EWM Taurus 401 Synergic FKG Operating Instructions Manual
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EWM Taurus 401 Synergic FKG Operating Instructions Manual

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Operating instructions
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099-005231-EW501
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Welding machine
Taurus 401 Synergic FKG
Taurus 401 Synergic FKW
10.05.2012
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  • Page 1 Operating instructions Welding machine 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...

  • Page 2: General Instructions

    © EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents..............................3 2 Safety instructions..........................7 Notes on the use of these operating instructions ................7 Explanation of icons........................8 General ............................9 Transport and installation ......................13 2.4.1 Lifting by crane ......................14 Ambient conditions........................
  • Page 4 Contents Notes on the use of these operating instructions 5.8.8 Welding task selection ....................42 5.8.8.1 Basic welding parameters ................42 5.8.8.2 Operating mode.....................42 5.8.8.3 Choke effect / dynamics ................42 5.8.8.4 Superpulses ....................43 5.8.8.5 Burn-back ......................43 5.8.9 MIG/MAG operating point .....................44 5.8.9.1 Selecting the display unit................44 5.8.9.2 Accessory components for operating point setting ........44...
  • Page 5 Resetting all JOBs ......................91 Vent coolant circuit........................92 Welding parameter calibration ..................... 93 8 Technical data ............................94 Taurus 401 Synergic FKG ......................94 Taurus 401 Synergic FKW......................95 9 Accessories ............................96 General accessories ........................96 Remote control / connection cable ....................96 Options............................
  • Page 6 Contents Notes on the use of these operating instructions 099-005231-EW501 10.05.2012...

  • Page 7: Safety Instructions

    Safety instructions Notes on the use of these operating instructions Safety instructions Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •...

  • Page 8: Explanation Of Icons

    Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine Switch on machine ENTER (enter the menu) NAVIGATION (Navigating in the menu) EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use...

  • Page 9: General

    Safety instructions General General DANGER Electric shock! Welding machines use high voltages which can result in potentially fatal electric shocks 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! •...
  • Page 10 Safety instructions General WARNING Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure when heated. • Move containers with inflammable or explosive liquids away from the working area! • Never heat explosive liquids, dusts or gases by welding or cutting! Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning.
  • Page 11 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
  • Page 12 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.

  • Page 13: Transport And Installation

    Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •...

  • Page 14: Lifting By Crane

    Safety instructions Transport and installation 2.4.1 Lifting by crane DANGER Risk of injury during lifting by crane! When lifting the equipment by crane, serious injuries can be inflicted by falling equipment or add-on units. • Transport on all lifting lugs at the same time (see Fig.

  • Page 15: Ambient Conditions

    Safety instructions Ambient conditions Ambient conditions CAUTION Installation site! The machine 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 lighting for the place of work.

  • Page 16: Intended Use

    Intended use Applications Intended use This machine has been manufactured according to the latest developments in technology and current regulations and standards. It must only be operated in line with the instructions on correct usage. WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly.

  • Page 17: Documents Which Also Apply

    Intended use Documents which also apply Documents which also apply 3.2.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.2.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •...

  • Page 18: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view NOTE Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. Figure 4-1 099-005231-EW501 10.05.2012...
  • Page 19 Machine description – quick overview Front view Item Symbol Description Lifting lug Ready for operation signal light Signal light on when the machine is switched on and ready for operation Main switch, machine on/off Carrying handle Cooling air inlet Automatic cut-out of coolant pump key button press to reset a triggered fuse Quick connect coupling (red) coolant return...

  • Page 20: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-005231-EW501 10.05.2012...
  • Page 21 Machine description – quick overview Rear view Item Symbol Description Wire feed unit cover lock Securing elements for shielding gas cylinder (strap/chain) Wire delivery unit cover Wire spool inspection window Check wire supply Cooling air outlet Bracket for shielding gas cylinder Wheels, fixed castors PC interface, serial (D-Sub connection socket, 9-pole) Connecting nipple G¼, shielding gas connection...

  • Page 22: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements VOLT PROG HOLD Taurus Synergic m/min Figure 4-3 099-005231-EW501 10.05.2012...
  • Page 23 Machine description – quick overview Machine control – Operating elements Item Symbol Description Lid (see chap. "Machine control – concealed operating elements") Button, Parameter selection left Welding current Material thickness Wire speed After each completed welding process, the last parameter values used for the HOLD welding process are shown on the display in the main program;...

