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Rectifying faults

Checklist for rectifying faults

099-005407-EW501

8.2.2022

7.2 Checklist for rectifying faults

The correct machine equipment for the material and process gas in use is a fundamental

requirement for perfect operation!

Legend

Symbol

Description



Fault/Cause



Remedy

Functional errors



Mains fuse triggers - unsuitable mains fuse



Set up recommended mains fuse

> see 8 chapter



Machine does not start up after switching on (device fan and possibly coolant pump have no function).



Connect the control cable of the wire feeder.



All machine control signal lights are illuminated after switching on



No machine control signal light is illuminated after switching on



No welding power



Phase failure > check mains connection (fuses)



Machine restarts continuously



Wire feeder without function



System does not start up



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



Properly fasten the contact tip and contact tip holder.

Coolant error/no coolant flowing



Insufficient coolant flow



Check coolant level and refill if necessary



Air in the coolant circuit



Vent coolant circuit

> see 7.3 chapter

Wire feed problems



Contact tip blocked



Clean and, if necessary, replace.



Setting the spool brake

> see 5.3.3.4 chapter



Check settings and correct if necessary



Setting pressure units

> see 5.3.3.3 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 packages



Extend and lay out the torch hose package



Wire guide core or spiral is dirty or worn



Clean core or spiral; replace kinked or worn cores

Содержание Taurus 355 Synergic S HP MM TKM

Страница 1: ...Operating instructions EN Welding machine Taurus 355 Synergic S HP MM TKM 099 005407 EW501 Observe additional system documents 8 2 2022...

Страница 2: ...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 ac...

Страница 3: ...ent conditions 25 5 2 2 Machine cooling 25 5 2 3 Workpiece lead general 25 5 2 4 Notes on the installation of welding current leads 26 5 2 5 Stray welding currents 27 5 2 6 Mains connection 28 5 2 6 1...

Страница 4: ...rive 62 5 3 15 Expert menu MIG MAG 63 5 3 15 1 Selection 63 5 3 15 2 Programme limit 64 5 4 MMA welding 64 5 4 1 Connecting the electrode holder and workpiece lead 64 5 4 2 Welding task selection 65 5...

Страница 5: ...11 3 20Electronic gas flow control type P22 85 5 11 3 21Program settings for relative programs P23 85 5 11 3 22Correction or nominal voltage display P24 86 5 11 3 23JOB selection in Expert mode P25 8...

Страница 6: ...arts 103 10 1 Wire feed rollers 103 10 1 1 Wire feed rollers for steel wire 103 10 1 2 Wire feed rollers for aluminium wire 103 10 1 3 Wire feed rollers for cored wire 104 10 1 4 Wire guide 104 11 App...

Страница 7: ...and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning sym bol The hazard is also highlighted using a symbol in the page margin CAUTION Working or oper...

Страница 8: ...ch 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 gre...

Страница 9: ...al specialist may interconnect the sources as per standard IEC 60974 9 2010 Installa tion and use and German Accident Prevention Regulation BVG D1 formerly VBG 15 or country specific regulations Befor...

Страница 10: ...temperatures of 100 C or higher and arcing and work on live components Hearing protection against harming noise Explosion risk Apparently harmless substances in closed containers may generate excessiv...

Страница 11: ...specified in the standard 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...

Страница 12: ...lacement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the ma chine is switched off Requirements for connection to the public...

Страница 13: ...n or connection points can heat up significantly during operation water cooled version When opening the coolant circuit escaping coolant may cause scalding Open the coolant circuit only when the power...

Страница 14: ...ntation in the relevant chapter Machine series Main process Secondary process Standard MIG MAG welding Pulsed MIG MAG welding TIG welding lift arc MMA welding Gouging forceArc rootArc coldArc pipeSolu...

Страница 15: ...t Spare parts can be obtained from the relevant authorised dealer 3 3 5 Calibration Validation An original certificate is enclosed with the product The manufacturer recommends calibration validation a...

Страница 16: ...view rear view 16 099 005407 EW501 8 2 2022 4 Machine description quick overview 4 1 Front view rear view The device configuration shown may differ in case of an additional ex works options or retrof...

Страница 17: ...socket digital For connecting digital accessory components documentation interface robot interface or remote control etc 13 8 pole connection socket Cooling unit control lead 14 4 pole connection soc...

Страница 18: ...elements Depending on the machine series there are added information stickers on the inside of the flap for the operation and maintenance of the machine 2 Slide latch lock for the protective cap 3 Wir...

