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Design and function

Notes on the installation of welding current leads

099-005341-EW501

27.01.2016

23

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

Figure 5-2

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 5-3

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Summary of Contents for Taurus 351

Page 1: ...lding machine Taurus 351 551 Synergic S MM FDG FDW 099 005341 EW501 Observe additional system documents 27 01 2016 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For det...

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: ...on 21 5 3 Machine cooling 21 5 4 Workpiece lead general 21 5 5 Notes on the installation of welding current leads 22 5 6 Welding torch cooling system 24 5 6 1 List of coolants 24 5 6 2 Maximal hose pa...

Page 4: ...1 Resetting a single JOB 42 7 3 2 Resetting all JOBs 43 7 4 Vent coolant circuit 44 8 Technical data 45 8 1 Taurus 351 Synergic S MM FDG 45 8 2 Taurus 351 Synergic S MM VRD FDG 46 8 3 Taurus 351 Syner...

Page 5: ...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 6: ...rs 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 Time...

Page 7: ...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 8: ...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 allo...

Page 9: ...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 10: ...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 11: ...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 12: ...s 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 Avoid any...

Page 13: ...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 14: ...MMA welding as secondary process It may be possible to expand the functionality by using accessories see the documentation in the relevant chapter 3 1 Use and operation solely with the following machi...

Page 15: ...is enclosed with the unit 3 3 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 16: ...erview Front view 16 099 005341 EW501 27 01 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 17: ...ecified in the relevant standard see technical data The voltage reduction device is only active on VRD machine versions 3 Ready for operation signal light Signal light on when the machine is switched...

Page 18: ...Machine description quick overview Rear view 18 099 005341 EW501 27 01 2016 4 2 Rear view 6 7 4 3 2 1 10 5 9 11 12 8 13 14 Figure 4 2...

Page 19: ...n on wire feed unit 5 Connection socket welding current MIG MAG cored wire welding Welding current to wire feed torch 6 Quick connect coupling red coolant return 7 Quick connect coupling blue coolant...

Page 20: ...ction 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 turning in clockwise di...

Page 21: ...ION Installation site The machine must not be operated in the open air and must only be set up and operated on a suitable stable and level base The operator must ensure that the ground is non slip and...

Page 22: ...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 parallel with a distance of 20 cm to avoid HF sparkove...

Page 23: ...27 01 2016 23 Use an individual welding lead to the workpiece for each welding machine Figure 5 2 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Alw...

Page 24: ...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 25: ...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 26: ...esulting network has to be suitable for operating devices according to protection class 1 5 7 1 Mains configuration The machine may be connected to a three phase system with four conductors and an ear...

Page 27: ...ece lead should be connected to the welding current socket Observe the information from the electrode manufacturer Figure 5 6 Item Symbol Description 0 1 Wire feed unit 2 Intermediate hose package 3 I...

Page 28: ...mproper handling and insufficient securing of shielding gas cylinders can cause serious injuries Secure shielding gas cylinders using the standard fastening elements on the unit chain belt The fasteni...

Page 29: ...racket Secure the shielding gas cylinder using a securing chain Figure 5 7 Item Symbol Description 0 1 Pressure regulator 2 Shielding gas cylinder 3 Output side of the pressure regulator 4 Cylinder va...

Page 30: ...3 m water cooled welding 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 b...

Page 31: ...rameter rL1 must be aligned for all machine combinations In case of welding systems with a second power circuit if two wire feeders are to be operated from a single power source for example a second a...

Page 32: ...nected to the welding current socket and the workpiece lead should be connected to the welding current socket Observe the information from the electrode manufacturer Figure 5 9 Item Symbol Description...

Page 33: ...connected to the Euro torch connector of the wire feeder only To do so the welding current lead of the intermediate hose package must be connected to the welding current connection at the rear of the...

Page 34: ...e welding current connection If fitted Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant return an...

Page 35: ...ated surface 5 13 1 Connecting the electrode holder and workpiece lead Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging Figure 5 12 Item Symbol Des...

Page 36: ...accessory components into the relevant connection socket when the machine is switched off The remote controls are operated on the 7 pole remote control connection socket digital Please note the relev...

Page 37: ...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 38: ...ch 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 guideline...

Page 39: ...ti spatter spray and replace if necessary Setting the spool brake Check settings and correct if necessary Setting pressure units Check settings and correct if necessary Worn wire rolls Check and repla...

Page 40: ...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 41: ...he 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 a...

Page 42: ...customised welding parameters that are stored will be replaced by the factory settings 7 3 1 Resetting a single JOB JOB LIST JOB LIST Figure 7 1 Display Setting selection RESET to factory settings The...

Page 43: ...2016 43 7 3 2 Resetting all JOBs JOBs 1 128 and 170 256 will be reset Custom JOBs 129 169 are maintained JOB LIST JOB LIST Figure 7 2 Display Setting selection RESET to factory settings The RESET will...

Page 44: ...upling 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 sys...

Page 45: ...00 DC 350 A Load alternation 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 25 A M...

Page 46: ...circuit voltage 79 V Open circuit voltage VRD 24 V 79 V Mains voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 25 A Mains connection lead H07RN F4G6 Maximu...

Page 47: ...ow blow 3 x 25 A Mains connection lead H07RN F4G6 Maximum connected load 15 4 kVA 10 9 kVA 14 3 kVA Recommended generator rating 20 8 kVA cos efficiency 0 99 90 Insulation class protection classificat...

Page 48: ...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 32 A Mains connection lead H07RN F4G6 Maximum connected load 18 2 k...

Page 49: ...ow blow 3 x 32 A Mains connection lead H07RN F4G6 Maximum connected load 18 5 kVA 13 5 kVA 17 5 kVA Recommended generator rating 25 0 kVA cos efficiency 0 99 90 Insulation class protection classificat...

Page 50: ...lding 4 min break 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 25 A Mains connection lead H07RN F4G6 Maximum connected...

Page 51: ...fety fuse slow blow 3 x 25 A Mains connection lead H07RN F4G6 Maximum connected load 22 2 kVA 16 3 kVA 21 1 kVA Recommended generator rating 29 7 kVA Cos efficiency 0 99 90 Insulation class protection...

Page 52: ...C 550 A Load alternation 10 min 60 DC 6 min welding 4 min break 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 32 A Mains...

Page 53: ...00 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 32 A Mains connection lead H07RN F4G6 Maximum connected load 29 5 kVA 22 6 kVA 29 2 kVA Recommended generator rating 39 8 kVA Cos...

Page 54: ...n Item no AK300 Wire spool adapter K300 094 001803 00001 TYP 1 Frost protection tester 094 014499 00000 KF 23E 10 Coolant 10 C 9 3 l 094 000530 00000 KF 23E 200 Coolant 10 C 200 litres 094 000530 0000...

Page 55: ...port 092 002112 00000 and 092 002113 00000 092 002117 00000 ON Hose FR Mount Optional holder for tubes and remote control for machines without pivot support 092 002116 00000 ON Filter T P Retrofit opt...

Page 56: ...www ewm cn info ewm cn info ewm group cn EWM HIGHTEC WELDING GmbH Wiesenstra e 27b 4812 Pinsdorf Austria Tel 43 7612 778 02 0 Fax 20 www ewm austria at info ewm austria at EWM HIGHTEC WELDING UK Ltd...

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