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Design and function

MIG/MAG welding

099-005230-EW501

02.04.2014

5.8.4

MIG/MAG functional sequences / operating modes

5.8.5

Explanation of signs and functions

Symbol

Meaning

Press torch trigger

Release torch trigger

Tap torch trigger (press briefly and release)

Shielding gas flowing

Welding output

Wire electrode is being conveyed

Wire creep

Wire burn-back

Gas pre-flows

Gas post-flows

Non-latched

Latched

Time

PSTART

Ignition program

Main program

PEND

End program

Содержание Taurus 401 Basic FKW

Страница 1: ...tions Welding machine Taurus 401 Basic FKW Taurus 501 Basic FKW 099 005230 EW501 02 04 2014 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warranty...

Страница 2: ...ment 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 monit...

Страница 3: ...view 20 4 4 Machine control Operating elements 22 5 Design and function 24 5 1 General 24 5 2 Installation 25 5 3 Machine cooling 25 5 4 Workpiece lead general 25 5 5 Welding torch cooling system 26 5...

Страница 4: ...rk intervals 56 6 2 1 Daily maintenance tasks 56 6 2 1 1 Visual inspection 56 6 2 1 2 Functional test 56 6 2 2 Monthly maintenance tasks 57 6 2 2 1 Visual inspection 57 6 2 2 2 Functional test 57 6 2...

Страница 5: ...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 6: ...ess Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exit the menu 4 s Time display example wait 4s...

Страница 7: ...pment sensitive to radiation accordingly The correct functioning of pacemakers may be affected obtain advice from a doctor if necessary Do not carry out any unauthorised repairs or modifications To av...

Страница 8: ...hand in the working area Thoroughly remove any residue of flammable substances from the workpiece before starting welding Only continue work on welded workpieces once they have cooled down Do not allo...

Страница 9: ...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 10: ...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 11: ...during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to EN 60974 A2 Set up and transport the machine on level solid ground Secure add on parts using suitable equipme...

Страница 12: ...ft all lifting eyes simultaneously When using retrofitted craning frames etc always use at least two lifting points positioned as far apart as possible observe option description Avoid any jerky movem...

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: ...1 1 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 atmosphere by shielding...

Страница 15: ...d 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 electrical hazar...

Страница 16: ...Machine description quick overview Front view 16 099 005230 EW501 02 04 2014 4 Machine description quick overview 4 1 Front view Figure 4 1...

Страница 17: ...workpiece connection MIG MAG cored wire welding welding current connection for the welding torch MMA welding electrode holder connection 13 Connection socket welding current MIG MAG welding welding cu...

Страница 18: ...Machine description quick overview Rear view 18 099 005230 EW501 02 04 2014 4 2 Rear view Figure 4 2...

Страница 19: ...additional stickers with information on the replacement parts and JOB lists will be located on the inside 4 Wire spool inspection window Check wire supply 5 Cooling air outlet 6 Bracket for shielding...

Страница 20: ...Machine description quick overview Inside view 20 099 005230 EW501 02 04 2014 4 3 Inside view Figure 4 3...

Страница 21: ...Machine description quick overview Inside view 099 005230 EW501 02 04 2014 21 Item Symbol Description 0 1 Wire spool holder 2 Wire feed unit...

Страница 22: ...Machine description quick overview Machine control Operating elements 22 099 005230 EW501 02 04 2014 4 4 Machine control Operating elements Figure 4 4...

Страница 23: ...perating mode button Non latched Latched 7 Push button throttling effect arc dynamics Arc is harder and more narrow Arc is softer and wider 8 Rotary dial welding voltage Adjustment of the welding volt...

Страница 24: ...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 25: ...e must not be operated in the open air and must only be set up and operated on a suitable stable and level base The operator must ensure that the ground is non slip and level and provide sufficient li...

Страница 26: ...or KF 23E must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components The coolant must be checked for adequate frost protect...

Страница 27: ...e filter sieve insert close sealing cover again NOTE 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 a...

Страница 28: ...etwork has to be suitable for operating devices according to protection class 1 5 6 1 Mains configuration NOTE The machine may be connected to a three phase system with four conductors and an earthed...

Страница 29: ...the shielding gas cylinder Do not attach any element to the shielding gas cylinder valve Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compresse...

Страница 30: ...Screw gas hose connection crown nut onto the output side of the pressure regulator Fasten the gas hose to the shielding gas connecting nipple at the back of the machine using the crown nut 5 7 1 Gas...

Страница 31: ...welding aluminium Wire diameter x 13 5 l min 100 argon Helium rich gas mixtures require a higher gas volume The table below can be used to correct the gas volume calculated where necessary Shielding g...

Страница 32: ...lection push button can be used to switch the display between welding voltage welding performance and gas flow rate option What is shown on the displays depends among other things on the selected weld...

Страница 33: ...hard high alloy wire electrodes CrNi Use a plastic core to weld or braze soft wire electrodes high alloy wire electrodes or aluminium materials Preparation for connecting welding torches with a plasti...

Страница 34: ...e For connecting analogue accessory components remote control welding torch control lead etc 6 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and torch trigger in...

Страница 35: ...g current lead insert polarity selection into the welding current connection socket and lock Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return li...

Страница 36: ...analogue For connecting analogue accessory components remote control welding torch control lead etc 6 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and torch tr...

Страница 37: ...g current lead insert polarity selection into the welding current connection socket and lock Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return li...

Страница 38: ...y 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...

Страница 39: ...and the material Check the roller label to verify that the rollers are suitable for the wire diameter Turn or change if necessary use V groove rollers with for steel wires and other hard wires use U...