Страница 19: ...out 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 Infinite adjustment of...

Страница 20: ...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 thickness see 5 3 7 chapter...

Страница 21: ...Arc length correction selection of welding program rotary 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 prog...

Страница 22: ...WF max Correction 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...

Страница 23: ...he system starts again from the beginning Figure 4 6 The display shows Nominal values before welding Actual values during welding Hold values after welding MIG MAG Parameter Nominal values Actual valu...

Страница 24: ...nner Welding wire can be conveyed at very high speeds and if conveyed incorrectly may es cape in an uncontrolled manner and injure persons Before mains connection set up the complete wire guide system...

Страница 25: ...arge amounts of smoke steam oily fumes grinding dust and corrosive ambient air In operation Temperature range of the ambient air 25 C to 40 C 13 F to 104 F 1 Relative humidity up to 50 at 40 C 104 F u...

Страница 26: ...th HF igniter TIG for as long as pos sible 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 Al...

Страница 27: ...eck 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 trans por...

Страница 28: ...s 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 in structions The network c...

Страница 29: ...upply 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 des...

Страница 30: ...essure regulator Switch on the power source at the main switch Trigger gas test see 5 2 7 4 chapter function welding voltage and wire feed motor remain switched off no accidental arc ignition Set the...

Страница 31: ...5s 0 Figure 5 8 5 2 7 5 Purge hose package 5s 0 300s Figure 5 9 5 2 8 Welding torch cooling system 5 2 8 1 Cooling unit connection Figure 5 10 Item Symbol Description 0 1 Cooling module 2 4 pole conne...

Страница 32: ...into the 8 pole connection socket on the welding machine 5 2 9 Welding torch holder The item described in the following is part of the machine s scope of delivery Figure 5 11 Item Symbol Description 0...

Страница 33: ...o the right and remove the protective cap 5 2 11 Dirt filter These accessory components can be retrofitted as an option see 9 chapter When using a dirt filter the cooling air throughput is reduced and...

Страница 34: ...i Use a plastic or teflon liner when welding or brazing soft wire electrodes high alloy wire electrodes or aluminium materials Preparation for connecting welding torches with a spiral guide Check that...

Страница 35: ...o quick connect coupling red coolant return and supply line blue to quick connect coupling blue coolant supply Some wire electrodes e g self shielding cored wire are welded using negative polarity In...

Страница 36: ...rt Before you start working always check the wire spool is securely fastened Standard D300 wire spool holder can be used Adapters are required when using standardised basket coils DIN 8559 see 9 chapt...

Страница 37: ...ing 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 Fold...

Страница 38: ...ire feed roll overview table Material Diameter Colour code Groove form mm inch Steel Stainless steel Brazing 0 6 024 monochrome light pink V groove 0 8 031 white 0 8 0 9 1 0 031 035 039 bicolour white...

Страница 39: ...inching speed is infinitely adjustable by simultaneously pressing the wire inching push button and turning the wire speed rotary knob The left display shows the wire feed speed selected the right dis...

Страница 40: ...ht hand mounting Figure 5 20 Automatic inching stop Touch the welding torch against the workpiece during inching Inching of the welding wire will stop as soon it touches the workpiece 5 3 3 4 Spool br...

Страница 41: ...red process parameters depending on the operating point specified one knob operation via wire feed speed rotary transducer You can adjust additional parameters at the machine control or using the PC30...

Страница 42: ...eters are defined ex works The welding power can be represented as average value ex works or solely as program A value If the average value display is activated the signal lights of the main PA and re...

Страница 43: ...et the measured value e g 5 mm at the machine control This set value corresponds to a specific wire feed speed Switching the display to this parameter will show the associated value In this example a...

Страница 44: ...ulse 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 weldi...

Страница 45: ...if applicable intermediate hose packages Avoid loops 5 3 10 Operating modes functional sequences There are optimum pre sets for welding parameters such as gas pre flow and burn back etc for numerous...

Страница 46: ...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 St...

Страница 47: ...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 ti...

Страница 48: ...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 2...

Страница 49: ...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 Wir...

Страница 50: ...rkpiece 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...

Страница 51: ...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 eff...

Страница 52: ...tact 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 reduced...

Страница 53: ...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 Ste...

Страница 54: ...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 speci...

Страница 55: ...RT avoidance of cold welds at start of seam Main program PA constant welding Reduced main program PB targeted heat reduction End program PEND avoidance of end craters by targeted heat reduction The pr...

