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Summary of Contents for EWM Taurus Synergic drive 200C
- Page 1 Operating instructions Wire feed unit Taurus Synergic drive 200C Taurus Synergic drive 300C Observe additional system documents! 099-005211-EW501 23.08.2010 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
- Page 2 © EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer.
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Page 3: Table Of Contents
Welding in environments with increased electrical hazards......... 13 3.3.4 Service documents (spare parts and circuit diagrams) ..........13 4 Machine description – quick overview ....................14 Taurus Synergic drive 200C ......................14 4.1.1 Front view ........................14 4.1.2 Rear view........................15 4.1.3... - Page 4 Contents 5.4.11 forceArc.........................39 5.4.12 rootArc ..........................39 TIG welding ..........................40 5.5.1 Welding torch connection .....................40 5.5.1.1 Taurus Synergic drive 200C................40 5.5.1.2 Taurus Synergic drive 300C................41 5.5.2 Welding task selection ....................42 5.5.3 TIG arc ignition ......................42 5.5.3.1 Liftarc ignition ....................42 MMA welding..........................43 5.6.1...
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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 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 7: General
Safety instructions General General DANGER 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. •... - Page 8 Safety instructions General WARNING Validity of this document! This document is only valid in combination with the operating instructions for the power source being used (welding machine)! • Read the operating instructions, in particular the safety instructions for the power source (welding machine)! Risk of accidents if these safety instructions are not observed! Non-observance of these safety instructions is potentially fatal!
- Page 9 Safety instructions General CAUTION Noise exposure! Noise exceeding 70 dBA can cause permanent hearing damage! • Wear suitable ear protection! • Persons located within the working area must wear suitable ear protection! CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! •...
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Page 10: 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 11: 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 12: 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 13: Documents Which Also Apply
Intended use Documents which also apply Documents which also apply 3.3.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.3.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 14: Machine Description - Quick Overview
Machine description – quick overview Taurus Synergic drive 200C Machine description – quick overview Taurus Synergic drive 200C 4.1.1 Front view Figure 4-1 Item Symbol Description Carrying handle Cover for wire delivery unit and operating elements Wire spool inspection window... -
Page 15: Rear View
Machine description – quick overview Taurus Synergic drive 200C 4.1.2 Rear view Figure 4-2 Item Symbol Description Connecting nipple G¼, shielding gas connection Stirrup Intermediate tube package strain relief Rapid-action closure coupling, red (coolant return) Rapid-action closure coupling, blue (coolant supply) -
Page 16: Inside View
Machine description – quick overview Taurus Synergic drive 200C 4.1.3 Inside view Up / Down Up / Down Figure 4-3 Item Symbol Description Label, Wire feed parts subject to wear Sticker, JOB List Wire spool retainer Wire delivery unit Gas test button The welding voltage and wire feed remain off while testing and setting the gas flow. -
Page 17: Taurus Synergic Drive 300C
Machine description – quick overview Taurus Synergic drive 300C Taurus Synergic drive 300C 4.2.1 Front view Figure 4-4 Item Symbol Description Carrying handle Cover for wire delivery unit and operating elements Wire spool inspection window Check wire supply Wire feed unit cover lock Machine control See Machine control –... -
Page 18: Rear View
Machine description – quick overview Taurus Synergic drive 300C 4.2.2 Rear view Figure 4-5 Item Symbol Description Carrying handle Connecting nipple G¼, shielding gas connection Stirrup Intermediate tube package strain relief 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Connector plug, welding current "+"... -
Page 19: Operating Elements In The Machine
Machine description – quick overview Taurus Synergic drive 300C 4.2.3 Operating elements in the machine Up / Down Up / Down Figure 4-6 Item Symbol Description Label, Wire feed parts subject to wear Sticker, JOB List Wire spool retainer Wire delivery unit Gas test button The welding voltage and wire feed remain off while testing and setting the gas flow. -
Page 20: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Taurus Synergic 8 9 10 m/min Figure 4-7 Item Symbol Description 8 9 10 Rotary dial, wire speed Wire speed setting (welding performance, one-dial operation) Limits for the setting are defined by the JOB selected on the power source. -
Page 21: Design And Function
Design and function General Design and function NOTE Observe documentation of other system components when connecting! General DANGER 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. •... - Page 22 Design and function General 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. •...
