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Summary of Contents for EWM Taurus 301 Basic FKG
- Page 1 Operating instructions Welding machine Taurus 301 Basic FKG 099-005148-EW501 01.03.2012 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
Contents Notes on the use of these operating instructions Contents 1 Contents..............................3 2 Safety instructions..........................5 Notes on the use of these operating instructions ................5 Explanation of icons........................6 General ............................7 Transport and installation ......................11 2.4.1 Lifting by crane ......................12 Ambient conditions........................ - Page 4 Wire feed rollers for steel wire ..................51 10.1.2 Wire feed rollers for aluminium wire ................51 10.1.3 Wire feed rollers for cored wire..................51 10.1.4 Conversion sets ......................52 11 Appendix A............................53 11.1 Setting instructions........................53 12 Appendix B............................54 12.1 Overview of EWM branches......................54 099-005148-EW501 01.03.2012...
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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 Electric shock! Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents. • Do not touch any live parts in or on the machine! •... - Page 8 Safety instructions General WARNING Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure when heated. • Move containers with inflammable or explosive liquids away from the working area! • Never heat explosive liquids, dusts or gases by welding or cutting! Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning.
- Page 9 Safety instructions General CAUTION 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 10 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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Page 11: Transport And Installation
Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •... -
Page 12: Lifting By Crane
Safety instructions Transport and installation 2.4.1 Lifting by crane DANGER Risk of injury during lifting by crane! When lifting the equipment by crane, serious injuries can be inflicted by falling equipment or add-on units. • Transport on all lifting lugs at the same time (see Fig. -
Page 13: 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 14: 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 15: Documents Which Also Apply
Intended use Documents which also apply Documents which also apply 3.2.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.2.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Lifting lug Carrying handle Machine control See Machine control – operating elements chapter Main switch, machine on/off 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Cooling air inlet... -
Page 17: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Wire feed unit cover lock Securing elements for shielding gas cylinder (strap/chain) Wire spool inspection window Check wire supply Cooling air outlet Wheels, fixed castors Bracket for shielding gas cylinder D-sub connection socket, 9-pole With this machine series for maintenance purposes only (specialist staff) Mains connection cable... -
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 MIG/MAG welding GMAW MIG / MAG E-HAND MMA welding Air arc gouging MMAG FUGENHOBELN Status displays "Welding current display" signal light "Wire feed speed display"... - Page 19 Machine description – quick overview Machine control – Operating elements Item Symbol Description Rotary dial, arc length No function. Setting is made on the wire feed unit. Error/status displays "Excess temperature" signal light "Water deficiency" signal light (welding torch cooling) Display, right Welding voltage as set point, actual value or hold value.
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Page 20: Design And Function
Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 21: Installation
Design and function Installation CAUTION Damage due to incorrect connection! Accessory components and the power source itself can be damaged by incorrect connection! • Only insert and lock accessory components into the relevant connection socket when the machine is switched off. •... -
Page 22: Mains Connection
Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations (any phase sequence for three-phase machines)! -
Page 23: Shielding Gas Supply
Design and function Shielding gas supply Shielding gas supply 5.6.1 Connecting the shielding gas supply DANGER Risk of injury caused by shielding gas cylinders toppling over! Shielding gas cylinders may topple over and cause serious injury if not adequately secured! •... -
Page 24: Gas Test
Design and function Shielding gas supply Figure 5-2 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. •... -
Page 25: Setting The Shielding Gas Quantity
Design and function Shielding gas supply 5.6.4 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11.5 = l/min MIG brazing Wire diameter x 11.5 = l/min MIG welding (aluminium) Wire diameter x 13.5 = l/min (100 % argon) Helium-rich gas mixtures require a higher gas volume! The table below can be used to correct the gas volume calculated where necessary: Shielding gas... -
Page 26: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.7.1 Welding torch and workpiece line connection NOTE Fault with the wire guide! On delivery, the central connector (Euro) is fitted with a capillary tube for welding torches with spiral guides. Conversion is necessary if a welding torch with a plastic core is used! Welding torch with plastic core: •... -
Page 27: Mig/Mag Standard Welding
Design and function MIG/MAG welding 5.7.1.1 MIG/MAG standard welding Figure 5-4 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 Welding current cable, polarity selection Welding current to central connection/torch. -
Page 28: Mig/Mag Cored Wire Welding
Design and function MIG/MAG welding 5.7.1.2 MIG/MAG cored wire welding 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 Welding current cable, polarity selection Welding current to central connection/torch. -
Page 29: Spool Brake Setting
Design and function MIG/MAG welding 5.7.2 Spool brake setting Figure 5-6 Item Symbol Description Allen screw Securing the wire spool retainer and adjustment of the spool brake • Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect. NOTE Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation! -
Page 30: Inserting The Wire Spool
Design and function MIG/MAG welding 5.7.3 Inserting the wire spool NOTE Standard D300 wire spool holder can be used. Adapters (see accessories) are required when using standardised basket coils (DIN 8559). Figure 5-7 Item Symbol Description Carrier pin For fixing the wire spool Knurled nut For fixing the wire spool •... -
Page 31: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.7.4 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 32 Design and function MIG/MAG welding Figure 5-9 NOTE Depending on the design of the machine, the design of the wire feed may be the reverse of that shown! Item Symbol Description Pressure units Clamping units Knurled nut Pressure rollers Wire holding nipple Guide tube Drive rollers "Undetachable"...