Страница 56: ...min 6 Duration spot time and superpulse 0 01s to 20 0s 7 PB Wire speed relative Arc length correction relative 1 to 200 9 9V to 9 9V 8 Duration 0 01s to 20 0s 9 Slope duration from PA to PEND 0 0s to...

Страница 57: ...cial Figure 5 43 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 50...

Страница 58: ...ion 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 wire...

Страница 59: ...ion 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 Slo...

Страница 60: ...uls Wire speed Voltage correc tion Dynamics M3 7X Wire feeder control Yes Yes P0 Yes Yes Yes P1 15 Yes R20 Remote control Yes No P0 No Yes No P1 9 Yes 1 R40 Remote control Yes No P0 No Yes Yes No No R...

Страница 61: ...fined An operating point wire speed arc length correction dynamics choke effect can be defined permanently in each program Program P0 is an exception the settings for operating points are made manuall...

Страница 62: ...eration Figure 5 50 Item Symbol Description 0 1 Welding torch function changeover switch special welding torch required Changing over programs or JOBs Infinite adjustment of welding performance 5 3 14...

Страница 63: ...gram limit n cycle see 5 3 15 2 chapter 1 No JOB dependent program limit 2 9 JOB dependent program limit for max selectable programs Change welding process process switching With this function activat...

Страница 64: ...r JOB In addition a legacy option to set a global program limit is also available To set this option use special parameter P4 This setting is then applied to all JOBs for which no JOB dependent progra...

Страница 65: ...ocket depending on ap plication and lock in place by turning to the right The corresponding polarity will be based on the infor mation of the electrode manufacturer on the electrode packaging 5 4 2 We...

Страница 66: ...t t Time Figure 5 56 5 4 6 Antistick The Antistick feature prevents the electrode from annealing Should the electrode stick despite the Arcforce feature the machine au tomatically switches to the mini...

Страница 67: ...l Description 0 1 Welding torch 2 Polarity selector plug welding current cable Internal welding current cable for central connection welding torch Connection socket for welding current 3 Workpiece Ins...

Страница 68: ...s nozzle and tungsten electrode tip against the workpiece lift arc current flows independent of the set main current b Angle the torch above the torch gas nozzle until the distance between electrode t...

Страница 69: ...ws Non latched Special non latched Latched Special latched t Time PSTART Ignition program PA Main program PB Reduced main program PEND End program tS1 Slope duration from PSTART to PA 5 5 6 2 Automati...

Страница 70: ...cial non latched Figure 5 64 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...

Страница 71: ...ing 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 ef...

Страница 72: ...ing in start program PSTART Step 2 Release torch trigger Slope on main program PA The slope on main program PA is given at the earliest after the set time tSTART elapses and at the latest when the tor...

Страница 73: ...ings are a percentage based on the general welding current setting 5 6 Access control The key switch is only available for machines which are fitted with the OW KL XX5 option ex works To protect again...

Страница 74: ...ty becomes null and void in the event of unauthorised interference Appoint only skilled persons for repair work trained service personnel Unsuitable control cables or incorrect input output signal ass...

Страница 75: ...es accessory set consisting of software interface connection leads Data exchange between power source and PC Welding task administration JOBs Online data exchange Default settings for welding data mon...

Страница 76: ...the special parameters can be reset to the factory settings see 5 11 2 chapter 5 11 1 Selecting changing and saving parameters B A A l 0 B A A B Figure 5 70 Display Setting selection Wire inching wir...

Страница 77: ...B switching JOB range of the function torches PM 2U D PM RD2 Lower limit 129 ex works Upper limit remote JOB switching JOBarea of the function torch PM 2U D PM RD2 Upper limit 169 ex works HOLD functi...

Страница 78: ...nal voltage display JOB Selection with Expert operating mode see 5 11 3 23 chapter 0 SP1 SP3 Switching on the wire feeder if the machine has an expert control ex works 1 JOB selection of wire feeder p...

Страница 79: ...ding torch function changeover switch see 5 3 14 chapter Programs can only be switched when the changeover switch is in the program position Programs can be switched by means of a connected remote con...

Страница 80: ...welder is also to carry out wire and voltage correction in program mode correction operation must be switched on and limit values for wire and voltage must be specified Setting the correction limit fo...

Страница 81: ...t3 time has elapsed The program then switches automa tically to absolute program 4 Accessory components such as remote controls or special torches may not be connected Program switching at the wire f...

Страница 82: ...operating mode it is possible to switch straight to the second step by tapping the torch trigger it is not necessary for current to be flowing The welding can be halted by pressing the torch trigger f...

