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Design and function

MIG/MAG welding

099-005231-EW501

10.05.2012

5.8.13

MIG/MAG functional sequences / operating modes

NOTE

There are optimum pre-sets for welding parameters such as gas pre-flow and burn
back, etc. for numerous applications (although these can also be changed if required).

5.8.13.1

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

Special, non-latched

Latched

Special, latched

Time

PSTART Ignition program

Main program

Reduced main program

PEND

End program

Spot time

Содержание Taurus 401 Synergic FKG

Страница 1: ...Welding machine GB Taurus 401 Synergic FKG Taurus 401 Synergic FKW 099 005231 EW501 10 05 2012 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warra...

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: ...17 4 Machine description quick overview 18 4 1 Front view 18 4 2 Rear view 20 4 3 Machine control Operating elements 22 4 3 1 Covered operating elements 24 5 Design and function 26 5 1 General 26 5 2...

Страница 4: ...e aluminium welding latched special 61 5 8 14 6 Example visible seams latched super pulse 62 5 8 15 Main program A mode 63 5 8 15 1 Selecting parameters program A 64 5 8 16 Standard MIG MAG torch 65 5...

Страница 5: ...aults 88 7 1 Checklist for rectifying faults 88 7 2 Error messages power source 89 7 3 Resetting JOBs welding tasks to the factory settings 90 7 3 1 Resetting a single JOB 90 7 3 2 Resetting all JOBs...

Страница 6: ...Contents Notes on the use of these operating instructions 6 099 005231 EW501 10 05 2012...

Страница 7: ...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 8: ...scription Press Do not press Turn Switch l 0 Switch off machine l 0 Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display example wait 4s press Inter...

Страница 9: ...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 10: ...e objects such as matches or lighters Keep appropriate fire extinguishing equipment to hand in the working area Thoroughly remove any residue of flammable substances from the workpiece before starting...

Страница 11: ...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 12: ...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 13: ...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 14: ...shielding gas cylinders tool boxes wire feed units etc Avoid jerky movements when raising or lowering Use shackles and load hooks of the appropriate size m i n 1 m m i n 1 m 75 Fig Lifting principle R...

Страница 15: ...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 16: ...rt arc even with long welding leads ideal for simple reliable root welding without pool support easy gap bridging 3 1 3 MIG MAG standard welding Metal arc welding using a wire electrode whereby gas fr...

Страница 17: ...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 18: ...view Front view 18 099 005231 EW501 10 05 2012 4 Machine description quick overview 4 1 Front view NOTE Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines...

Страница 19: ...al connection torch TIG welding Welding current connection for welding torch 12 MMA welding Workpiece or electrode holder connection Connection socket welding current MIG MAG welding Welding current t...

Страница 20: ...Machine description quick overview Rear view 20 099 005231 EW501 10 05 2012 4 2 Rear view Figure 4 2...

Страница 21: ...n 3 Wire delivery unit cover 4 Wire spool inspection window Check wire supply 5 Cooling air outlet 6 Bracket for shielding gas cylinder 7 Wheels fixed castors 8 COM PC interface serial D Sub connectio...

Страница 22: ...description quick overview Machine control Operating elements 22 099 005231 EW501 10 05 2012 4 3 Machine control Operating elements HOLD AMP VOLT PROG m min DYN S Taurus Synergic 6 7 4 3 2 1 5 9 8 Fig...

Страница 23: ...dial For setting the welding performance for selecting the JOB welding task and for setting other welding parameters 5 Operating mode selection button Non latched Latched Signal light lights up in gr...

Страница 24: ...ogram 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 Signal light duration of main program PA Setting range 0 0 s t...

Страница 25: ...B List Illuminates upon display or selection of the JOB number 17 JOB LIST Key button JOB List Selection of the welding task JOB from the JOB list 18 Wire inching button See also Inching the Wire Elec...

Страница 26: ...ng current connection 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...

Страница 27: ...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 28: ...on KF 37E 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 fros...

