099 005425 EW501

099 005425 EW501

Operating instructions

EN

Welding machine

Taurus 351 Basic FKG

Taurus 401 Basic FKG

Taurus 501 Basic FKG

Taurus 351 Basic FKW

Taurus 401 Basic FKW

Taurus 501 Basic FKW

099-005425-EW501

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www.ewm-group.com

17.07.2015

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General instructions

CAUTION

Read the operating instructions!

The operating instructions provide an introduction to the safe use of the products.

• Read the operating instructions for all system components!

• Observe accident prevention regulations!

• Observe all local regulations!

• Confirm with a signature where appropriate.

In the event of queries on installation, commissioning, operation or special conditions at the installation site, or on usage, please contact your sales partner or our customer service department on +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. 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 in material damage and injure persons as a result. For this reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation, improper operation or incorrect usage and maintenance or any actions connected to this in any way.

© EWM AG · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany

The copyright to this document remains the property of the manufacturer.

Reprinting, including extracts, only permitted with written approval.

The content of this document has been prepared and reviewed with all reasonable care. The information provided is subject to change, errors excepted.

Contents

Notes on the use of these operating instructions

1

Contents

1 Contents .................................................................................................................................................. 3

2 Safety instructions ................................................................................................................................. 7

2.1

Notes on the use of these operating instructions .......................................................................... 7

2.2

Explanation of icons ....................................................................................................................... 8

2.3

General .......................................................................................................................................... 9

2.4

Transport and installation ............................................................................................................ 13

2.4.1

Lifting by crane ............................................................................................................. 14

2.5

Ambient conditions ....................................................................................................................... 15

2.5.1

In operation ................................................................................................................... 15

2.5.2

Transport and storage .................................................................................................. 15

3 Intended use ......................................................................................................................................... 16

3.1

Applications .................................................................................................................................. 16

3.1.1

MIG/MAG standard welding ......................................................................................... 16

3.1.1.1

MIG/MAG cored wire welding ....................................................................... 16

3.2

MMA welding ............................................................................................................................... 16

3.2.1

Air arc gouging ............................................................................................................. 16

3.3

Documents which also apply ....................................................................................................... 17

3.3.1

Warranty ....................................................................................................................... 17

3.3.2

Declaration of Conformity ............................................................................................. 17

3.3.3

Welding in environments with increased electrical hazards ......................................... 17

3.3.4

Service documents (spare parts and circuit diagrams) ................................................ 17

3.3.5

Calibration/Validation.................................................................................................... 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

5 Design and function ............................................................................................................................. 26

5.1

General ........................................................................................................................................ 26

5.2

Installation .................................................................................................................................... 27

5.3

Machine cooling ........................................................................................................................... 27

5.4

Workpiece lead, general .............................................................................................................. 27

5.5

Notes on the installation of welding current leads ....................................................................... 28

5.6

Welding torch cooling system ...................................................................................................... 30

5.7

General ........................................................................................................................................ 30

5.7.1

List of coolants .............................................................................................................. 30

5.7.2

Maximal hose package length ...................................................................................... 30

5.7.3

Adding coolant .............................................................................................................. 31

5.8

Mains connection ......................................................................................................................... 32

5.8.1

Mains configuration ...................................................................................................... 32

5.8.2

Shielding gas supply (shielding gas cylinder for welding machine) ............................. 33

5.8.2.1

Connection .................................................................................................... 34

5.8.2.2

Gas test ......................................................................................................... 35

5.8.2.3

Adjusting the gas post-flow time ................................................................... 35

5.8.2.4

Setting the shielding gas quantity ................................................................. 36

5.8.3

Rinse hose package function ....................................................................................... 36

5.8.4

Welding data display .................................................................................................... 37

5.9

MIG/MAG welding ........................................................................................................................ 38

5.9.1

Welding torch and workpiece line connection .............................................................. 38

5.9.1.1

MIG/MAG standard welding .......................................................................... 39

5.9.2

Wire feed ...................................................................................................................... 41

5.9.2.1

Open the protective flap of the wire feeder ................................................... 41

5.9.2.2

Inserting the wire spool ................................................................................. 41

5.9.2.3

Changing the wire feed rollers ...................................................................... 42

5.9.2.4

Inching the wire electrode ............................................................................. 44

5.9.2.5

Spool brake setting ....................................................................................... 46

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Contents

Notes on the use of these operating instructions

5.9.3

Welding task selection .................................................................................................. 47

5.9.3.1

Accessory components for operating point setting ....................................... 47

5.9.4

MIG/MAG functional sequences / operating modes ..................................................... 48

5.9.4.1

Explanation of signs and functions ................................................................ 48

5.9.5

Standard MIG/MAG torch ............................................................................................. 50

5.9.6

MIG/MAG special-torches ............................................................................................. 50

5.10

MMA welding ................................................................................................................................ 51

5.10.1

Connecting the electrode holder and workpiece lead .................................................. 51

5.10.2

Welding task selection .................................................................................................. 52

5.10.3

Welding current setting ................................................................................................. 52

5.10.4

Arcforce ......................................................................................................................... 53

5.10.5

Hotstart ......................................................................................................................... 53

5.10.6

Antistick ......................................................................................................................... 53

5.10.7

Air arc gouging .............................................................................................................. 54

5.10.7.1

Connection .................................................................................................... 54

5.10.8

Welding task selection .................................................................................................. 55

5.10.9

Welding current setting ................................................................................................. 55

5.11

Remote control ............................................................................................................................. 56

5.12

Special parameters (advanced settings) ...................................................................................... 56

5.12.1

Selecting, changing and saving parameters................................................................. 56

5.12.1.1

Reset to factory settings ................................................................................ 58

5.12.1.2

The special parameters in detail ................................................................... 58

5.13

Machine configuration menu ........................................................................................................ 59

5.13.1

Selecting, changing and saving parameters................................................................. 59

5.13.2

Power-saving mode (Standby) ..................................................................................... 59

5.13.3

Aligning the cable resistance ........................................................................................ 60

6 Maintenance, care and disposal ......................................................................................................... 62

6.1

General ......................................................................................................................................... 62

6.2

Maintenance work, intervals......................................................................................................... 62

6.2.1

Daily maintenance tasks ............................................................................................... 62

6.2.1.1

Visual inspection ........................................................................................... 62

6.2.1.2

Functional test ............................................................................................... 62

6.2.2

Monthly maintenance tasks .......................................................................................... 63

6.2.2.1

Visual inspection ........................................................................................... 63

6.2.2.2

Functional test ............................................................................................... 63

6.2.3

Annual test (inspection and testing during operation) .................................................. 63

6.3

Disposing of equipment ................................................................................................................ 63

6.3.1

Manufacturer's declaration to the end user .................................................................. 63

6.4

Meeting the requirements of RoHS .............................................................................................. 63

7 Rectifying faults .................................................................................................................................... 64

7.1

Checklist for rectifying faults ........................................................................................................ 64

7.2

Error messages (power source) ................................................................................................... 65

7.3

Welding parameter calibration ..................................................................................................... 67

7.4

Vent coolant circuit ....................................................................................................................... 68

8 Technical data ....................................................................................................................................... 69

8.1

Taurus 351 FKG ........................................................................................................................... 69

8.2

Taurus 401 FKG ........................................................................................................................... 70

8.3

Taurus 501 FKG ........................................................................................................................... 71

8.4

Taurus 351 FKW .......................................................................................................................... 72

8.5

Taurus 401 FKW .......................................................................................................................... 73

8.6

Taurus 501 FKW .......................................................................................................................... 74

9 Accessories .......................................................................................................................................... 75

9.1

General accessories .................................................................................................................... 75

9.2

Remote control / connection cable ............................................................................................... 75

9.3

Options ......................................................................................................................................... 75

10 Replaceable parts ................................................................................................................................. 76

10.1

Wire feed rollers ........................................................................................................................... 76

10.1.1

Wire feed rollers for steel wire ...................................................................................... 76

10.1.2

Wire feed rollers for aluminium wire ............................................................................. 77

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Notes on the use of these operating instructions

10.1.3

Wire feed rollers for cored wire .................................................................................... 77

10.1.4

Wire guide .................................................................................................................... 77

11 Appendix A ........................................................................................................................................... 78

11.1

Setting instructions ....................................................................................................................... 78

12 Appendix B ........................................................................................................................................... 79

12.1

Overview of EWM branches ........................................................................................................ 79

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Contents

Notes on the use of these operating instructions

6

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Safety instructions

2.1 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.

