EWM Taurus 401 Synergic S MM FKW Operating Instructions Manual
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EWM Taurus 401 Synergic S MM FKW Operating Instructions Manual

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Operating instructions
099-005339-EW501
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Welding machine
Taurus 401 Synergic S MM FKW
Taurus 501 Synergic S MM FKW
31.01.2014
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Summary of Contents for EWM Taurus 401 Synergic S MM FKW

  • Page 1 Operating instructions Welding machine Taurus 401 Synergic S MM FKW Taurus 501 Synergic S MM FKW 099-005339-EW501 31.01.2014 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...

  • Page 2: General Instructions

    +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. No other form of liability, regardless of type, shall be accepted.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................7 Notes on the use of these operating instructions ................7 Explanation of icons ........................8 General ............................9 Transport and installation ......................13 2.4.1 Lifting by crane ......................
  • Page 4 Contents Notes on the use of these operating instructions 5.9.2.4 Inching the wire electrode ................43 5.9.2.5 Spool brake setting ..................45 5.9.3 Definition of MIG/MAG welding tasks ................46 5.9.4 Welding task selection ....................46 5.9.4.1 Basic welding parameters ................46 5.9.4.2 Operating mode .....................
  • Page 5 Wire feed rollers for aluminium wire ................116 10.1.3 Wire feed rollers for cored wire .................. 116 10.1.4 Conversion sets ......................117 11 Appendix A ............................118 11.1 JOB-List ............................. 118 12 Appendix B ............................119 12.1 Overview of EWM branches ...................... 119 099-005339-EW501 31.01.2014...
  • Page 6 Contents Notes on the use of these operating instructions 099-005339-EW501 31.01.2014...

  • Page 7: 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 8: 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 (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu) EXIT 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 9: 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 10 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 11 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
  • Page 12 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.

  • Page 13: 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 14: Lifting By Crane

    Safety instructions Transport and installation 2.4.1 Lifting by crane WARNING Risk of injury during lifting by crane When lifting the machine by crane, persons may be severely injured by falling machines or mount-on components. • Simultaneous lifting of system components such as power source wire feeder or cooling unit is not allowed.

  • Page 15: Ambient Conditions

    Safety instructions Transport and installation 2.4.2 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 16: Intended Use

    Intended use Applications Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with proper usage and by trained or expert staff! •...

  • Page 17: 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 18: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view NOTE The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted (see "Accessories" chapter). Figure 4-1 099-005339-EW501 31.01.2014...
  • Page 19 Machine description – quick overview Front view Item Symbol Description Lifting lug Ready for operation signal light Signal light on when the machine is switched on and ready for operation Main switch, machine on/off Carrying handle Cooling air inlet Automatic cut-out of coolant pump key button press to reset a triggered fuse Quick connect coupling (red) coolant return...

  • Page 20: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-005339-EW501 31.01.2014...
  • Page 21 Machine description – quick overview Rear view Item Symbol Description Slide latch, lock for the protective cap Securing elements for shielding gas cylinder (strap/chain) 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 22: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-3 099-005339-EW501 31.01.2014...
  • Page 23 Machine description – quick overview Inside view Item Symbol Description Welding torch function changeover switch (special welding torch required) Changing over programs or JOBs Infinite adjustment of welding performance. Wire spool holder Wire feed unit 099-005339-EW501 31.01.2014...

  • Page 24: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 099-005339-EW501 31.01.2014...
  • Page 25 Machine description – quick overview Machine control – Operating elements Item Symbol Description Lid (see chap. "Machine control – concealed operating elements") Display, left Welding current, material thickness, wire speed, hold values Push-button, parameter selection left/power-saving mode Welding current Material thickness Wire feed speed Hold After welding, the values used last are shown from the main program.

