EWM Taurus 355 Synergic S HP MM TKW Operating Instructions Manual Download Page 106

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Rectifying faults

Vent coolant circuit

106

099-005444-EW501

17.03.2015

7.5

Vent coolant 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 7-3

Summary of Contents for Taurus 355 Synergic S HP MM TKW

Page 1: ...ing instructions Welding machine Taurus 355 Synergic S HP MM TKW 099 005444 EW501 17 03 2015 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm gro...

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: ...rview 16 4 1 Front view 16 4 2 Rear view 18 4 3 Operating elements in the machine 20 4 4 Machine control Operating elements 22 4 4 1 Functional sequence 24 5 Design and function 25 5 1 General 25 5 2...

Page 4: ...Main program A mode 66 5 10 10 1Selecting parameters program A 68 5 10 11 MIG MAG automatic cut out 68 5 10 12 Standard MIG MAG torch 69 5 10 13 MIG MAG special torches 69 5 10 13 1Program and Up dow...

Page 5: ...ctifying faults 102 7 1 Checklist for rectifying faults 102 7 2 Error messages 103 7 3 Error messages power source 103 7 4 Resetting JOBs welding tasks to the factory settings 105 7 4 1 Resetting a si...

Page 6: ...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 7: ...rve Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exi...

Page 8: ...hocks 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 Swit...

Page 9: ...accidents if these safety instructions are not observed Non observance of these safety instructions is potentially fatal Carefully read the safety information in this manual Observe the accident preve...

Page 10: ...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 11: ...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 12: ...itable for transport by hand only The machine may not be lifted by crane or suspended CAUTION Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself d...

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: ...rootArc Short arc with perfect weld modelling capabilities for effortless gap bridging and positional welding 3 1 1 3 MIG MAG cored wire welding Welding with cored wire electrodes consisting of a meta...

Page 15: ...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 16: ...005444 EW501 17 03 2015 4 Machine description quick overview 4 1 Front view The maximum possible machine configuration is given in the text description If necessary the optional connection may need to...

Page 17: ...upply to the welding torch 9 Quick connect coupling red Coolant return from the welding torch 10 Cooling air inlet 11 Coolant tank 12 Coolant tank cap 13 Welding current cable polarity selection Weldi...

Page 18: ...Machine description quick overview Rear view 18 099 005444 EW501 17 03 2015 4 2 Rear view Figure 4 2...

Page 19: ...nlet 5 Cooling air outlet 6 Machine feet 7 Automatic cut out of coolant pump key button press to reset a triggered fuse 8 Mains connection cable See 5 7 Mains connection chapter 9 External wire feed i...

Page 20: ...Machine description quick overview Operating elements in the machine 20 099 005444 EW501 17 03 2015 4 3 Operating elements in the machine Figure 4 3...

Page 21: ...button automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse 2 Welding torch function changeover switch special welding torch required Changing over programs or JOBs In...

Page 22: ...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 23: ...ary 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 24: ...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 25: ...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 26: ...is no accessory component being operated on that connection The cap must be replaced if faulty or if lost 5 2 Installation WARNING Risk of accident due to improper transport of machines that may not b...

Page 27: ...re 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 other objects to get into the machine 5 4 Workpiece lead ge...

Page 28: ...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 29: ...17 03 2015 29 Use an individual welding lead to the workpiece for each welding machine Figure 5 3 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Alw...

Page 30: ...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 31: ...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 32: ...uctions The resulting 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 conducto...

Page 33: ...rch 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...

Page 34: ...e package Shielding gas flows continuously until the Gas Test button is pressed again 5 8 3 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diame...

Page 35: ...s part of the machine s scope of delivery Figure 5 8 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...

Page 36: ...lectrodes or aluminium materials Preparation for connecting welding torches with a plastic core Push forward the capillary tube on the wire feed side in the direction of the Euro torch connector and r...

Page 37: ...welding current connection socket 8 welding current connection socket MIG MAG welding Workpiece connection 9 Workpiece Insert the central plug for the welding torch into the central connector and scre...

Page 38: ...come 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 w...

Page 39: ...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 Fo...

Page 40: ...r Colour code Groove form mm inch Steel Stainless steel Brazing 0 8 030 monochrome white V groove 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...

Page 41: ...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 hi...

Page 42: ...rive catches the welding wire and automatically guides it to the welding torch outlet A prerequisite for the automatic inching process is the correct preparation of the wire guide especially in the ca...

Page 43: ...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 44: ...arameters can be modified as required in the configuration menu on the control or using the PC300 NET welding parameter software 5 10 4 Welding task selection 5 10 4 1 Basic welding parameters Select...

Page 45: ...elds without weaving superPuls in combination with EWM welding processes offers many possibilities Welding performance can be represented as average value ex works or solely as program A value If the...

Page 46: ...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 47: ...rrent 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 be welded Mat...

Page 48: ...the machine in question for a more detailed description of the individual machines and their functions See 9 Accessories chapter 5 10 6 MIG MAG welding data display To the left and right of the contr...

Page 49: ...1 99 251 12 0 252 12 0 253 6 0 You can make use of these properties after selecting the forceArc process See 5 10 4 Welding task selection chapter As with pulse arc welding it is important to make sur...

Page 50: ...mation 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 CO2 2...

Page 51: ...lso be changed if required 5 10 8 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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...ecial Figure 5 33 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 5...

Page 64: ...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 65: ...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 66: ...lowing 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...