• The hazard is also highlighted using a symbol on the edge of the page.

WARNING

Working or operating procedures which must be closely observed to prevent serious and even fatal injuries.

• Safety notes include the "WARNING" keyword in the heading with a general warning symbol.

• The hazard is also highlighted using a symbol 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 the product.

• The safety information includes the "CAUTION" keyword in its heading without a general warning symbol.

• The hazard is explained using a symbol at the edge of the page.

Safety instructions

Notes on the use of these operating instructions

Special technical points which users must observe.

Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet points, e.g.:

• Insert the welding current lead socket into the relevant socket and lock.

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Safety instructions

Explanation of icons

2.2 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 the menu)

NAVIGATION

NAVIGATION (Navigating in the menu)

EXIT

4 s

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

8

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Safety instructions

General

2.3 General

DANGER

Electric shock!

Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents.

• Do not touch any live parts in or on the machine!

• Connection cables and leads must be free of faults!

• Switching off alone is not sufficient!

• Place welding torch and stick electrode holder on an insulated surface!

• The unit should only be opened by specialist staff after the mains plug has been unplugged!

• Only wear dry protective clothing!

• Wait for 4 minutes until the capacitors have discharged!

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.

• Observe the maintenance instructions - See 6 Maintenance, care and disposal chapter!

• Unwind welding leads completely!

• Shield devices or equipment 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 skilled persons for repair work (trained service personnel)!

WARNING

Risk of accidents if these safety instructions are not observed!

Non-observance of these safety instructions is potentially fatal!

• Carefully read the safety information in this manual!

• Observe the accident prevention regulations in your country.

• Inform persons in the working area that they must observe the regulations!

Risk of injury due to radiation or heat!

Arc radiation results in injury to skin and eyes.

Contact with hot workpieces and sparks results in burns.

• Use welding shield or welding helmet with the appropriate safety level (depending on the application)!

• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant regulations in the country in question!

• Protect persons not involved in the work against arc beams and the risk of glare using safety curtains!

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Safety instructions

General

WARNING

Explosion risk!

Apparently harmless substances in closed containers may generate excessive pressure when heated.

• Move containers with inflammable or explosive liquids away from the working area!

• Never heat explosive liquids, dusts or gases by welding or cutting!

Smoke and gases!

Smoke and gases can lead to breathing difficulties and poisoning. 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!

• Keep solvent vapour away from the arc beam field!

• Wear suitable breathing apparatus if appropriate!

Fire hazard!

Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts and hot slag produced during the welding process.

Stray welding currents can also result in flames forming!

• Check for fire hazards in the working area!

• Do not carry any easily flammable objects such as matches or lighters.

• Keep appropriate fire extinguishing equipment to 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 out by qualified personnel and in accordance with the manufacturer's guidelines. Before bringing the power sources into service for arc welding operations, a test has to verify that they cannot exceed the maximum allowed open circuit voltage.

• Connection of the machine may be carried out by qualified personnel only!

• When decommissioning individual power sources, all mains and welding current leads have to be safely disconnected from the welding system as a whole. (Danger due to inverse voltages

!

)

• Do not couple welding machines with pole reversing switch (PWS series) or machines for

AC welding, as a minor error in operation can cause the welding voltages to be combined.

CAUTION

Noise exposure!

Noise exceeding 70 dBA can cause permanent hearing damage!

• Wear suitable ear protection!

• Persons located within the working area must wear suitable ear protection!

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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.

• The regulations regarding work safety and accident prevention for the respective country.

• Setting up and operating the machine according to IEC 60974-9.

• Check at regular intervals that users are working in a safety-conscious way.

• Regular checks of the machine according to IEC 60974-4.

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!

• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.

Damage to the machine due to stray welding 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 vehicle and crane frames so they are insulated!

• Do not place any other electronic devices such as drillers or angle grinders, etc., on the power source, transport vehicle or crane frames unless they are insulated!

• Always put welding torches and electrode holders on an insulated surface when they are not in use!

Mains connection

Requirements for connection to the public mains network

High-performance machines can influence the mains quality by taking current from the mains network. For some types of machines, connection restrictions or requirements relating to the maximum possible line impedance or the necessary minimum supply capacity at the interface with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect, attention is also drawn to the machines' technical data. In this case, it is the responsibility of the operator, where necessary in consultation with the mains network operator, to ensure that the machine can be connected.

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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. When ensuring the electromagnetic compatibility of class A machines, difficulties can arise in these areas due to interference not only in the supply lines but also in the form of radiated interference.

Class B machines fulfil the EMC requirements in industrial as well as residential areas, including residential areas connected to the low-voltage public mains network.

Setting up and operating

When operating arc welding systems, in some cases, electro-magnetic interference can occur although all of the welding machines comply with the emission limits specified in the standard.

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, especially if they have a pacemaker or wear a hearing aid

• Calibration and measuring equipment

• The immunity to interference of other equipment in the surrounding area

• The time of day at which the welding work must be carried out

Recommendations for reducing interference emission

• Mains connection, e.g. additional mains filter or shielding with a metal tube

• Maintenance of the arc welding equipment

• Welding leads should be as short as possible and run closely together along the ground

• Potential equalization

• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly, it should be connected by means of suitable capacitors.

• Shielding from other equipment in the surrounding area or the entire welding system

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Safety instructions

Transport and installation

2.4

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!

• Place shielding gas cylinders in the holders provided for them and secure with fixing devices.

• Avoid heating the shielding gas cylinder!

CAUTION

Risk of tipping!

There is a risk of the machine tipping over and injuring persons or being damaged itself 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 lines which have not been disconnected (mains supply leads, control leads, etc.) may cause hazards such as connected equipment tipping over and injuring persons!

• Disconnect supply lines!

CAUTION

Equipment damage when not operated in an upright position!

The units are designed for operation in an upright position!

Operation in non-permissible positions can cause equipment damage.

• Only transport and operate in an upright position!

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Safety instructions

Transport and installation

2.4.1 Lifting by crane

WARNING

Risk of injury during lifting by crane

!

When lifting the machine by crane, persons may be severely injured by falling machines or mount-on components.

• Simultaneous lifting of system components such as power source

,

wire feeder or cooling unit without suitable crane components is not allowed. Each system component has to be lifted separately!

