EWM Taurus **5 Basic S Series Operating Instructions Manual Download

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Operating instructions

Welding machine

Taurus 405 Basic S
Taurus 505 Basic S
Taurus 405 Steel Synergic S
Taurus 505 Steel Synergic S
Taurus 405 Steel puls S
Taurus 505 Steel puls S

099-005589-EW501

Observe additional system documents!

20.03.2019

Summary of Contents for Taurus **5 Basic S Series

Page 1: ...EN Welding machine Taurus 405 Basic S Taurus 505 Basic S Taurus 405 Steel Synergic S Taurus 505 Steel Synergic S Taurus 405 Steel puls S Taurus 505 Steel puls S 099 005589 EW501 Observe additional system documents 20 03 2019 ...

Page 2: ...authorised sales partners can be found at www ewm group com en specialist dealers 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 to monitor whether or n...

Page 3: ...15 3 3 4 Service documents spare parts and circuit diagrams 15 3 3 5 Calibration Validation 15 4 Machine description quick overview 16 4 1 Front view rear view 16 5 Design and function 18 5 1 Transport and installation 18 5 2 Scope of delivery 18 5 2 1 Ambient conditions 19 5 2 1 1 In operation 19 5 2 1 2 Transport and storage 19 5 3 Transport and installation 20 5 3 1 Ambient conditions 20 5 3 1 ...

Page 4: ... Connecting gouging torch 30 5 6 3 Welding task selection 30 6 Maintenance care and disposal 31 6 1 General 31 6 1 1 Cleaning 31 6 1 2 Dirt filter 31 6 2 Maintenance work intervals 32 6 2 1 Daily maintenance tasks 32 6 2 2 Monthly maintenance tasks 32 6 2 3 Annual test inspection and testing during operation 32 6 3 Disposing of equipment 33 7 Rectifying faults 34 7 1 Error messages power source 34...

Page 5: ...Contents Notes on the use of these operating instructions 099 005589 EW501 20 03 2019 5 ...

Page 6: ... 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 warning symbol The ri...

Page 7: ...itch off machine Release Switch on machine Press and hold Switch Incorrect Invalid Turn Correct Valid Numerical value adjustable Input Signal light lights up in green Navigation Signal light flashes green Output Signal light lights up in red Time representation e g wait 4 s actuate Signal light flashes red Interruption in the menu display other setting options possible Tool not required do not use...

Page 8: ...l other parts of these instructions Read and observe the operating instructions for all system components especially the safety instructions The illustration shows a general example of a welding system Figure 2 1 Item Documentation A 1 Wire feeder A 2 Conversion instructions A 3 Power source A 4 Cooling unit voltage converter tool box etc A 5 Trolley A 6 Welding torch A 7 Remote control A 8 Contro...

Page 9: ...hen taking individual power sources out of operation all mains and welding current leads must be safely disconnected from the welding system as a whole Hazard due to reverse polarity voltage Do not interconnect welding machines with pole reversing switch PWS series or machines for AC welding since a minor error in operation can cause the welding voltages to be combined which is not permitted Risk ...

Page 10: ... fire extinguishers are available in the working area Thoroughly remove any residue of flammable materials from the workpiece prior to starting to weld Only further process workpieces after they have cooled down Do not allow them to contact any flammable materials CAUTION Smoke and gases Smoke and gases can lead to breathing difficulties and poisoning In addition solvent vapour chlorinated hydroca...

Page 11: ...ied out Recommendations for reducing interference emission Mains connection e g additional mains filter or shielding with a metal tube Maintenance of the arc welding system Welding leads should be as short as possible and run closely together along the ground Potential equalization Earthing of the workpiece In cases where it is not possible to earth the workpiece directly it should be connected by...

Page 12: ...irements for connection to the public mains network High performance machines can influence the mains quality by taking current from the mains network For some types of machines connection restrictions or requirements relating to the maximum possible line impedance or the necessary minimum supply capacity at the interface with the public network Point of Common Coupling PCC can therefore apply In ...