  • Page 26: Machine Control - Concealed Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Concealed operating elements 4.4.1 Figure 4-5 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used.
  • Page 27 Machine description – quick overview Machine control – Operating elements Item Symbol Description Key button, JOB-List Selection of the welding task (JOB) from the JOB list Push-button, wire inching/motor current (wire feed mechanism) Cf. chapter "Inching the wire electrode". Gas test / rinse button •...

  • Page 28: 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 29: 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 30: Notes On The Installation Of Welding Current Leads

    Design and function Notes on the installation of welding current leads Notes on the installation of welding current leads NOTE Incorrectly installed welding current leads can cause faults in the arc (flickering). Install welding lead and hose package in parallel and as close together as possible. Keep the welding lead and hose packages of each welding machine separate, with an installation distance of at least 15 cm! Fully unroll welding current leads, torch hose packages and intermediate hose...

  • Page 31: Welding Torch Cooling System

    Design and function Welding torch cooling system Welding torch cooling system 5.6.1 General CAUTION 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 32: Adding Coolant

    Design and function Welding torch cooling system 5.6.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. NOTE After the initial filling, wait for at least one minute when the machine is switched on so that the hose package is filled with coolant completely and without bubbles.

  • Page 33: 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 34: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) 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 35: Connection

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.8.1 Connection • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. Figure 5-4 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator...

  • Page 36: Gas Test

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.8.2 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 37: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.9.1 Welding torch and workpiece line connection CAUTION Equipment damage due to improperly connected coolant lines! If the coolant lines are not connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •...

  • Page 38: Mig/Mag Standard Welding

    Design and function MIG/MAG welding 5.9.1.1 MIG/MAG standard welding Figure 5-5 Item Symbol Description Workpiece "-" welding current connection socket • MIG/MAG welding: Workpiece connection Welding torch Welding torch hose package 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...

  • Page 39: Mig/Mag Cored Wire Welding With A Negative Wire Electrode

    Design and function MIG/MAG welding 5.9.1.2 MIG/MAG cored wire welding with a negative wire electrode Figure 5-6 Item Symbol Description Workpiece Connection socket, "+" welding current • MIG/MAG cored wire welding: Workpiece connection Welding torch Welding torch hose package 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)
  • Page 40 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 41: Wire Feed

    Design and function MIG/MAG welding 5.9.2 Wire feed 5.9.2.1 Open the protective flap of the wire feeder CAUTION To perform the following steps, the protective flap of the wire feeder needs to be opened. Make sure to close the protective flap again before starting to work. •...

  • Page 42: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.9.2.3 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 43: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.9.2.4 Inching the wire electrode 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 44 Design and function MIG/MAG welding Figure 5-9 Item Symbol Description Pressure unit Clamping unit Knurled nut Pressure roller Wire feed nipple Guide tube Drive rollers "Undetachable" knurled screws Wire feed nipple with wire stabiliser • Extend and lay out the torch hose package. •...

  • Page 45: Spool Brake Setting

    Design and function MIG/MAG welding 5.9.2.5 Spool brake setting Figure 5-10 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 46: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.9.3 Definition of MIG/MAG welding tasks This range of machines feature simple operation with a very wide range of functions. • Various JOBs (i.e. welding tasks consisting of welding process, material type, wire diameter and shielding gas type) have been pre-defined (see appendix for a list of JOBs).

  • Page 47: Choke Effect / Dynamics

    EWM welding processes offers many possibilities. Welding performance can be represented as average value (ex works) or solely as program A value. If the average value display is activated the signal lights of the main (PA) and reduced main program (PB) are illuminated simultaneously.

  • Page 48: Burn-Back

    Design and function MIG/MAG welding 5.9.4.5 Burn-back EXIT ENTER m /m in Figure 5-13 Display Setting/selection menu burn back Set burn back Parameter setting (setting range 0 to 499) Back-burn set too high: large drops developing on the wire electrode result in poor ignition properties or the wire electrode sticking to the welding nozzle.