• Remove any supply leads and accessories before lifting by crane

(e.g. hose package

,

wire spool

,

shielding gas cylinder

,

toolbox, wire feeder

, remote control,etc.)!)

• Properly close and lock all casing covers and protective caps before lifting by crane!

• Use the correct number of hoisting equipment of the right size in the correct position! Observe craning principle (see figure)!

• For machines with lifting eyes: always lift 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 occupational safety and accident prevention for the respective country.

Craning principle

Risk of injury due to unsuitable lifting eye!

In case of improper use of lifting eyes or the use of unsuitable lifting eyes, persons can be seriously damaged by falling equipment or add-on components!

• The lifting eye must be completely screwed in!

• The lifting eye must be positioned flat onto and in full contact with the supporting surfaces!

• Check that the lifting eyes are securely fastened before use and check for any damage

(corrosion, deformation)!

• Do not use or screw in damaged lifting eyes!

• Avoid lateral loading of the lifting eyes!

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Safety instructions

Ambient conditions

2.5

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.

• Safe operation of the machine must be guaranteed at all times.

CAUTION

Equipment damage due to dirt accumulation!

Unusually high quantities 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 distance of 0.5 m from obstacles!

2.5.1 In operation

Temperature range of the ambient air:

• -25 °C to +40 °C

Relative air humidity:

• Up to 50% at 40 °C

• Up to 90% at 20 °C

2.5.2 Transport and storage

Storage in an enclosed space, temperature range of the ambient air:

• -30 °C to +70 °C

Relative air humidity

• Up to 90% at 20 °C

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Intended use

Applications

3

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!

• Do not modify or convert the equipment improperly!

3.1 Applications

3.1.1 MIG/MAG standard welding

Metal arc welding using a wire electrode, where the arc and the weld pool are shielded from the atmosphere with inert (MIG) or active (MAG) gasses or gas mixtures.

3.1.1.1 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 arc by means of the powder core (self-shielding cored wires).

3.2

MMA welding

Manual arc welding or, for short, MMA welding. It is characterised by the fact that the arc burns between a melting electrode and the molten pool. There is no external protection; any protection against the atmosphere comes from the electrode.

3.2.1 Air arc gouging

During gouging, an arc burns between a carbon electrode and the workpiece, heating the workpiece until it is molten. At the same time, the molten metal is blown out with compressed air. Special electrode holders with a compressed-air connection and carbon electrodes are required for gouging.

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Intended use

Documents which also apply

3.3 Documents which also apply

3.3.1 Warranty

For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com

!

3.3.2 Declaration of Conformity

The designated machine conforms to EC Directives and standards in terms of its design and construction:

• EC Low Voltage Directive (2006/95/EC),

• EC EMC Directive (2004/108/EC),

This declaration shall become null and void in the event of unauthorised modifications, improperly conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted conversion work not specifically authorised by the manufacturer.

The original copy of the declaration of conformity is enclosed with the unit.

3.3.3 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.

3.3.4 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 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)!

Original copies of the circuit diagrams are enclosed with the unit.

Spare parts can be obtained from the relevant authorised dealer.

3.3.5 Calibration/Validation

We hereby confirm that this machine has been tested using calibrated measuring equipment, as stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.

Recommended calibration interval: 12 months

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Machine description

– quick overview

Front view

4

Machine description – quick overview

4.1 Front view

Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling.

18

Figure 4-1

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Machine description

– quick overview

Front view

4

5

6

9

10

11

12

Item Symbol Description 0

1

2

3

Lifting lug

Ready for operation signal light

Signal light on when the machine is switched on and ready for operation

Main switch, machine on/off

7

8

13

14

15

16

17

Carrying handle

Cooling air inlet

Automatic cut-out of coolant pump key button

press to reset a triggered fuse

Quick connect coupling (red)

coolant return

Quick connect coupling (blue)

coolant supply

Wheels, guide castors

Coolant tank

Coolant tank cap

Connection socket, “-” welding current

• MIG/MAG welding:

• MIG/MAG cored wire welding:

• MMA welding: workpiece connection welding current connection for the welding torch electrode holder connection

Connection socket, “+” welding current

• MIG/MAG welding: welding current connection for the welding torch

• MIG/MAG cored wire welding:

• MMA welding: workpiece connection workpiece connection

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

Welding torch connection (Euro or Dinse torch connector)

Welding current, shielding gas and torch trigger integrated

19-pole connection socket (analogue)

For connecting analogue remote controls

Machine control- See 4.4 Machine control

– Operating elements chapter

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Machine description

– quick overview

Rear view

4.2 Rear view

20

Figure 4-2

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Machine description

– quick overview

Rear view

Item Symbol Description 0

1

2

Slide latch, lock for the protective cap

Securing elements for shielding gas cylinder (strap/chain)

3

4

5

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.

Wire spool inspection window

Check wire supply

Cooling air outlet

6

Bracket for shielding gas cylinder

7

Wheels, fixed castors

8

D-sub connection socket, 9-pole

With this machine series for maintenance purposes only (specialist staff)

9

Connecting nipple G¼, shielding gas connection

10

11

Key button, automatic cutout

Wire feed motor supply voltage fuse press to reset a triggered fuse

Mains connection cable

- See 5.8 Mains connection chapter

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Machine description

– quick overview

Inside view

4.3 Inside view

Figure 4-3

22

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Item Symbol Description 0

1

Wire spool holder

2

Wire feed unit

Machine description

– quick overview

Inside view

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23

Machine description

– quick overview

Machine control

– Operating elements

4.4 Machine control

– Operating elements

24

Figure 4-4

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Machine description

– quick overview

Machine control

– Operating elements

Item Symbol Description 0

1

Button, welding process

MIG/MAG welding

2

3

4

5

6

7

MMA welding

Air arc gouging

Display, left

Welding current, wire feed speed

Status displays

"Welding current display" signal light

" Wire feed speed display" signal light

Display, welding process

J1

J2

J3

MIG/MAG welding

MMA welding

Gouging

Welding parameter setting, rotary dial

For setting the welding performance, for selecting the JOB (welding task) and for setting other welding parameters.

Select operating mode button

Non-latched

Latched

Push-button, throttling effect (arc dynamics)

8

9

10

11

12

Arc is harder and more narrow

Arc is softer and wider

Rotary dial, welding voltage

Adjustment of the welding voltage from min. to max.

(twin-knob operation: wire speed/welding voltage)

Button, Parameter selection (right)

VOLT Welding voltage kW Welding performance display

Gas flow quantity (optional)

Display, right

Welding voltage, welding performance, motor current (wire feed mechanism) during wire inching, shielding gas flow rate (option)

Gas test / rinse button

• Gas test:

For setting the shielding gas quantity

• Rinse:

For rinsing longer hose packages

- See 5.8.2 Shielding gas supply (shielding gas cylinder for welding machine) chapter

Push-button, wire inching/motor current (wire feed mechanism)

- See 5.9.2.4 Inching the wire electrode chapter

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Design and function

General

5

Design and function

5.1

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!

• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead, interfaces) may only be connected when the machine is switched off!

CAUTION

Insulate the arc welder from welding voltage!

Not all active parts of the welding current circuit can be shielded from direct contact. To avoid any associated risks it is vital for the welder to adhere to the relevant safety regulations. Even low voltages can cause a shock and lead to accidents.

• Wear dry and undamaged protective clothing (shoes with rubber soles/welder's gloves made from leather without any studs or braces)!

• Avoid direct contact with non-insulated connection sockets or connectors!

