EWM Taurus 401 Synergic S MM FKW, Operating Instructions Manual

Page 1: ...elding 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 Details for ewm warranty www ewm group com ...

Page 2: ...pment No other form of liability regardless of type shall be accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are observed during installation operation usage and maintenance of the equipment An incorrectly performed installation can result i...

Page 3: ...on 17 4 Machine description quick overview 18 4 1 Front view 18 4 2 Rear view 20 4 3 Inside view 22 4 4 Machine control Operating elements 24 4 4 1 Machine control Concealed operating elements 26 5 Design and function 28 5 1 General 28 5 2 Installation 29 5 3 Machine cooling 29 5 4 Workpiece lead general 29 5 5 Notes on the installation of welding current leads 30 5 6 Welding torch cooling system ...

Page 4: ... 66 5 9 8 6 Example visible seams latched super pulse 67 5 9 9 Main program A mode 68 5 9 9 1 Selecting parameters program A 70 5 9 10 MIG MAG automatic cut out 70 5 9 11 Standard MIG MAG torch 71 5 9 12 MIG MAG special torches 71 5 9 12 1 Program and Up down operation 71 5 9 12 2 Switching between Push Pull and intermediate drive 71 5 9 13 Expert menu MIG MAG 72 5 9 13 1 Selection 72 5 10 TIG wel...

Page 5: ...Manufacturer s declaration to the end user 105 6 5 Meeting the requirements of RoHS 105 7 Rectifying faults 106 7 1 Checklist for rectifying faults 106 7 2 Error messages 107 7 3 Resetting JOBs welding tasks to the factory settings 109 7 3 1 Resetting a single JOB 109 7 3 2 Resetting all JOBs 110 7 4 Vent coolant circuit 111 8 Technical data 112 8 1 Taurus 401 Synergic S FKW 112 8 2 Taurus 501 Syn...

Page 6: ...Contents Notes on the use of these operating instructions 6 099 005339 EW501 31 01 2014 ...

Page 7: ...ol in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading with a general warning symbol The risk is explained using a symbol on the edge of the page CAUTION Working and operating procedures which must be followed precisely to avoid damaging or destroying t...

Page 8: ...ress Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exit the menu 4 s 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: ...ipment sensitive to radiation accordingly The correct functioning of pacemakers may be affected obtain advice from a doctor if necessary 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 Appoint only skil...

Page 10: ...o hand in the working area Thoroughly remove any residue of flammable substances from the workpiece before starting welding Only continue work on welded workpieces once they have cooled down Do not allow to come into contact with flammable material Connect welding leads correctly Danger when coupling multiple power sources Coupling multiple power sources in parallel or in series has to be carried ...

Page 11: ...g currents Stray welding currents can destroy protective earth conductors damage equipment and electronic devices and cause overheating of components leading to fire Make sure all welding leads are securely connected and check regularly Always ensure a proper and secure electrical connection to the workpiece Set up attach or suspend all conductive power source components like casing transport vehi...

Page 12: ...The user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the user must consider the following see also EN 60974 10 Appendix A Mains control signal and telecommunication lines Radios and televisions Computers and other control systems Safety equipment The health of neighbouring persons especi...

Page 13: ... during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to EN 60974 A2 Set up and transport the machine on level solid ground Secure add on parts using suitable equipment Replace damaged wheels and their fixing elements Fix external wire feed units during transport avoid uncontrolled rotation Damage due to supply lines not being disconnected During transport supply...

Page 14: ...ift all lifting eyes simultaneously When using retrofitted craning frames etc always use at least two lifting points positioned as far apart as possible observe option description Avoid any jerky movements Ensure that the load is distributed evenly Use chain hoists and chain slings of the same length only Stay outside the danger zone underneath the machine Observe the regulations regarding occupat...

Page 15: ...ities of dust acid corrosive gases or substances may damage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambient conditions Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Keep the cooling air inlet and outlet clear Observe the minimum distan...

Page 16: ... rootArc Short arc with perfect weld modelling capabilities for effortless gap bridging and positional welding 3 1 1 3 MIG MAG cored wire welding Welding with cored wire electrodes consisting of a metal casing and a powder core As with MIG MAG standard welding the arc is protected from the atmosphere by shielding gas The gas is supplied either externally gas shielded cored wires or produced in the...

