 C Machine cooling torch cooling Fan AF gas or water Workpiece lead 70 mm Insulation class protection classification H IP 23 EMC class A Safety identification Cooling capacity at 1 l min 1500 W Max flow rate 5 l min Max coolant outlet pressure 3 5 bar Tank capacity 12 l Wire feed speed 0 5 m min to 25 m min Standard roll installation 1 0 mm 1 2 mm for steel w...

Page 68: ...erature 25 C to 40 C Machine cooling torch cooling Fan AF gas or water Workpiece lead 70 mm Insulation class protection classification H IP 23 EMC class A Safety identification Other standards used IEC 60974 1 2 5 10 Cooling capacity at 1 l min 1500 W Max flow rate 5 l min Max coolant outlet pressure 3 5 bar Tank capacity 12 l Wire spool diameter Standardized wire spools up to 300 mm Wire feed spe...

Page 69: ...ent temperature 25 C to 40 C Machine cooling torch cooling Fan AF gas or water Workpiece lead 95 mm Insulation class protection classification H IP 23 EMC class A Safety identification Other standards used IEC 60974 1 2 5 10 Cooling capacity at 1 l min 1500 W Max flow rate 5 l min Max coolant outlet pressure 3 5 bar Tank capacity 12 l Wire feed speed 0 5 m min to 25 m min Standard roll installatio...

Page 70: ...6 00000 KF 37E 200 Coolant 20 C 200 l 094 006256 00001 SPL Sharpener for plastic liners 094 010427 00000 HC PL Hose cutter 094 016585 00000 9 2 Remote control connection cable Type Designation Item no R11 19POL Remote control 090 008601 00502 RG11 19POL 5M Remote control 090 008107 00000 RA5 19POL 5M Remote control e g connection cable 092 001470 00005 RA10 19POL 10M Remote control e g connection ...

Page 71: ... 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 V groove for steel stainless steel and brazing 092 002770 00012 FE 4R 1 4 MM 0 052 INCH GREEN Drive roll set 37 mm 4 rolls V groove for steel stainless steel and brazing 092 002770 00014 FE 4R 1 6 MM 0 06 INCH BLACK Drive ro...

Page 72: ...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 Drive roll set 37 mm 4 rolls V groove knurled for flux cored wire 092 002848 00012 FUEL 4R 1 4 MM 0 052 INCH GREEN ORANGE Drive roll set 37 mm 4 rolls V groove knurled for flux cored wire 092 002848 ...

Page 73: ...Appendix A Setting instructions 099 005425 EW501 14 07 2016 73 11 Appendix A 11 1 Setting instructions Figure 11 1 ...

Page 74: ...Appendix B Overview of EWM branches 74 099 005425 EW501 14 07 2016 12 Appendix B 12 1 Overview of EWM branches ...

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