EWM Taurus 351 Basic FKG Operating Instructions Manual
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Summary of Contents for EWM Taurus 351 Basic FKG
- Page 1 Operating instructions Welding machine Taurus 351 Basic FKG Taurus 401 Basic FKG Taurus 351 Basic FKW Taurus 401 Basic FKW Taurus 501 Basic FKW 099-005425-EW501 14.07.2016...
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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. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 Safety instructions .......................... 8 Transport and installation ......................12 3 Intended use ............................ - Page 4 Wire feed rollers for aluminium wire ................72 10.1.3 Wire feed rollers for cored wire ..................72 10.1.4 Wire guide ........................72 11 Appendix A ............................73 11.1 Setting instructions ........................73 12 Appendix B ............................74 12.1 Overview of EWM branches......................74 099-005425-EW501 14.07.2016...
- Page 5 Contents Notes on the use of these operating instructions 099-005425-EW501 14.07.2016...
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Page 6: 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 7: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release/tap/tip user must observe. Switch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Numerical value – adjustable Correct Menu entry Signal light lights up in green... -
Page 8: Safety Instructions
Safety instructions Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 9 Safety instructions Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times. The protective equipment has to include: •...
- Page 10 Safety instructions Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
- Page 11 Safety instructions Safety instructions CAUTION Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •...
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Page 12: Transport And Installation
Safety instructions Transport and installation Transport and installation 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! • Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air! •... -
Page 13: Intended Use
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product. -
Page 14: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. Figure 4-1 099-005425-EW501 14.07.2016... - Page 15 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 16: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 099-005425-EW501 14.07.2016... - Page 17 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 18: Inside View
Machine description – quick overview Inside view Inside view Figure 4-3 Item Symbol Description Wire spool holder Wire feed unit 099-005425-EW501 14.07.2016... -
Page 19: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 Item Symbol Description Button, welding process J1 --------- MIG/MAG welding J2 --------- MMA welding J3 --------- Air arc gouging Display, left Welding current, wire feed speed Status displays AMP ----- "Welding current display"... - Page 20 Machine description – quick overview Machine control – Operating elements Item Symbol Description Push-button, throttling effect (arc dynamics) ---- Arc is harder and more narrow ---- Arc is softer and wider Rotary dial, welding voltage Adjustment of the welding voltage from min. to max. (twin-knob operation: wire speed/welding voltage) Push-button, parameter selection right/power-saving mode VOLT --- Welding voltage...
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Page 21: Design And Function
Design and function Transport and installation Design and function 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 22: Ambient Conditions
Design and function Transport and installation 5.1.2 Ambient conditions T he 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 23: Welding Torch Cooling System
Design and function Transport and installation 5.1.5 Welding torch cooling system Insufficient frost protection in the welding torch coolant! Depending on the ambient conditions, different liquids are used for cooling the welding torch > see 5.1.5.1 chapter. Coolants with frost protection (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. -
Page 24: Adding Coolant
Design and function Transport and installation 5.1.5.3 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 • Unscrew and remove the coolant tank sealing cover. -
Page 25: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.6 Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc (flickering). Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel. -
Page 26: Stray Welding Currents
Design and function Transport and installation Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders. Figure 5-4 5.1.7 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and... -
Page 27: Mains Connection
Design and function Transport and installation 5.1.8 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only operate machine using a socket that has correctly fitted protective earth. • The mains voltage indicated on the rating plate must match the supply voltage. -
Page 28: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Transport and installation 5.1.9 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 29: Shielding Gas Hose Connection
Design and function Transport and installation 5.1.9.2 Shielding gas hose connection Figure 5-8 Item Symbol Description Connecting nipple G¼, shielding gas connection • Connect crown nut of the shielding gas line to the G¼“ connecting nipple. 099-005425-EW501 14.07.2016... -
Page 30: Gas Test - Setting The Shielding Gas Volume
Design and function Transport and installation Gas test – setting the shielding gas volume 5.1.9.3 • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. • Set the relevant gas quantity for the application on the pressure regulator. •... -
Page 31: Welding Data Display
Design and function Welding data display Welding data display Figure 5-10 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 32: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.3.1 Welding torch and workpiece line connection Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •... - Page 33 Design and function MIG/MAG welding Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity. In this case, the welding current lead should be connected to the "-" welding current socket, and the workpiece lead should be connected to the "+" welding current socket. Observe the information from the electrode manufacturer! Figure 5-11 Item Symbol...