• Always place torches and electrode holders on an insulated surface!

Risk of burns on the welding current connection!

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 or moving parts or drive components!

• Keep casing covers or protective caps closed during operation!

Risk of injury due to welding wire escaping in an unpredictable manner!

Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may escape in an uncontrolled manner and injure persons!

• Before mains connection, set up the complete wire guide system from the wire spool to the welding torch!

• Remove the pressure rollers from the wire feeder if no welding torch is fitted!

• Check wire guide at regular intervals!

• Keep all casing covers or protective caps closed during operation!

Risk from electrical current!

If welding is carried out alternately using different methods and if a welding torch and an electrode holder remain connected to the machine, the open-circuit/welding voltage is applied simultaneously on all cables.

• The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks.

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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.

• Comprehensive descriptions can be found in the operating instructions for the relevant accessory components.

• Accessory components are detected automatically after the power source is switched on.

Using protective dust caps!

Protective dust caps protect the connection sockets and therefore the machine against dirt and damage.

• The protective dust cap must be fitted if there is no accessory component being operated on that connection.

• The cap must be replaced if faulty or if lost!

5.2

Installation

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.

• 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 should be observed:

• Ensure that the working area is adequately ventilated.

• Do not obstruct the air inlets and outlets of the machine.

• Do not allow metal parts, dust or other objects to get into the machine.

5.4 Workpiece lead, general

CAUTION

Risk of burns due to incorrect connection of the workpiece lead!

Paint, rust and dirt on the connection restrict the power flow and may lead to stray welding currents.

Stray welding currents may cause fires and injuries!

• Clean the connections!

• Fix the workpiece lead securely!

• Do not use structural parts of the workpiece as a return lead for the welding current!

• Take care to ensure faultless power connections!

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Design and function

Notes on the installation of welding current leads

5.5 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.

Lay the workpiece lead and hose package of power sources with HF igniter (TIG) for as long as possible in parallel with a distance of 20 cm to avoid HF sparkover.

Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences

Always keep leads as short as possible! For optimum welding results max. 30 m (welding lead + intermediate hose package + torch lead).

28

Figure 5-1

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Design and function

Notes on the installation of welding current leads

Use an individual welding lead to the workpiece for each welding machine!

Figure 5-2

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.

Figure 5-3

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Design and function

Welding torch cooling system

5.6 Welding torch cooling system

Only with water-cooled welding machines!

5.7 General

CAUTION

Coolant mixtures!

Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void!

• Only use the coolant described in this manual (overview of coolants).

• Do not mix different coolants.

• When changing the coolant, the entire volume of liquid must be changed.

Insufficient frost protection in the welding torch coolant!

Depending on the ambient conditions, different liquids are used for cooling the welding

torch - See 5.7.1 List of coolants chapter.

Coolants with frost protection (KF 37E or KF 23E) must 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 .

• Replace coolant as necessary if frost protection is inadequate!

The disposal of coolant must be carried out according to official regulations and observing the relevant safety data sheets (German waste code number: 70104)!

Coolant must not be disposed of together with household waste.

Coolant must not be discharged into the sewerage system.

Recommended cleaning agent: water, if necessary with cleaning agent added.

5.7.1 List of coolants

The following coolants may be used - See 9 Accessories chapter:

Coolant

KF 23E (Standard)

Temperature range

-10 °C to +40 °C

KF 37E -20 °C to +10 °C

5.7.2 Maximal hose package length

Pump 3.5 bar Pump 4.5 bar

Machines with or without separate wire feeder

Compact machines with additional intermediate drive (example. miniDrive)

30 m

20 m

60 m

30 m

Machines with separate wire feeder and additional intermediate drive (example: miniDrive)

20 m 60 m

Data as a rule refer to the entire hose package length including welding torch. The pump output is shown on the type plate (parameter: Pmax).

Pump 3.5 bar: Pmax = 0.35 MPa (3.5 bar)

Pump 4.5 bar: Pmax = 0.45 MPa (4.5 bar)

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5.7.3 Adding coolant

The unit is supplied ex works with a minimum level of coolant.

Design and function

General

Figure 5-4

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.

After the initial filling, wait for at least one minute when the machine is switched on so that the hose package is filled with coolant completely and without bubbles.

With frequent changes of torch and during the initial filling process, the cooling unit tank should be topped up as necessary.

The level of coolant must never fall below the “min” mark.

If there is less coolant in the coolant tank than the minimum required you may need to vent the coolant circuit. In this case the welding machine will automatically shut down the coolant pump

and signal an error, "- See 7 Rectifying faults chapter".

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Design and function

Mains connection

5.8

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!

• Mains plug, socket and lead must be checked regularly by an electrician!

• When operating the generator always ensure it is earthed as stated in the operating instructions. The resulting network has to be suitable for operating devices according to protection class 1.

5.8.1 Mains configuration

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 5-5

Legend

Item

L1

L2

L3

N

PE

Designation

Outer conductor 1

Outer conductor 2

Outer conductor 3

Neutral conductor

Protective conductor

Colour code

brown black grey blue green-yellow

CAUTION

Operating voltage - mains voltage!

The operating voltage shown on the rating plate must be consistent with the mains voltage, in order to avoid damage to the machine!

• - See 8 Technical data chapter!

• Insert mains plug of the switched-off machine into the appropriate socket.

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Design and function

Mains connection

5.8.2 Shielding gas supply (shielding gas cylinder for welding machine)

WARNING

Risk of injury due to improper handling of shielding gas cylinders!

Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries!

• Secure shielding gas cylinders using the standard fastening elements on the unit (chain/belt)!

• The fastening elements must tightly enclose the shielding gas cylinder!

• Attach the fastening elements within the upper half of 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 requirement for optimum welding results. In addition, a blocked shielding gas supply may result in the welding torch being destroyed.

• Always re-fit the yellow protective cap when not using the shielding gas connection.

• All shielding gas connections must be gas tight.

Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to expel any dirt.

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Design and function

Mains connection

5.8.2.1 Connection

• Place the shielding gas cylinder into the relevant cylinder bracket.

• Secure the shielding gas cylinder using a securing chain.

Figure 5-6

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 back of the machine using the crown nut.

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Design and function

Mains connection

5.8.2.2 Gas test

• Slowly open the gas cylinder valve.

• Open the pressure regulator.

• Switch on the power source at the main switch.

• Initiate gas test function on the machine control.

• Set the relevant gas quantity for the application on the pressure regulator.

• The gas test is triggered on the machine control by pressing the

button briefly.

Shielding gas flows for around 25 seconds or until the button is pressed again.

5.8.2.3 Adjusting the gas post-flow time

ENTER EXIT

3 s

3 s

Figure 5-7

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Design and function

Mains connection

5.8.2.4 Setting the shielding gas quantity

Welding process

MAG welding

MIG brazing

Recommended shielding gas quantity

Wire diameter x 11.5 = l/min

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

75% Ar/25% He

Factor

1.14

50% Ar/50% He

25% Ar/75% He

100% He

1.35

1.75

3.16

Incorrect shielding gas setting!

• If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to form.

• Adjust the shielding gas quantity to suit the welding task!

5.8.3 Rinse hose package function

Operating

Element

Action Result

5 s

Select rinse hose package.

Shielding gas flows continuously until the Gas Test button is pressed again.

