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Related Manuals for EWM Taurus 551 Basic FDG
Summary of Contents for EWM Taurus 551 Basic FDG
- Page 1 Operating instructions Welding machine Taurus 351 Basic FDG Taurus 401 Basic FDG Taurus 451 Basic FDG Taurus 551 Basic FDG Taurus 351 Basic FDW Taurus 401 Basic FDW Taurus 451 Basic FDW Taurus 551 Basic FDW 099-005149-EW501 Observe additional system documents!
- Page 2 +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.
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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 Safety instructions .......................... 7 Transport and installation ......................11 3 Intended use ............................ - Page 4 Taurus 351, 451, 551 Basic FDW ....................58 9 Accessories ............................59 System components ........................59 General accessories ........................59 Options ............................59 10 Appendix A ............................60 10.1 Setting instructions ........................60 11 Appendix B ............................61 11.1 Overview of EWM branches......................61 099-005149-EW501 11.08.2016...
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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 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 7: 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 8 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 9 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 10 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 11: 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 12: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate. -
Page 13: Documents Which Also Apply
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 Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. Front view Figure 4-1 099-005149-EW501 11.08.2016... - Page 15 Machine description – quick overview Front view Item Symbol Description Lifting lug Voltage reduction device (VRD) signal light The VRD signal light is illuminated when the voltage reduction device is operating without fault and the output voltage is reduced to a value specified in the relevant standard (see technical data).
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Page 16: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 099-005149-EW501 11.08.2016... - Page 17 Machine description – quick overview Rear view Item Symbol Description Intermediate hose package strain relief 19-pole connection socket (analogue) Wire feed unit control lead connection D-sub connection socket, 9-pole With this machine series for maintenance purposes only (specialist staff) Connector plug, welding current "+" Welding current connection on wire feed unit Connection socket, “-”...
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Page 18: 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 19 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, arc length No function. Setting is made on the wire feed unit. Push-button, parameter selection right/power-saving mode VOLT ---- Welding voltage kW ------- Welding power display...
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Page 20: 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 21: 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 22: Intermediate Hose Package Connection
Design and function Transport and installation 5.1.5 Intermediate hose package connection 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 "+"... - Page 23 Design and function Transport and installation • Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right. • Insert the plug on the welding current lead into the welding current connection socket "+" and lock. •...
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Page 24: Welding Torch Cooling System
Design and function Transport and installation 5.1.6 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 5.1.6.1 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 25: Adding Coolant
Design and function Transport and installation 5.1.6.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. Figure 5-2 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 26: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.7 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 27: 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 5-5 5.1.7.1 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and... -
Page 28: 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 29: 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 30: Shielding Gas Hose Connection
Design and function Transport and installation 5.1.9.2 Shielding gas hose connection Figure 5-9 Item Symbol Description Connecting nipple G¼, shielding gas connection • Connect crown nut of the shielding gas line to the G¼“ connecting nipple. 099-005149-EW501 11.08.2016... -
Page 31: 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 32: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.2.1 Connection for workpiece lead 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 "+"... -
Page 33: Welding Task Selection
Design and function MIG/MAG welding 5.2.2 Welding task selection 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. -
Page 34: Further Welding Parameters