- Page 34 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 35: Wire Feed
Design and function MIG/MAG welding 5.3.2 Wire feed 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 36: Inserting The Wire Spool
Design and function MIG/MAG welding 5.3.2.2 Inserting the wire spool CAUTION Risk of injury due to incorrectly secured wire spool. If the wire spool is not secured properly, it may come loose from the wire spool support and fall to the ground, causing damage to the machine and injuries. •... -
Page 37: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.3.2.3 Changing the wire feed rollers Figure 5-13 Item Symbol Description Tommy The tommy is used to secure the closure brackets of the wire feed rollers. Closure bracket The closure brackets are used to secure the wire feed rollers. Feed roll tensioner Fixing the clamping unit and setting the pressure. - Page 38 Design and function MIG/MAG welding Unsatisfactory welding results due to faulty wire feeding! The wire feed rolls must be suitable for the diameter of the wire and the material. The wire feed rolls are colour-coded to facilitate distinction (see the Wire feed roll overview table). When working with a wire diameter of >...
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Page 39: Inching The Wire Electrode
Design and function MIG/MAG welding 5.3.2.4 Inching the wire electrode CAUTION Risk of injury due to welding wire escaping from the welding torch! The welding wire can escape from the welding torch at high speed and cause bodily injury including injuries to the face and eyes! •... -
Page 40: Spool Brake Setting
Design and function MIG/MAG welding A prerequisite for the automatic inching process is the correct preparation of the wire guide, especially in the capillary and wire guide tube area > see 5.3.1 chapter. • The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll tensioner setting nuts depending on the welding consumable used. -
Page 41: Welding Task Selection
Design and function MIG/MAG welding 5.3.3 Welding task selection Figure 5-17 5.3.3.1 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 42: Further Welding Parameters
Design and function MIG/MAG welding 5.3.4 Further welding parameters ENTER NAVIGATION EXIT Figure 5-18 Display Setting/selection Dynamic correction • Increase value > harder arc • Decrease value > softer arc Gas pre-flow time Gas post-flow time Correct wire burn-back If too high a value is set, a large ball will form at the tip of the wire electrode (bad re- ignition) or the wire electrode sticks to the contact tip. -
Page 43: Mig/Mag Functional Sequences / Operating Modes
Design and function MIG/MAG welding 5.3.5 MIG/MAG functional sequences / operating modes 5.3.5.1 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... - Page 44 Design and function MIG/MAG welding Non-latched mode 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 flows. •...
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Page 45: Standard Mig/Mag Torch
Design and function MIG/MAG welding Latched mode Figure 5-20 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 46: 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 47: Connecting The Electrode Holder And Workpiece Lead
Design and function MMA welding 5.4.1 Connecting the electrode holder and workpiece lead Figure 5-21 Item Symbol Description Workpiece Electrode holder Connection socket, “-” welding current Connection socket, “+” welding current • Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right. -
Page 48: Welding Task Selection
Design and function MMA welding 5.4.2 Welding task selection Figure 5-22 5.4.3 Arcforce Figure 5-23 Setting: • Negative values: rutile electrode types • Values at zero: basic electrode types • Positive values: cellulose electrode types 5.4.4 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) =... -
Page 49: Air Arc Gouging
Design and function MMA welding 5.4.6 Air arc gouging 5.4.6.1 Connection Read and observe the documentation to all system and accessory components! During gouging, an arc burns between a carbon electrode and the workpiece, heating the workpiece until it is molten. At the same time, the molten metal is blown out with compressed air. Special electrode holders with a compressed-air connection and carbon electrodes are required for gouging. -
Page 50: Welding Task Selection
Design and function MMA welding 5.4.7 Welding task selection Figure 5-27 099-005425-EW501 14.07.2016... -
Page 51: Remote Control
Design and function Remote control Remote control 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 52 Design and function Special parameters (advanced settings) Enter Exit Figure 5-28 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 53: Reset To Factory Settings
Design and function Special parameters (advanced settings) 5.6.1.1 Reset to factory settings All special parameters saved by the user will be overwritten by the factory settings! RESET Figure 5-29 Display Setting/selection Initialisation complete All customised welding parameters haven been overwritten by the factory settings. 5.6.1.2 Special parameters in detail Ramp time for wire inching (P1) -
Page 54: Machine Configuration Menu
Design and function Machine configuration menu Machine configuration menu 5.7.1 Selecting, changing and saving parameters ENTER (Enter the menu) • Switch off the machine at the main switch. • Press and hold down the "Welding procedure" push-button and switch the machine on again at the same time. -
Page 55: Power-Saving Mode (Standby)
Design and function Machine configuration menu 5.7.2 Power-saving mode (Standby) You can activate the power-saving mode by either pressing the push-button > see 5.7 chapter for a prolonged time or by setting a parameter in the machine configuration menu (time-controlled power- saving mode ) >... - Page 56 Design and function Machine configuration menu 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Trim the welding wire so that it is flush with the contact tip. • Retract the welding wire a little (approx. 50 mm) on the wire feeder. There should now be no more welding wire in the contact tip.