Page 17: ...ed with the unit 3 2 3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be used in environments with an increased electrical hazard 3 2 4 Service documents spare parts and circuit diagrams DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repaired or mod...

Page 18: ...005339 EW501 31 01 2014 4 Machine description quick overview 4 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 Figure 4 1 ...

Page 19: ...to central connection torch MIG MAG cored wire welding Workpiece connection TIG welding Workpiece connection MMA welding Workpiece or electrode holder connection 14 Welding current cable polarity selection Welding current to the central connector torch enables polarity selection MIG MAG Connection socket for welding current Self shielding cored wire TIG Connection socket for welding current 15 Wel...

Page 20: ...Machine description quick overview Rear view 20 099 005339 EW501 31 01 2014 4 2 Rear view Figure 4 2 ...

Page 21: ... replacement parts and JOB lists will be located on the inside 4 Wire spool inspection window Check wire supply 5 Cooling air outlet 6 Bracket for shielding gas cylinder 7 Wheels fixed castors 8 PC interface serial D Sub connection socket 9 pole 9 Connecting nipple G shielding gas connection 10 Key button automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse 11 7 pol...

Page 22: ...Machine description quick overview Inside view 22 099 005339 EW501 31 01 2014 4 3 Inside view Figure 4 3 ...

Page 23: ...iew 099 005339 EW501 31 01 2014 23 Item Symbol Description 0 1 Welding torch function changeover switch special welding torch required Changing over programs or JOBs Infinite adjustment of welding performance 2 Wire spool holder 3 Wire feed unit ...

Page 24: ...Machine description quick overview Machine control Operating elements 24 099 005339 EW501 31 01 2014 4 4 Machine control Operating elements Figure 4 4 ...

Page 25: ...Welding parameter setting rotary dial For setting the welding performance for selecting the JOB welding task and for setting other welding parameters 6 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 7 Push button throttling effect arc dynamics Arc is harder and more narrow Arc is so...

Page 26: ...ength 9 9 V to 9 9 V 7 Signal light duration of main program PA Setting range 0 1 s to 20 0 s 0 1 s increments Used e g in connection with the super pulse function 8 Signal light reduced main program PB Wire speed 1 to 200 of the main program PA Correction of the arc length 9 9 V to 9 9 V 9 Signal light duration reduced main program PB Setting range 0 0 s to 20 0 s 0 1 s increments Used e g in con...

Page 27: ...0 16 Key button JOB List Selection of the welding task JOB from the JOB list 17 Push button wire inching motor current wire feed mechanism Cf chapter Inching the wire electrode 18 Gas test rinse button Gas test For setting the shielding gas quantity Rinse For rinsing longer hose packages See also Shielding Gas Supply chapter ...

Page 28: ...ection If the welding current connections are not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by turning in clockwise direction if necessary 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 ...

Page 29: ...ne 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 Safe operation of the machine must be guaranteed at all times 5 3 Machine cooling To obtain an optimal duty cycle from the power components the following precautions shou...

Page 30: ...as close together as possible B Keep the welding lead and hose packages of each welding machine separate with an installation distance of at least 15 cm C Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops D Use an individual welding lead to the workpiece for each welding machine Connect the work clamp close to the welding point E Always keep leads as...

Page 31: ...ust be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components The coolant must be checked for adequate frost protection with the TYP 1 frost protection tester see accessories Replace coolant as necessary if frost protection is inadequate NOTE The disposal of coolant must be carried out according to official regulations and obs...

Page 32: ... up as necessary Figure 5 2 Item Symbol Description 0 1 Coolant tank cap 2 Coolant filter sieve 3 Coolant tank 4 Min mark Minimum coolant level Unscrew and remove the coolant tank sealing cover Check filter sieve insert for dirt clean if necessary and reinsert into position Top up coolant to the filter sieve insert close sealing cover again NOTE The level of coolant must never fall below the min m...

Page 33: ...network has to be suitable for operating devices according to protection class 1 5 7 1 Mains configuration NOTE The machine may be connected to a three phase system with four conductors and an earthed neutral conductor a three phase system with three conductors of which any one can be earthed e g the outer conductor Figure 5 3 Legend Item Designation Colour code L1 Outer conductor 1 brown L2 Outer...

Page 34: ... the shielding gas cylinder Do not attach any element to the shielding gas cylinder valve Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air Avoid heating the shielding gas cylinder CAUTION Faults in the shielding gas supply An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requ...