Page 13: ...nsport the machine on level solid ground Secure add on parts using suitable equipment Risk of accidents due to incorrectly installed leads Incorrectly installed leads mains control and welding leads or intermediate hose packages can present a tripping hazard Lay the supply lines flat on the floor avoid loops Avoid laying the leads on passage ways The units are designed for operation in an upright ...

Page 14: ...cations 3 1 1 Taurus Steel Puls S MMA welding system for GMAW pulse and standard welding as a MMA welding secondary process It may be possible to expand the range of functions by using accessories see the documentation in the relevant chapter 3 1 2 Taurus Synergic S Taurus Basic S MMA welding system for GMAW standard welding as a MMA welding secondary process It may be possible to expand the range...

Page 15: ...cific declaration of conformity is included with every product 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 WARNING Do not carry out any unauthorised repairs or modifications To avoid injury and equipme...

Page 16: ...Machine description quick overview Front view rear view 16 099 005589 EW501 20 03 2019 4 Machine description quick overview 4 1 Front view rear view Figure 4 1 ...

Page 17: ...e see 5 chapter 5 Cooling air inlet 6 Machine feet 7 Key button Automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse 8 7 pole connection socket digital Wire feed unit connection 9 8 pole connection socket Cooling unit control lead 10 Cooling air outlet 11 Connection socket welding current How to connect the accessories depends on the welding procedure Please observe...

Page 18: ...cumentation to all system and accessory components 5 1 Transport and installation CAUTION Risk of accidents due to supply lines During transport attached supply lines mains leads control cables etc can cause risks e g by causing connected machines to tip over and injure persons Disconnect all supply lines before transport 5 2 Scope of delivery The delivery is checked and packaged carefully before ...

Page 19: ...hine observe maintenance intervals Avoid large amounts of smoke steam oily fumes grinding dust and corrosive ambient air 5 2 1 1 In operation Temperature range of the ambient air 10 C to 40 C 13 F to 104 F Relative humidity up to 50 at 40 C 104 F up to 90 at 20 C 68 F 5 2 1 2 Transport and storage Storage in a closed area temperature range of the ambient air 25 C to 55 C 13 F to 131 F Relative hum...

Page 20: ... place of work Safe operation of the machine must be guaranteed at all times Equipment damage due to contamination Unusually high amounts of dust acids corrosive gases or substances can damage the machine observe maintenance intervals see 6 2 chapter Avoid large amounts of smoke steam oily fumes grinding dust and corrosive ambient air 5 3 1 1 In operation Temperature range of the ambient air 25 C ...

Page 21: ...turning to the right when necessary Clean workpiece connection thoroughly and secure properly Do not use structural parts of the workpiece as welding current return lead 5 3 4 Welding torch cooling system 5 3 4 1 Cooling unit connection Figure 5 1 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 I...

Page 22: ... 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 2 Item Symbol Description 0 1 Stirrup Intermediate hose package strain relief 2 Snap hooks 3 Intermediate hose package strain ...

Page 23: ...e manufacturer Figure 5 3 Item Symbol Description 0 1 Wire 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 t...

Page 24: ...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 Fixing screws x 4 4 Fan type lock washers 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 25: ...ains plug socket and lead must be checked by a qualified 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 3 7 1 Mains configuration The machine may be connected to a three phase system with four conductors and an earthed ne...

Page 26: ... 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 package torch lead Figure 5 6 Use an individual welding lead to the workpiece for each weldin...

Page 27: ... 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 drills or angle grinders on the power source transport vehicle or crane frames unless they are ins...

Page 28: ...formation from the electrode manufacturer Figure 5 10 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 workpiece lead into the welding current connection socket and lock 5 4 2 Welding torch connection For connection description see...

Page 29: ...bol Description 0 1 Workpiece 2 Connection socket welding current 3 Connection socket welding current 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 packaging 5 5 2 Electrode holder connection For connection description see the r...

