EWM Taurus 355 Synergic S TDM Operating Instructions Manual Download

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Operating instructions

Welding machine

Taurus 355 Synergic S TDM
Taurus 405 Synergic S TDM
Taurus 505 Synergic S TDM

099-005219-EW501

Observe additional system documents!

10.06.2013

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*Details for ewm-warranty

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Summary of Contents for Taurus 355 Synergic S TDM

Page 1: ...nergic S TDM Taurus 405 Synergic S TDM Taurus 505 Synergic S TDM 099 005219 EW501 Observe additional system documents 10 06 2013 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warranty www ewm group com ...

Page 2: ...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 to monitor whether or not these instructions or the conditions and methods are observed during installation operation usage and maintenance of the equipment An incorrectly performed installation can result in materia...

Page 3: ...d circuit diagrams 15 3 3 5 Calibration Validation 15 4 Machine description quick overview 16 4 1 Front view 16 4 2 Rear view 18 5 Design and function 20 5 1 General 20 5 2 Machine cooling 21 5 3 Workpiece lead general 21 5 4 Installation 22 5 5 Notes on the installation of welding current leads 23 5 6 Welding torch cooling system 24 5 6 1 Cooling module connection 24 5 7 Mains connection 25 5 7 1...

Page 4: ...ration to the end user 37 6 5 Meeting the requirements of RoHS 37 7 Rectifying faults 38 7 1 Checklist for rectifying faults 38 7 2 Error messages power source 39 7 3 Resetting JOBs welding tasks to the factory settings 41 7 3 1 Resetting a single JOB 41 7 3 2 Resetting all JOBs 42 7 4 Vent coolant circuit 43 8 Technical data 44 8 1 Taurus 355 TDM 44 8 2 Taurus 405 TDM 45 8 3 Taurus 505 TDM 46 9 A...

Page 5: ...ol 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 warning symbol The risk is explained using a symbol on the edge of the page CAUTION Working and operating procedures which must be followed precisely to avoid damaging or destroying t...

Page 6: ...ress Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exit the menu 4 s Time display example wait 4s press Interruption in the menu display other setting options possible Tool not required do not use Tool required use ...

Page 7: ...ks 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 Switching off alone is not sufficient Place welding torch and stick electrode holder on an insulated surface The unit should only be opened by specialist staff after the mains plug has been unplugged Only we...

Page 8: ...w to come into contact with flammable material Connect welding leads correctly Risk of 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 prevention regulations in your country Inform persons in the working area that they must observe the regulations Dange...

Page 9: ...g 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 securely connected and check regularly Always ensure a proper and secure electrical connection to the workpiece Set up attach or suspend all conductive power source components like casing transport vehi...

Page 10: ...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 following see also EN 60974 10 Appendix A Mains control signal and telecommunication lines Radios and televisions Computers and other control systems Safety equipment The health of neighbouring persons especi...

Page 11: ...uitable 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 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 equipme...

Page 12: ...ities 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 ambient conditions 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 distan...

Page 13: ...if the equipment is not used correctly No liability is accepted for any damages arising from improper usage The equipment must only be used in line with proper usage and by trained or expert staff Do not modify or convert the equipment improperly 3 1 Use and operation solely with the following machines NOTE A suitable wire feed unit system component is required in order to operate the welding mach...

Page 14: ...g leads ideal for simple reliable root welding without pool support easy gap bridging 3 2 2 TIG Liftarc welding TIG welding process with arc ignition by means of workpiece contact 3 2 3 MMA welding Manual arc welding or for short MMA welding It is characterised by the fact that the arc burns between a melting electrode and the molten pool There is no external protection any protection against the ...

Page 15: ...ed 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 electrical hazard 3 3 4 Service documents spare parts and circuit diagrams DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repaired or mod...

Page 16: ...005219 EW501 10 06 2013 4 Machine description quick overview NOTE The maximum possible machine configuration is given in the text description If necessary the optional connection may need to be retrofitted see Accessories chapter 4 1 Front view Figure 4 1 ...