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Design and function

Mains connection

5.8.4 Welding data display

Figure 5-8

The machine control displays show all welding parameters that are required by the welder. The lower centre display shows the selected welding task (JOB number). The "parameter selection" ( ) pushbutton can be used to switch the display between welding voltage, welding performance and gas flow rate

(option).

What is shown on the displays depends, among other things, on the selected welding procedure and the machine state (welding, power-saving mode, machine error).

MIG/MAG welding

Parameter

Welding current

Nominal values

Actual values

Hold values

Wire feed speed

Welding voltage

Welding performance

MMA welding

Parameter

Welding current

Welding voltage

Welding performance

Nominal values

Actual values

Hold values

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Design and function

MIG/MAG welding

5.9 MIG/MAG welding

5.9.1 Welding torch and workpiece line connection

CAUTION

Equipment damage due to improperly connected coolant pipes!

If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur.

• Connect all coolant pipes correctly!

• Completely unroll the hose package and the torch hose package!

• Observe maximal hose package length - See 9 Accessories chapter.

• When using a gas-cooled welding torch, use a hose bridge to establish the coolant circuit -

See 9 Accessories chapter.

On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used!

• Operate welding torches with a liner > with a guide tube.

• Operate welding torches with a steel liner > with a capillary tube.

Depending on the wire electrode diameter or type, either a steel liner or liner with the correct inner diameter must be inserted in the torch!

Recommendation:

• Use a steel liner when welding hard, unalloyed wire electrodes (steel).

• Use a chrome nickel liner when welding hard, high-alloy wire electrodes (CrNi).

• Use a liner to weld or braze soft wire electrodes, high-alloy wire electrodes or aluminium materials.

Preparation for connecting welding torches with a liner:

• Push forward the capillary tube on the wire feed side in the direction of the Euro torch connector and remove it there.

• Insert the liner guide tube from the Euro torch connector side.

• Carefully insert the welding torch connector with as yet too long a liner into the Euro torch connector and secure with a crown nut.

• Cut off the liner with a liner cutter just before the wire feed roller.

• Loosen the welding torch connector and remove.

• Carefully chamfer the cut off end of the liner with a liner sharpener and sharpen.

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MIG/MAG welding

5.9.1.1 MIG/MAG standard welding

Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity. In this case, the welding current lead should be connected to the "-" welding current socket, and the workpiece lead should be connected to the "+" welding current socket. Observe the information from the electrode manufacturer!

Figure 5-9

Item Symbol Description 0

1

Workpiece

2

3

"-" welding current connection socket

MIG/MAG welding: Workpiece connection

Welding torch

4

5

6

7

8

9

Welding torch hose package

19-pole connection socket (analogue)

For connecting analogue accessory components (remote control, welding torch control lead, etc.)

Welding torch connection (Euro or Dinse torch connector)

Welding current, shielding gas and torch trigger integrated

Welding current cable, polarity selection

Welding current to central connection/torch. Permits polarity selection for MIG/MAG welding.

Standard applications > Connection for "+" welding current connection socket

Quick connect coupling (red)

coolant return

Quick connect coupling (blue)

coolant supply

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Design and function

MIG/MAG welding

• Insert the central plug for the welding torch into the central connector and screw together with crown nut.

• Insert the plug on the workpiece lead into the "-" welding current connection socket and lock.

• Welding current lead, insert polarity selection into 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).

Where applicable:

• 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 (coolant supply).

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Design and function

MIG/MAG welding

5.9.2 Wire feed

5.9.2.1 Open the protective flap of the wire feeder

CAUTION

To perform the following steps, the protective flap of the wire feeder needs to be opened. Make sure to close the protective flap again before starting to work.

• Unlock and open protective flap.

5.9.2.2 Inserting the wire spool

CAUTION

Risk of injury due to incorrectly secured wire spool.

If the wire spool is not secured properly, it may 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.

Standard D300 wire spool holder can be used. Adapters - See 9 Accessories chapter are required

when using standardised basket coils (DIN 8559).

Figure 5-10

Item Symbol Description 0

1

Carrier pin

For fixing the wire spool

2

Knurled nut

For fixing the wire spool

• Loosen knurled nut from spool holder.

• Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore.

• Fasten wire spool using knurled nut.

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Design and function

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5.9.2.3 Changing the wire feed rollers

Figure 5-11

Item Symbol Description 0

1

Tommy

The tommy is used to secure the closure brackets of the wire feed rollers.

2

3

4

Closure bracket

The closure brackets are used to secure the wire feed rollers.

Feed roll tensioner

Fixing the clamping unit and setting the pressure.

Clamping unit

5

Wire feed roller

see the Wire feed roller overview table

• Rotate the tommy by 90° clockwise or anti-clockwise (tommy locks into place).

• Fold the closure brackets outwards by 90°.

• Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards).

• Remove the wire feed rollers from the roller support.

• Select new wire feed rollers accoridng to the Wire feed roller overview table and reassemble the wire feed mechanism in reverse order.

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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

mm

inch

Colour code Groove form

Steel

Stainless steel

Brazing

Aluminium

0.6

0.8

0.9/1.0

1.2

1.4

1.6

2.0

2.4

2.8

3.2

0.8

0.9/1.0

1.2

1.6

2.0

2.4

2.8

.023

.030

.035/.040

045

052

060

.080

.095

.110

.125

.030

.035/.040

.045

.060

.080

.095

.110 monochrome bichrome red black grey brown

Light green purple white blue light pink white blue red green black grey brown

Light green purple white blue

- yellow

V-groove

U-groove

Flux cored wire

3.2

0.8

0.9

1.0

1.2

1.4

1.6

2.0

2.4

.125

.030

.035

.040

.045

.052

.060

.080

.095

- See 10 Replaceable parts chapter

bichrome red green black grey brown orange

V-groove, knurled

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Design and function

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5.9.2.4 Inching the wire electrode

CAUTION

Risk of injury due to moving parts!

The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons!

• Do not reach into rotating or moving parts or drive components!

• Keep casing covers or protective caps closed during operation!

Risk of injury due to welding wire escaping in an unpredictable manner!

Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may escape in an uncontrolled manner and injure persons!

• Before mains connection, set up the complete wire guide system from the wire spool to the welding torch!

• Remove the pressure rollers from the wire feeder if no welding torch is fitted!

• Check wire guide at regular intervals!

• 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 pressure!

Incorrect contact pressure will cause extensive wear of the wire feed rollers!

• With the adjusting nuts of the pressure units set the contact pressure so that the wire electrode is conveyed but will still slip through if the wire spool jams.

• Set the contact pressure of the front rollers (in wire feed direction) to a higher value!

The inching speed is infinitely adjustable by simultaneously pressing the wire inching pushbutton and turning the wire speed rotary knob. The left display shows the wire feed speed selected, the right display shows the current motor current of the wire feed mechanism.

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Design and function

MIG/MAG welding

Figure 5-12

Item Symbol Description 0

1

Welding wire

2

Wire feed nipple

3

Guide tube

4

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.

• Press the inching push-button (the drive catches the welding wire and automatically guides it to the welding torch outlet).

A prerequisite for the automatic inching process is the correct preparation of the wire guide, especially in the capillary and wire guide tube area .

• The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll tensioner setting nuts depending on the welding consumable used. A table with the setting values can be found on a sticker near the wire drive.

Version 1: left hand mounting Version 2: right hand mounting

Automatic inching stop

Touch the welding torch against the workpiece during inching. Inching of the welding wire will stop as soon it touches the workpiece.

