EWM Taurus 355 Basic TKM Operating Instructions Manual
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EWM Taurus 355 Basic TKM Operating Instructions Manual

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Operating instructions
Welding machine
Taurus 355 Basic TKM
EN
099-005406-EW501
Observe additional system documents!
30.03.2022

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Summary of Contents for EWM Taurus 355 Basic TKM

  • Page 1 Operating instructions Welding machine Taurus 355 Basic TKM 099-005406-EW501 Observe additional system documents! 30.03.2022...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. 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 using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use ..........................
  • Page 4 Error messages (power source) ................... 54 Welding parameter calibration ..................... 56 Vent coolant circuit ....................... 57 8 Technical data ..........................58 Taurus 355 Basic TKM ......................58 9 Accessories ..........................59 Welding torch cooling system ....................59 9.1.1 Coolant - type blueCool ..................59 9.1.2...

  • Page 5: For Your Safety

    For your safety Notes on using these operating instructions For your safety Notes on using 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

    For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the u- Activate and release / Tap / Tip ser must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Correct / Valid...

  • Page 7: Safety Instructions

    For your safety 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 8 For your safety 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.
  • Page 9 For your safety 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 10: Transport And Installation

    For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.
  • Page 11 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.

  • Page 12: Intended Use

    3.1.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.1.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration.

  • Page 13: Part Of The Complete Documentation

    Intended use Applications 3.1.6 Part of the complete documentation This document is part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system.

  • Page 14: Machine Description - Quick Overview

    Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-005406-EW501 30.03.2022...
  • Page 15 Machine description – quick overview Front view / rear view Item Symbol Description Carrying handle Machine control > see 4.2 chapter 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 Park socket, polarity selection plug Retainer for the polarity selection plug in MMA mode or for transport.

  • Page 16: Operating Elements In The Machine

    Machine description – quick overview Front view / rear view 4.1.1 Operating elements in the machine Figure 4-2 Item Symbol Description Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, there are added information stickers on the inside of the flap for the operation and maintenance of the machine.

  • Page 17: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 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 18: Welding Data Display

    Machine description – quick overview Machine control – Operating elements Item Symbol Description Rotary dial, welding voltage Adjustment of the welding voltage from min. to max. (twin-knob operation: wire speed/welding voltage) Pushbutton, parameter selection on the right / power-saving mode VOLT ---- Welding voltage kW ------- Welding power display --------- Gas flow rate (no function in this system)

  • Page 19: Design And Function

    Design and function Transport and installation Design and function WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •...

  • Page 20: Workpiece Lead, General

    Design and function Transport and installation 5.1.3 Workpiece lead, general CAUTION Risk of burning due to incorrect welding current connection! If the welding current plugs (machine connections) are not locked or if the workpiece connection is contaminated (paint, corrosion), these connections and leads can heat up and cause burns when touched! •...

  • Page 21: Notes On The Installation Of Welding Current Leads

    Design and function Transport and installation 5.1.5 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 22: Stray Welding Currents

    Design and function Transport and installation 5.1.6 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. •...

  • Page 23: Mains Connection

    Design and function Transport and installation 5.1.7 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • The connection (mains plug or cable), the repair or voltage adjustment of the device must be carried out by a qualified electrician in accordance with the respective local laws or nati- onal regulations! •...

  • Page 24: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Transport and installation 5.1.8 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 25: Shielding Gas Hose Connection

    Design and function Transport and installation 5.1.8.2 Shielding gas hose connection Figure 5-8 Item Symbol Description Shielding gas cylinder / pressure regulator Connection thread - G¼" Shielding gas connection (inlet) • Screw the gas hose connection to the shielding gas connection (inlet) on the machine gas-tight. 5.1.8.3 Shielding gas volume settings If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause...

  • Page 26: Gas Test

    Design and function Transport and installation 5.1.8.4 Gas test Figure 5-9 5.1.8.5 Purge hose package 300s Figure 5-10 099-005406-EW501 30.03.2022...

  • Page 27: Welding Torch Holder

    Design and function Transport and installation 5.1.9 Welding torch holder The item described in the following is part of the machine´s scope of delivery. Figure 5-11 Item Symbol Description Crossmember of the transport handle Torch holder Fixing screws (x 4) Fan-type lock washers •...

