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Design and function

MIG/MAG welding

099-005215-EW501

29.06.2011

41

5.7.10

forceArc

The forceArc process is welding in the spray arc range with a considerably shortened arc.
Disadvantages of short-circuit phases are compensated by the fast control inverter technology.

Benefits of forceArc welding:

• Good

fusion

penetration

• Directionally

stable

arc

• No

undercuts

• Higher

welding

speed

• Small heat-affected zone

You can make use of these properties after selecting the forceArc process (see the "Selecting a
MIG/MAG welding task" chapter).

As with pulse arc welding, it is important to make sure of a good welding current connection.
• Keep welding current cables as short as possible and ensure that cable cross-sections are adequate!

• Fully unroll welding current cables, torche tube packages and, if applicable, intermediate tube

packages. Avoid loops!

• Use welding torches, preferably water-cooled, that are suitable for the higher power range.

• Use welding wire with adequate copper coating when welding steel. The wire spool should have layer

spooling.

NOTE

Unstable arc!
Welding current cables that are not fully unrolled can cause faults in the arc (flickering).
• Fully unroll welding current cables, torch tube packages and, if applicable, intermediate

tube packages. Avoid loops!

5.7.11

rootArc

The rootArc process is welding with a stable, soft, short arc, even when using welding leads.

The benefits of rootArc welding:

• Easy, reliable root welding without pool support.

• Effortless gap bridging.

You can make use of these properties after selecting the rootArc process (see the "Selecting a MIG/MAG
welding task" chapter).

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Содержание Taurus 335 Synergic S TKM

Страница 1: ...nstructions Welding machine GB Taurus 335 Synergic S TKM 099 005215 EW501 29 06 2011 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warranty www ewm...

Страница 2: ...ther 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 whethe...

Страница 3: ...S 16 4 1 1 Front view 16 4 1 2 Rear view 18 4 2 Machine control Operating elements 20 4 2 1 Machine control Concealed operating elements 22 4 2 2 Operating elements in the machine 23 5 Design and func...

Страница 4: ...out 59 5 7 16 Standard MIG MAG torch 60 5 7 17 MIG MAG special torches 60 5 7 17 1 Program and Up down operation 60 5 7 18 Remote control 61 5 7 19 Advanced settings 62 5 7 19 1 Selecting changing an...

Страница 5: ...6 4 Disposing of equipment 92 6 4 1 Manufacturer s declaration to the end user 92 6 5 Meeting the requirements of RoHS 92 7 Rectifying faults 93 7 1 Customer checklist 93 7 2 Error messages power sour...

Страница 6: ...l 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...

Страница 7: ...scription Press Do not press Turn Switch 0 1 Switch off machine 0 1 Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display example wait 4s press Inter...

Страница 8: ...s 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 Switchin...

Страница 9: ...ith 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 t...

Страница 10: ...suspend all conductive power source components like casing transport vehicle and crane frames so they are insulated Do not place any other electronic devices such as drillers or angle grinders etc on...

Страница 11: ...he 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...

Страница 12: ...d 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...

Страница 13: ...s 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...

Страница 14: ...om the atmosphere 3 1 2 MIG MAG cored wire welding Welding with cored wire electrodes consisting of a metal casing and a powder core As with MIG MAG standard welding the arc is protected from the atmo...

Страница 15: ...ted conversion work not specifically authorised by the manufacturer The original copy of the declaration of conformity is enclosed with the unit 3 2 3 Welding in environments with increased electrical...

Страница 16: ...01 29 06 2011 4 Machine description quick overview 4 1 Taurus 335 Synergic S 4 1 1 Front view NOTE The maximum possible machine configuration is given in the text description If necessary the optional...

Страница 17: ...accessory components remote control welding torch control lead etc 12 Connection socket welding current MIG MAG cored wire welding Workpiece connection TIG welding Workpiece connection MMA welding Wor...

Страница 18: ...Machine description quick overview Taurus 335 Synergic S 18 099 005215 EW501 29 06 2011 4 1 2 Rear view Figure 4 2...

Страница 19: ...ltage supply 4 8 pole connection socket Cooling unit control lead 5 digital 7 pole connection socket digital For connecting digital accessory components documentation interface robot interface or remo...