  • Page 24: Covered Operating Elements

    Machine description – quick overview Machine control – Operating elements 4.3.1 Covered operating elements M 3.74 Material Wire JOB- LIST Super- puls Figure 4-4 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used.
  • Page 25 Machine description – quick overview Machine control – Operating elements Item Symbol Description Signal light, JOB-List Material Illuminates upon display or selection of the JOB number Wire Key button, JOB-List JOB- Selection of the welding task (JOB) from the JOB list LIST Wire inching button See also “Inching the Wire Electrode”...

  • Page 26: Design And Function

    Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •...

  • Page 27: Installation

    Design and function Installation CAUTION Damage due to incorrect connection! Accessory components and the power source itself can be damaged by incorrect connection! • Only insert and lock accessory components into the relevant connection socket when the machine is switched off. •...

  • Page 28: Welding Torch Cooling System

    Design and function Welding torch cooling system Welding torch cooling system NOTE Only with water-cooled welding machines! 5.5.1 General CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! •...

  • Page 29: Adding Coolant

    Design and function Welding torch cooling system 5.5.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. NOTE After the initial filling, wait for at least one minute when the machine is switched on so that the tube package is filled with coolant completely and without bubbles.

  • Page 30: Mains Connection

    Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations! •...

  • Page 31: Shielding Gas Supply

    Design and function Shielding gas supply Shielding gas supply 5.7.1 Connecting the shielding gas supply WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •...

  • Page 32: Gas Test

    Design and function Shielding gas supply Figure 5-3 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. •...

  • Page 33: Setting The Shielding Gas Quantity

    Design and function Shielding gas supply 5.7.4 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11.5 = l/min MIG brazing Wire diameter x 11.5 = l/min MIG welding (aluminium) Wire diameter x 13.5 = l/min (100 % argon) 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:...

  • Page 34: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.8.1 Welding torch and workpiece line connection NOTE Fault with the wire guide! On delivery, the central connector (Euro) is fitted with a capillary tube for welding torches with spiral guides. Conversion is necessary if a welding torch with a plastic core is used! Welding torch with plastic core: •...

  • Page 35: Mig/Mag Standard Welding

    Design and function MIG/MAG welding 5.8.1.1 MIG/MAG standard welding Figure 5-4 Item Symbol Description Workpiece "-" welding current connection socket • MIG/MAG welding: Workpiece connection Welding torch Welding torch hose package 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger...

  • Page 36: Mig/Mag Cored Wire Welding

    Design and function MIG/MAG welding 5.8.1.2 MIG/MAG cored wire welding Figure 5-5 Item Symbol Description Welding torch Welding torch hose package 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger Workpiece Connection socket, "+"...
  • Page 37 Design and function MIG/MAG welding 099-005231-EW501 10.05.2012...

  • Page 38: Removing The Wire Feed Unit Cover

    Design and function MIG/MAG welding 5.8.2 Removing the wire feed unit cover CAUTION For the following processes the cover must be removed; to protect the machine it is essential that the cover is fitted back into position afterwards. • Unlock the right-hand cover on the machine. •...

  • Page 39: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.8.4 Changing the wire feed rollers NOTE Unsatisfactory welding results due to faulty wire feeding! Wire feed rollers must be suitable for the diameter of the wire and the material. • Check the roller label to verify that the rollers are suitable for the wire diameter. Turn or change if necessary! •...
  • Page 40 Design and function MIG/MAG welding Figure 5-8 Item Symbol Description Pressure unit Clamping unit Knurled nut Pressure roller Wire feed nipple Guide tube Drive rollers "Undetachable" knurled screws Wire feed nipple with wire stabiliser • Extend and lay out the torch hose package. •...

  • Page 41: Spool Brake Setting

    Design and function MIG/MAG welding 5.8.6 Spool brake setting Figure 5-9 Item Symbol Description 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 spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation!

  • Page 42: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.8.7 Definition of MIG/MAG welding tasks This range of machines feature simple operation with a very wide range of functions. • Various JOBs (i.e. welding tasks consisting of welding process, material type, wire diameter and shielding gas type) have been pre-defined (see appendix for a list of JOBs).