Design and function MIG/MAG welding 5.2.3 Further welding parameters ENTER NAVIGATION EXIT Figure 5-13 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 35: Mig/Mag Functional Sequences / Operating Modes
Design and function MIG/MAG welding 5.2.4 MIG/MAG functional sequences / operating modes 5.2.4.1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger (press briefly and release) Shielding gas flowing Welding output Wire electrode is being conveyed Wire creep Wire burn-back Gas pre-flows... - Page 36 Design and function MIG/MAG welding Non-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 37 Design and function MIG/MAG welding Latched mode Figure 5-15 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 38: 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 39: Connecting The Electrode Holder And Workpiece Lead
Design and function MMA welding 5.3.1 Connecting the electrode holder and workpiece lead Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging. Figure 5-16 Item Symbol Description Connection socket, “+” welding current Connection socket, “-” welding current Workpiece Electrode holder •... -
Page 40: Welding Task Selection
Design and function MMA welding 5.3.2 Welding task selection Figure 5-17 5.3.3 Arcforce Figure 5-18 Setting: • Negative values: rutile electrode types • Values at zero: basic electrode types • Positive values: cellulose electrode types 5.3.4 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) =... -
Page 41: Air Arc Gouging
Design and function MMA welding 5.3.6 Air arc gouging Please note the relevant documentation of the 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 42: Welding Task Selection
Design and function Special parameters (advanced settings) 5.3.7 Welding task selection Figure 5-22 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 parameters is generally not required. - Page 43 Design and function Special parameters (advanced settings) Enter Exit Figure 5-23 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 44: Reset To Factory Settings
Design and function Voltage reducing device 5.4.1.1 Reset to factory settings All special parameters saved by the user will be overwritten by the factory settings! RESET Figure 5-24 Display Setting/selection Initialisation complete All customised welding parameters haven been overwritten by the factory settings. 5.4.1.2 Special parameters in detail Ramp time for wire inching (P1) -
Page 45: Machine Configuration Menu
Design and function Machine configuration menu Machine configuration menu 5.6.1 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 46: Power-Saving Mode (Standby)
Design and function Power-saving mode (Standby) Power-saving mode (Standby) You can activate the power-saving mode by either pressing the push-button > see 5.6 chapter for a prolonged time or by setting a parameter in the machine configuration menu (time-controlled power- saving mode ) >... - Page 47 Design and function Power-saving mode (Standby) 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 48: 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 49: 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 50: 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 51: 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 52: 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 53 Rectifying faults Error messages (power source) Error Category Possible cause Remedy (Err) 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 54: 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 7-1 099-005149-EW501 11.08.2016... -
Page 55: Technical Data
Technical data Taurus 401 Basic FDG Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Taurus 401 Basic FDG MIG/MAG 5 A–400 A Setting range for welding current 20.2 V–36.0 V 14.3 V–34.0 V Setting range for welding voltage Duty cycle at 40 °C 400 A... -
Page 56: Taurus 401 Basic Fdw
Technical data Taurus 401 Basic FDW Taurus 401 Basic FDW MIG/MAG 5 A–400 A Setting range for welding current 20.2 V–36.0 V 14.3 V–34.0 V Setting range for welding voltage 400 A Duty cycle at 40 °C (100% DC) 10 min. (60% DC 6 min. welding, 4 min. pause) Load cycle 79 V Open circuit voltage... -
Page 57: Taurus 351, 451, 551 Basic Fdg
Technical data Taurus 351, 451, 551 Basic FDG Taurus 351, 451, 551 Basic FDG Setting range of welding current/voltage: 5 to 350 A 5 to 450 A 5 to 550 A 20.2 to 34.0 V 20.2 to 38 V 20.2 to 42 V MIG/MAG 5 to 350 A 5 to 450 A... -
Page 58: Taurus 351, 451, 551 Basic Fdw
Technical data Taurus 351, 451, 551 Basic FDW Taurus 351, 451, 551 Basic FDW Setting range for welding current/voltage: 5 to 350 A 5 to 450 A 5 to 550 A 20.2 to 34.0 V 20.2 to 38 V 20.2 to 42 V MIG/MAG 5 to 350 A 5 to 450 A... -
Page 59: Accessories
Accessories System components Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. System components Type Designation Item no. drive 4 Basic Wire feeder, water, Euro torch connector 090-005401-00502 drive 4 Basic MMA Wire feeder, water, Euro torch connector 090-005401-51502 drive 4 IC Basic... -
Page 60: Setting Instructions
Appendix A Setting instructions Appendix A 10.1 Setting instructions Figure 10-1 099-005149-EW501 11.08.2016... -
Page 61: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 11.1 Overview of EWM branches 099-005149-EW501 11.08.2016...
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