EWM Taurus 401 Basic FKW Operating Instructions Manual
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Summary of Contents for EWM Taurus 401 Basic FKW
- Page 1 Operating instructions 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...
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Page 2: General Instructions
+49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 General ............................7 Transport and installation ......................11 2.4.1 Lifting by crane ...................... - Page 4 Error messages (power source) ....................60 Welding parameter calibration ..................... 62 Vent coolant circuit ........................63 8 Technical data............................64 Taurus 401 Basic FKW ........................ 64 Taurus 501 Basic FKW ........................ 65 9 Accessories ............................66 General accessories ........................66 Remote control / connection cable ....................
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Page 5: 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 6: 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 (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu) EXIT 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 7: 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 8 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 9 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 10 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.
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Page 11: 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 12: Lifting By Crane
Safety instructions Transport and installation 2.4.1 Lifting by crane WARNING Risk of injury during lifting by crane When lifting the machine by crane, persons may be severely injured by falling machines or mount-on components. • Simultaneous lifting of system components such as power source wire feeder or cooling unit is not allowed. -
Page 13: Ambient Conditions
Safety instructions Transport and installation 2.4.2 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 14: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with proper usage and by trained or expert staff! •... -
Page 15: 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 16: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-005230-EW501 02.04.2014... - Page 17 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...
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Page 18: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 099-005230-EW501 02.04.2014... - Page 19 Machine description – quick overview Rear view Item Symbol Description Slide latch, lock for the protective cap Securing elements for shielding gas cylinder (strap/chain) Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside.
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Page 20: Inside View
Machine description – quick overview Inside view Inside view Figure 4-3 099-005230-EW501 02.04.2014... - Page 21 Machine description – quick overview Inside view Item Symbol Description Wire spool holder Wire feed unit 099-005230-EW501 02.04.2014...
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Page 22: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 099-005230-EW501 02.04.2014... - Page 23 Machine description – quick overview Machine control – Operating elements Item Symbol Description Button, welding process MIG/MAG welding MMA welding Air arc gouging Display, left Welding current, wire feed speed Status displays "Welding current display" signal light "Wire feed speed display" signal light Display, welding process MIG/MAG welding MMA welding...
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Page 24: 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 25: 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 26: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! • Only use the coolant described in this manual (overview of coolants). •... -
Page 27: Adding Coolant
Design and function Welding torch cooling system 5.5.2 Adding coolant The unit is supplied ex works with a minimum level of coolant. Figure 5-1 Item Symbol Description Coolant tank cap Coolant filter sieve Coolant tank "Min" mark Minimum coolant level •... -
Page 28: 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 29: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Shielding gas supply (shielding gas cylinder for welding machine) Shielding gas supply (shielding gas cylinder for welding machine) WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! •... -
Page 30: Gas Test
Design and function Shielding gas supply (shielding gas cylinder for welding machine) • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. Figure 5-3 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve... -
Page 31: Setting The Shielding Gas Quantity
Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.7.3 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) Helium-rich gas mixtures require a higher gas volume! -
Page 32: Welding Data Display
Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.7.4 Welding data display Figure 5-5 The machine control displays show all welding parameters that are required by the welder. The lower centre display shows the selected welding task (JOB number). The "parameter selection" ( ) push- button can be used to switch the display between welding voltage, welding performance and gas flow rate (option). -
Page 33: 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 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 34: Mig/Mag Standard Welding
Design and function MIG/MAG welding 5.8.1.1 MIG/MAG standard welding Figure 5-6 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.) Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated... - Page 35 Design and function MIG/MAG welding • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the plug on the workpiece lead into the "-" welding current connection socket and lock. •...
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Page 36: Mig/Mag Cored Wire Welding
Design and function MIG/MAG welding 5.8.1.2 MIG/MAG cored wire welding Figure 5-7 Item Symbol Description Workpiece Connection socket, "+" welding current • MIG/MAG cored wire 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.) Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated... - Page 37 Design and function MIG/MAG welding • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the plug on the workpiece lead into the "+" welding current connection socket and lock. •...
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Page 38: Wire Feed
Design and function MIG/MAG welding 5.8.2 Wire feed 5.8.2.1 Open the protective flap of the wire feeder CAUTION To perform the following steps, the protective flap of the wire feeder needs to be opened. Make sure to close the protective flap again before starting to work. •... -
Page 39: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.8.2.3 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: Inching The Wire Electrode
Design and function MIG/MAG welding 5.8.2.4 Inching the wire electrode CAUTION Risk of injury due to moving parts! The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons! • Do not reach into rotating or moving parts or drive components! •... - Page 41 Design and function MIG/MAG welding Figure 5-10 Item Symbol Description Feed roll tensioner Fixing the clamping unit and setting the pressure. Clamping unit Knurled nut Pressure roller Wire feed nipple Guide tube Drive rollers "Undetachable" knurled screws Wire feed nipple with wire stabiliser •...