  • Page 43: Superpulses

    Design and function MIG/MAG welding 5.8.8.4 Superpulses m /m in Figure 5-11 Display Setting/selection Selects super pulses Switches function on or off. Switch on Switching on machine function Switch off Switching off machine function 5.8.8.5 Burn-back m /m in Figure 5-12 Display Setting/selection menu burn back...

  • Page 44: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.8.9 MIG/MAG operating point The operating point (welding output) is specified using the principle of MIG/MAG one-dial operation, i.e. the user need only specify the operating point by setting the required wire speed, for example, and the digital system will calculate the optimum values for welding current and voltage (operating point).

  • Page 45: Mig/Mag Welding Data Display

    Design and function MIG/MAG welding 5.8.10 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 displayed. Each press of the button advances the display to the next parameter (LEDs next to the button indicate the selection).

  • Page 46: Rootarc

    Design and function MIG/MAG welding 5.8.11 rootArc Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding. Figure 5-15 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion • Un-alloyed and low-alloy steels •...

  • Page 47: Forcearc

    Design and function MIG/MAG welding 5.8.12 forceArc Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range. Figure 5-16 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 48: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 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...
  • Page 49 Design and function MIG/MAG welding Non-latched mode Figure 5-17 Step 1 • Press and hold torch trigger. • Shielding 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. •...
  • Page 50 Design and function MIG/MAG welding Non-latched operation with superpulse Figure 5-18 Step 1 • Press and hold torch trigger. • Shielding 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. •...
  • Page 51 Design and function MIG/MAG welding Special, non-latched START Figure 5-19 Step 1 • Press and hold torch trigger • Shielding 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 is flowing (start program P for the time t START...
  • Page 52 Design and function MIG/MAG welding Spot welding START Figure 5-20 NOTE The ignition time t must be added to the spot time t start 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed"...
  • Page 53 Design and function MIG/MAG welding Special, non-latched with superpulse START Figure 5-21 Step 1 • Press and hold torch trigger • Shielding 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 is flowing (start program P for the time t START...
  • Page 54 Design and function MIG/MAG welding Latched mode Figure 5-22 Step 1 • Press and hold torch trigger • Shielding 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. •...
  • Page 55 Design and function MIG/MAG welding Latched mode with superpulse Figure 5-23 Step 1: • Press and hold torch trigger • Shielding 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. •...
  • Page 56 Design and function MIG/MAG welding Latched special START Figure 5-24 Step 1 • Press and hold torch trigger • Shielding 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 is flowing (start program P START Step 2...
  • Page 57 Design and function MIG/MAG welding Special, latched with superpulse START Figure 5-25 Step 1 • Press and hold torch trigger • Shielding 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 is flowing (start program P for the time t START...

  • Page 58: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.8.14 MIG/MAG program sequence ("Program steps" mode) Certain materials, such as aluminium, require special functions in order to be able to weld them safely and at high quality. The latched special operating mode is used here with the following programs: •...

  • Page 59: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.8.14.2 MIG/MAG overview of parameters Super- puls Figure 5-27 Basic Parameters Item Meaning / Explanation Setting Range Gas pre-flow time 0.0s to 20.0s 1% to 200% START Wire speed, relative -9.9V to +9.9V Arc length correction Duration 0.0s to 20.0s Slope duration from P...

  • Page 60: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.8.14.3 Example, tack welding (non-latched) Figure 5-28 Basic parameters Parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 61: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.8.14.5 Example, aluminium welding (latched special) START Figure 5-30 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 500 "P "...

  • Page 62: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.8.14.6 Example, visible seams (latched super pulse) START Figure 5-31 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 500 PROC.SP.

  • Page 63: Main Program A Mode

    Design and function MIG/MAG welding 5.8.15 Main program A mode Different welding tasks or positions on a workpiece demand various welding performances (operating points) or welding programs. The following parameters are stored in each of the up to 16 programs: •...

  • Page 64: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.8.15.1 Selecting parameters (program A) Operating Action Result Display element Change welding data display over to program display. (LED PROG is on) Select program number. Display example: Program "1". Select program sequence parameter "Main program (P )".

  • Page 65: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.8.16 Standard MIG/MAG torch The MIG welding torch trigger is essentially used to start and stop the welding process. Operating elements Functions Torch trigger • Start/stop welding Other functions are also possible by tapping the torch trigger, depending on the machine type and control configuration: •...

