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Summary of Contents for EWM Taurus 335 Basic S KGE
- Page 1 Operating instructions Welding machine Taurus 335 Basic S KGE 099-005214-EW501 19.05.2011 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
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Page 2: General Instructions
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer. -
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 General ............................8 Transport and installation ......................12 Ambient conditions........................13 2.5.1 In operation........................ - Page 4 Wire feed rollers ...........................53 9.4.1 Wire feed rollers for steel wire ..................53 9.4.2 Wire feed rollers for aluminium wire ................53 9.4.3 Wire feed rollers for cored wire..................53 9.4.4 Conversion sets ......................53 Options ............................53 10 Appendix A............................54 10.1 Overview of EWM branches......................54 099-005214-EW501 19.05.2011...
- Page 5 Contents Notes on the use of these operating instructions 099-005214-EW501 19.05.2011...
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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 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 8: 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 9 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 10 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 11 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 12: 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 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 Taurus 335 Basic S Machine description – quick overview Taurus 335 Basic S 4.1.1 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). - Page 17 Machine description – quick overview Taurus 335 Basic S Item Symbol Description Transport bar Carrying handle Cover for wire delivery unit and operating elements Wire spool inspection window Check wire supply Slide latch, lock for the protective cap Machine control See Machine control –...
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Page 18: Rear View
Machine description – quick overview Taurus 335 Basic S 4.1.2 Rear view Figure 4-2 099-005214-EW501 19.05.2011... - Page 19 Machine description – quick overview Taurus 335 Basic S Item Symbol Description Main switch, machine on/off Connecting nipple G¼, shielding gas connection 4-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead Mains connection cable 19-pole interface for mechanised welding (analogue), optional (see “Design and function“...
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Page 20: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements M 3.77 GMAW GMAW MIG / MAG MIG / MAG E-HAND E-HAND MMAG MMAG FUGENHOBELN FUGENHOBELN Taurus Basic S m/min Figure 4-3 Item Symbol Description Button, welding process MIG/MAG welding GMAW... -
Page 21: Operating Elements In The Machine
Machine description – quick overview Machine control – Operating elements Item Symbol Description Operating mode changeover switch Switching between non-latched and latched operating modes Non-latched operation Latched operation Dynamics/choke effect button Arc harder and narrower Arc softer and wider 4.2.1 Operating elements in the machine Figure 4-4 Item... -
Page 22: 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 23: 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 24: Protective Cap
Design and function Machine cooling 5.2.1 Protective cap Figure 5-1 Item Symbol Description Protective cap Bracket, protective cap To change or replace the protective flap: • 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 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 (any phase sequence for three-phase machines)! -
Page 26: Cooling Module Connection
Design and function Cooling module connection Cooling module connection NOTE Observe the fitting and connection instructions given in the relevant operating instructions for the cooling unit. Figure 5-3 Item Symbol Description 4-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead Cooling module •... -
Page 27: 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 28: 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 Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger 19-pole connection socket (analogue) Connection for welding torch control lead Welding current cable, polarity selection Welding current to central connection/torch. -
Page 29: Mig/Mag Cored Wire Welding With A Negative Wire Electrode
Design and function MIG/MAG welding 5.7.1.2 MIG/MAG cored wire welding with a negative wire electrode Figure 5-5 Item Symbol Description Welding torch Welding torch hose package Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger 19-pole connection socket (analogue) Connection for welding torch control lead Connection socket, “+”... -
Page 30: Mig/Mag Cored Wire Welding With A Positive Wire Electrode
Design and function MIG/MAG welding 5.7.1.3 MIG/MAG cored wire welding with a positive wire electrode NOTE To connect the positive wire electrode, follow the procedure in the "MIG/MAG standard welding" chapter! 5.7.2 Inserting the wire spool NOTE Standard D300 pin reels can be used. Adapters (see accessories) are required when using standardised basket coils (DIN 8559). -
Page 31: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.7.3 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 32: Inching The Wire Electrode
Design and function MIG/MAG welding 5.7.4 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 33: Spool Brake Setting
Design and function MIG/MAG welding • Extend and lay out the torch tube package. • Unfasten pressure units and fold out (clamping units and counter-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. -
Page 34: Welding Task Selection
Design and function MIG/MAG welding 5.7.6 Welding task selection 5.7.6.1 Basic welding parameters Operating Action Result element Welding process selection GMAW MIG / MAG Signal light GMAW MIG / MAG 5.7.6.2 Operating mode Operating Action Result element Operating mode selection No change The signal light indicates the selected operating mode. -
Page 35: Accessory Components For Operating Point Setting
Design and function MIG/MAG welding 5.7.6.5 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" chapter. See the operating instructions for the machine in question for a more detailed description of the individual machines and their functions. -
Page 36: Mig/Mag Functional Sequences / Operating Modes
Design and function MIG/MAG welding 5.7.8 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. 5.7.8.1 Explanation of signs and functions Symbol... - Page 37 Design and function MIG/MAG welding Non-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. •...