Страница 40: ...tervals 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 high...

Страница 41: ...its and fold out clamping units and pressure rollers will automatically flip upwards Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller gr...

Страница 42: ...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 NOTE Tighten the s...

Страница 43: ...etting The operating point setting can also be made with the accessory components R11 RG11 remote control Up Down torch with two rockers 2 U D You will find an overview of accessory components in the...

Страница 44: ...of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I Welding output Wire electrode is being conveyed Wir...

Страница 45: ...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 46: ...Step 2 Release torch trigger no effect Step 3 Press torch trigger no effect Step 4 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post...

Страница 47: ...d surface 5 9 1 Connecting the electrode holder and workpiece lead Figure 5 15 Item Symbol Description 0 1 Workpiece 2 Electrode holder 3 Connection socket welding current 4 Connection socket welding...

Страница 48: ...ection Figure 5 16 NOTE Special electrode holders and carbon electrodes are required for air arc gouging 5 9 3 Welding current setting The welding current is normally set using the Wire speed rotary d...

Страница 49: ...Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current a Hotstart time b Hotstart current I Welding current t Time Figure 5 17 5 9 6 Antistick...

Страница 50: ...on electrodes are required for air arc gouging Figure 5 19 Item Symbol Description 0 1 Workpiece 2 Connection socket welding current 3 Gouging torch 4 Connection socket welding current Insert the goug...

Страница 51: ...EW501 02 04 2014 51 5 9 8 Welding task selection Figure 5 20 5 9 9 Welding current setting The welding current is normally set using the Wire speed rotary dial Operating element Action Result Display...

Страница 52: ...fic configuration of machine functions This allows the user maximum flexibility in optimising their requirements These settings are not configured directly on the machine control since a regular setti...

Страница 53: ...g 10s ramp time 1 fast inching 3s ramp time Ex works Lat and sp lat tapping start 0 no latched tapping start Ex works 1 latched tapping start possible Support for wire feeders with voltage sensing 0 F...

Страница 54: ...5 11 3 The special parameters in detail Ramp time for wire inching P1 The wire inching starts with a speed 1 0 m min for 2 secs It is subsequently increased to a ramp function to 6 0 m min The ramp t...

Страница 55: ...l 0 Figure 5 22 Display Setting selection Lead resistance 1 Lead resistance for the first welding circuit 0 m 60 m 8 m ex works Only qualified service personnel may change the parameters Time based p...

Страница 56: ...ve the torch from the hose package Never clamp the torch body in a vice or similar as this can cause the torch to be irreparably destroyed If damage occurs to the torch or to the hose package which ca...

Страница 57: ...panying supplementary sheets Machine and Company Data Maintenance and Testing Warranty A periodic test according to IEC 60974 4 Periodic inspection and test has to be carried out In addition to the re...

Страница 58: ...ded 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...

Страница 59: ...ol brake see Setting the spool brake chapter Check settings and correct if necessary Setting pressure units see Inching wire electrodes chapter Check settings and correct if necessary Worn wire rolls...

Страница 60: ...ire feeder speedometer error Check the wire feeder speedometer is not issuing a signal M3 00 defective inform Service Error 6 gas x Shielding gas error Check shielding gas supply for machines with shi...

Страница 61: ...end for categories error reset a The error message will disappear once the error has been rectified b The error message can be reset by pressing a key button Welding machine control Key button RC1 RC2...

Страница 62: ...ed easily with this function ENTER 0 5 1 1 5 2 2 5 3 3 5 4 5 6 7 8 9 10 11 12 13 14 15 16 18 20 22 24 m min 0 5 1 1 5 2 2 5 3 3 5 4 5 6 7 8 9 10 11 12 13 14 15 16 18 20 22 24 m min 0 5 1 1 5 2 2 5 3 3...

Страница 63: ...circuit NOTE Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling To vent the cooling system always use the blue coolant connection which...

Страница 64: ...H07RN F4G6 Maximum connected load MIG MAG 17 5 kVA MMA 18 5 kVA Recommended generator rating 25 kVA cos 0 99 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machin...

Страница 65: ...d Max connected load 24 9 kVA 25 6 kVA Recommended generator rating 34 6 kVA Cos 0 99 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine torch cooling Fan gas...

Страница 66: ...ener for plastic liners 094 010427 00000 HC PL Hose cutter 094 016585 00000 9 2 Remote control connection cable Type Designation Item no R11 19POL Remote control 090 008601 00502 RG11 19POL 5M Remote...

Страница 67: ...92 000841 00000 FE 2DR4R 1 0 1 2 Drive rollers 37 mm steel 092 000842 00000 FE 2DR4R 1 2 1 6 Drive rollers 37 mm steel 092 000843 00000 FE AL 2GR4R Pressure rollers smooth 37mm 092 000844 00000 10 1 2...

Страница 68: ...092 000846 00000 URUE AL 4ZR4R 1 2 1 6 Conversion kit 37mm 4 roller drive for aluminium 092 000847 00000 URUE AL 4ZR4R 2 4 3 2 Conversion kit 37mm 4 roller drive for aluminium 092 000868 00000 URUE R...

Страница 69: ...Appendix A Setting instructions 099 005230 EW501 02 04 2014 69 11 Appendix A 11 1 Setting instructions Figure 11 1...

Страница 70: ...Appendix B Overview of EWM branches 70 099 005230 EW501 02 04 2014 12 Appendix B 12 1 Overview of EWM branches...

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