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Design and function

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5.9.2.5 Spool brake setting

Figure 5-13

Item Symbol 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.

Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation!

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5.9.3 Welding task selection

Design and function

MIG/MAG welding

Figure 5-14

5.9.3.1 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.

- See 9 Accessories chapter

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5.9.4 MIG/MAG functional sequences / operating modes

5.9.4.1 Explanation of signs and functions

Symbol Meaning

Press torch trigger

Release torch trigger

Tap torch trigger (press briefly and release)

Shielding gas flowing

I

Welding output

Wire electrode is being conveyed

Wire creep

Wire burn-back

Gas pre-flows

Gas post-flows

Non-latched

Latched

t

Time

PSTART Ignition program

PA

Main program

PEND

End program

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Non-latched mode

Figure 5-15

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.

• 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.

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Latched mode

Figure 5-16

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.

• Change over to pre-selected WF speed (main program P

A

).

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.

5.9.5 Standard MIG/MAG torch

The MIG welding torch trigger is essentially used to start and stop the welding process.

Operating elements

Torch trigger

Functions

• Start/stop welding

5.9.6 MIG/MAG special-torches

Function specifications and more indepth information can be found in the operating manual for the relevant welding torch!

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Design and function

MMA welding

5.10 MMA welding

CAUTION

Risk of being crushed or burnt.

When replacing spent or new stick electrodes

• Switch off machine at the main switch

• Wear appropriate safety gloves

• Use insulated tongs to remove spent stick electrodes or to move welded workpieces and

• Always put the electrode holder down on an insulated surface.

5.10.1 Connecting the electrode holder and workpiece lead

Figure 5-17

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 "-" welding current connection socket and lock by turning to the right.

Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

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Design and function

MMA welding

5.10.2 Welding task selection

Figure 5-18

Special electrode holders and carbon electrodes are required for air arc gouging.

5.10.3 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

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Design and function

MMA welding

5.10.4 Arcforce

Operating element

Action Result Display

Select arcforcing welding parameter

LED for the button is on.

Arcforcing setting for electrode types:

(Setting range -40 to 40)

Negative values Rutile

Values around zero Basic

Positive values Cellulose

5.10.5 Hotstart

The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = b) =

I = t =

Hotstart time

Hotstart current

Welding current

Time

Figure 5-19

5.10.6 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 5-20

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Design and function

MMA welding

5.10.7 Air arc gouging

5.10.7.1 Connection

Please note the relevant documentation of the accessory components.

Special electrode holders and carbon electrodes are required for air arc gouging.

Figure 5-21

Item Symbol Description 0

1

Workpiece

2

Connection socket, “-” welding current

3

Gouging torch

4

Connection socket, “+” welding current

• Insert the gouging torch cable plug into the "+" welding current connection socket and lock in place by turning to the right.

• Insert cable plug on the workpiece lead into the "-" welding current socket and lock by turning to the right.

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Design and function

MMA welding

5.10.8 Welding task selection

Figure 5-22

5.10.9 Welding current setting

The welding current is normally set using the "Wire speed" rotary dial.

Operating element

Action Result

Welding current is set

Displays

Setpoint setting

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Design and function

Remote control

5.11 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!

• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.

The remote controls are operated on the 19-pole remote control connection socket (analogue).

Please note the relevant documentation of the accessory components.

5.12 Special parameters (advanced settings)

Special parameters (P1 to Pn) are applied for customer-specific configuration of machine functions. This allows the user maximum flexibility in optimising their requirements.

These settings are not configured directly on the machine control since a regular setting of the parameters is generally not required. The number of selectable special 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- See 5.12.1.1 Reset to factory settings chapter.

5.12.1 Selecting, changing and saving parameters

ENTER (Enter the menu)

• Switch off the machine at the main switch.

• Press and hold the "operating mode" push-button and switch the machine on again at the same time.

NAVIGATION (Navigate the menu)

• Select parameters by turning the "welding parameter setting" rotary knob.

• Set or change the parameters by turning the "welding voltage" rotary knob.

EXIT (Exit the menu)

• Press the "gas test" push-button (switch machine off and on again).

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ENTER

0 l

+

Design and function

Special parameters (advanced settings)

EXIT

Display

Figure 5-23

Setting/selection

Ramp time for wire inching

0 = normal inching (10s ramp time)

1 = fast inching (3s ramp time) (Ex works)

Lat. and sp. lat. tapping start

0 = no latched tapping start (Ex works)

1 = latched tapping start possible

Support for wire feeders with voltage-sensing.

0 = Function switched off

1 = Function switched on (ex works)

Alternative remote control coding (FRC)

0 = no alternative remote control coding (works setting)

1-15 = alternative remote control coding

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Design and function

Special parameters (advanced settings)

5.12.1.1 Reset to factory settings

All special parameters saved by the user will be overwritten by the factory settings!

Operating element

Action Result left

Display right

Switch off welding machine

Press and hold push-button

Switch on welding machine

Release push-button

Wait for about 3 s

Switch off the welding machine and restart in order to implement the changes.

5.12.1.2 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.

Changing the speed has no effect on the ramp time.

Latched/special-latched tap start (P9)

In latched

– tap start – operating mode it is possible to switch straight to the second step by tapping the torch trigger; it is not necessary for current to be flowing.

The welding can be halted by pressing the torch trigger for a second time.

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Design and function

Machine configuration menu

5.13 Machine configuration menu

5.13.1 Selecting, changing and saving parameters

ENTER (Enter the menu)

• Switch off the machine at the main switch.

• Press and hold the "welding procedure" push-button and switch the machine on again at the same time.

NAVIGATION (Navigate the menu)

• Select parameters by turning the "welding parameter setting" rotary knob.

• Set or change the parameters by turning the "welding voltage" rotary knob.

EXIT (Exit the menu)

• Press the "gas test" push-button (switch machine off and on again).

ENTER EXIT

0 0 l

+

l

NAVIGATION

Figure 5-24

Display Setting/selection

Lead resistance 1

Lead resistance for the first welding circuit 0 mΩ–60 mΩ (8 mΩ ex works).

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

5.13.2 Power-saving mode (Standby)

The power-saving function can be activated either by pressing the button for a longer time - See 4.4

Machine control

– Operating elements chapter or by setting a parameter in the configuration menu (time-

based power-saving mode).

When power-saving mode is activated, both machine displays show the horizontal digit in the centre of the display only.

Pressing any operating element (e.g. tapping the torch trigger) deactivates power-saving mode and the machine is ready for welding again.

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Design and function

Machine configuration menu

5.13.3 Aligning the cable resistance

The resistance value of the cables can be set directly or be aligned by the power source. In the delivery status the cable resistance of the power source is set to 8 mOhm. This value corresponds to a grounding cable of 5 m, an intermediate hose package of 1.5 m and a water-cooled welding torch of 3 m. The electric cable resistance should be aligned again whenever an accessory component, such as the welding torch or the intermediate hose package, has been changed.

1

0

50mm

l

2

+ m /m in

3

B

A

4

0 l

Figure 5-25

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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.

2 Configuration

• Press the “Welding procedure” push-button while simultaneously switching on the welding machine.

Release push-button.

• The required parameter can now be selected using the 'Welding parameter setting' rotary knob.

Parameter rL1 must be adjusted for all machine combinations.