Страница 20: ...l Operating elements 20 099 005215 EW501 29 06 2011 4 2 Machine control Operating elements sec sec sec sec sec sec DYN sec sec Super puls HOLD AMP VOLT PROG m min DYN S Wire Gas Material JOB LIST M 3...

Страница 21: ...ry dial For setting the welding performance for selecting the JOB welding task and for setting other welding parameters 5 Select operating mode button Non latched Latched Signal light lights up in gre...

Страница 22: ...e 0 0 s to 20 0 s 0 1 s increments 6 Signal light main program PA Wire speed WF min to WF max Correction of the arc length 9 9 V to 9 9 V 7 DYN Signal light dynamics Setting range 40 to 40 8 sec Signa...

Страница 23: ...Inching the Wire Electrode chapter 19 Gas test rinse button Gas test For setting the shielding gas quantity Rinse For rinsing longer tube packages See also Shielding Gas Supply chapter 4 2 2 Operatin...

Страница 24: ...feed units are equipped with moving parts which can trap hands hair clothing or tools and thus injure persons Do not reach into rotating or moving parts or drive components Keep casing covers closed d...

Страница 25: ...NG Risk of accident due to improper transport of machines that may not be lifted Do not lift or suspend the machine The machine can fall down and cause injuries The handles and brackets are suitable f...

Страница 26: ...orking 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 general CAUTION...

Страница 27: ...ctions The resulting network has to be suitable for operating devices according to protection class 1 5 5 1 Mains configuration NOTE The machine may be connected to a three phase system with four cond...

Страница 28: ...ling unit 2 1 3 Figure 5 3 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...

Страница 29: ...s steel Use a plastic core to weld or braze soft high alloy wire electrodes or aluminium materials Preparation for connecting welding torches with a plastic core Push forward the capillary tube on the...

Страница 30: ...ts polarity selection for MIG MAG welding 5 Standard applications Connection for welding current connection socket welding current connection socket 6 MIG MAG welding Workpiece connection 7 Workpiece...

Страница 31: ...current 7 Workpiece Insert the central plug for the welding torch into the central connector and screw together with crown nut Insert the plug on the workpiece lead into the welding current connectio...

Страница 32: ...accessories are required when using standardised basket coils DIN 8559 2 1 Figure 5 6 Item Symbol Description 0 1 Carrier pin For fixing the wire spool 2 Knurled nut For fixing the wire spool Loosen...

Страница 33: ...injury due to welding wire escaping from the welding torch The welding wire can escape from the welding torch at high speed and cause bodily injury including injuries to the face and eyes Never direc...

Страница 34: ...nwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe Pres...

Страница 35: ...ten the Allen screw 8 mm in the clockwise direction to increase the braking effect NOTE Do not jam the wire spool Tighten the spool brake until the wire spool no longer turns when the wire feed motor...

Страница 36: ...enu on the control or using the PC300 NET welding parameter software 5 7 7 Welding task selection 5 7 7 1 Basic welding parameters Select JOB welding task using the JOB list On decompact welding syste...

Страница 37: ...min Figure 5 10 Display Setting selection Dynamics setting 40 Arc harder and narrower 40 Arc softer and wider 5 7 7 4 Superpulses m min Figure 5 11 Display Setting selection Selects super pulses Switc...

Страница 38: ...ng selection menu wire burn back Set wire burn back Parameter setting setting range 0 to 499 Wire back burn set too high large drops developing on the wire electrode result in poor ignition properties...

Страница 39: ...ay between AMP Welding current Material thickness Wire speed Application example Aluminium is to be welded Material AlMg Gas Ar 100 Wire diameter 1 2 mm The correct wire speed is not known and is to b...

Страница 40: ...ual machines and their functions 5 7 9 MIG MAG welding data display To the left and right of the control displays are the Parameter selection buttons They are used to select welding parameters to be d...

Страница 41: ...cross sections are adequate Fully unroll welding current cables torche tube packages and if applicable intermediate tube packages Avoid loops Use welding torches preferably water cooled that are suita...

Страница 42: ...also be changed if required 5 7 12 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I We...

Страница 43: ...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...

Страница 44: ...speed Arc 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 sp...

Страница 45: ...re flows Wire 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 pro...

Страница 46: ...gnites after the wire 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...

Страница 47: ...tact with the workpiece 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 parameter...

Страница 48: ...ed motor 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 trigg...

Страница 49: ...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...

