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Design and function

MIG/MAG welding

40

099-005444-EW501

17.03.2015

Unsatisfactory welding results due to faulty wire feeding!
The wire feed rollers must be suitable for the diameter of the wire and the material. The wire feed
rollers are colour-coded to facilitate distinction (see the Wire feed roller overview table).

Wire feed roller overview table

Material

Diameter

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
green

3.2

.125

purple

Aluminium

0.8

.030

bichrome

white

yellow

U-groove

0.9/1.0

.035/.040

blue

1.2

.045

red

1.6

.060

black

2.0

.080

grey

2.4

.095

brown

2.8

.110

Light
green

3.2

.125

purple

Flux cored
wire

0.8

.030

bichrome

white

orange

V-groove,

knurled

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

- See 10 Replaceable parts chapter

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Содержание Taurus 355 Synergic S HP MM TKW

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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