Page 67: ...igure 5 37 Example 3 Aluminium welding of different sheet metal thicknesses non latched or latched special Figure 5 38 Up to 16 programs PA0 to PA15 can be defined An operating point wire speed arc le...

Page 68: ...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 69: ...torch function changeover switch special welding torch required Changing over programs or JOBs Infinite adjustment of welding performance 5 10 13 2Switching between Push Pull and intermediate drive DA...

Page 70: ...ar setting 5 10 15 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 71: ...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 72: ...ch enables polarity selection TIG Connection socket for welding current 7 Connection socket welding current TIG welding Workpiece connection 8 Workpiece Insert the central plug for the welding torch i...

Page 73: ...s set Setpoint setting 5 11 4 TIG arc ignition 5 11 4 1 Liftarc ignition Figure 5 42 The arc is ignited on contact with the workpiece a Carefully place the torch gas nozzle and tungsten electrode tip...

Page 74: ...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 Special non latched...

Page 75: ...cial non latched Figure 5 44 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 76: ...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 77: ...n 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 78: ...t welding current MMA welding Workpiece connection 3 welding current connection socket MMA welding electrode holder connection 4 Park socket polarity selection plug Retainer for the polarity selection...

Page 79: ...machine adopts the required setting after approx 3 seconds 5 12 2 1 Welding current setting The welding current is normally set using the Wire speed rotary dial Operating element Action Result Display...

Page 80: ...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 over...

Page 81: ...f the accessory components 5 14 Interfaces for automation DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repaired or modif...

Page 82: ...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 83: ...he key switch is only available for machines which are fitted with the OW KL XX5 option ex works To protect against unauthorised or unintentional adjustment of the welding parameters on the machine th...

Page 84: ...ter selection button and switch the machine on again at the same time NAVIGATION Navigate the menu Select parameters by turning the welding parameter setting rotary dial Set or change the parameters b...

Page 85: ...ks 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 and sp lat...

Page 86: ...functions are available and activated the pulsed arc welding process is always executed in the main program PA ex factory Predefined absolute value for relative programs Start program PSTART down slop...

Page 87: ...n pulse Up down operation Change 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 selectio...

Page 88: ...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 89: ...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 90: ...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 91: ...flow time elapses 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 not necessary for cu...

Page 92: ...e As for the actual JOB list JOB changeover is also possible with accessory components such as the PowerControl 2 torch Creating user defined JOB lists A consecutive memory range where accessories suc...

Page 93: ...on By repeating the last two steps the same source JOB can be copied to multiple target JOBs If the control does not register any user activity for longer than 5 seconds the parameter display is shown...

Page 94: ...the welding parameters manually Selection of JOB 0 can be prevented via the key switch or with the block program 0 parameter P2 Key switch position 0 or special parameter P2 0 JOB 0 is blocked Key sw...

Page 95: ...ogram PA ex factory Function inactive P20 0 Predefined execution of the pulsed arc welding process in the PA program is disabled Predefined absolute value for relative programs P21 Start program PSTAR...

Page 96: ...ad resistance for the first welding circuit 0 m 60 m 8 m ex works Lead resistance 2 Lead resistance for the second welding circuit 0 m 60 m 8 m ex works Only qualified service personnel may change the...

Page 97: ...oled 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 by means of re...

Page 98: ...re 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...

Page 99: ...the type designation and item number of the spare part 6 1 General When used in the specified environmental conditions and under normal operating conditions this machine is largely maintenance free an...

Page 100: ...Annual test inspection and testing during operation The welding machine may only be tested by competent capable personsl A capable person is one who because of his training knowledge and experience i...

Page 101: ...d for this purpose According to German law law governing the distribution taking back and environmentally correct disposal of electric and electronic equipment ElektroG from 16 03 2005 used machines a...

Page 102: ...ontact tip blocked Clean spray with anti spatter spray and replace if necessary Setting the spool brake See 5 10 2 5 Spool brake setting chapter Check settings and correct if necessary Setting pressur...

Page 103: ...Spe x Wire feeder speedometer error Check the wire feeder speedometer is not issuing a signal M3 51 defective inform Service Error 6 gas x Shielding gas error Check shielding gas supply for machines w...

Page 104: ...drive Error 56 no Pha x Mains phase failure Check mains voltages Legend for categories error reset a The error message will disappear once the error has been rectified b The error message can be reset...

Page 105: ...1 Display Setting selection Reset to factory settings The RESET will be done after pressing the button The menu will be ended when no changes are done after 3 sec JOB number example The shown JOB will...

Page 106: ...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 107: ...ts Do not touch any live parts in or on the machine Connection cables and leads must be free of faults Switching off alone is not sufficient Place welding torch and stick electrode holder on an insula...

Page 108: ...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 F4G2 5 Max...

Page 109: ...ontrol 10 programs 090 008088 00000 R50 7POL Remote 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 000...

Page 110: ...549 00000 9 4 Computer communication Type Designation Item no PC300 Net PC300 Net welding parameter software kit incl cable and SECINT X10 USB interface 090 008777 00000 FRV 7POL 5 m Extension connect...

Page 111: ...t 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...

Page 112: ...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 113: ...Appendix A JOB List 099 005444 EW501 17 03 2015 113 11 Appendix A 11 1 JOB List Figure 11 1...

Page 114: ...Appendix B Overview of EWM branches 114 099 005444 EW501 17 03 2015 12 Appendix B 12 1 Overview of EWM branches...

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