Page 35: ...ing a securing chain Figure 5 4 Item Symbol Description 0 1 Pressure regulator 2 Shielding gas cylinder 3 Output side of the pressure regulator 4 Cylinder valve Tighten the pressure regulator screw connection on the gas bottle valve to be gas tight Screw gas hose connection crown nut onto the output side of the pressure regulator Fasten the gas hose to the shielding gas connecting nipple at the ba...

Page 36: ...tity 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 TIG Gas nozzle diameter in mm corresponds to l min gas throughput 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 Factor 75 Ar 25 He 1 14 50 Ar 50 He 1 35 25 ...

Page 37: ...either a spiral guide or plastic core with the correct inner diameter has to be inserted in the torch Recommendation Use a spiral guide to weld hard unalloyed wire electrodes steel Use a plastic core to weld or braze soft high alloy wire electrodes or aluminium materials Preparation for connecting welding torches with a plastic core Push forward the capillary tube on the wire feed side in the dire...

Page 38: ...IG MAG welding Standard applications Connection for welding current connection socket 8 Quick connect coupling red coolant return 9 Quick connect coupling blue coolant supply 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 Welding current lead insert ...

Page 39: ...onnection socket analogue For connecting analogue accessory components remote control welding torch control lead etc 6 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and torch trigger integrated 7 Welding current cable polarity selection Welding current to central connection torch Permits polarity selection for MIG MAG welding Cored wire welding Connection for...

Page 40: ...to the welding current connection socket and lock Insert the welding torch control cable into the 19 pole connection socket and lock MIG MAG torches with additional control cables only Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant return and supply line blue to quick connect coupling blue cool...

Page 41: ...ay come loose from the wire spool holder and fall to the ground causing damage to the machine and injuries Securely fasten the wire spool to the wire spool holder using the knurled nut Before you start working always check the wire spool is securely fastened NOTE Standard D300 wire spool holder can be used Adapters see accessories are required when using standardised basket coils DIN 8559 Figure 5...

Page 42: ...e and the material Check the roller label to verify that the rollers are suitable for the wire diameter Turn or change if necessary use V groove rollers with for steel wires and other hard wires use U groove rollers for aluminium wires and other soft alloyed wires Slide new drive rollers into place so that the diameter of the wire used is visible on the drive roller Screw the drive rollers in plac...

Page 43: ...ntervals Keep all casing covers or protective caps closed during operation 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 Never direct the welding torch towards your own body or towards other persons CAUTION Extensive wear due to incorrect contact pre...

Page 44: ...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 Press the clamping element with the pressure roller back downwards and fold the wire units back up again wire electrode should be in the groove on the drive roller Set the contact pressure with the adjusting nuts of the pre...

Page 45: ... Description 0 1 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: ... dial Additional parameters can be modified as required in the configuration menu on the control or using the PC300 NET welding parameter software 5 9 4 Welding task selection 5 9 4 1 Basic welding parameters Select JOB welding task with JOB list The JOB list sticker can be found on the inside of the protective flap of the wire feeder You can only change the JOB number when no welding current is f...

Page 47: ...p welds without weaving superPuls in combination with 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 The display variants can be changed using special parameter P19 see ch...

Page 48: ...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 Back burn set too low Wire electrode sticks in the molten pool ...

Page 49: ... current material thickness or wire speed Operating element Action Result n x Switching the display between Welding current Material thickness Wire speed Application example Aluminium is to be welded Material AlMg Gas Ar 100 Wire diameter 1 2 mm The correct wire speed is not known and is to be determined Select the appropriate JOB see JOB list sticker Switch to the material thickness display Set t...

Page 50: ...he left and right of the control displays are the Parameter selection buttons They are used to select welding parameters to be displayed Each press of the button advances the display to the next parameter LEDs next to the button indicate the selection After the last parameter is reached the system starts again from the beginning Figure 5 15 The display shows Nominal values before welding Actual va...

Page 51: ...251 12 0 252 12 0 253 6 0 You can make use of these properties after selecting the forceArc process see the Selecting a MIG MAG welding task chapter As with pulse arc welding it is important to make sure of a good welding current connection Keep welding current cables as short as possible and ensure that cable cross sections are adequate Fully unroll welding current cables torche hose packages and...