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Page 23: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system 5.2.1 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! • Only use the coolant described in this manual (overview of coolants). •... -
Page 24: Intermediate Hose Package Connection
Design and function Intermediate hose package connection Intermediate hose package connection 5.3.1 Intermediate tube package strain relief CAUTION Missing or incorrectly fitted strain relief! Connection sockets or connection plugs on the machine, or the intermediate tube package, may be damaged if the strain relief is missing or incorrectly fitted. The strain relief takes the strain from cables, plugs and sockets. -
Page 25: Taurus Synergic Drive 200C
Design and function Intermediate hose package connection 5.3.2 Taurus Synergic drive 200C Figure 5-2 Item Symbol Description Power source Intermediate tube package Connecting nipple G¼, shielding gas connection Stirrup Intermediate tube package strain relief 19-pole connection socket (analogue) For connecting analogue remote controls Rapid-action closure coupling, red (coolant return) Connector plug, welding current "+"... -
Page 26: Taurus Synergic Drive 300C
Design and function Intermediate hose package connection 5.3.3 Taurus Synergic drive 300C Figure 5-3 Item Symbol Description Power source Intermediate tube package Connecting nipple G¼, shielding gas connection Stirrup Intermediate tube package strain relief 19-pole connection socket (analogue) For connecting analogue remote controls Connector plug, welding current "+"... -
Page 27: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.4.1 Welding torch connection CAUTION Equipment damage due to improperly connected coolant lines! If the coolant lines are not connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •... -
Page 28: Taurus Synergic Drive 200C
Design and function MIG/MAG welding 5.4.1.1 Taurus Synergic drive 200C Figure 5-4 Item Symbol Description Welding torch Welding torch hose package Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger Rapid-action closure coupling (blue) coolant supply... -
Page 29: Taurus Synergic Drive 300C
Design and function MIG/MAG welding 5.4.1.2 Taurus Synergic drive 300C 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 Rapid-action closure coupling (blue) coolant supply... -
Page 30: Fixing The Wire Spool Retainer (Pre-Tension Adjustment)
Design and function MIG/MAG welding 5.4.2 Fixing the wire spool retainer (pre-tension adjustment) NOTE Because the spool brake also secures the wire spool retainer, the following steps are to be carried out for every spool change and before every adjustment of the spool brake. Figure 5-6 Item Symbol Description... -
Page 31: Spool Brake Setting
Design and function MIG/MAG welding 5.4.3 Spool brake setting Figure 5-7 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 Do not jam the wire spool! Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but... -
Page 32: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.4.5 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 33: Inching The Wire Electrode
MIG/MAG welding 5.4.6 Inching the wire electrode 5.4.6.1 Taurus Synergic drive 200C 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 34: Taurus Synergic Drive 300C
Design and function MIG/MAG welding 5.4.6.2 Taurus Synergic drive 300C 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 35 Design and function MIG/MAG welding • Extend and lay out the torch tube package. • Unfasten pressure units and fold out (clamping units and counter-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 pipe into the capillary tube and Teflon core using guide pipe.
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Page 36: Standard Mig/Mag Torch
Design and function MIG/MAG welding 5.4.7 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 5.4.8 MIG/MAG special-torches Function specifications and more indepth information can be found in the operating manual for the relevant welding torch! The following special torches can be used together with this welding machine: •... -
Page 37: Welding Task Selection
Design and function MIG/MAG welding 5.4.10 Welding task selection NOTE Selection of a welding task involves the interaction of the controls on the welding machine and the wire feed unit. After the basic settings are made on the welding machine, the operating point and other parameters can be set on the wire feed unit. JOB- LIST m /m in... - Page 38 Design and function MIG/MAG welding Operating Action Result 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 Operating mode changeover switch Switching between non-latched and latched operation or between special non-latched and special latched.