3 Alignment/measurement

• Applying slight pressure, put the welding torch in place with the contact tip on a clean, purged location on the workpiece and then press the torch trigger for approx. 2 seconds. A short-circuit current will flow briefly, which is used to determine and display the cable resistance. The value can be between

0 mΩ and 40 mΩ. The new value is immediately saved without requiring further confirmation. If no value is shown on the right-hand display, then measurement failed. The measurement must be repeated.

4 Restoring welding standby mode

• Switch off the welding machine.

• Screw the gas nozzle onto the welding torch.

• Switch on the welding machine

• Insert the welding wire.

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Maintenance, care and disposal

General

6

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.

• Appoint only skilled persons for repair work (trained service personnel)!

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!

• Wait for 4 minutes until the capacitors have discharged!

Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine. Return deliveries of defective equipment subject to warranty may only be made through your dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the machine type, serial number and item number of the machine, as well as the type designation and item number of the spare part.

6.1 General

When used in the specified environmental conditions and under normal operating conditions, this machine is largely maintenance-free and requires a minimum of care.

There are some points, which should be observed, to guarantee fault-free operation of your welding machine. Among these are regular cleaning and checking as described below, depending on the pollution level of the environment and the length of time the unit is in use.

6.2 Maintenance work, intervals

6.2.1 Daily maintenance tasks

• Check that all connections and wearing parts are hand-tight and tighten if necessary.

• Check that all screw and plug connections and replaceable parts are secured correctly, tighten if necessary.

• Remove any spatter.

• Clean the wire feed rollers on a regular basis (depending on the degree of soiling).

6.2.1.1 Visual inspection

• Check hose package and power connections for exterior damage and replace or have repaired by specialist staff as necessary!

• Mains supply lead and its strain relief

• Gas tubes and their switching equipment (solenoid valve)

• Other, general condition

6.2.1.2 Functional test

• Check correct mounting of the wire spool.

• Welding current cables (check that they are fitted correctly and secured)

• Gas cylinder securing elements

• Operating, message, safety and adjustment devices (Functional test)

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Maintenance, care and disposal

Disposing of equipment

6.2.2 Monthly maintenance tasks

6.2.2.1 Visual inspection

• Casing damage (front, rear and side walls)

• Wheels and their securing elements

• Transport elements (strap, lifting lugs, handle)

• Check coolant tubes and their connections for impurities

6.2.2.2 Functional test

• Selector switches, command devices, emergency stop devices, voltage reducing devices, message and control lamps

• Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.

6.2.3 Annual test (inspection and testing during operation)

The welding machine may only be tested by competent, capable personsl. A capable person is one who, because of his training, knowledge and experience, is able to recognise the dangers that can occur while testing welding power sources as well as possible subsequent damage and who is able to implement the required safety procedures.

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.

6.3 Disposing of equipment

Proper disposal!

The machine contains valuable raw materials, which should be recycled, and electronic components, which must be disposed of.

• Do not dispose of in household waste!

• Observe the local regulations regarding disposal!

6.3.1 Manufacturer's declaration to the end user

• According to European provisions (guideline 2002/96/EG of the European Parliament and the Council of January, 27th 2003), used electric and electronic equipment may no longer be placed in unsorted municipal waste. It must be collected separately. The symbol depicting a waste container on wheels indicates that the equipment must be collected separately.

This machine is to be placed for disposal or recycling in the waste separation systems provided 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 households can be disposed of free of charge.

• 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.

• In addition to this, returns are also possible throughout Europe via EWM sales partners.

6.4 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).

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Rectifying faults

Checklist for rectifying faults

7

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.

7.1 Checklist for rectifying faults

The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation!

Legend Symbol

Description

Fault/Cause

Remedy

Coolant error/no coolant flowing

 Insufficient coolant flow

Check coolant level and refill if necessary

Air in the coolant circuit

Vent coolant circuit

Wire feed problems

 Contact tip blocked

Clean, spray with anti-spatter spray and replace if necessary

 Setting the spool brake - See 5.9.2.5 Spool brake setting chapter

Check settings and correct if necessary

 Setting pressure units - See 5.9.2.4 Inching the wire electrode 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 packages

Extend and lay out the torch hose package

 Wire guide core or spiral is dirty or worn

Clean core or spiral; replace kinked or worn cores

Functional errors

 Machine control without displaying the signal lights after switching on

Phase failure > check mains connection (fuses)

 No welding performance

Phase failure > check mains connection (fuses)

 Connection problems

Make control lead connections and check that they are fitted correctly.

Loose welding current connections

Tighten power connections on the torch and/or on the workpiece

Tighten contact tip correctly

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Error messages (power source)

7.2 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).

• Document machine errors and inform service staff as necessary.

• If multiple errors occur, these are displayed in succession.

Error Category a) b) c)

Possible cause

- - x Mains overvoltage

Remedy

Error 1

(Ov.Vol)

Error 2

(Un.Vol)

Error 3

(Temp)

Error 4

(Water)

- - x Mains undervoltage x - - Welding machine excess temperature x x - Low coolant level

Check the mains voltages and compare with the connection voltages of the welding machine

Error 5

(Wi.Spe)

Error 6

(gas)

Error 7

(Se.Vol)

Error 8

(no PE)

Error 9

(fast stop) x - - Wire feeder/speedometer error x - - Shielding gas error

- - x Secondary excess voltage

Allow the machine to cool down (mains switch to "1")

Top off the coolant

Leak in the coolant circuit > rectify the leak and top off the coolant

Coolant pump is not working > check excess current trigger on air cooling unit

Check the wire feeder speedometer is not issuing a signal,

M3.51 defective > inform Service

Check shielding gas supply (for machines with shielding gas monitoring)

Inverter error > inform Service

Separate the connection between the welding wire and casing or an earthed object

Rectify error on robot

Error 10

(no arc)

Error 11

(no ign)

Error 14

(no DV)

Error 15

(DV2?)

Error 16

(VRD)

Error 18

(Wf.Sl.)

Error 17

(WF. Ov.)

- - x Earth fault between welding wire and earth line x - - Fast cut-out triggered by BUSINT X11 or

RINT X12

- x - Arc break triggered by BUSINT X11 or

RINT X12

- x - Ignition fault after 5 s triggered by BUSINT X11 or

RINT X12

- x - Wire feeder not detected.

Control cable not connected.

Incorrect ID numbers assigned during operation with multiple wire feeders.

- x - Wire feeder 2 not detected.

Control cable not connected.

- - x VRD (open circuit voltage reduction error) x - - Auxiliary drive/ speedometer error

- x x Wire feed mechanism overcurrent detection

Check wire feeding

Check wire feeding

Check cable connection

Check assignment of ID numbers

Check cable connection

Inform Service

Check auxiliary drive tachogenerator not issuing signals.

M3.51 defective > inform Service

Check the wire feeding

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Rectifying faults

Error messages (power source)

Error

Error 18

(WF. Sl.)

Error 56

(no Pha)

Category a) b) c)

Possible cause

- x x No speedometer signal from second wire feeder (slave drive)

- - x Mains phase failure

Remedy

Check the connection and particularly the speedometer of the second wire feeder

(slave drive).

Check mains voltages

Legend for categories (error reset)

a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a key button:

Welding machine control Key button

RC1 / RC2

RC1 / RC2

Expert

CarExpert / Progress (M3.11) not possible alpha Q / Concept / Basic / Basic S / Synergic /

Synergic S / Progress (M3.71) / Picomig 305 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.