Page 52: ...ion and secure sidewall fusion Un alloyed and low alloy steels Manual and automated applications rootArc welding up to Wire Ø mm 0 6 0 8 0 9 1 1 2 1 6 Material Gas JOB JOB JOB JOB JOB JOB Steel CO2 204 7 0 205 5 0 Ar 80 90 206 8 0 207 6 0 NOTE Unstable arc Welding current cables that are not fully unrolled can cause faults in the arc flickering Fully unroll welding current cables torch hose packag...

Page 53: ...n also be changed if required 5 9 7 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I Welding output Wire electrode is being conveyed Wire creep Wire burn back Gas pre flows Gas post flows Non latched Special non latched Latched Special latched t Time PSTART Ignition program PA Main prog...

Page 54: ...ng 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 Change over to pre selected wire speed Step 2 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses ...

Page 55: ...rc ignites after the wire electrode makes contact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 2 Release torch trigger Super pulse function is ended WF motor stops Arc is extinguished after the preselected wire burn back time ex...

Page 56: ...e feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART for the time tstart Slope to main program PA Step 2 Release torch trigger Slope to end program PEND for the time tend WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses ...

Page 57: ... wire electrode makes contact with the workpiece welding current is flowing start program PSTART spot time starts Slope to main program PA After the set spot time elapses slope goes to end program PEND Wire feed motor stop welding Arc is extinguished after the pre selected wire burn back time elapses Gas post flow time elapses 2nd cycle Release torch trigger Releasing the torch trigger step 2 inte...

Page 58: ...workpiece welding current is flowing start program PSTART for the time tstart Slope on main program PA Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 2 Release torch trigger Super pulse function is ended Slope to end program PEND for the time tend WF motor stops Arc is e...

Page 59: ...r runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Change over to pre selected WF speed main program PA Step 2 Release torch trigger no effect Step 3 Press torch trigger no effect Step 4 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses ...

Page 60: ...ontact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 2 Release torch trigger no effect Step 3 Press torch trigger no effect Step 4 Release torch trigger Super pulse function is ended WF motor stops Arc is extinguished after the p...

Page 61: ...ime tSTART elapses and at the latest when the torch trigger is released Tapping1 can be used to change over to the reduced main program PB Repeated tapping will switch back to the main program PA Step 3 Press and hold torch trigger Slope to end program PEND Step 4 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses N...

Page 62: ...ng start program PSTART for the time tstart Step 2 Release torch trigger Slope on main program PA Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 3 Press the torch trigger Super pulse function is ended Slope in the end program PEND for the time tend Step 4 Release torch t...

Page 63: ...t of the seam Main program PA continuous welding Reduced main program PB targeted heat reduction End program PEND minimisation of end craters via targeted heat reduction The programs include the parameters wire speed operating point arc length correction slope times program duration etc Figure 5 27 NOTE This function can only be enabled with the PC300 NET software See operating instructions for th...

Page 64: ...ration spot time and superpulse 0 01s to 20 0s 7 8 PB Wire speed relative Arc length correction relative 1 to 200 9 9V to 9 9V 8 9 Duration 0 01s to 20 0s 9 1 0 Slope duration from PA to PEND 0 0s to 20s 10 1 1 PEND Wire speed relative Arc length correction 1 to 200 9 9V to 9 9V 11 1 2 Duration superpulse 0 0s to 20s 12 1 3 Gas post flow time 0 0s to 20s 13 1 4 Superpulses On Off NOTE PSTART PB an...

Page 65: ...ecial Figure 5 30 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 PSTART start program Welding parameter Meaning explanation Setting range DVstart Wire speed 0 to 200 Ustart Arc length correction 9 9V to 9 9V tstart Duration 0 0s to 20s PA main program Welding pa...

Page 66: ...ation Setting range DVstart Wire speed 0 to 200 ustart Arc length correction 9 9V to 9 9V tstart Duration 0 0s to 20s PA main program Welding parameter Meaning explanation Setting range Setting the wire speed PB reduced main program Welding parameter Meaning explanation Setting range DV3 Wire speed 0 to 200 U3 Arc length correction 9 9V to 9 9V PEND end crater program Welding parameter Meaning exp...