  • Page 66: Advanced Settings

    Design and function MIG/MAG welding 5.8.19 Advanced settings The special parameters cannot be viewed directly since they are normally only set and stored once. The machine control offers the following special functions: 5.8.19.1 Selecting, changing and saving parameters VOLT A M P PROG HOLD m /m in...
  • Page 67 Design and function MIG/MAG welding Display Setting/selection Ramp time for wire inching 0 = normal inching (10s ramp time) 1 = fast inching (3s ramp time) (Ex works) Block program "0" 0 = P0 enabled (Ex works) 1 = P0 blocked Program limitation Programs 1 to max.

  • Page 68: Reset To Factory Settings

    Design and function MIG/MAG welding 5.8.19.2 Reset to factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings. Operating Action Result Displays element Left Right Switch off welding machine VOLT Keep the button pressed PROG Switch on welding machine VOLT...
  • Page 69 Design and function MIG/MAG welding Correction operation, threshold value setting (P7) The correction operation is switched on and off for all JOBs and their programs at the same time. A correction operation is specified for wire speed (DV) and welding voltage correction (Ukorr) for each JOB. The correction value is saved separately for each program.
  • Page 70 Design and function MIG/MAG welding Setting the correction range: • Switch on the "Correction operation" special parameter (P7=1) and save the setting. (See chapter entitled "Selecting, changing and saving parameters".) • Key switch to position "1". • Set correction range according to the following table: Operating Action Result...
  • Page 71 Design and function MIG/MAG welding Specific latched special (n cycle) In the n cycle program sequence, the unit starts in the 1st cycle with start program P from P start In the second cycle, the machine switches to absolute program 2, once the start time "tstart" has elapsed. Tapping switches to other programs (P to max.
  • Page 72 Design and function MIG/MAG welding N cycle setting NOTE The n cycle function should always be activated before the n cycle setting (see "Program changeover with standard torch (P8)". m /m in Figure 5-39 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;...
  • Page 73 Design and function MIG/MAG welding Selecting programs with the standard torch trigger (P17) Allows you to select a program or switch a program before starting welding. You switch to the next program by tapping the torch trigger. Once the last enabled program is reached, you start again at the beginning.

  • Page 74: Tig Welding

    Design and function TIG welding TIG welding 5.9.1 Welding torch and workpiece line connection Figure 5-40 Item Symbol Description Welding torch Welding torch hose package 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger Workpiece...

  • Page 75: Welding Task Selection

    Design and function TIG welding 5.9.2 Welding task selection • Select JOB 127 (TIG welding task). It is only possible to change the JOB number when no welding current is flowing. On decompact welding systems, the "JOB list" sticker is located on the inside on the wire feed unit cover; with compact machines it is on the right-hand power source cover.

  • Page 76: Pulses, Function Sequences

    Design and function TIG welding 5.9.4 Pulses, function sequences 5.9.4.1 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 Gas pre-flows Gas post-flows Non-latched Special, non-latched Latched Special, latched...
  • Page 77 Design and function TIG welding Non-latched mode Figure 5-42 Selection • Select non-latched 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 •...
  • Page 78 Design and function TIG welding Latched mode Figure 5-44 Selection • Select latched 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 •...

  • Page 79: Tig Automatic Cut-Out

    Design and function TIG welding Latched special START Figure 5-45 Selection • Select 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 at pre-selected setting in start program "P ".

  • Page 80: Tig Program Sequence ("Program Steps" Mode)

    Design and function TIG welding 5.9.6 TIG program sequence ("Program steps" mode) 5.9.6.1 TIG parameter overview Super- puls Figure 5-46 Basic parameters Item Meaning/explanation Setting range Gas pre-flow time 0 s to 0.9 s START 0% to 200% Ignition current Duration (start program) 0 s to 20 s Slope duration from P...

  • Page 81: Mma Welding

    Design and function MMA welding 5.10 MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •...

  • Page 82: Welding Task Selection

    Design and function MMA welding 5.10.2 Welding task selection Operating Action Result Display element Material Select JOB list Material Wire (LED is on) Wire JOB- LIST Set JOB number. Wait 3s until the setting has been adopted. m/min Welding current is set Setpoint setting 8 9 10 m /m in...

  • Page 83: Hotstart

    Design and function MMA welding 5.10.3 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current Welding current Time Figure 5-48 5.10.4 Antistick Anti-stick prevents the 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...