  • Page 28: 5.1.10 Protective Flap, Welding Machine Control

    Design and function MIG/MAG welding 5.1.10 Protective flap, welding machine control Figure 5-12 Item Symbol Description Protective cap Bracket, protective cap • Push the right-hand bracket of the protective cap to the right and remove the protective cap. MIG/MAG welding 5.2.1 Assemble the wire guide The Euro torch connector is factory-fitted with a guide tube for welding torches with steel liner.

  • Page 29: Welding Torch And Workpiece Line Connection

    Design and function MIG/MAG welding Preparation for connecting welding torches with a liner: • Push forward the capillary tube on the wire feed side in the direction of the Euro torch connector and remove it there. • Insert the liner guide tube from the Euro torch connector side. •...
  • Page 30 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 5-15 Item Symbol...

  • Page 31: Mig/Mag Function Torch

    Design and function MIG/MAG welding 5.2.2.1 MIG/MAG function torch The torch trigger on the MIG welding torch is generally used to start and finish the welding process. Func- tion torches feature additional operating elements to set the wire feed speed and voltage correction. Welding torches with one rotary knob, one rocker or one pair of buttons only must be configured on the machine control appropriately.
  • Page 32 Design and function MIG/MAG welding Standard D300 wire spool holder can be used. Adapters are required when using standardised basket coils (DIN 8559) > see 9 chapter. Figure 5-17 Item Symbol Description Carrier pin For fixing the wire spool Knurled nut For fixing the wire spool •...

  • Page 33: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.2.3.2 Changing the wire feed rollers Figure 5-19 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 34 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 >...

  • Page 35: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.2.3.3 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 in- jury including injuries to the face and eyes! •...

  • Page 36: Spool Brake Setting

    Design and function MIG/MAG welding • The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll ten- sioner setting nuts depending on the welding consumable used. A table with the setting values can be found on a sticker near the wire drive.

  • Page 37: Welding Task Selection

    Design and function MIG/MAG welding 5.2.4 Welding task selection Figure 5-23 5.2.4.1 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 38: Further Welding Parameters

    Design and function MIG/MAG welding 5.2.5 Further welding parameters ENTER NAVIGATION EXIT Figure 5-24 Display Setting/selection Dynamic correction • Increase value > harder arc • Decrease value > softer arc Gas pre-flow time Gas post-flow time Burn-back time • ----------- Increase value > increase wire burn-back •...
  • Page 39 Design and function MIG/MAG welding Symbol Meaning Welding output Wire electrode is being conveyed Wire creep Wire burn-back Gas pre-flows Gas post-flows Non-latched Latched Time PSTART Ignition program Main program End program PEND Non-latched mode Figure 5-25 Step 1 • Press and hold torch trigger.

  • Page 40: Standard Mig/Mag Torch

    Design and function MIG/MAG welding Latched mode Figure 5-26 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 41: Mma Welding

    Design and function MMA welding MMA welding 5.3.1 Connecting the electrode holder and workpiece lead CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. •...

  • Page 42: Welding Task Selection

    Design and function MMA welding 5.3.2 Welding task selection Figure 5-28 5.3.3 Arcforce Figure 5-29 Setting: • Negative values: rutile electrode types • Values at zero: basic electrode types • Positive values: cellulose electrode types 5.3.4 Hotstart The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent metal at the beginning of the welding process.

  • Page 43: Air Arc Gouging

    Design and function Air arc gouging Air arc gouging 5.4.1 Gouging torch and workpiece line 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.

  • Page 44: Welding Task Selection

    Design and function Remote control 5.4.2 Welding task selection Figure 5-33 Remote control The remote controls are operated on the 19-pole remote control connection socket (analogue). PC interface Welding parameter software Set all welding parameters on the PC and simply transfer to one or more welding machines (accessory, set consisting of software, interface, connection leads) •...

  • Page 45: Special Parameters (Advanced Settings)

    Design and function Special parameters (advanced settings) Special parameters (advanced settings) Special parameters (P1 to Pn) are applied for customer-specific configuration of machine functions. This allows the user maximum flexibility in optimising their requirements. These settings are not configured directly on the machine control since a regular setting of the parame- ters is generally not required.

  • Page 46: Reset To Factory Settings

    Design and function Special parameters (advanced settings) 5.7.2 Reset to factory settings All special parameters saved by the user will be overwritten by the factory settings! RESET Figure 5-36 Display Setting/selection Initialisation complete All customised welding parameters haven been overwritten by the factory settings. 5.7.3 Special parameters in detail 5.7.3.1...

