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Summary of Contents for EWM Taurus 505 VRD Basic TDM
- Page 1 Operating instructions Welding machine Taurus 505 VRD Basic TDM 099-005261-EW501 Observe additional system documents! 11.04.2012 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 Ambient conditions........................12 2.5.1 In operation........................ - Page 4 Vent coolant circuit........................45 8 Technical data............................46 Taurus 505 ...........................46 9 Accessories ............................47 System components........................47 Options ............................47 Welding torch cooling system ......................47 Transport systems........................47 General accessories ........................47 10 Appendix A............................48 10.1 Setting instructions........................48 11 Appendix B............................49 11.1 Overview of EWM branches......................49 099-005261-EW501 11.04.2012...
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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 Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •... - Page 8 Safety instructions General WARNING 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 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: 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 13: 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 14: Documents Which Also Apply
Intended use Documents which also apply Documents which also apply 3.3.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.3.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 15: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-005261-EW501 11.04.2012... - Page 16 Machine description – quick overview Front view Item Symbol Description Carrying handle Ready for operation signal light Signal light on when the machine is switched on and ready for operation VRD open circuit voltage reducing device (VRD machine version) The VRD signal light is illuminated, when the voltage reducing 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 17: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 099-005261-EW501 11.04.2012... - Page 18 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) 19-pole connection socket (analogue) Wire feed unit control lead connection Connection socket, “+” welding current •...
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Page 19: 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 20 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 21: Design And Function
Design and function General Design and function NOTE Observe documentation of other system components when connecting! 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. •... -
Page 22: 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 23: Protective Cap
Design and function Machine cooling 5.2.1 Protective cap Figure 5-1 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. Machine cooling To obtain an optimal duty cycle from the power components, the following precautions should be observed: •... -
Page 24: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system 5.5.1 Cooling module connection NOTE Observe the fitting and connection instructions given in the relevant operating instructions for the cooling unit. Figure 5-2 Item Symbol Description 4-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead... -
Page 25: 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! •... -
Page 26: Connecting The Intermediate Hose Package To The Power Source
Design and function Connecting the intermediate hose package to the power source Connecting the intermediate hose package to the power source 5.7.1 Intermediate hose package strain relief CAUTION Missing or incorrectly fitted strain relief! Connection sockets or connection plugs on the machine, or the intermediate tube package, may be damaged if the strain relief is missing or incorrectly fitted. -
Page 27: Intermediate Hose Package Connection
Design and function Connecting the intermediate hose package to the power source 5.7.2 Intermediate hose package connection NOTE Note the polarity of the welding current! 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 28: Shielding Gas Supply
Design and function Shielding gas supply Shielding gas supply 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! • The fastening elements must tightly enclose the shielding gas cylinder! •... -
Page 29: Gas Test
Design and function Shielding gas supply 5.8.1 Gas test • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. • Initiate gas test function on the machine control. •... -
Page 30: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.9.1 Connection for workpiece lead Figure 5-8 Item Symbol Description Workpiece "-" welding current connection socket • MIG/MAG welding: Workpiece connection Connection socket, "+" welding current • MIG/MAG cored wire welding: Workpiece connection •... -
Page 31: Welding Task Selection
Design and function MIG/MAG welding 5.9.2 Welding task selection NOTE Selection of a welding task involves the interaction of the controls on the welding machine and the wire feed unit. After the basic settings are made on the welding machine, the operating point and other parameters can be set on the wire feed unit. GM A W M IG / M AG 8 9 10... -
Page 32: Mig/Mag Functional Sequences / Operating Modes
Design and function MIG/MAG welding 5.9.3 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. 5.9.3.1 Explanation of signs and functions Symbol... - Page 33 Design and function MIG/MAG welding Non-latched mode Figure 5-10 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 34 Design and function MIG/MAG welding 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. •...
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Page 35: Welding Torch Holder
Design and function MIG/MAG welding 5.9.4 Welding torch holder NOTE The item described in the following is part of the machine´s scope of delivery. Figure 5-12 Item Symbol Description Crossmember of the transport handle Torch holder Fan-type lock washers Fixing screws (x 4) •... -
Page 36: Mma Welding
Design and function MMA welding 5.10 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 37: 5.10.2 Welding Task Selection
Design and function MMA welding 5.10.2 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 38: 5.10.4 Arcforce
Design and function Voltage reducing device 5.10.4 Arcforce Operating Action Result Display element Select arcforcing welding parameter LED for the button is on. Arcforcing setting for electrode types: (Setting range -40 to 40) Negative values Rutile Values around zero Basic m/min Positive values Cellulose... -
Page 39: 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 40: 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 41: 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 42: 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 43: 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 44: 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 45: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit NOTE Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. 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 7-2 099-005261-EW501... -
Page 46: Technical Data
Technical data Taurus 505 Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Taurus 505 MIG/MAG Setting range for welding current 5 A–500 A Setting range for welding voltage 14.3 V–39.0 V 20.2 V–40.0 V Duty cycle 40 °C 25 °C... -
Page 47: Accessories
Accessories System components Accessories NOTE 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. Taurus Basic drive 4 WE Wire feed unit, water, Euro/central connector 090-005152-00502 Taurus Basic drive 4L WE Wire feed unit, water, Euro/central connector... -
Page 48: Setting Instructions
Appendix A Setting instructions Appendix A 10.1 Setting instructions Figure 10-1 099-005261-EW501 11.04.2012... -
Page 49: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 11.1 Overview of EWM branches 099-005261-EW501 11.04.2012...
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