Страница 83: ...which switching with accessory components such as a function torch between JOBs is possible is created Set special parameters P12 to 2 Set switch Program or Up Down Function to Up Down position Selec...

Страница 84: ...JOB operation Set the Program or Up Down function changeover switch to Program Set the JOB list to actual JOB list special parameter P12 1 Enable block JOB mode special parameter P16 1 Switch to block...

Страница 85: ...lue from program A PA and program B PB is shown on the display ex factory Function inactive P19 0 Only the performance of program A is displayed for superPuls If the function is enabled and only 000 i...

Страница 86: ...umables such as aluminium or flux cored wire 5 11 3 25Mode switching at welding start P27 With the selected 4 cycle Special mode the user can determine by the time of the torch trigger operation in wh...

Страница 87: ...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 parameters Only qualified service personnel may chan...

Страница 88: ...elding torch With other hose package lengths it is ne cessary to carry out a voltage correction to optimise welding properties The voltage correction value can be set close to zero by means of realign...

Страница 89: ...ment 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...

Страница 90: ...e the maintenance instructions see 6 3 chapter In the event that the provisions of one of the below stated tests are not met the machine must not be operated again until it has been repaired and a new...

Страница 91: ...EW501 8 2 2022 91 6 2 Explanation of icons Person Welder operator Service staff expert qualified person Test Visual inspection Functional check Period interval One shift operation Multi shift operati...

Страница 92: ...lines and their connections pipes hoses hose packages for damage or leaks Checking the welding system for damage to the housing Transport elements strap lifting eyes handle wheels parking brake corres...

Страница 93: ...tem separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private households can be disposed of free of c...

Страница 94: ...ice staff as necessary If multiple errors occur these are displayed in succession Category Possible cause Remedy a b c 1 Mains overvoltage Check the mains voltages and compare with the connection volt...

Страница 95: ...ase failure Check mains voltages 58 Short circuit Check welding circuit for short circuit put down welding torch isolated 59 Machine incompatible Check machine usage 60 Software update required Inform...

Страница 96: ...ot start up 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 Properly fasten the...

Страница 97: ...with a suitable tool connection open 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 2 Posit...

Страница 98: ...ng tasks to the factory settings All customised welding parameters that are stored will be replaced by the factory settings 7 4 1 Resetting a single JOB ENTER EXIT 3s 3s RESET 3s Figure 7 3 7 4 2 Rese...

Страница 99: ...ion 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 cooling Torch cooling Fan AF gas Wire feed speed 0 5 m min to 25m min F...

Страница 100: ...000 9 1 2 Coolant type KF Type Designation Item no KF 23E 5 Coolant up to 10 C 14 F 5 l 094 000530 00005 KF 23E 200 Coolant 10 C 200 litres 094 000530 00001 KF 37E 5 Coolant up to 20 C 4 F 5 l 094 006...

Страница 101: ...kplace 090 008776 00000 FRV 7POL 0 5 m Extension connecting cable 092 000201 00004 FRV 7POL 1 m Extension connecting cable 092 000201 00002 FRV 7POL 5 m Extension connecting cable 092 000201 00003 FRV...

Страница 102: ...casing 090 008833 00502 Xnet WiFi Gateway WiFi gateway in external casing 090 008834 00502 Xnet Extended Set LAN Xnet retrofit set LAN One machine licence a LAN gateway and a network cable 10 m 091 0...

Страница 103: ...ainless steel and brazing 092 002770 00020 FE 4R 2 4 MM 0 095 INCH BROWN Drive roll set 37 mm 4 rolls V groove for steel stainless steel and brazing 092 002770 00024 FE 4R 2 8 MM 0 11 INCH LIGHT GREEN...

Страница 104: ...FUEL 4R 1 6 MM 0 06 INCH BLACK ORANGE Drive roll set 37 mm 4 rolls V groove knurled for flux cored wire 092 002848 00016 FUEL 4R 2 0 MM 0 08 INCH GREY ORANGE Drive roll set 37 mm 4 rolls V groove knu...

Страница 105: ...Appendix JOB List 099 005407 EW501 8 2 2022 105 11 Appendix 11 1 JOB List Figure 11 1...

Страница 106: ...9 9 9 9 Slope time of start program PSTART to main program PA 1 s 0 20 Slope time of main program PA to end program PEND 1 s 0 20 End crater current 1 0 200 Correction of arc length in end program PE...

Страница 107: ...Appendix Searching for a dealer 099 005407 EW501 8 2 2022 107 11 3 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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