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Page 39: 5.4.11 Forcearc
Design and function MIG/MAG welding 5.4.11 forceArc The forceArc process is welding in the spray arc range with a considerably shortened arc. Disadvantages of short-circuit phases are compensated by the fast control inverter technology. Benefits of forceArc welding: • Good fusion penetration •... -
Page 40: Tig Welding
Design and function TIG welding TIG welding 5.5.1 Welding torch connection 5.5.1.1 Taurus Synergic drive 200C Figure 5-13 Item Symbol Description Welding torch Welding torch hose package Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger... -
Page 41: Taurus Synergic Drive 300C
Design and function TIG welding 5.5.1.2 Taurus Synergic drive 300C Figure 5-14 Item Symbol Description Welding torch Welding torch hose package Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Rapid-action closure coupling (blue) coolant supply... -
Page 42: Welding Task Selection
Design and function TIG welding 5.5.2 Welding task selection NOTE Selection of a welding task involves the interaction of the controls on the welding machine and the wire feed unit. After the basic settings are made on the welding machine, the operating point and other parameters can be set on the wire feed unit. JOB- LIST m /m in... -
Page 43: Mma Welding
Design and function MMA welding MMA welding 5.6.1 Welding task selection JOB- LIST m /m in 8 9 10 1 ,5 m /m in DY N m /m in Figure 5-17 Operating Action Result Display element Material Select JOB list Material Wire (LED... -
Page 44: Shielding Gas Supply
Design and function Shielding gas supply Shielding gas supply 5.7.1 Gas test • Slowly open the gas cylinder valve. • Open the pressure reducer. • Switch on the power source at the main switch. • Trigger gas test function on the machine control inside the machine. •... -
Page 45: Interfaces
Design and function Interfaces Interfaces 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 46: 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 47: Repair Work
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 48: Rectifying Faults
Rectifying faults Meeting the requirements of RoHS Rectifying faults Legend : Fault/Cause : Remedy NOTE The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation! Wire feed problems Contact nozzle blocked Clean, spray with separating agent and replace if necessary Setting the spool brake (see "Setting the spool brake"... -
Page 49: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) 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 50: Resetting Jobs (Welding Tasks) To The Factory Settings
Rectifying faults Resetting JOBs (welding tasks) to the factory settings Resetting JOBs (welding tasks) to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings. 7.2.1 Resetting a single JOB JOB- JOB- LIST LIST m /m in... -
Page 51: Resetting All Jobs
Rectifying faults General operating problems 7.2.2 Resetting all JOBs 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. The menu will be ended when no changes are done after 3 sec. General operating problems 7.3.1 Interface for mechanised welding... -
Page 52: 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 m /m in DY N m /m in... -
Page 53: Technical Data
Technical data Taurus Synergic drive 200C Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Taurus Synergic drive 200C Supply voltage 42 VAC Max. welding current at 60% DC 550 A Wire feed speed 0.5 m/min to 24 m/min... -
Page 54: Accessories, Options
Accessories, options General accessories Accessories, options 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 Schlauch Bruecke Tube bridge 092-007843-00000 Remote control / connection cable... -
Page 55: Conversion Sets
Accessories, options Wire feed rollers 9.4.5 Conversion sets Type Designation Item no. URUE VERZ>UNVERZ FE/AL Conversion kit, 37mm, 4-roller drive on non-toothed 092-000415-00000 4R SF rollers (steel/aluminium) URUE ROE 2DR4R Conversion kit, 37 mm, 4-roller drive for cored wire 092-000410-00000 0,8/0,9+0,8/0,9 SF URUE ROE 2DR4R Conversion kit, 37 mm, 4-roller drive for cored wire... -
Page 56: Conversion Sets
Accessories, options Wire feed rollers 9.4.10 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 57: Overview Of Ewm Branches
420 412 358-551 www.ewm-group.com/cz · info.cz@ewm-group.com Tel: · Fax: +49 5384 90798-0 www.ewm-group.com/handel · nl-nord@ewm-group.com EWM HIGHTEC WELDING SALES s.r.o. EWM HIGHTEC WELDING UK Ltd. Unit B Coopies Way Prodejní a poradenské centrum Tyr š ova 2106 Coopies Lane Industrial Estate Morpeth ·...
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