Страница 50: ...after the set 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...

Страница 51: ...current is flowing 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 c...

Страница 52: ...n 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 parameters wire speed...

Страница 53: ...rom PSTART to PA 0 0s to 20 0s 5 PA Wire speed absolute 0 1 m min to 40 m min 6 Dynamics 40 to 40 7 Duration spot time and superpulse 0 01s to 20 0s 8 PB Wire speed relative Arc length correction rela...

Страница 54: ...t I PA PEND PSTART Figure 5 27 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...

Страница 55: ...ing explanation 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 Sett...

Страница 56: ...start Arc length correction 9 9V to 9 9V tstart Duration 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 th...

Страница 57: ...elding parameters for the main programs using the following components Program changeover Program Operating mode Welding process Superpulse Wire speed Voltage correction Dynamics P0 Yes 1 Yes 2 M3 71...

Страница 58: ...A3 PA3 PA4 PA5 Figure 5 31 Example 3 Aluminium welding of different sheet metal thicknesses non latched or latched special PA0 PA1 PA8 PA9 t I Figure 5 32 NOTE Up to 16 programs PA0 to PA15 can be def...

Страница 59: ...t arc length correction Display example 0 8 V correction Setting range 9 9 V to 9 9 V 1 x Select Dynamic program sequence parameter LED DYN is on sec sec sec sec sec sec DYN sec sec Super puls m min S...

Страница 60: ...ing special torches can be used together with this welding machine UP DOWN welding torch with one rocker for setting the wire speed or to change up to 10 weldingprograms POWERCONTROL 1 welding torch w...

Страница 61: ...re directly dependent on the configuration of the respective welding machine or wire feed unit The settings are defined by changeover switches or by setting special parameters dependent on the control...

Страница 62: ...1 HOLD AM P VOLT PROG m min m min Figure 5 34 NOTE ENTER Enter the menu Switch off machine at the main switch Press and hold the left parameter selection button and switch the machine on again at the...

Страница 63: ...ff Ex works 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 a...

Страница 64: ...works 1 program selection possible 5 7 19 2 Reset to factory settings NOTE All special parameters saved by the user will be overwritten by the factory settings Displays Operating element Action Result...

Страница 65: ...ge 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 selection depends on the position of t...

Страница 66: ...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 voltage must be...

Страница 67: ...ess button and hold down for approx 4 s Left Current limit value of the wire feed speed correction VOLT PROG 4 s Right Current limit value of the voltage correction m min Set limit value for the wire...

Страница 68: ...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 unit contr...

Страница 69: ...sec can switch to other programs Programs PA1 to PA9 are possible 3rd cycle Press and hold torch trigger Slope to end program PEND from PAN The program can be stopped at any time by pressing the torc...

Страница 70: ...with key switches optional see Key switches chapter must be configured as masters P10 1 The wire feed configured as the master is active after the welding machine is switched on There are no other fun...

Страница 71: ...nfigure special parameter P12 to P12 2 or P12 1 Operating element Action Result Display JOB LIST 1 x Select JOB list m min Select the source JOB Wait for around 3 seconds until the JOB has been transf...

Страница 72: ...to set the welding parameters manually Selection of JOB 0 can be prevented via the key switch or with the block program 0 parameter P2 See List of special parameters chapter Key switch position 0 or...

Страница 73: ...nterference Appoint only skilled persons for repair work trained service personnel CAUTION Test Before re commissioning it is essential that an inspection and test during operation is carried out conf...

Страница 74: ...e central connector torch enables polarity selection 5 TIG Connection socket for welding current Connection socket welding current 6 TIG welding Workpiece connection 7 Workpiece Insert the central plu...

Страница 75: ...ipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant return and supply line blue to quick connect coupling blue coolan...

Страница 76: ...sing the Wire speed rotary dial Operating element Action Result Displays m min Welding current is set Setpoint setting 5 8 4 TIG arc ignition 5 8 4 1 Liftarc ignition a b c Figure 5 40 The arc is igni...

Страница 77: ...ns and functions 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 Sp...

Страница 78: ...on latched t t I 1 2 PA PEND PSTART Figure 5 42 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 W...

Страница 79: ...ed operating 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 trig...

Страница 80: ...gram PA is given 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 wi...