Page 67: ...ation 0 0s to 20s PA main program Welding parameter Meaning explanation Setting range tS1 Slope duration from PSTART to PA 0 0s to 20s DV3 Setting the wire speed 0 to 200 t2 Duration 0 1s to 20s tS3 Slope duration from PB to PA 0 0s to 20s PB reduced main program Welding parameter Meaning explanation Setting range tS2 Slope duration from PA to PB 0 0s to 20s DV3 Wire speed 0 to 200 U3 Arc length c...

Page 68: ...lowing components Program switching JOB switching Program Operating mode superPuls Wire speed Voltage correction Dynamics M3 7x Wire feeder control Yes Yes P0 Yes Yes Yes P1 15 Yes R20 Remote control Yes No P0 No Yes No P1 9 Yes 1 R40 Remote control Yes No P0 No Yes Yes No No R50 Remote control Yes No P0 Yes Yes P1 15 PC 300 NET Software No No P0 Yes No P1 15 Yes Up Down Welding torch Yes No P0 No...

Page 69: ...gure 5 34 Example 3 Aluminium welding of different sheet metal thicknesses non latched or latched special Figure 5 35 NOTE Up to 16 programs PA0 to PA15 can be defined An operating point wire speed arc length correction dynamics choke effect can be defined permanently in each program Program P0 is an exception the settings for operating points are made manually here Changes to the welding paramete...

Page 70: ...m 1 n x Select program sequence parameter Main program PA LED is on Set wire speed Absolute value Set arc length correction Display example 0 8 V correction Setting range 9 9 V to 9 9 V 1 x Select Dynamic program sequence parameter Set dynamic Setting range 40 to 40 40 Arc hard and narrow 40 Arc soft and wide 5 9 10 MIG MAG automatic cut out NOTE The welding machine ends the ignition process or th...

Page 71: ... operation Figure 5 36 Item Symbol Description 0 1 Welding torch function changeover switch special welding torch required Changing over programs or JOBs Infinite adjustment of welding performance 5 9 12 2 Switching between Push Pull and intermediate drive DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repaired or modifi...

Page 72: ...tting 5 9 13 1 Selection NOTE ENTER Enter the menu Keep the welding parameters push button pressed for 3 s NAVIGATION Navigate the menu Select parameters by pressing the welding parameters push button Set or change the parameters by turning the welding parameter setting rotary knob EXIT Exit the menu After 3 s the machine will return automatically to the ready to operate status EXIT 3 s ENTER 3 s ...

Page 73: ...pecial latched you can switch to the next program by tapping the torch trigger in the main program see the special parameters description 1 No JOB dependent program limit 2 9 JOB dependent program limit for max selectable programs Change welding process process switching With this function activated the welding process switches from standard arc welding to pulse arc welding Switching is effected b...

Page 74: ...les polarity selection TIG Connection socket for welding current 7 Quick connect coupling red coolant return 8 Quick connect coupling blue coolant supply Insert the central plug for the welding torch into the central connector and screw together with crown nut Insert the cable plug on the work piece lead into the welding current connection socket and lock by turning to the right Welding current le...

Page 75: ... is set Setpoint setting 5 10 3 TIG arc ignition 5 10 3 1 Liftarc ignition Figure 5 39 The arc is ignited on contact with the workpiece a Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger liftarc current flowing regardless of the main current set b Incline the torch over the torch gas nozzle to produce a gap of approx 2 3 mm between the ...

Page 76: ... Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I Welding output Gas pre flows Gas post flows Non latched Special non latched Latched Special latched t Time PSTART Ignition program PA Main program PB Reduced main program PEND End program tS1 Slope duration from PSTART to PA ...

Page 77: ...ecial non latched Figure 5 41 Selection Select non 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 with pre selected setting in start program PSTART After the tstart ignition current time elapses the welding current rises with the set upslope time tS1 to the main program PA Step 2 Release torch trig...

Page 78: ...ating 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 Release torch trigger no effect Step 3 Press torch trigger no effect Step 4 Release torch trigger Arc is extinguished Gas post flow time elapses ...

Page 79: ...n at the earliest after the set time tSTART elapses and at the latest when the torch trigger is released Tapping can be used to switch to the reduced main program PB Repeated tapping will switch back to the main program PA Step 3 Press the torch trigger Slope to end program PEND Step 4 Release torch trigger Arc is extinguished Gas post flow time elapses 5 10 5 TIG automatic cut out NOTE The weldin...