  • Page 49: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.9.5 MIG/MAG operating point The operating point (welding output) is specified using the principle of MIG/MAG one-dial operation, i.e. the user need only specify the operating point by setting the required wire speed, for example, and the digital system will calculate the optimum values for welding current and voltage (operating point).

  • Page 50: Arc Length Correction Setting

    Design and function MIG/MAG welding 5.9.5.3 Arc length correction setting The arc length can be corrected as follows. Operating Action Result Display element "Arc length correction" setting (Display example: -0.9V, setting range -9.9 V to +9.9 V) 5.9.5.4 Accessory components for operating point setting The operating point can also be set with various accessory components such as •...

  • Page 51: Forcearc

    Design and function MIG/MAG welding 5.9.6.1 forceArc Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range. Figure 5-16 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 52: Rootarc

    Design and function MIG/MAG welding 5.9.6.2 rootArc Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding. Figure 5-17 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion • Un-alloyed and low-alloy steels •...

  • Page 53: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.9.7 MIG/MAG functional sequences / operating modes NOTE There are optimum pre-sets for welding parameters such as gas pre-flow and burn back, etc. for numerous applications (although these can also be changed if required). 5.9.7.1 Explanation of signs and functions Symbol Meaning...
  • Page 54 Design and function MIG/MAG welding Non-latched mode Figure 5-18 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 55 Design and function MIG/MAG welding Non-latched operation with superpulse Figure 5-19 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 56 Design and function MIG/MAG welding Special, non-latched 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 is flowing (start program P for the time t START...
  • Page 57 Design and function MIG/MAG welding Spot welding Figure 5-21 NOTE The ignition time t must be added to the spot time t start 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" •...
  • Page 58 Design and function MIG/MAG welding Special, non-latched with superpulse Figure 5-22 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 is flowing (start program P for the time t START...
  • Page 59 Design and function MIG/MAG welding Latched mode Figure 5-23 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 60 Design and function MIG/MAG welding Latched mode with superpulse Figure 5-24 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 61 Design and function MIG/MAG welding Latched special Figure 5-25 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 is flowing (start program P START Step 2...
  • Page 62 Design and function MIG/MAG welding Special, latched with superpulse 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 is flowing (start program P for the time t START...

  • Page 63: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.9.8 MIG/MAG program sequence ("Program steps" mode) Certain materials, such as aluminium, require special functions in order to be able to weld them safely and at high quality. The latched special operating mode is used here with the following programs: •...

  • Page 64: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.9.8.2 MIG/MAG overview of parameters Figure 5-28 Basic Parameters Item Meaning / Explanation Setting Range 1 Gas pre-flow time 0.0s to 20.0s START Wire speed, relative 1% to 200% Arc length correction -9.9V to +9.9V 3 Duration 0.0s to 20.0s 4 Slope duration from P...

  • Page 65: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.9.8.3 Example, tack welding (non-latched) Figure 5-29 Basic parameters Parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 66: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.9.8.5 Example, aluminium welding (latched special) Figure 5-31 Basic parameters Welding parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20.0s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 67: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.9.8.6 Example, visible seams (latched super pulse) Figure 5-32 Basic parameters Welding parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20.0s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 68: Main Program A Mode

    Design and function MIG/MAG welding 5.9.9 Main program A mode Different welding tasks or positions on a workpiece demand various welding performances (operating points) or welding programs. The following parameters are stored in each of the up to 16 programs: •...
  • Page 69 Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-33 Example 2: Welding different positions on a workpiece (latched) Figure 5-34 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-35 NOTE...

  • Page 70: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.9.9.1 Selecting parameters (program A) NOTE Changes to the welding parameters can only be made when the key switch is in position "1". Operating Action Result Display element Change welding data display over to program display.

  • Page 71: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.9.11 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 Other functions are also possible by tapping the torch trigger, depending on the machine type and control configuration: •...