Page 17: ...hine is switched on and ready for operation 3 Main switch machine on off 4 Cooling air inlet 5 Machine feet 6 Connection socket welding current MIG MAG cored wire welding Workpiece connection TIG welding Workpiece connection MMA welding Workpiece connection 7 welding current connection socket MIG MAG welding Workpiece connection MMA welding electrode holder connection 8 Torch holder ...

Page 18: ...Machine description quick overview Rear view 18 099 005219 EW501 10 06 2013 4 2 Rear view Figure 4 2 ...

Page 19: ... Wire feed unit connection 4 Connection socket welding current Standard MIG MAG welding intermediate hose package 5 Connection socket welding current Connection for welding current plug from intermediate hose package MIG MAG flux cored wire welding TIG welding 6 Stirrup Intermediate hose package strain relief 7 Cooling air outlet 8 8 pole connection socket Cooling unit control lead 9 4 pole connec...

Page 20: ...tact with non insulated connection sockets or connectors Always place torches and electrode holders on an insulated surface Risk of burns on the 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 turning in clockwise direction if necessary Risk from ele...

Page 21: ...he power components 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 other objects to get into the machine 5 3 Workpiece lead general CAUTION Risk of burns due to incorrect connection of the workpiece lead Paint rust and dirt on the connection restrict the po...

Page 22: ... machine may not be lifted by crane or suspended Depending on machine type equipment for lifting by crane or use while suspended is available as a retrofitting option see chapter Accessories CAUTION 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 leve...

Page 23: ...as close together as possible B Keep the welding lead and hose packages of each welding machine separate with an installation distance of at least 15 cm C Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops D Use an individual welding lead to the workpiece for each welding machine Connect the work clamp close to the welding point E Always keep leads as...

Page 24: ...nstructions for the cooling unit Figure 5 2 Item Symbol Description 0 1 4 pole connection socket Cooling unit voltage supply 2 8 pole connection socket Cooling unit control lead 3 Cooling module Insert and lock the 8 pole control lead plug on the cooling unit into the 8 pole connection socket on the welding machine Insert and lock the 4 pole supply plug on the cooling unit into the 4 pole connecti...

Page 25: ...network has to be suitable for operating devices according to protection class 1 5 7 1 Mains configuration NOTE The machine may be connected to a three phase system with four conductors and an earthed neutral conductor a three phase system with three conductors of which any one can be earthed e g the outer conductor Figure 5 3 Legend Item Designation Colour code L1 Outer conductor 1 brown L2 Outer...

Page 26: ...e tube package may be damaged if the strain relief is missing or 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 4 Item Symbol Description 0 1 Stirrup Intermediate hose package strain relief 2 Snap hooks 3 Inte...

Page 27: ...e feed unit 2 Intermediate hose package 3 7 pole connection socket digital Wire feed unit connection 4 Connection socket welding current Standard MIG MAG welding intermediate hose package 5 Connection socket welding current Connection for welding current plug from intermediate hose package MIG MAG flux cored wire welding TIG welding Insert the end of the hose package through the strain relief of t...

Page 28: ...elding gas supply An unhindered shielding gas 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 NOTE Before co...

Page 29: ...ng is part of the machine s scope of delivery Figure 5 7 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 30: ...rrent lead should be connected 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 8 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 Inse...

Page 31: ...ted to the wire feeder Observe the operating instructions for the wire feeder system component 5 12 2 Connection for workpiece lead Figure 5 9 Item Symbol Description 0 1 Workpiece 2 Connection socket welding current TIG welding Workpiece connection Insert the plug on the welding current lead into the welding current connection socket and lock ...

Page 32: ...ed surface 5 13 1 Connecting the electrode holder and workpiece lead Figure 5 10 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 wel...

Page 33: ... cause damage to the machines Observe the operating instructions for the welding machine or wire feed unit Switch off the welding machine before connecting NOTE Please note the relevant documentation of the accessory components The operation of the remote control and its settings are directly dependent on the configuration of the respective welding machine or wire feed unit The settings are define...