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Page 57: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Incorrect maintenance and testing! The machine may be cleaned, repaired and tested by skilled and qualified personnel only. A qualified person is one who, due to their training, knowledge and experience, can detect any hazards and possible consequential damage when checking the machine, and can take the necessary safety measures. -
Page 58: Maintenance Work, Intervals
Maintenance, care and disposal Maintenance work, intervals Maintenance work, intervals Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine. -
Page 59: Annual Test (Inspection And Testing During Operation)
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives on the Declaration of Conformity on your machine). -
Page 60: 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 61: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) 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 62 Rectifying faults Error messages (power source) Error Category Possible cause Remedy (Err) Machine incompatible Check machine used Software update required Inform Service. Legend for categories (reset error) a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a push-button: Welding machine control Push-button RC1 / RC2...
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Page 63: 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 Figure 7-1 099-005425-EW501 14.07.2016... -
Page 64: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-2 099-005425-EW501... -
Page 65: Technical Data
Technical data Taurus 351 FKG Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Taurus 351 FKG MIG/MAG Setting range for welding current 5 A to 350 A Setting range for welding voltage 14.3 V–31.5 V 20.2 V–34 V Duty cycle at 40 °C 100% DC... -
Page 66: Taurus 401 Fkg
Technical data Taurus 401 FKG Taurus 401 FKG MIG/MAG 5 A to 400 A Setting range for welding current 14.3 V–34.0 V 20.2 V–36 V Setting range for welding voltage Duty cycle at 40 °C 400 A 100% DC Load cycle 10 min. -
Page 67: Taurus 351 Fkw
Technical data Taurus 351 FKW Taurus 351 FKW MIG/MAG Setting range for welding current 5 A–350 A Setting range for welding voltage 14.3 V–31.5 V 20.2 V–34.0 V Duty cycle at 40 °C 100% DC 350 A Load cycle 10 min. -
Page 68: Taurus 401 Fkw
Technical data Taurus 401 FKW Taurus 401 FKW MIG/MAG 5 A–400 A Setting range for welding current 14.3 V–34.0 V 20.2 V–36.0 V Setting range for welding voltage Duty cycle at 40 °C 400 A 100% DC Load cycle 10 min. -
Page 69: Taurus 501 Fkw
Technical data Taurus 501 FKW Taurus 501 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 at 40 °C 60% DC 500 A 100% DC 430 A ... -
Page 70: Accessories
Accessories General accessories Accessories 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 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 GH 2X1/4'' 2M... -
Page 71: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable 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 72: 10.1.2 Wire Feed Rollers For Aluminium Wire
Replaceable parts Wire feed rollers 10.1.2 Wire feed rollers for aluminium wire Type Designation Item no. AL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, for aluminium 092-002771-00008 WHITE AL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, for aluminium 092-002771-00010 BLUE AL 4R 1.2 MM/0.045 INCH... -
Page 73: Setting Instructions
Appendix A Setting instructions Appendix A 11.1 Setting instructions Figure 11-1 099-005425-EW501 14.07.2016... -
Page 74: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005425-EW501 14.07.2016...
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