Страница 81: ...reduced main program Welding current 1 to 100 8 Duration reduced main program 0 01 s to 20 0 s 9 Slope duration from PA to PEND 0 s to 20 s 10 PEND end program Welding current 1 to 100 11 Duration en...

Страница 82: ...selection plug Retainer for the polarity selection plug in MMA mode or for transport 5 Electrode holder Insert cable plug of the electrode holder into either the or welding current connection socket a...

Страница 83: ...Result Display JOB LIST 1 x Select JOB number input comes on m min Set the JOB number The machine adopts the required setting after approx 3 seconds 5 9 3 Welding current setting The welding current i...

Страница 84: ...ks in spite of the Arcforce device the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating Check the welding current setting and...

Страница 85: ...s in the holders provided for them and secure with fixing devices Avoid heating the shielding gas cylinder CAUTION Faults in the shielding gas supply An unhindered shielding gas supply from the shield...

Страница 86: ...n gas hose on pressure regulator to be gas tight 5 10 2 Gas test Slowly open the gas cylinder valve Open the pressure regulator Switch on the power source at the main switch Initiate gas test function...

Страница 87: ...pores to form Adjust the shielding gas quantity to suit the welding task 5 11 Interfaces CAUTION Damage due to the use of non genuine parts The manufacturer s warranty becomes void if non genuine par...

Страница 88: ...er 1 must be unplugged on PCB M320 1 in the welding machine Contact open welding current off F Output 0 V Reference potential G P Output I 0 Power relay contact galvanically isolated max 15 V 100 mA H...

Страница 89: ...ctly Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission The PC may be destroyed due to high frequency ignition pulses Interface SECINT X10USB must be co...

Страница 90: ...ng parameters on the machine the control input can be locked with the aid of a key switch In key switch position 1 all functions and parameters can be set without restriction In key switch position 0...

Страница 91: ...securing elements Operating message safety and adjustment devices Functional test Other general condition 6 2 2 Monthly maintenance tasks Casing damage front rear and side walls Wheels and their secu...

Страница 92: ...pean provisions guideline 2002 96 EG of the European Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must...

Страница 93: ...nching wire electrodes chapter Check settings and correct if necessary a Worn wire rolls Check and replace if necessary a Wire feed motor without supply voltage automatic cutout triggered by overloadi...

Страница 94: ...olant level Top up the coolant Leak in the coolant circuit rectify the leak and top up the coolant Coolant pump is not working check excess current release on air cooling unit Err 5 x Error WF unit WF...

Страница 95: ...customised welding parameters that are stored will be replaced by the factory settings 7 3 1 Resetting a single JOB JOB LIST JOB LIST m min Figure 7 1 Display Setting selection Reset to factory settin...

Страница 96: ...r 3 sec 7 4 General operating problems 7 4 1 Interface for mechanised welding WARNING No function of the external shut down devices emergency stop switch If the emergency stop circuit has been realise...

Страница 97: ...on 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 16 A Mains connection lead H07RN...

Страница 98: ...000914 00000 GS25L G1 4 SW 17 Pilot static tube 094 001100 00000 5POLE CEE 16A M Machine plug 094 000712 00000 9 2 Remote control connection cable Type Designation Item no R10 19POL Remote control 09...

Страница 99: ...Net welding parameter software set incl cable and SECINT X10 USB interface 090 008265 00000 WELDQAS1 Station Stationary welding data monitoring and docu set for one welding machine 090 008215 00000 WE...

Страница 100: ...000849 00000 AL 4ZR4R 2 4 3 2 Twin rollers 37 mm for aluminium 092 000870 00000 10 1 3 Wire feed rollers for cored wire Type Designation Item no ROE 2DR4R 0 8 0 9 0 8 0 9 Drive rollers 37 mm cored wi...

Страница 101: ...Replaceable parts Wire feed rollers 099 005215 EW501 29 06 2011 101 Figure 10 1...

Страница 102: ...olid Wire 1 34 98 42 106 190 189 188 131 130 129 126 187 127 128 3 35 99 43 107 254 179 4 36 100 44 108 255 180 5 37 101 45 109 256 181 6 8 9 10 CuSi L ten Brazing CuAl L ten Brazing 114 115 116 117 1...

Страница 103: ...Appendix B Overview of EWM branches 099 005215 EW501 29 06 2011 103 12 Appendix B 12 1 Overview of EWM branches...

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