Page 34: ... destroyed due to high frequency ignition pulses Interface SECINT X10USB must be connected between the PC and the welding machine The connection must only be made using the cables supplied do not use any additional extension cables NOTE Please note the relevant documentation of the accessory components PC 300 welding parameter software Create all welding parameters quickly on the PC and easily tra...

Page 35: ...ove the torch from the hose package Never clamp the torch body in a vice or similar as this can cause the torch to be irreparably destroyed If damage occurs to the torch or to the hose package which cannot be corrected as part of the maintenance work the entire torch must be returned to the manufacturer 6 2 1 Daily maintenance tasks Check that all connections and wearing parts are hand tight and t...

Page 36: ...mpanying supplementary sheets Machine and Company Data Maintenance and Testing Warranty A periodic test according to IEC 60974 4 Periodic inspection and test has to be carried out In addition to the regulations on testing given here the relevant local laws and regulations must also be observed 6 3 Maintenance work DANGER Do not carry out any unauthorised repairs or modifications To avoid injury an...

Page 37: ...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 are to be placed in a collection system separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private households...

Page 38: ...ool brake see Setting the spool brake chapter Check settings and correct if necessary Setting pressure units see Inching wire electrodes 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 power source by pressing the key button Kinked hose pa...

Page 39: ...Wire feeder speedometer error Check the wire feeder speedometer is not issuing a signal M3 00 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 Inverter error inform Service Error 8 no PE x Earth fault between welding wire and earth line Phoenix 330 only Separate the connection ...

Page 40: ... error message can be reset by pressing a key button Welding machine control Key button RC1 RC2 Expert 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 6 can be reset by pressing the Welding parameters key button ...

Page 41: ... to the factory settings 7 3 1 Resetting a single JOB EXIT RESET ENTER 3 s JOB LIST m min 3 s JOB LIST 3 s Figure 7 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 be set to ex works ...

Page 42: ...OBs NOTE All customised welding parameters that are stored will be replaced by the factory settings ENTER 3 s EXIT RESET 3 s JOB LIST m min JOB LIST 3 s Figure 7 2 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 ...

Page 43: ... circuit NOTE 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 ...

Page 44: ...0 300 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 Mains connection lead H07RN F4G4 Max connected load 13 9 kVA 10 6 kVA 15 0 kVA Recommended generator rating 20 2 kVA cosϕ 0 99 Insulation class protection classification H IP 23 Ambient temperature 25 C to...

Page 45: ...en 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 35 A Mains connection lead H07RN F4G4 Max connected load 13 1 kVA 17 2 kVA 18 2 kVA Recommended generator rating 25 0 kVA cosϕ 0 99 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine torch cooling Fan gas Workpiece lead 70 mm2 Dimensio...

Page 46: ...nation 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 35 A Mains connection lead H07RN F4G4 Max connected load 18 9 kVA 24 6 kVA 25 3 kVA Recommended generator rating 35 0 kVA cosϕ 0 99 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine torc...

Page 47: ...e transport ram protection Phoenix Taurus 405 505 092 007895 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 9 3 Welding torch cooling system Type Designation Item no cool50 2 U40 Cooling module 090 008603 00502 9 4 Transport systems Type Designation Item no ON TR Trolly 55 2 2 Cross arm and holder...

Page 48: ...ation Item no PC300 Net PC300 Net welding parameter software kit incl cable and SECINT X10 USB interface 090 008777 00000 CD PC300 Net update PC300 Net Update on CD ROM 092 008172 00001 FRV 7POL 5 m Extension connecting cable 092 000201 00003 FRV 7POL 10 m Extension connecting cable 092 000201 00000 FRV 7POL 20 m Extension connecting cable 092 000201 00001 QDOC9000 V2 0 Set consisting of interface...

Page 49: ...Appendix A JOB List 099 005219 EW501 10 06 2013 49 10 Appendix A 10 1 JOB List Figure 10 1 ...

Page 50: ...Appendix B Overview of EWM branches 50 099 005219 EW501 10 06 2013 11 Appendix B 11 1 Overview of EWM branches ...

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