Page 80: ...A 0 s to 20 s 5 PA main program Welding current absolute 5 A to 550 A 6 Duration PA 0 01 s to 20 0 s 7 PB reduced main program Welding current 1 to 100 8 Duration reduced main program 0 01 s to 20 0 s 9 Slope duration from PA to PEND 0 s to 20 s 10 PEND end program Welding current 1 to 100 11 Duration end program 0 s to 20 s 12 Gas post flow time 0 s to 20 s 13 Superpulsing on off PSTART PB and PE...

Page 81: ...ed surface 5 11 1 Connecting the electrode holder and workpiece lead Figure 5 45 Item Symbol Description 0 1 Workpiece 2 Electrode holder 3 Connection socket welding current 4 Connection socket welding current 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 wel...

Page 82: ...e machine adopts the required setting after approx 3 seconds 5 11 2 1 Welding current setting The welding current is normally set using the Wire speed rotary dial Operating element Action Result Displays Welding current is set Setpoint setting 5 11 3 Arcforce Operating element Action Result Display Select arcforcing welding parameter LED for the button is on Arcforcing setting for electrode types ...

Page 83: ...de 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 47 5 11 6 Parameter overview Figure 5 48 Basic parameters Item Meaning explanation Setting range 1 Welding current...

Page 84: ...ge the unit must only be repaired or modified by specialist skilled persons The warranty becomes null and void in the event of unauthorised interference Appoint only skilled persons for repair work trained service personnel 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 int...

Page 85: ...cification 0 V 10 V wire feed speed E Output Reference potential 0 V F S Input Welding power start stop S1 G Input Control voltage specification 0 V 10 V arc length correction P Input Activation of control voltage specification for wire feed speed S2 For activation put signal to reference potential 0 V pin E R Input Activation of control voltage specification for arc length correction S3 For activ...

Page 86: ...isting of software interface connection leads The ideal tool for welding data documentation of for example welding voltage and current wire speed and motor current WELDQAS welding data monitoring and documentation system Network compatible welding data monitoring and documentation system for digital machines 5 15 Protecting welding parameters from unauthorised access NOTE The key switch is only av...

Page 87: ...al parameters can deviate between the machine controls used in the welding system also see the relevant standard operating instructions If required the special parameters can be reset to the factory settings NOTE 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 NAVIGATION Navigate the menu...

Page 88: ... 16 1 Selecting changing and saving parameters ENTER EXIT m min NAVIGATION m min l 0 AMP Hold Prog VOLT kW 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 0 P0 enabled Ex works 1 P0 blocked ...

Page 89: ...cle active Lat and sp lat tapping start 0 no latched tapping start Ex works 1 latched tapping start possible One or two wire feed operation 0 single operation Ex works 1 dual operation this unit is the master 2 dual operation this unit is the slave Special latched tapping time 0 tapping function switched off 1 300ms Ex works 2 600ms JOB list changeover 0 task oriented JOB list 1 actual JOB list Ex...

Page 90: ...ogram is disabled Predefined absolute value for relative programs Start program PSTART down slope program PB and end program PEND can be set relative to the main program PA or in an absolute manner as desired 0 Relative parameter setting ex factory 1 Absolute parameter setting 5 16 2 Reset to factory settings NOTE All special parameters saved by the user will be overwritten by the factory settings...

Page 91: ...n pulse Up down operation Change up down setting and up down symbol Program limit P4 Program selection can be limited with the special parameter P4 The setting is adopted for all JOBs Program selection depends on the position of the welding torch function changeover switch see Machine description Programs can only be switched when the changeover switch is in the program position Programs can be sw...

Page 92: ...am can only be carried out with these values To allow the welder also to perform wire and voltage correction in program mode the correction mode must be switched on and limit values for wire and voltage must be specified Setting of the correction limit value WFlimit 20 Ulimit 1 9 V Now the wire speed can be corrected by 20 8 0 up to 12 0 m min and the welding voltage by 1 9 V 3 8 V In the example ...

Page 93: ...ogram number 4 s Press button and hold down for approx 4 s Left Current limit value of the wire feed speed correction Right Current limit value of the voltage correction Set limit value for the wire feed speed correction Set limit value for voltage correction After approx 5 s without further user intervention the set values are adopted and the display switches back to the program display Key switc...