Страница 29: ...up as necessary Figure 5 1 Item Symbol Description 0 1 Coolant tank cap 2 Coolant filter sieve 3 Coolant tank 4 Min mark Minimum coolant level Unscrew and remove the coolant tank sealing cover Check f...

Страница 30: ...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 31: ...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 shieldi...

Страница 32: ...en gas hose on pressure regulator to be gas tight 5 7 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 33: ...TIG Gas nozzle diameter in mm corresponds to l min gas throughput Helium rich gas mixtures require a higher gas volume The table below can be used to correct the gas volume calculated where necessary...

Страница 34: ...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 35: ...plications Connection for welding current connection socket 8 Quick connect coupling red coolant return 9 Quick connect coupling blue coolant supply Insert the central plug for the welding torch into...

Страница 36: ...ed wire welding Connection for welding current connection socket 8 Quick connect coupling red coolant return 9 Quick connect coupling blue coolant supply Insert the central plug for the welding torch...

Страница 37: ...Design and function MIG MAG welding 099 005231 EW501 10 05 2012 37...

Страница 38: ...ardised 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 knurled nut from spool holder Fix welding...

Страница 39: ...er Welding wire can be conveyed at very high speeds and if conveyed incorrectly may escape in an uncontrolled manner and injure persons Before mains connection set up the complete wire guide system fr...

Страница 40: ...amping 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 grooves and the guide...

Страница 41: ...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 42: ...Welding task selection 5 8 8 1 Basic welding parameters Select JOB welding task using the JOB list On decompact welding systems the JOB list sticker is located on the inside on the wire feed unit cov...

Страница 43: ...hine function Switch off Switching off machine function 5 8 8 5 Burn back m min Figure 5 12 Display Setting selection menu burn back Set burn back Parameter setting setting range 0 to 499 Back burn se...

Страница 44: ...e display 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...

Страница 45: ...arameter LEDs next to the button indicate the selection After the last parameter is reached the system starts again from the beginning HOLD AMP VOLT PROG Taurus Synergic Figure 5 14 The display shows...

Страница 46: ...dewall fusion Un alloyed and low alloy steels Manual and automated applications Wire mm rootArc welding up to 0 6 0 8 0 9 1 1 2 1 6 Material Gas JOB JOB JOB JOB JOB JOB CO2 x x x x x x 204 6 0 205 5 0...

Страница 47: ...251 12 0 252 12 0 253 6 0 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 s...

Страница 48: ...also be changed if required 5 8 13 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 49: ...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 50: ...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 51: ...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 52: ...es 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 end...

Страница 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...t I PA PEND PSTART Figure 5 29 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 61: ...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 62: ...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 63: ...h different sheet metal thicknesses non latched t I PA0 PA1 PA8 PA9 Figure 5 32 Example 2 Welding different positions on a workpiece latched t I PA0 PA1 PA2 PA4 PA3 PA3 PA4 PA5 Figure 5 33 Example 3 A...

Страница 64: ...parameter Main program PA LED is on sec sec sec sec sec sec DYN sec sec Super puls m min Set wire speed Absolute value Set arc length correction Display example 0 8 V correction Setting range 9 9 V t...

Страница 65: ...ng machine or wire feed unit Switch off the welding machine before connecting The operation of the remote control and its settings are directly dependent on the configuration of the respective welding...

Страница 66: ...AM P VOLT PROG m min m min l 0 Figure 5 35 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 sa...

Страница 67: ...er Ex works 1 special latched 2 specific latched special n cycle active Lat and sp lat tapping start 0 no latched tapping start Ex works 1 latched tapping start possible Special latched tapping time 0...

Страница 68: ...sible irrespective of the key switch position 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 posit...

Страница 69: ...This corresponds to a welding voltage U of 21 9 V When the key switch is set to 0 position welding in this program can only be carried out with these values To allow the welder also to perform wire a...

Страница 70: ...d correction VOLT PROG 4 s Right Current limit value of the voltage correction m min Set limit value for the wire feed speed correction Set limit value for voltage correction After approx 5 s without...

