EWM Taurus 355 Synergic S HP MM TKW Operating Instructions Manual
  1. Manuals
  2. Brands
  3. EWM Manuals
  4. Welding System
  5. Taurus 355 Synergic S HP MM TKW
  6. Operating instructions manual
EWM Taurus 355 Synergic S HP MM TKW Operating Instructions Manual

EWM Taurus 355 Synergic S HP MM TKW Operating Instructions Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operating instructions
099-005444-EW501
Register now
and benefit!
Jetzt Registrieren
und Profitieren!
www.ewm-group.com
Welding machine
Taurus 355 Synergic S HP MM TKW
17.03.2015
*

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Taurus 355 Synergic S HP MM TKW and is the answer not in the manual?

Questions and answers

Related Manuals for EWM Taurus 355 Synergic S HP MM TKW

Summary of Contents for EWM Taurus 355 Synergic S HP MM TKW

  • Page 1 Operating instructions Welding machine Taurus 355 Synergic S HP MM TKW 099-005444-EW501 17.03.2015 Register now and 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 ..........................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 General ............................8 Transport and installation ......................12 2.4.1 Ambient conditions .......................
  • Page 4 Contents Notes on the use of these operating instructions 5.10.3 Definition of MIG/MAG welding tasks ................44 5.10.4 Welding task selection ....................44 5.10.4.1 Basic welding parameters ................44 5.10.4.2 Operating mode ..................... 44 5.10.4.3 Choke effect / dynamics ................45 5.10.4.4 superPuls ......................
  • Page 5 Wire feed rollers for aluminium wire ................112 10.1.3 Wire feed rollers for cored wire .................. 112 10.1.4 Wire guide ........................112 11 Appendix A ............................113 11.1 JOB-List ............................. 113 12 Appendix B ............................114 12.1 Overview of EWM branches ...................... 114 099-005444-EW501 17.03.2015...

  • 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 Special technical points which users must observe. Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER ENTER (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu)

  • 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 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 11 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes - See 8 Technical data chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.

  • 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 Transport and installation 2.4.1 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 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 15: Documents Which Also Apply

    3.2.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.2.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •...

  • Page 16: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted- See 9 Accessories chapter. Figure 4-1 099-005444-EW501 17.03.2015...
  • Page 17 Machine description – quick overview Front view Item Symbol Description Protective cap - See 5.2.1 Protective flap, welding machine control chapter Machine control - See 4.4 Machine control – Operating elements 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 18: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-005444-EW501 17.03.2015...
  • Page 19 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 - See 5.7 Mains connection chapter External wire feed inlet...

  • Page 20: Operating Elements In The Machine

    Machine description – quick overview Operating elements in the machine Operating elements in the machine Figure 4-3 099-005444-EW501 17.03.2015...
  • Page 21 Machine description – quick overview Operating elements in the machine Item Symbol Description Key button, automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse Welding torch function changeover switch (special welding torch required) Changing over programs or JOBs Infinite adjustment of welding performance.

  • Page 22: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 Item Symbol Description Functional sequence - See 4.4.1 Functional sequence chapter Push-button, welding task selection (JOB) Select the welding task using the welding task list (JOB-LIST) (not applicable for Phoenix Expert).
  • Page 23 Machine description – quick overview Machine control – Operating elements Item Symbol Description Select operating mode button Non-latched Latched Signal light lights up in green: Special non-latched Signal light lights up in red: MIG spot welding Special latched Push-button, throttling effect (arc dynamics) Arc is harder and more narrow Arc is softer and wider Standard MIG/MAG welding signal light...

  • Page 24: Functional Sequence

    Machine description – quick overview Machine control – Operating elements 4.4.1 Functional sequence 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. Signal light, gas pre-flow time Setting range 0.0 s to 20.0 s Signal light, start program (P...

  • Page 25: 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 26: 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 27: Protective Flap, Welding Machine Control

    Design and function Machine cooling 5.2.1 Protective flap, welding machine control 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 28: 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 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 29 Design and function Notes on the installation of welding current leads Use an individual welding lead to the workpiece for each welding machine! Figure 5-3 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.

  • Page 30: Welding Torch Cooling System

    Design and function Welding torch cooling system Welding torch cooling system 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 31: 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. Figure 5-5 Item Symbol Description Coolant tank cap Coolant filter sieve Coolant tank "Min" mark Minimum coolant level •...

  • Page 32: 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 33: 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 Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. •...

  • Page 34: Gas Test

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) 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 35: Welding Torch Holder

    Design and function Welding torch holder Welding torch holder The item described in the following is part of the machine´s scope of delivery. Figure 5-8 Item Symbol Description Crossmember of the transport handle Torch holder Fan-type lock washers Fixing screws (x 4) •...