Page 94: ...3 time has elapsed The program then switches automatically to absolute program 4 Accessory components such as remote controls or special torches may not be connected Program switching at the wire feed unit control is disabled Figure 5 52 Specific latched special n cycle In the n cycle program sequence the unit starts in the 1st cycle with start program Pstart from P1 In the second cycle the machin...

Page 95: ... latest when the torch trigger is released Tapping pressing briefly and releasing within 0 3 sec can switch to other programs Programs PA1 to PA9 are possible 3rd cycle Press and hold torch trigger Slope to end program PEND from PAN The program can be stopped at any time by pressing the torch trigger longer than 0 3 sec PEND from PAN is then executed 4th cycle Release torch trigger WF motor stops ...

Page 96: ...switches optional see Protecting welding parameters from unauthorised access chapter must be configured as masters P10 1 The wire feed configured as the master is active after the welding machine is switched on There are no other functional differences between the wire feeds Latched special tapping time setting P11 The tapping time for changing over between the main program and reduced main progra...

Page 97: ...nge is between 129 169 First configure special parameter P12 to P12 2 or P12 1 Operating element Action Result Display 1 x Select JOB list Select the source JOB Wait for around 3 seconds until the JOB has been transferred 1 x Keep button pressed for around 5s Setting to copy function Copy to Select JOB number of the target JOB 1 x Save The JOB is copied to the new position By repeating the last tw...

Page 98: ...his JOB allows you to set the welding parameters manually Selection of JOB 0 can be prevented via the key switch or with the block program 0 parameter P2 See List of special parameters chapter Key switch position 0 or special parameter P2 0 JOB 0 is blocked Key switch position 1 or special parameter P2 1 JOB 0 can be selected JOBs 1 9 Nine JOBs can be called up in each special JOB see table Nomina...

Page 99: ... program PA ex factory Function inactive P20 0 Predefined execution of the pulsed arc welding process in the PA program is disabled Predefined absolute value for relative programs P21 Start program PSTART down slope program PB and end program PEND can be set relative to the main program PA or in an absolute manner as desired Function active P21 1 Absolute parameter setting Function inactive P21 0 ...

Page 100: ...esistance 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 5 min 60 min Time to activation of power saving mode in case of inactivity off inactivated ...

Page 101: ...water cooled welding torch With other hose package lengths it is necessary to carry out a voltage correction to optimise welding properties The voltage correction value can be set close to zero by means of re matching the cable resistance It is recommended to match the electric cable resistance after replacing accessories such as torches or intermediate hose packages In case a second wire feeder i...

Page 102: ...d area of the workpiece and push the torch trigger for approx 2 s A short circuit current temporarily flows which is used to determine and display the new cable resistance The value can be between 0 mΩ and 40 mΩ The newly established value is instantly saved and does not have to be confirmed If no value is shown on the right display the measurement failed Measuring has to be carried out again 4 Re...

Page 103: ...ove the torch from the hose package Never clamp the torch body in a vice or similar as this can cause the torch to be irreparably destroyed If damage occurs to the torch or to the hose package which cannot be corrected as part of the maintenance work the entire torch must be returned to the manufacturer 6 2 1 Daily maintenance tasks Check that all connections and wearing parts are hand tight and t...

Page 104: ...mpanying supplementary sheets Machine and Company Data Maintenance and Testing Warranty 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 6 3 Maintenance work DANGER Do not carry out any unauthorised repairs or modifications To avoid injury an...

Page 105: ...ided for this purpose According to German law law governing the distribution taking back and environmentally correct disposal of electric and electronic equipment ElektroG from 16 03 2005 used machines are to be placed in a collection system separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private h...

Page 106: ...ool brake see Setting the spool brake chapter Check settings and correct if necessary Setting pressure units see Inching wire electrodes chapter Check settings and correct if necessary Worn wire rolls Check and replace if necessary Wire feed motor without supply voltage automatic cutout triggered by overloading Reset triggered fuse rear of the power source by pressing the key button Kinked hose pa...

Page 107: ...peedometer error Check the wire feeder speedometer is not issuing a signal M3 00 defective inform Service Error 6 gas x Shielding gas error Check shielding gas supply for machines with shielding gas monitoring Error 7 Se Vol x Secondary excess voltage Inverter error inform Service Error 8 no PE x Earth fault between welding wire and earth line Phoenix 330 only Separate the connection between the w...