- Page 38 Design and function MIG/MAG welding Latched mode Figure 5-13 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 39: Standard Mig/Mag Torch
Design and function MIG/MAG welding 5.7.9 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 5.7.10 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 40: Shielding Gas Supply
Design and function Shielding gas supply Shielding gas supply 5.8.1 Connecting the shielding gas supply 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 41: Gas Test
Design and function Shielding gas supply Figure 5-14 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 42: Setting The Shielding Gas Quantity
Design and function Shielding gas supply 5.8.4 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 43: 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 44: Welding Task Selection
Design and function MMA welding • Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right. • Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and lock by turning to the right. -
Page 45: Antistick
Design and function Interfaces 5.9.6 Antistick Anti-stick prevents the electrode from annealing. If the electrode sticks in spite of the Arcforce device, the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating. Check the welding current setting and correct according to the welding task! Figure 5-17 5.10... -
Page 46: 5.10.1 Automation Interface
Design and function Interfaces 5.10.1 Automation interface NOTE These accessory components can be retrofitted as an option, see Accessories chapter. Input / Description Diagram output Output Connection for cable shielding Output IGRO Current flows signal I>0 (maximum load 20 (open mA / 15 V) collector) 0 V = welding current flows... -
Page 47: 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 48: Maintenance Work
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 49: Rectifying Faults
Rectifying faults Customer checklist 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 50: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) 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 51: Technical Data
Technical data Taurus 335 Basic S Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Taurus 335 Basic S Setting range: Welding current/voltage 5 A-330 A MIG/MAG 5 A-330 A Duty cycle at 40 °C ambient temperature 35% DC 330 A 60% DC... -
Page 52: 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. Trolly 55-2 Transport vehicle 090-008628-00000 cool 50 Cooling module 090-008598-00502 AK300 Adapter for K300 basket coil 094-001803-00001 DM1 32L/MIN... -
Page 53: Wire Feed Rollers
Accessories Wire feed rollers Wire feed rollers 9.4.1 Wire feed rollers for steel wire Type Designation Item no. FE 2DR4R 0,6+0,8 Drive rollers, 37 mm, steel 092-000839-00000 FE 2DR4R 0,8+1,0 Drive rollers, 37 mm, steel 092-000840-00000 FE 2DR4R 0,9+1,2 Drive rollers, 37 mm, steel 092-000841-00000 FE 2DR4R 1,0+1,2 Drive rollers, 37 mm, steel... -
Page 54: Overview Of Ewm Branches
50259 Pulheim · Germany · Tel: +49 2234 697-047 · Fax: -048 www.ewm-group.com/handel · nl-koeln@ewm-group.com Sales and Service International EWM HIGHTEC WELDING GmbH EWM HIGHTEC WELDING Sales s.r.o. / Prodejní a poradenské centrum Fichtenweg 1 Tyršova 2106 4810 Gmunden · Austria · Tel: +43 7612 778 02-0 · Fax: -20 256 01 Benešov u Prahy ·...
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