EWM Taurus 355 Basic TKW Operating Instructions Manual
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EWM Taurus 355 Basic TKW Operating Instructions Manual

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Operating instructions
Welding machine
EN
Taurus 355 Basic TKW
099-005442-EW501
02.09.2016

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Summary of Contents for EWM Taurus 355 Basic TKW

  • Page 1 Operating instructions Welding machine Taurus 355 Basic TKW 099-005442-EW501 02.09.2016...
  • 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.

  • 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 ................70 10.1.3 Wire feed rollers for cored wire ..................70 10.1.4 Wire guide ........................70 11 Appendix A ............................71 11.1 Setting instructions ........................71 12 Appendix B ............................72 12.1 Overview of EWM branches......................72 099-005442-EW501 02.09.2016...
  • Page 5 Contents Notes on the use of these operating instructions 099-005442-EW501 02.09.2016...

  • 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. •...

  • 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 Figure 4-1 099-005442-EW501 02.09.2016...
  • Page 15 Machine description – quick overview Front view Item Symbol Description Protective cap > see 5.1.4 chapter Machine control > see 4.3 chapter 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.

  • Page 16: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-005442-EW501 02.09.2016...
  • Page 17 Machine description – quick overview Rear view Item Symbol Description Transport bar Main switch, machine on/off Connecting nipple G¼, shielding gas connection Cooling air inlet Cooling air outlet Machine feet Automatic cut-out of coolant pump key button press to reset a triggered fuse Mains connection cable >...

  • Page 18: Operating Elements In The Machine

    Machine description – quick overview Rear view 4.2.1 Operating elements in the machine Figure 4-3 099-005442-EW501 02.09.2016...
  • Page 19 Machine description – quick overview Rear view Item Symbol Description Key button, automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse D-sub connection socket, 9-pole With this machine series for maintenance purposes only (specialist staff) Wire spool holder Wire feed unit 099-005442-EW501...

  • Page 20: 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 21 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...

  • Page 22: Design And Function

    Design and function Transport and installation Design and function Transport and installation 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. •...

  • Page 23: Machine Cooling

    Design and function Transport and installation 5.1.2 Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage. • Observe the ambient conditions! • Keep the cooling air inlet and outlet clear! • Observe the minimum distance of 0.5 m from obstacles! 5.1.3 Workpiece lead, general CAUTION...

  • Page 24: Welding Torch Cooling System

    Design and function Transport and installation 5.1.5 Welding torch cooling system 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 25: 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 5-2 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 5.1.6 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 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 5.1.6.1 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 5.1.7 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 5.1.8 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 30: Shielding Gas Hose Connection

    Design and function Transport and installation 5.1.8.2 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. 099-005442-EW501 02.09.2016...

  • Page 31: Gas Test - Setting The Shielding Gas Volume

    Design and function Transport and installation Gas test – setting the shielding gas volume 5.1.8.3 If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to form. Adjust the shielding gas quantity to suit the welding task! •...

  • Page 32: Welding Data Display

    Design and function Welding data display Welding data display Figure 5-11 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 33: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.3.1 Welding torch and workpiece line connection On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used! •...
  • Page 34 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 5-12 Item Symbol...
  • Page 35 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. •...

  • Page 36: 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 37: 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 38: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.3.2.3 Changing the wire feed rollers Figure 5-14 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 39 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 40: 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 41: 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 42: Welding Task Selection

    Design and function MIG/MAG welding 5.3.3 Welding task selection Figure 5-18 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 43: Further Welding Parameters

    Design and function MIG/MAG welding 5.3.4 Further welding parameters ENTER NAVIGATION EXIT Figure 5-19 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 44: 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 45 Design and function MIG/MAG welding Non-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 Design and function MIG/MAG welding Latched mode Figure 5-21 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 47: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.3.6 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 5.3.7 MIG/MAG special-torches Function specifications and more indepth information can be found in the operating manual for the relevant welding torch! 099-005442-EW501 02.09.2016...

  • Page 48: 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 49: Welding Task Selection

    Design and function MMA welding 5.4.2 Welding task selection Figure 5-23 5.4.3 Arcforce Figure 5-24 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 50: Air Arc Gouging

    Design and function MMA welding 5.4.6 Air arc gouging 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 51: Welding Task Selection

    Design and function MMA welding 5.4.7 Welding task selection Figure 5-28 099-005442-EW501 02.09.2016...

  • Page 52: 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 53 Design and function Special parameters (advanced settings) Enter Exit Figure 5-29 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.

  • Page 54: 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 5-30 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 55: 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 56: 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 57 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.

  • Page 58: 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 59: 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 60: 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 61: 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 62: 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 63 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...

  • Page 64: 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 7-1 099-005442-EW501 02.09.2016...

  • Page 65: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit 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 7-2 099-005442-EW501 02.09.2016...

  • Page 66: Fixing The Pump Shaft (Coolant Circuit)

    Rectifying faults Fixing the pump shaft (coolant circuit) Fixing the pump shaft (coolant circuit) WARNING Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference.

  • Page 67: Technical Data

    Technical data Fixing the pump shaft (coolant circuit) Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! MIG/MAG Current setting range 5 A–350 A Voltage setting range 14.3 V–31.5 V 20.2 V–34.0 V Duty cycle at 40 °C ambient temperature 40% DC 350 A 60% DC...

  • Page 68: Accessories

    Accessories General accessories Accessories General accessories Type Designation Item no. Trolly 55-5 Transport cart, assembled 090-008632-00000 TYP 1 Frost protection tester 094-014499-00000 KF 23E-10 Coolant (-10 °C), 9.3 l 094-000530-00000 KF 23E-200 Coolant (-10 °C), 200 litres 094-000530-00001 KF 37E-10 Coolant (-20 °C), 9.3 l 094-006256-00000 KF 37E-200...

  • Page 69: 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 70: 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 71: Setting Instructions

    Appendix A Setting instructions Appendix A 11.1 Setting instructions Figure 11-1 099-005442-EW501 02.09.2016...

  • Page 72: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005442-EW501 02.09.2016...

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