  • Page 72: Expert Menu (Mig/Mag)

    Design and function MIG/MAG welding 5.9.13 Expert menu (MIG/MAG) The expert menu includes functions and parameters which are either not set on the machine control, or which do not require regular setting. 5.9.13.1 Selection NOTE ENTER (Enter the menu) • Keep the "welding parameters"...
  • Page 73 Design and function MIG/MAG welding Display Setting/selection Correct wire burn-back (setting range 0–499) 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. If too low a value is set, the wire electrode sticks to the weld pool.

  • Page 74: Tig Welding

    Design and function TIG welding 5.10 TIG welding 5.10.1 Welding torch and workpiece line connection Figure 5-38 Item Symbol Description Workpiece Connection socket, "+" welding current • TIG welding: Workpiece connection Welding torch Welding torch hose package Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Welding current cable, polarity selection Welding current to the central connector/torch, enables polarity selection.

  • Page 75: Welding Task Selection

    Design and function TIG welding 5.10.2 Welding task selection • Select JOB 127 (TIG welding task). It is only possible to change the JOB number when no welding current is flowing. Operating Action Result Display element Select JOB number input Set the JOB number The machine adopts the required setting after approx.

  • Page 76: Function Sequences/Operating Modes

    Design and function TIG welding 5.10.4 Function sequences/operating modes 5.10.4.1 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 Gas pre-flows Gas post-flows Non-latched Special, non-latched Latched Special, latched...
  • Page 77 Design and function TIG welding Non-latched mode Figure 5-40 Selection • Select non-latched operating mode Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). The arc is ignited using liftarc. • Welding current flows with pre-selected setting. Step 2 •...
  • Page 78 Design and function TIG welding Latched mode Figure 5-42 Selection • Select latched operating mode Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) The arc is ignited using liftarc. • Welding current flows with pre-selected setting. Step 2 •...

  • Page 79: Tig Automatic Cut-Out

    Design and function TIG welding Latched special Figure 5-43 Selection • Select latched special mode Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). The arc is ignited using liftarc. • Welding gas flows at pre-selected setting in start program "P ".

  • Page 80: Tig Program Sequence ("Program Steps" Mode)

    Design and function TIG welding 5.10.6 TIG program sequence ("Program steps" mode) Figure 5-44 Basic parameters Item Meaning/explanation Setting range Gas pre-flow time 0 s to 0.9 s START 0% to 200% Ignition current Duration (start program) 0 s to 20 s Slope duration from P to P 0 s to 20 s...

  • Page 81: Mma Welding

    Design and function MMA welding 5.11 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 82: Welding Task Selection

    Design and function MMA welding 5.11.2 Welding task selection • Select JOB 128 (MMA welding task). It is only possible to change the JOB number when no welding current is flowing. Operating Action Result Display element Select JOB number input Set the JOB number The machine adopts the required setting after approx.

  • Page 83: Hotstart

    Design and function MMA welding 5.11.4 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current Welding current Time Figure 5-46 For hotstart parameter settings, see "parameter overview" chapter 5.11.5 Antistick Anti-stick prevents the electrode from annealing.

  • Page 84: Remote Control

    Design and function Remote control 5.12 Remote control NOTE The remote controls are operated via the 19-pole remote control connection socket (analogue) or the 7-pole remote control connection socket (digital), depending on the model. Please note the relevant documentation of the accessory components. 5.13 Interfaces for automation DANGER...

  • Page 85: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.13.1 Remote control connection socket, 19-pole Figure 5-49 Signal form Short description Output Connection for PE cable screen Output Reference voltage for potentiometer 10 V (max. 10 mA) Control voltage specification (0 V–10 V) – wire feed speed Input Output Reference potential (0 V)

  • Page 86: Pc Interfaces

    Design and function PC Interfaces 5.14 PC Interfaces CAUTION Equipment damage or faults may occur if the PC is connected incorrectly! Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission. The PC may be destroyed due to high frequency ignition pulses. •...

