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Design and function

MIG/MAG welding

099-005221-EW501

05.09.2016

33

5.3.2

Welding task selection

Selection of a welding task involves the interaction of the controls on the welding machine and
the wire feed unit. After the basic settings are made on the welding machine, the operating point
and other parameters can be set on the wire feed unit.

1

4

2

3

Figure 5-14

5.3.2.1 Accessory components for operating point setting

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

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Summary of Contents for Taurus 355 Basic TDM

Page 1: ...e Taurus 355 Basic TDM Taurus 405 Basic TDM Taurus 505 Basic TDM 099 005221 EW501 Observe additional system documents 05 09 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: ...ne control 22 5 1 5 Intermediate hose package strain relief 23 5 1 6 Intermediate hose package connection 24 5 1 7 Welding torch holder 25 5 1 8 Notes on the installation of welding current leads 26 5 1 8 1 Stray welding currents 27 5 1 9 Mains connection 28 5 1 9 1 Mains configuration 28 5 1 10 Shielding gas supply shielding gas cylinder for welding machine 29 5 1 10 1 Pressure regulator connecti...

Page 4: ...hly maintenance tasks 48 6 3 2 1 Visual inspection 48 6 3 2 2 Functional test 48 6 3 3 Annual test inspection and testing during operation 49 6 4 Disposing of equipment 49 6 4 1 Manufacturer s declaration to the end user 49 6 5 Meeting the requirements of RoHS 49 7 Rectifying faults 50 7 1 Checklist for rectifying faults 50 7 2 Error messages power source 51 7 3 Welding parameter calibration 53 8 ...

Page 5: ...Contents Notes on the use of these operating instructions 099 005221 EW501 05 09 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: ...ment must only be used in line with its designated purpose and by trained or expert personnel Do not improperly modify or convert the equipment Arc welding machine for gas shielded metal arc welding and MMA welding as secondary process It may be possible to expand the range of functions by using accessories see the documentation in the relevant chapter 3 1 Use and operation solely with the followi...

Page 14: ...pecific declaration of conformity is included with every product 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 electrical hazard 3 2 4 Service documents spare parts and circuit diagrams WARNING Do not carry out any unauthorised repairs or modifications To avoid injury and equip...

Page 15: ...view Front view 099 005221 EW501 05 09 2016 15 4 Machine description quick overview The device configuration shown may differ in case of an additional ex works options or retrofitting options see 9 chapter 4 1 Front view Figure 4 1 ...

Page 16: ...switch machine on off 4 Cooling air inlet 5 Machine feet 6 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 7 welding current connection socket MIG MAG welding Workpiece connection MMA welding electrode holder connection 8 Machine control see 4 3 chapter 9 Protective c...

Page 17: ...Machine description quick overview Rear view 099 005221 EW501 05 09 2016 17 4 2 Rear view Figure 4 2 ...

Page 18: ...et welding current Standard MIG MAG welding intermediate hose package 4 Connection socket welding current MIG MAG cored wire welding Welding current to wire feed torch 5 Stirrup Intermediate hose package strain relief 6 Cooling air outlet 7 8 pole connection socket Cooling unit control lead 8 4 pole connection socket Cooling unit voltage supply 9 Mains connection cable see 5 1 9 chapter 10 D sub c...

Page 19: ...MA welding 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 Rotary dial welding parameters MIG MAG setting dynamics choke effect MMA setting MMA welding current 6 Button select operating mode No function Setting is...

Page 20: ...ton 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 10 3 chapter 12 Push butto...

Page 21: ... connected when the machine is switched off Risk of accident due to improper transport of machines that must not be lifted Do not lift or suspend the machine The machine can drop and cause injuries The handles straps or brackets are suitable for transport by hand only The machine must not be suspended or lifted using a crane Read and observe the documentation to all system and accessory components...

Page 22: ...t plugs machine connections are not locked or if the workpiece connection is contaminated paint corrosion these connections and leads can heat up and cause burns when touched Check welding current connections on a daily basis and lock by turning to the right when necessary Clean workpiece connection thoroughly and secure properly Do not use structural parts of the workpiece as welding current retu...

Page 23: ...r incorrectly fitted The strain relief takes the strain from cables plugs and sockets Check the strain relief function by pulling in all directions Cables and hoses must have sufficient play when the relief cord is fully stretched Figure 5 2 Item Symbol Description 0 1 Stirrup Intermediate hose package strain relief 2 Snap hooks 3 Intermediate hose package strain relief see 5 1 5 chapter Insert th...