  • Page 36: Mig/Mag Welding

    Design and function MIG/MAG welding 5.10 MIG/MAG welding 5.10.1 Welding torch and workpiece line connection On delivery, the central connector 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 37 Design and function MIG/MAG welding Item Symbol Description Welding torch Welding torch hose package Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated 19-pole connection socket (analogue) Connection for welding torch control lead Quick connect coupling (red) coolant return Quick connect coupling (blue)

  • Page 38: Wire Feed

    Design and function MIG/MAG welding 5.10.2 Wire feed 5.10.2.1 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 39: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.10.2.3 Changing the wire feed rollers Figure 5-11 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 40 Design and function MIG/MAG welding Unsatisfactory welding results due to faulty wire feeding! The wire feed rollers must be suitable for the diameter of the wire and the material. The wire feed rollers are colour-coded to facilitate distinction (see the Wire feed roller overview table). Wire feed roller overview table Material Diameter...

  • Page 41: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.10.2.4 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 42 Design and function MIG/MAG welding Figure 5-12 Item Symbol Description Welding wire Wire feed nipple Guide tube Adjusting nut • Extend and lay out the torch hose package. • Carefully unwind the welding wire from the wire spool and insert through the wire feed nipples up to the wire feed rollers.

  • Page 43: Spool Brake Setting

    Design and function MIG/MAG welding 5.10.2.5 Spool brake setting Figure 5-13 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. Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation! 099-005444-EW501...

  • Page 44: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.10.3 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 .

  • Page 45: 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 46: Burn-Back

    Design and function MIG/MAG welding 5.10.4.5 Burn-back EXIT ENTER Figure 5-16 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 47: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.10.5 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 48: Arc Length Correction Setting

    Design and function MIG/MAG welding 5.10.5.3 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) 5.10.5.4 Accessory components for operating point setting The operating point can also be set with various accessory components such as •...

  • Page 49: Forcearc

    Design and function MIG/MAG welding 5.10.6.1 forceArc Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range. Figure 5-19 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 50: Rootarc

    Design and function MIG/MAG welding 5.10.6.2 rootArc Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding. Figure 5-20 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion • Un-alloyed and low-alloy steels •...

  • Page 51: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.10.7 MIG/MAG functional sequences / operating modes 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). 5.10.8 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 52 Design and function MIG/MAG welding Non-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 53 Design and function MIG/MAG welding Non-latched operation 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 flows. •...
  • Page 54 Design and function MIG/MAG welding Special, non-latched 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 is flowing (start program P for the time t START...
  • Page 55 Design and function MIG/MAG welding Spot welding Figure 5-24 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 56 Design and function MIG/MAG welding Special, non-latched with superpulse 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 for the time t START...
  • Page 57 Design and function MIG/MAG welding Latched mode 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 flows. •...
  • Page 58 Design and function MIG/MAG welding Latched mode with superpulse Figure 5-27 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 59 Design and function MIG/MAG welding Latched special Figure 5-28 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 60 Design and function MIG/MAG welding Special, latched with superpulse Figure 5-29 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 61: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.10.9 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 62: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.10.9.2 MIG/MAG overview of parameters Figure 5-31 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 63: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.10.9.3 Example, tack welding (non-latched) Figure 5-32 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 64: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.10.9.5 Example, aluminium welding (latched special) Figure 5-34 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 65: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.10.9.6 Example, visible seams (latched super pulse) Figure 5-35 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 66: Main Program A Mode

    Design and function MIG/MAG welding 5.10.10 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 67 Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-36 Example 2: Welding different positions on a workpiece (latched) Figure 5-37 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-38 Up to 16 programs (P...

  • Page 68: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.10.10.1 Selecting parameters (program A) 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. (LED Prog is on) Select program number.

  • Page 69: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.10.12 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- See 5.17 Special parameters (advanced settings) chapter: •...

  • Page 70: Expert Menu (Mig/Mag)

    Design and function MIG/MAG welding 5.10.14 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. 5.10.15 Selection ENTER (Enter the menu) • Keep the "welding parameters" push-button pressed for 3 s. NAVIGATION (Navigate the menu) •...
  • Page 71 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 72: Tig Welding

    Design and function TIG welding 5.11 TIG welding 5.11.1 Welding torch and workpiece line connection Figure 5-41 Item Symbol Description Welding torch Welding torch hose package Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Quick connect coupling (red) coolant return Quick connect coupling (blue)

  • Page 73: Welding Task Selection

    Design and function TIG welding 5.11.2 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 74: Function Sequences/Operating Modes

    Design and function TIG welding 5.11.5 Function sequences/operating modes 5.11.5.1 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 Gas pre-flows Gas post-flows Non-latched Special, non-latched Latched Special, latched...
  • Page 75 Design and function TIG welding Non-latched mode Figure 5-43 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 76 Design and function TIG welding Latched mode Figure 5-45 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 77: Tig Automatic Cut-Out

    Design and function TIG welding Latched special Figure 5-46 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 78: Mma Welding

    Design and function MMA welding 5.12 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 79: Welding Task Selection

    Design and function MMA welding 5.12.2 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 80: Hotstart

    Design and function MMA welding 5.12.2.3 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 5-48 For hotstart parameter settings, - See 5.12.3 Parameter overview chapter 5.12.2.4 Antistick Anti-stick prevents the electrode from annealing.