  • Page 87: Special Parameters (Advanced Settings)

    Design and function Special parameters (advanced settings) 5.16 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 88: Selecting, Changing And Saving Parameters

    Design and function Special parameters (advanced settings) 5.16.1 Selecting, changing and saving parameters ENTER EXIT VOLT Prog Hold NAVIGATION m /m in m /m in Figure 5-50 Display Setting/selection Ramp time for wire inching 0 = normal inching (10s ramp time) 1 = fast inching (3s ramp time) (Ex works) Block program "0"...
  • Page 89 Design and function Special parameters (advanced settings) Display Setting/selection Display mode for Up/Down welding torch with one-digit 7-segment display (two keys) 0 = normal display (ex works) program number/JOB or welding performance/welding voltage correction is shown 1 = alternating display display switches between program number and welding method Program limitation Programs 1 to max.

  • Page 90: Reset To Factory Settings

    Design and function Special parameters (advanced settings) Display Setting/selection Predefined execution of the pulsed arc welding process in the PA program If the superPuls and welding process switching functions are available and activated, the pulsed arc welding process is always executed in the main program PA (ex factory).

  • Page 91: The Special Parameters In Detail

    Design and function Special parameters (advanced settings) 5.16.3 The special parameters in detail Ramp time for wire inching (P1) The wire inching starts with a speed 1.0 m/min for 2 secs. It is subsequently increased to a ramp function to 6.0 m/min. The ramp time can be set between two ranges. During wire inching, the speed can be changed by means of the welding parameter setting rotary dial.
  • Page 92 Design and function Special parameters (advanced settings) Correction operation, threshold value setting (P7) The correction operation is switched on and off for all JOBs and their programs at the same time. A correction operation is specified for wire speed (DV) and welding voltage correction (Ukorr) for each JOB. The correction value is saved separately for each program.
  • Page 93 Design and function Special parameters (advanced settings) Operating Action Result Display (examples) element Left Right Press button until "PROG" LED comes Left: Wire feed speed Right: Program number Press button and hold down for approx. Left: Current limit value of the wire feed speed correction Right: Current limit value of the...
  • Page 94 Design and function Special parameters (advanced settings) Switching programs with the standard torch trigger (P8) Special latched (latched absolute program sequence) • Cycle 1: absolute program 1 is run • Cycle 2: absolute program 2 is run after completion of "tstart". •...
  • Page 95 Design and function Special parameters (advanced settings) The number of programs (P ) corresponds to the cycle number specified under N cycle. 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". •...
  • Page 96 Design and function Special parameters (advanced settings) "Single or dual operation" (P10) setting NOTE If the system is fitted with two wire feeds, no further accessory components may be operated on the 7-pole connection socket (digital)! This relates to digital remote controls, robot interfaces, documentation interfaces, welding torches with digital control lead connection, etc.
  • Page 97 Design and function Special parameters (advanced settings) Creating user-defined JOB lists A consecutive memory range where accessories such as the POWERCONTROL 2 torch can be used to switch between JOBs will be created. • Set special parameter P12 to "2". •...
  • Page 98 Design and function Special parameters (advanced settings) Block JOB mode (P16) The following accessory components support block JOB mode: • Up/Down welding torch with one-digit 7-segment display (two keys) Program 0 is always active in JOB 0 and program 1 in all other JOBs In this operating mode, a total of 27 JOBs (welding tasks) divided into three blocks can be called up using accessory components.

  • Page 99: Machine Configuration Menu

    Design and function Machine configuration menu Mean value display for super pulses (P19) Function active (P19 = 1) • For super pulses, the mean power from program A (P ) and program B (P ) is shown in the display (factory setting).
  • Page 100 Design and function Machine configuration menu ENTER EXIT VOLT Prog NAVIGATION m /m in Figure 5-54 Display Setting/selection Lead resistance 1 Lead resistance for the first welding circuit 0 mΩ–60 mΩ (8 mΩ ex works). Lead resistance 2 Lead resistance for the second welding circuit 0 mΩ–60 mΩ (8 mΩ ex works). Only qualified service personnel may change the parameters! Only qualified service personnel may change the parameters! Time-based power-saving mode...