Page 30: ...or workpiece lead Figure 5 12 Item Symbol Description 0 1 Workpiece 2 Connection socket welding current 3 Connection socket welding current Insert cable plug on the workpiece lead into the welding current socket and lock by turning to the right Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging 5 6 2 Connecting gouging torch For connection descrip...

Page 31: ...ight to claim under warranty is void In all service matters always consult the dealer who supplied the machine Return deliveries of defective equipment subject to warranty may only be made through your dealer When replacing parts use only original spare parts When ordering spare parts please quote the machine type serial number and item number of the machine as well as the type designation and ite...

Page 32: ...tly tighten if necessary Remove any spatter Clean the wire feed rollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks Visual inspection Casing damage front rear and side walls Wheels and their securing elements Transport elements strap lifting lugs handle Check coolant tubes and their connections for impurities Functional test Selector switches command devic...

Page 33: ...er on wheels indicates that the equipment must be collected separately This machine has to be disposed of or recycled in accordance with the waste separation systems in use According to German law law governing the distribution taking back and environmentally correct disposal of electric and electronic equipment ElektroG used machines are to be placed in a collection system separate from unsorted ...

Page 34: ... push button c The error message can only be reset by switching the machine off and on again Category Error Possible cause Remedy a b c 3 Tacho error Error of wire feeder Check connections connections pipes Permanent overload of the wire drive Do not place the liner in tight radii check wire core for smooth movement 4 Excess temperature Power source overheated Allow the power source to cool down m...

Page 35: ...with automated machines Check the wire feeding check the connections of the load cables in the welding circuit clean corroded surfaces on the workpiece before welding if applicable 49 Arc interruption An arc interruption occurred during welding with an automated system Check wire feeding adjust welding speed 51 Emergency stop The emergency stop circuit of the power source has been activated Disabl...

Page 36: ...of multiple warnings these are displayed in sequence Document machine warning and inform service personnel if required Warning Possible cause 1 Excess temperature Shut down due to excess temperature imminent 4 Shielding gas 2 Check shielding gas supply 5 Coolant flow 3 Flow rate 0 7l min 0 18 gal min 1 6 low wire Nearly no wire left on the spool 7 CAN bus failure Wire feeder not connected automati...

Page 37: ...tion fuses Connection problems Make control lead connections and check that they are fitted correctly Loose welding current connections Tighten power connections on the torch and or on the workpiece Tighten contact tip correctly Coolant error no coolant flowing Insufficient coolant flow Check coolant level and refill if necessary Air in the coolant circuit Vent coolant circuit Wire feed problems C...

Page 38: ...e category Ⅲ Contamination level 3 Insulation class protection classification H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 4 25 C to 40 C Machine torch cooling Fan AF gas or water Mains connection cable H07RN F4G6 Workpiece lead 70 mm EMC class A Safety marking Standards used See declaration of conformity appliance documents Dimensions L x W...

Page 39: ...ection classification H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 4 25 C to 40 C Machine torch cooling Fan AF gas or water Mains connection cable H07RN F4G6 Workpiece lead 95 mm EMC class A Safety marking Standards used See declaration of conformity appliance documents Dimensions L x W x H 625 x 298 x 531 mm 24 6 x 11 7 x 20 9 inch Weight 4...

Page 40: ...ssembly kit 092 001356 00000 Trolly 35 2 2 Transport vehicle 090 008296 00000 Trolly 39 1 Transport vehicle power source 090 008708 00000 Trolly 55 5 Transport cart assembled 090 008632 00000 Trolly 55 6 Transport cart assembled 090 008825 00000 ON TR Trolly 55 Cross arm and holder for wire feeder Trolly 55 5 and Trolly 55 6 092 002700 00000 ON PS Trolly 55 5 55 6 Pivot support 092 002712 00000 ON...

Page 41: ...endix Searching for a dealer 099 005589 EW501 20 03 2019 41 10 Appendix 10 1 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide ...

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