  • Page 47: Machine Configuration Menu

    Design and function Machine configuration menu Machine configuration menu 5.8.1 Selecting, changing and saving parameters Exit Enter Figure 5-37 Display Setting/selection Lead resistance 1 Lead resistance for the first welding circuit 0 mΩ–60 mΩ (8 mΩ ex works). Only qualified service personnel may change the parameters! Time-based power-saving mode >...

  • Page 48: Aligning The Cable Resistance

    Design and function Power-saving mode (Standby) 5.9.1 Aligning the cable resistance The resistance value of the cables can be set directly or be aligned by the power source. In the delivery status the cable resistance of the power source is set to 8 mOhm. This value corresponds to a grounding cable of 5 m, an intermediate hose package of 1.5 m and a water-cooled welding torch of 3 m.
  • Page 49 Design and function Power-saving mode (Standby) • The required parameter can now be selected using the 'Welding parameter setting' rotary knob. Para- meter rL1 must be adjusted for all machine combinations. 3 Alignment/measurement • Applying slight pressure, put the welding torch in place with the contact tip on a clean, purged location on the workpiece and then press the torch trigger for approx.

  • Page 50: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed.

  • Page 51: Maintenance Work, Intervals

    A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-005406-EW501 30.03.2022...

  • Page 52: Disposing Of Equipment

    Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html.

  • Page 53: 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 dea- ler.

  • Page 54: Error Messages (Power Source)

    Rectifying faults Error messages (power source) Error messages (power source) The possible error numbers displayed depend on the machine series and version! Depending on the options of the machine display, a fault is shown as follows: Display type - machine control Display Graphic display two 7-segment displays...
  • Page 55 Rectifying faults Error messages (power source) Category Possible cause Remedy Overcurrent detection on wire Check ease of wire feeding feeder Error in tachometer generator Check the connection and particularly the ta- signal chometer generator of the second wire fee- der (slave drive). Mains phase failure Check mains voltages Short circuit...

  • Page 56: 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 7-1 099-005406-EW501 30.03.2022...

  • Page 57: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit Figure 7-2 • Switch off the machine and fill the coolant tank to the maximum level. • Unlock the quick-connect coupling with a suitable tool (connection open). 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 •...

  • Page 58: Technical Data

    Technical data Taurus 355 Basic TKM Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Taurus 355 Basic TKM MIG/MAG Welding current (I 5 A to 350 A Welding voltage according to stan- 14,3 V to 31,5 V...

  • Page 59: Accessories

    Accessories Welding torch cooling system Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Welding torch cooling system Type Designation Item no. cool50 U40 Cooling module 090-008598-00502 cool50-2 U42 Cooling unit with reinforced pump 090-008797-00502 HOSE BRIDGE UNI Tube bridge...

  • Page 60: Options

    Accessories Options Options Type Designation Item no. ON D Barrel TG.0003 Wire guide Rolliner for drum feed 092-007929-00000 Tool box for mounting to trolly Trolly 55-5 / Trolly ON Case 092-002899-00000 55-6 ON CS Crane suspension for Picomig 180 / 185 D3 / 305 092-002549-00000 T.005/TG.0003/D.0002 D3, Phoenix and Taurus 355 compact, drive 4...

  • Page 61: Replaceable Parts

    Replaceable parts Wire feed rollers Replaceable parts Performance specifications and guarantee only in connection with original spare and replacement parts! 10.1 Wire feed rollers 10.1.1 Wire feed rollers for steel wire Type Designation Item no. FE 4R 0.6 MM/0.023 INCH Drive roll set, 37 mm, 4 rolls, V-groove for steel, 092-002770-00006 LIGHT PINK...

  • Page 62: 10.1.3 Wire Feed Rollers For Cored Wire

    Replaceable parts Wire feed rollers 10.1.3 Wire feed rollers for cored wire Type Designation Item no. FUEL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00008 WHITE/ORANGE flux cored wire FUEL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00010 BLUE/ORANGE...

  • Page 63: Appendix

    Appendix Setting instructions Appendix 11.1 Setting instructions Figure 11-1 099-005406-EW501 30.03.2022...

  • Page 64: Searching For A Dealer

    Appendix Searching for a dealer 11.2 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005406-EW501 30.03.2022...

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