Страница 71: ...s after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART from PA1 2nd cycle Release torch trigger Slope to main program PA1 The slope to main program...

Страница 72: ...ping the torch trigger it is not necessary for current to be flowing The welding can be halted by pressing the torch trigger for a second time Latched special tapping time setting P11 The tapping time...

Страница 73: ...ed for the selected JOB by the n cycle setting see parameter P8 Welding starts when the torch trigger is held for longer than 0 64 s You can select programs with the standard torch trigger in all oper...

Страница 74: ...ection socket for welding current 8 Quick connect coupling red coolant return 9 Quick connect coupling blue coolant supply Insert the central plug for the welding torch into the central connector and...

Страница 75: ...ng after approx 3 seconds 5 9 3 TIG arc ignition 5 9 3 1 Liftarc ignition a b c Figure 5 41 The arc is ignited on contact with the workpiece a Carefully place the torch gas nozzle and tungsten electro...

Страница 76: ...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 Latch...

Страница 77: ...on latched t t I 1 2 PA PEND PSTART Figure 5 43 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 78: ...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 79: ...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 80: ...program 0 s to 20 s 4 Slope duration from PSTART to PA 0 s to 20 s 5 PA main program Welding current absolute 5 A to 550 A 6 Duration PA 0 01 s to 20 0 s 7 PB reduced main program Welding current 1 to...

Страница 81: ...d surface 5 10 1 Connecting the electrode holder and workpiece lead Figure 5 47 Item Symbol Description 0 1 Workpiece 2 Electrode holder 3 Connection socket welding current 4 Connection socket welding...

Страница 82: ...erial is on m min Set JOB number Wait 3s until the setting has been adopted 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 Welding current is set Setpoint setting DYN Select...

Страница 83: ...ice 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 correct according to the weldin...

Страница 84: ...easily transfer them to one or more welding machines accessories set consisting of software interface connection leads 5 12 Protecting welding parameters from unauthorised access To protect against un...

Страница 85: ...it is in use 6 2 Maintenance work intervals 6 2 1 Daily maintenance tasks Clean the wire feed rollers on a regular basis depending on the degree of soiling 6 2 1 1 Visual inspection Mains supply lead...

Страница 86: ...here the relevant local laws and regulations must also be observed 6 3 Maintenance work DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit...

Страница 87: ...his 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 are to b...

Страница 88: ...ake see Setting the spool brake chapter Check settings and correct if necessary a Setting pressure units see Inching wire electrodes chapter Check settings and correct if necessary a Worn wire rolls C...

Страница 89: ...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 shielding gas...

Страница 90: ...le c The error message can only be reset by switching the machine off and on again The shielding gas error Err 6 can be reset by pressing the Welding parameters key button 7 3 Resetting JOBs welding t...

Страница 91: ...esetting all JOBs NOTE All customised welding parameters that are stored will be replaced by the factory settings JOB LIST JOB LIST m min Figure 7 2 Display Setting selection Reset to factory settings...

Страница 92: ...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 93: ...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 5 4 5 6 7 8 9 10 11 12 13 14 15 1...

Страница 94: ...e 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 35 A Mains connection lead H07RN F4G4 Maximum connected load MIG MAG 17...

Страница 95: ...07RN F4G4 Maximum connected load MIG MAG 17 2 kVA TIG 13 1 kVA MMA 18 2 kVA Recommended generator rating 25 0 kVA cos 0 99 Insulation class protection classification H IP 23 Ambient temperature 20 C t...

Страница 96: ...m no R10 19POL Remote control 090 008087 00000 RG10 19POL 5M Remote control to set the wire speed and welding voltage correction 090 008108 00000 RA5 19POL 5M Remote control e g connection cable 092 0...

Страница 97: ...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 98: ...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 99: ...CrNi Metal CrNi Rutil Basic 2 SG2 3 G3 4 Si1 Massivdraht Solid 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...

Страница 100: ...Appendix B Overview of EWM branches 100 099 005231 EW501 10 05 2012 12 Appendix B 12 1 Overview of EWM branches...

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