  • Page 81: Remote Control

    Design and function Remote control 5.13 Remote control 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 82: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.14.1 Remote control connection socket, 19-pole Figure 5-51 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 83: Pc Interfaces

    Design and function PC Interfaces 5.15 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 84: Selecting, Changing And Saving Parameters

    Design and function Special parameters (advanced settings) 5.17.1 Selecting, changing and saving parameters ENTER (Enter the menu) • Switch off machine at the main switch. • Press and hold the "left parameter selection" button and switch the machine on again at the same time.
  • Page 85 Design and function Special parameters (advanced settings) 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" 0 = P0 enabled (Ex works) 1 = P0 blocked Display mode for Up/Down welding torch with one-digit 7-segment display (two keys) 0 = normal display (ex works)

  • Page 86: Reset To Factory Settings

    Design and function Special parameters (advanced settings) Display Setting/selection Program selection with standard torch trigger 0 = no program selection (Ex works) 1 = program selection possible Mean value display for super pulses Function switched off Function switched on (factory setting) Predefined execution of the pulsed arc welding process in the PA program Predefined execution of the pulsed arc welding process in the PA program is disabled.

  • Page 87: The Special Parameters In Detail

    Design and function Special parameters (advanced settings) 5.17.1.2 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 88 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 89 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 90 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 91 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 92 Design and function Special parameters (advanced settings) Latched special tapping time setting (P11) The tapping time for changing over between the main program and reduced main program can be set in three levels. 0 = no tapping 1 = 320ms (factory setting) 2 = 640ms JOB list switching (P12) Value Designation...
  • Page 93 Design and function Special parameters (advanced settings) Copying JOBs, "Copy to" function The possible target range is between 129 - 169. • First configure special parameter P12 to P12 = 2 or P12 = 1! Operating Action Result Display element Select JOB list Select the source JOB Wait for around 3 seconds until the JOB has...
  • Page 94 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 95: 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 96 Design and function Machine configuration menu EXIT ENTER VOLT Prog NAVIGATION Figure 5-56 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 97: Adjusting The Cable Resistance

    Design and function Machine configuration menu 5.18.2 Adjusting 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 98: Power-Saving Mode (Standby)

    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 99: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal DANGER 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 100: Monthly Maintenance Tasks

    For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed.

  • Page 101: 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 2011/65/EU).

  • Page 102: 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 103: Error Messages

    Rectifying faults Error messages Error messages 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 104 Rectifying faults Error messages (power source) Error Category Possible cause Remedy Error 17 Wire feed mechanism Check the wire feeding (WF. Ov.) overcurrent detection Error 18 No speedometer signal from Check the connection and particularly the (WF. Sl.) second wire feeder (slave speedometer of the second wire feeder drive) (slave drive).

  • Page 105: 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 All customised welding parameters that are stored will be replaced by the factory settings. 7.4.1 Resetting a single JOB RESET ENTER EXIT Figure 7-1 Display Setting/selection...

  • Page 106: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit 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 7-3 099-005444-EW501...

  • Page 107: Fixing The Pump Shaft (Coolant Circuit)

    Rectifying faults Fixing the pump shaft (coolant circuit) Fixing the pump shaft (coolant circuit) DANGER 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 108: Technical Data

    Technical data Taurus 355 Synergic S TKW Technical data Taurus 355 Synergic S TKW Performance specifications and guarantee only in connection with original spare and replacement parts! MIG/MAG Setting range for welding current 5 A–350 A Setting range for welding voltage 14.3 V–31.5 V 10.2 V–24.0 V 20.2 V–34.0 V...

  • Page 109: Accessories

    Accessories General accessories Accessories 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 55-5 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...

  • Page 110: Options

    Accessories Options Options Type Designation Item no. ON D BARREL Wire guide Rolliner for drum feed 092-007929-00000 ON MF XX5 Dirt filter 092-002662-00000 ON CS 55 Crane suspension, retrofit option 092-002549-00000 Computer communication Type Designation Item no. PC300.Net PC300.Net welding parameter software kit incl. 090-008777-00000 cable and SECINT X10 USB interface FRV 7POL 5 m...

  • Page 111: 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 112: 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 113: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List Figure 11-1 099-005444-EW501 17.03.2015...

  • Page 114: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005444-EW501 17.03.2015...

This manual is also suitable for:

Taurus 355 synergic s lp mm tkw

Table of Contents