Page 108: ... 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 Synergic S Progress M3 71 Picomig 305 not possible c The error message can only be reset by switching the machine off and on again The shielding gas error Err 6 can be reset by pressing the Welding parameters key button ...

Page 109: ...lding parameters that are stored will be replaced by the factory settings 7 3 1 Resetting a single JOB EXIT RESET ENTER 3 s m min 3 s 3 s JOB LIST JOB LIST Figure 7 1 Display Setting selection Reset to factory settings The RESET will be done after pressing the button The menu will be ended when no changes are done after 3 sec JOB number example The shown JOB will be set to ex works ...

Page 110: ...ting all JOBs NOTE JOBs 1 128 and 170 256 will be reset Custom JOBs 129 169 are maintained ENTER 3 s EXIT RESET 3 s m min 3 s JOB LIST JOB LIST Figure 7 2 Display Setting selection Reset to factory settings The RESET will be done after pressing the button The menu will be ended when no changes are done after 3 sec ...

Page 111: ...t 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 ...

Page 112: ...s voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 35 A Mains connection lead H07RN F4G4 Maximum connected load MIG MAG 17 2 kVA TIG 13 1 kVA MMA 18 2 kVA Recommended generator rating 25 0 kVA cos 0 99 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine torch cooling Fan gas or water Cooling capacity at 1 l min 15...

Page 113: ...Mains connection lead H07RN F4G6 Maximum connected load Max connected load 18 9 kVA 24 6 kVA 25 3 kVA Recommended generator rating 35 0 kVA Cos 0 99 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine torch cooling Fan gas or water Cooling capacity at 1 l min 1500 W Max flow rate 5 l min Max coolant outlet pressure 3 5 bar Max tank capacity 12 l Coolant Ex w...

Page 114: ...8088 00000 R50 7POL Remote control all welding machine functions can be set directly at the workplace 090 008776 00000 FRV 7POL 0 5 m Extension connecting cable 092 000201 00004 FRV 7POL 5 m Extension connecting cable 092 000201 00003 FRV 7POL 10 m Extension connecting cable 092 000201 00000 FRV 7POL 20 m Extension connecting cable 092 000201 00001 FRV 7POL 25M Extension connecting cable 092 00020...

Page 115: ... 002116 00000 ON Filter T P Retrofit option contamination filter for air inlet 092 002092 00000 ON Tool Box Retrofit option tool box 092 002138 00000 9 4 Computer communication Type Designation Item no PC300 Net PC300 Net welding parameter software kit incl cable and SECINT X10 USB interface 090 008777 00000 CD PC300 Net update PC300 Net Update on CD ROM 092 008172 00001 FRV 7POL 5 m Extension con...

Page 116: ... 092 000841 00000 FE 2DR4R 1 0 1 2 Drive rollers 37 mm steel 092 000842 00000 FE 2DR4R 1 2 1 6 Drive rollers 37 mm steel 092 000843 00000 FE AL 2GR4R Pressure rollers smooth 37mm 092 000844 00000 10 1 2 Wire feed rollers for aluminium wire Type Designation Item no AL 4ZR4R 0 8 1 0 Twin rollers 37 mm for aluminium 092 000869 00000 AL 4ZR4R 1 0 1 2 Twin rollers 37 mm for aluminium 092 000848 00000 A...

Page 117: ...um 092 000846 00000 URUE AL 4ZR4R 1 2 1 6 Conversion kit 37mm 4 roller drive for aluminium 092 000847 00000 URUE AL 4ZR4R 2 4 3 2 Conversion kit 37mm 4 roller drive for aluminium 092 000868 00000 URUE ROE 2DR4R 0 8 0 9 0 8 0 9 Conversion kit 37mm 4 roller drive for cored wire 092 000830 00000 URUE ROE 2DR4R 1 0 1 2 1 4 1 6 Conversion kit 37mm 4 roller drive for cored wire 092 000831 00000 URUE ROE...

Page 118: ...Appendix A JOB List 118 099 005339 EW501 31 01 2014 11 Appendix A 11 1 JOB List Figure 11 1 ...

Page 119: ...Appendix B Overview of EWM branches 099 005339 EW501 31 01 2014 119 12 Appendix B 12 1 Overview of EWM branches ...