- Page 33 Design and function MIG/MAG welding • Extend and lay out the torch hose package. • Unfasten pressure units and fold out (clamping units and 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 34: Welding Task Selection
Design and function MIG/MAG welding 5.7.6 Welding task selection GM A W GM A W M IG / M AG M IG / M AG M M A M M A E-H A N D E-H A N D M M A G M M A G FU GEN HOBELN FU GEN HOBELN... -
Page 35: Mig/Mag Functional Sequences / Operating Modes
Design and function MIG/MAG welding 5.7.7 MIG/MAG functional sequences / operating modes NOTE Welding parameters such as gas pre-flows wire burn-back etc. are pre-set with optimal values for numerous applications. These values can, however, be changed with the PC300.NET software as required. 5.7.7.1 Explanation of signs and functions Symbol... - Page 36 Design and function MIG/MAG welding Non-latched mode Figure 5-11 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 5-12 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: Standard Mig/Mag Torch
Design and function MIG/MAG welding 5.7.8 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 5.7.9 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 39: 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 40: Welding Task Selection
Design and function MMA welding 5.8.2 Welding task selection GM A W GM A W M IG / M AG M IG / M AG GM A W GM A W M IG / M AG M IG / M AG M M A M M A E-H A N D... -
Page 41: Welding Current Setting
Design and function MMA welding 5.8.3 Welding current setting The welding current is normally set using the "Wire speed" rotary dial. Operating Action Result Displays element Welding current is set Setpoint setting m/min 5.8.4 Arcforce Operating Action Result Display element Select arcforcing welding parameter LED for the button is on. -
Page 42: 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 43: 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 44: Annual Test (Inspection And Testing During Operation)
Maintenance, care and disposal Maintenance work 6.2.3 Annual test (inspection and testing during operation) NOTE The welding machine may only be tested by competent, capable personsl. A capable person is one who, because of his training, knowledge and experience, is able to recognise the dangers that can occur while testing welding power sources as well as possible subsequent damage and who is able to implement the required safety procedures. -
Page 45: Disposing Of Equipment
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 46: 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 47: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) NOTE A welding machine error is indicated by an error code being displayed (see table) on the display on the machine control. In the event of a machine error, the power unit is shut down. The display of possible error numbers depends on the machine version (interfaces/functions). -
Page 48: Welding Parameter Calibration
Rectifying faults Welding parameter calibration b) The error message can be reset by pressing a key button: Welding machine control Key button RC1 / RC2 Expert CarExpert / Progress (M3.11) alpha Q / Concept / Basic / Basic S / Synergic / not possible Synergic S / Progress (M3.71) c) The error message can only be reset by switching the machine off and on again. -
Page 49: Technical Data
Technical data Taurus 301 Basic Technical data Taurus 301 Basic NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Welding current/voltage setting range: 5A /20.2 V-300 A/32.0 V MIG/MAG 5A /14.3 V-300 A/29.0 V Duty cycle at 25 °C 300 A 100% 270 A... -
Page 50: Accessories
Accessories General accessories Accessories NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. AK300 Adapter for K300 basket coil 094-001803-00001 DM1 32L/MIN Manometer pressure regulator 094-000009-00000 GH 2X1/4'' 2M Gas hose... -
Page 51: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •... -
Page 52: 10.1.4 Conversion Sets
Replaceable parts Wire feed rollers 10.1.4 Conversion sets Type Designation Item no. URUE VERZ>UNVERZ FE/AL Conversion kit, 37mm, 4-roller drive on non-toothed 092-000845-00000 rollers (steel/aluminium) URUE AL 4ZR4R 0,8+1,0 Conversion kit, 37mm, 4-roller drive for aluminium 092-000867-00000 URUE AL 4ZR4R 1,0+1,2 Conversion kit, 37mm, 4-roller drive for aluminium 092-000846-00000 URUE AL 4ZR4R 1,2+1,6... -
Page 53: Setting Instructions
Appendix A Setting instructions Appendix A 11.1 Setting instructions Figure 11-1 099-005148-EW501 01.03.2012... -
Page 54: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005148-EW501 01.03.2012...
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