  • Page 84: Pc Interfaces

    Design and function PC Interfaces 5.11 PC Interfaces CAUTION Equipment damage or faults may occur if the PC is connected incorrectly! 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. •...

  • Page 85: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! •...

  • Page 86: Annual Test (Inspection And Testing During Operation)

    Maintenance, care and disposal Maintenance work 6.2.3 Annual test (inspection and testing during operation) NOTE The welding machine may only be tested by competent, capable personsl. A capable person is one who, because of his training, knowledge and experience, is able to recognise the dangers that can occur while testing welding power sources as well as possible subsequent damage and who is able to implement the required safety procedures.

  • Page 87: Disposing Of Equipment

    Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922. •...

  • Page 88: Rectifying Faults

    Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer.

  • Page 89: Error Messages (Power Source)

    Rectifying faults Error messages (power source) Error messages (power source) NOTE A welding machine error is indicated by an error code being displayed (see table) on the display on the machine control. In the event of a machine error, the power unit is shut down. The display of possible error numbers depends on the machine version (interfaces/functions).

  • Page 90: Resetting Jobs (Welding Tasks) To The Factory Settings

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings b) The error message can be reset by pressing a key button: Welding machine control Key button RC1 / RC2 Expert CarExpert / Progress (M3.11) alpha Q / Concept / Basic / Basic S / Synergic / not possible Synergic S / Progress (M3.71) c) The error message can only be reset by switching the machine off and on again.

  • Page 91: Resetting All Jobs

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings 7.3.2 Resetting all JOBs NOTE All customised welding parameters that are stored will be replaced by the factory settings. JOB- JOB- LIST LIST m /m in Figure 7-2 Display Setting/selection Reset to factory settings The RESET will be done after pressing the button.

  • Page 92: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant 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 is located as deep as possible inside the system (close to the coolant tank)! Figure 7-3 099-005231-EW501...

  • Page 93: Welding Parameter Calibration

    Rectifying faults Welding parameter calibration Welding parameter calibration When differentiating between the welding parameters set on the wire feed unit/remote control and those shown on the welding machine, they can be calibrated easily with this function. DY N DY N DY N DY N DY N...

  • Page 94: Technical Data

    Technical data Taurus 401 Synergic FKG Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Taurus 401 Synergic FKG Setting range for welding current/voltage: 5 A/10.2 V to 400 A/26.0 V 5 A/20.2 V to 400 A/36.0 V MIG/MAG 5 A/14.3 V to 400 A/34.0 V...

  • Page 95: Taurus 401 Synergic Fkw

    Technical data Taurus 401 Synergic FKW Taurus 401 Synergic FKW Setting range for welding current/voltage: 5 A/10.2 V to 400 A/26.0 V 5 A/20.2 V to 400 A/36.0 V MIG/MAG 5 A/14.3 V to 400 A/34.0 V Duty cycle at 25 °C 400 A 100% 390 A...

  • Page 96: Accessories

    Accessories General accessories Accessories NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. AK300 Adapter for K300 basket coil 094-001803-00001 DM1 35L/MIN Manometer pressure regulator 094-000009-00000 GH 2X1/4'' 2M Gas hose...

  • Page 97: Replaceable Parts

    Replaceable parts Wire feed rollers Replaceable parts CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...

  • Page 98: Conversion Sets

    Replaceable parts Wire feed rollers 10.1.4 Conversion sets Type Designation Item no. URUE VERZ>UNVERZ FE/AL Conversion kit, 37mm, 4-roller drive on non-toothed 092-000845-00000 rollers (steel/aluminium) URUE AL 4ZR4R 0,8+1,0 Conversion kit, 37mm, 4-roller drive for aluminium 092-000867-00000 URUE AL 4ZR4R 1,0+1,2 Conversion kit, 37mm, 4-roller drive for aluminium 092-000846-00000 URUE AL 4ZR4R 1,2+1,6...

  • Page 99: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List NOTE We recommend using the characteristics for 1.0-mm solid wire electrodes also for the 0.9-mm solid wire electrodes. 094-015723-00500 Wire Material Job-Nr. CO 100 / C1 SG2/3 G3/4 Si1 Ar80-90 / M2 Figure 11-1 099-005231-EW501 10.05.2012...

  • Page 100: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005231-EW501 10.05.2012...

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