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Page 42: Spool Brake Setting
Design and function MIG/MAG welding 5.8.2.5 Spool brake setting Figure 5-11 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 43: Welding Task Selection
Design and function MIG/MAG welding 5.8.3 Welding task selection Figure 5-12 5.8.3.1 Accessory components for operating point setting 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 "Accessories"... -
Page 44: Mig/Mag Functional Sequences / Operating Modes
Design and function MIG/MAG welding 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... - Page 45 Design and function MIG/MAG welding Non-latched mode Figure 5-13 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. •...
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Page 46: Standard Mig/Mag Torch
Design and function MIG/MAG welding Latched mode Figure 5-14 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 47: Mma Welding
Design and function MMA welding 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 48: Welding Task Selection
Design and function MMA welding 5.9.2 Welding task selection 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 dial. Operating Action Result... -
Page 49: Arcforce
Design and function MMA welding 5.9.4 Arcforce Operating Action Result Display element Select arcforcing welding parameter LED for the button is on. Arcforcing setting for electrode types: (Setting range -40 to 40) Negative values Rutile Values around zero Basic Positive values Cellulose 5.9.5 Hotstart... -
Page 50: Air Arc Gouging
Design and function MMA welding 5.9.7 Air arc gouging 5.9.7.1 Connection NOTE Please note the relevant documentation of the accessory components. Special electrode holders and carbon electrodes are required for air arc gouging. Figure 5-19 Item Symbol Description Workpiece Connection socket, “-” welding current Gouging torch Connection socket, “+”... -
Page 51: Welding Task Selection
Design and function MMA welding 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 Action Result Displays element Welding current is set Setpoint setting 099-005230-EW501 02.04.2014... -
Page 52: Remote Control
Design and function Remote control 5.10 Remote control 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 53 Design and function Special parameters (advanced settings) ENTER EXIT Figure 5-21 Display Setting/selection Ramp time for wire inching 0 = normal inching (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.
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Page 54: 5.11.2 Reset To Factory Settings
Design and function Special parameters (advanced settings) 5.11.2 Reset to factory settings NOTE All special parameters saved by the user will be overwritten by the factory settings! Operating Action Result Display element left right Switch off welding machine Press and hold push-button Switch on welding machine Release push-button Wait for about 3 s... -
Page 55: Machine Configuration Menu
Design and function Machine configuration menu 5.12 Machine configuration menu 5.12.1 Selecting, changing and saving parameters NOTE ENTER (Enter the menu) • Switch off the machine at the main switch. • Press and hold the "welding procedure" push-button and switch the machine on again at the same time. -
Page 56: 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 57: Monthly Maintenance Tasks
Maintenance, care and disposal Maintenance work 6.2.2 Monthly maintenance tasks 6.2.2.1 Visual inspection • Casing damage (front, rear and side walls) • Wheels and their securing elements • Transport elements (strap, lifting lugs, handle) • Check coolant tubes and their connections for impurities 6.2.2.2 Functional test •... -
Page 58: Disposing Of Equipment
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC). -
Page 59: 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 60: 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 61 Rectifying faults Error messages (power source) Error Category Possible cause Remedy Error 18 No speedometer signal from Check the connection and particularly the (WF. Sl.) second wire feeder (slave speedometer of the second wire feeder drive) (slave drive). Legend for categories (error reset) a) The error message will disappear once the error has been rectified.
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Page 62: 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. ENTER NAVIGATION EXIT 8 9 10 8 9 10 8 9 10 8 9 10... -
Page 63: 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 7-2 099-005230-EW501... -
Page 64: Technical Data
Technical data Taurus 401 Basic FKW Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Taurus 401 Basic FKW Setting range for welding current/voltage: 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 40 °C... -
Page 65: Taurus 501 Basic Fkw
Technical data Taurus 501 Basic FKW Taurus 501 Basic FKW MIG/MAG Setting range for welding current 5 A–500 A Setting range for welding voltage 14.3 V–39.0 V 20.2 V–40.0 V Duty cycle 40 °C 25 °C 40 °C 25 °C 500 A 500 A 500 A... -
Page 66: 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 Wire spool adapter K300 094-001803-00001 DM AR/MIX 35L/MIN Manometer pressure regulator 094-000009-00000 GH 2X1/4'' 2M Gas hose... -
Page 67: 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 68: 10.1.4 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 69: Setting Instructions
Appendix A Setting instructions Appendix A 11.1 Setting instructions Figure 11-1 099-005230-EW501 02.04.2014... -
Page 70: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005230-EW501 02.04.2014...
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