  • Page 101: Matching The Cable Resistance

    Design and function Machine configuration menu 5.17.2 Matching the cable resistance The resistance value of cables can either be set directly or it can be matched using the power source. The factory setting of the power sources is 8 m-ohm. This value correponds to a 5 m earth cable, a 1.5 m intermediate hose package and a 3 m water-cooled welding torch.

  • Page 102: Power-Saving Mode

    Design and function Machine configuration menu 1 Preparation • Switch off the welding machine. • Remove the gas nozzle from the welding torch. • Cut the wire flush on the contact tip. • Slightly withdraw the wire at the wire feeder (approx. 50 mm). There should be no wire left in the contact tip.

  • Page 103: 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 104: Monthly Maintenance Tasks

    Maintenance, care and disposal Maintenance work 6.2.2 Monthly maintenance tasks 6.2.2.1 Visual inspection • Casing damage (front, rear and side walls) • Wheels and their securing elements • Transport elements (strap, lifting lugs, handle) • Check coolant tubes and their connections for impurities 6.2.2.2 Functional test •...

  • Page 105: Disposing Of Equipment

    In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).

  • Page 106: 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 107: Error Messages

    Rectifying faults Error messages Error messages 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 108 Rectifying faults Error messages Legend for categories (error reset) a) The error message will disappear once the error has been rectified. 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 /...

  • Page 109: Resetting Jobs (Welding Tasks) To The Factory Settings

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings Resetting JOBs (welding tasks) to the factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings. 7.3.1 Resetting a single JOB RESET ENTER JOB- JOB- LIST...

  • Page 110: Resetting All Jobs

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings 7.3.2 Resetting all JOBs NOTE JOBs 1–128 and 170–256 will be reset. Custom JOBs 129–169 are maintained. RESET ENTER JOB- JOB- LIST LIST EXIT m /m in Figure 7-2 Display Setting/selection Reset to factory settings The RESET will be done after pressing the button.

  • Page 111: 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 7-3 099-005339-EW501...

  • Page 112: Technical Data

    Technical data Taurus 401 Synergic S FKW Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Ambient temperature depends on coolant! Observe the coolant temperature range for the welding torch cooling! Taurus 401 Synergic S FKW Setting range for welding current/voltage: 5 A/10.2 V to 400 A/26.0 V 5 A/20.2 V to 400 A/36.0 V...

  • Page 113: Taurus 501 Synergic S Fkw

    Technical data Taurus 501 Synergic S FKW Taurus 501 Synergic S FKW MIG/MAG Setting range for welding current 5 A–500 A Setting range for welding voltage 10.2 V–30.0 V 14.3 V–39.0 V 20.2 V–40.0 V Duty cycle 40 °C 25 °C 40 °C 25 °C 40 °C...

  • Page 114: 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 Wire spool adapter K300 094-001803-00001 TYP 1 Frost protection tester 094-014499-00000 KF 23E-10 Coolant (-10 °C), 9.3 l...

  • Page 115: Options

    Accessories Options Options Type Designation Item no. ON LB Wheels 160x40MM Retrofit option for locking brake for machine wheels 092-002110-00000 ON Holder Gas Bottle <50L Holding plate for gas cylinders smaller than 50 litres 092-002151-00000 ON Shock Protect Ram protection retrofit option 092-002154-00000 ON Hose/FR Mount Optional holder for tubes and remote control for...

  • Page 116: 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 117: 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 118: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List Figure 11-1 099-005339-EW501 31.01.2014...

  • Page 119: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005339-EW501 31.01.2014...

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