Page 24: ...termediate hose package 3 19 pole connection socket analogue Wire feed unit control lead connection 4 Connection socket welding current Standard MIG MAG welding intermediate hose package 5 Connection socket welding current MIG MAG cored wire welding Welding current to wire feed torch Insert the welding current cable plug into the relevant welding current connection socket and lock by turning to th...

Page 25: ...ing is part of the machine s scope of delivery Figure 5 4 Item Symbol Description 0 1 Crossmember of the transport handle 2 Torch holder 3 Fan type lock washers 4 Fixing screws x 4 Use the mounting screws to screw the torch holder onto the crossmember of the transport handle Insert the welding torch into the welding torch holder as shown ...

Page 26: ... 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 27: ...tors 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 dri...

Page 28: ...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 9 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 29: ... 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 10 1 Pressure regulator connection Figure 5 10 Item Sym...

Page 30: ...ther at the control or underneath the protective cap next to wire feeder welding voltage and wire feed motor remain switched off no unintentional arc ignition Shielding gas flows for around 25 seconds or until the button is pressed again Setting instructions Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11 5 l min MIG brazing Wire diameter x 11 5 l min MIG welding ...

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: ...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 13 Item Symbol Description 0 1 Workpiece 2 welding current connection socket MIG MAG welding Workpiece connection 3 Connection socket welding current MIG MAG cored wire welding Workpiece connection Insert the plug on the work...

Page 33: ... other parameters can be set on the wire feed unit 1 4 2 3 Figure 5 14 5 3 2 1 Accessory components for operating point setting 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 ...

Page 34: ...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 35: ...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 36: ...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 37: ...r 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 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 ...

Page 38: ...lated surface 5 4 1 Connecting the electrode holder and workpiece lead Figure 5 18 Item Symbol Description 0 1 Workpiece 2 Electrode holder 3 Connection socket 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 w...

Page 39: ...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 21 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 40: ...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 23 Item Symbol Description 0 1 Gouging torch 2 Connection socket welding current 3 Workpiece 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 41: ...able 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 factory settings see 5 5 1 1 chapter 5 5 1 Selecting changing and saving parameters ENTER Enter the menu Switch off the machine at the main switch Press and hold the operating mode push button and sw...

Page 42: ... 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 43: ...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 44: ... 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 27 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 45: ...any operating element e g tapping the torch trigger deactivates power saving mode and the machine is ready for welding again 5 6 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 46: ...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 47: ... 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 48: ... 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 49: ... 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 50: ...t tip blocked Clean spray with anti 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 replace if necessary Wire feed motor without supply voltage automatic cutout triggered by overloading Reset triggered fuse rear of the power source by pressing the key butt...

Page 51: ... 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 52: ...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 53: ...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 54: ... 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 20 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 88 Ambient temperature 25 C to 40 C Machine cooling torch cooling Fan AF gas Insulation class protection classification ...

Page 55: ... 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 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 mm2 Insulation class protection classification H IP 23 EMC class A Safety identification Other s...

Page 56: ... 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 Max connected load 24 6 kVA 25 2 kVA Recommended generator rating 34 0 kVA cos efficiency 0 99 90 Ambient temperature 25 C to 40 C Machine cooling torch cooling Fan AF gas Workpiece lead 95 mm2 Insulation class protection classification H IP 23 EMC class A Safety identificat...

Page 57: ...5 505 50 Contamination filter for air inlet 092 002698 00000 ON FC CS 405 505 Pedestal for transport with floor conveyors 092 007896 00000 ON WAK CS 405 505 Wheel assembly kit for CS 505 092 007897 00000 ON CS D Crane console transport ram protection Phoenix Taurus 405 505 092 007895 00000 9 3 Welding torch cooling system Type Designation Item no cool50 2 U40 Cooling module 090 008603 00502 9 4 Tr...

Page 58: ...Appendix A Setting instructions 58 099 005221 EW501 05 09 2016 10 Appendix A 10 1 Setting instructions Figure 10 1 ...

Page 59: ...Appendix B Overview of EWM branches 099 005221 EW501 05 09 2016 59 11 Appendix B 11 1 Overview of EWM branches ...

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