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Rectifying faults

Welding parameter calibration

7.3 Welding parameter calibration

When differentiating between the welding parameters set on the wire feed unit/remote control and those shown on the welding machine, they can be calibrated easily with this function.

ENTER NAVIGATION EXIT

0 l

+

3,5

3

4

2,5

2

1,5

1

0,5

5

6

7 8 9 10

11

12

13

14

15

24

22

16

18

20 m /m in

3,5

3

4

2,5

2

1,5

1

0,5

5

6

7 8 9 10

11

12

13

14

15

24

22

16

18

20 m /m in

3,5

3

4

2,5

2

1,5

1

0,5

5

6

7 8 9 10

11

12

13

14

15

24

22

16

18

20 m /m in

3,5

3

4

2,5

2

1,5

1

0,5

5

6

7 8 9 10

11

12

13

14

15

24

22

16

18

20 m /m in

20

25

15

10

30

35

40

50

45

20

25

30

35

40

15

10 50

45

Figure 7-1

20

25

30

35

40

15

10 50

45

20

25

15

10

30

35

40

45

50

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Rectifying faults

Vent coolant circuit

7.4 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)!

68

Figure 7-2

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Technical data

Taurus 351 FKG

8

Technical data

Performance specifications and guarantee only in connection with original spare and replacement parts!

8.1 Taurus 351 FKG

Setting range for welding current

Setting range for welding voltage

Duty cycle at 40 °C

100%

Load cycle

Open circuit voltage

Mains voltage (tolerances)

Frequency

Mains fuse (safety fuse, slow-blow)

Mains connection lead

Maximum connected load

Recommended generator rating cos

/efficiency

Insulation class/protection classification

Ambient temperature*

Machine/welding torch cooling

Workpiece lead

Wire feed speed

Standard roller installation

Wire drive type

Wire spool diameter

Welding torch connection

EMC class

Dimensions L x W x H in mm

Weight

Constructed to standard

MIG/MAG

14.3 V

–31.5 V

5 A

–350 A

MMA

20.2 V

–34.0 V

350 A

10 min. (60% DC

6 min. welding, 4 min. pause)

79 V

3 x 400 V (-25% to +20%)

50/60 Hz

3 x 25 A

H07RN-F4G6

13.9 kVA 15.0 kVA

20.3 kVA

0.99/88%

H/IP 23

-25 °C to +40 °C

Fan/gas

70 mm²

0.5 m/min. to 24 m/min.

1.0 mm + 1.2 mm (for steel wire)

4 rolls (37 mm)

Standardized wire spools up to 300 mm

Euro torch connector

A

1100 x 455 x 950

110.5 kg

IEC 60974-1, -5, -10

/

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Technical data

Taurus 401 FKG

8.2 Taurus 401 FKG

Setting range for welding current/voltage:

MMA

MIG/MAG

Duty cycle at 40 °C

100%

Load alternation

Open circuit voltage

Mains voltage (tolerances)

Frequency

Mains fuse (safety fuse, slow-blow)

Mains connection lead

Maximum connected load

MIG/MAG

MMA

Recommended generator rating cos

Insulation class/protection classification

Ambient temperature

Machine/torch cooling

Welding lead

Dimensions L x W x H in mm

Weight

Wire feed speed

Standard roller installation

Drive type

Welding torch connection

EMC class

Constructed to standards

5 A/20.2 V to 400 A/36.0 V

5 A/14.3 V to 400 A/34.0 V

400 A

10 min. (60% DC

6 min. welding, 4 min. pause)

79 V

3 x 400 V (-25% to +20%)

50/60 Hz

3 x 35 A

H07RN-F4G4

17.2 kVA

18.2 kVA

25.0 kVA

0.99

H/IP 23

-20 °C to +40 °C

Fan/gas

70 mm²

1100 x 455 x 950

105 kg

0.5 m/min to 24 m/min

1.0 mm + 1.2 mm (for steel wire)

4-roller (37 mm)

Euro torch connector

A

IEC 60974-1, -5, -10

/

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8.3 Taurus 501 FKG

Setting range for welding current

Setting range for welding voltage

Duty cycle at 40 °C

60%

100%

Load cycle

Open circuit voltage

Mains voltage (tolerances)

Frequency

Mains fuse (safety fuse, slow-blow)

Mains connection lead

Maximum connected load

Recommended generator rating cos

/efficiency

Insulation class/protection classification

Ambient temperature*

Machine/welding torch cooling

Workpiece lead

Wire feed speed

Standard roller installation

Drive type

Wire spool diameter

Welding torch connection

EMC class

Dimensions L x W x H in mm

Weight

Constructed to standard

Technical data

Taurus 501 FKG

MIG/MAG

14.3 V

–39 V

5 A

–500 A

MMA

20.2 V

–40 V

500 A

430 A

10 min. (60% DC

6 min. welding, 4 min. pause)

79 V

3 x 400 V (-25% to +20%)

50/60 Hz

3 x 32 A

H07RN-F4G6

24.6 kVA 25.2 kVA

34 kVA

0.99/90%

H/IP 23

-25 °C to +40 °C

Fan/gas

70 mm²

0.5 m/min. to 24 m/min.

1.0 mm + 1.2 mm (for steel wire)

4 rolls (37 mm)

Standardized wire spools up to 300 mm

Euro torch connector

A

1100 x 455 x 950

110.5 kg

IEC 60974-1, -5, -10

/

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Technical data

Taurus 351 FKW

8.4 Taurus 351 FKW

Setting range for welding current

Setting range for welding voltage

Duty cycle at 40 °C

100%

Load cycle

Open circuit voltage

Mains voltage (tolerances)

Frequency

Mains fuse (safety fuse, slow-blow)

Mains connection lead

Maximum connected load

Recommended generator rating cos

/efficiency

Insulation class/protection classification

Ambient temperature*

Machine/welding torch cooling

Cooling capacity at 1 l/min

Max. flow rate

Max. coolant outlet pressure

Max. tank capacity

Workpiece lead

Wire feed speed

Standard roller installation

Wire drive type

Wire spool diameter

Welding torch connection

EMC class

Dimensions L x W x H in mm

Weight

Constructed to standard

MIG/MAG

14.3 V

–31.5 V

5 A

–350 A

MMA

20.2 V

–34.0 V

350 A

10 min. (60% DC

6 min. welding, 4 min. pause)

79 V

3 x 400 V (-25% to +20%)

50/60 Hz

3 x 25 A

H07RN-F4G6

14.3 kVA 15.4 kVA

20.8 kVA

0.99/90%

H/IP 23

-25 °C to +40 °C

Fan/gas or water

1500 W

5 l/min

3.5 bar

12 l

70 mm²

0.5 m/min. to 24 m/min.

1.0 mm + 1.2 mm (for steel wire)

4 rolls (37 mm)

Standardized wire spools up to 300 mm

Euro torch connector

A

1100 x 455 x 950

121.5 kg

IEC 60974-1, -2, -5, -10

/

*Ambient temperature depends on coolant! Observe the coolant temperature range for the welding torch cooling!

72

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Technical data

Taurus 401 FKW

8.5 Taurus 401 FKW

Setting range for welding current/voltage:

MMA

MIG/MAG

Duty cycle at 40 °C

100%

Load alternation

Open circuit voltage

Mains voltage (tolerances)

Frequency

Mains fuse (safety fuse, slow-blow)

Mains connection lead

Maximum connected load

MIG/MAG

MMA

Recommended generator rating cos

Insulation class/protection classification

Ambient temperature*

Machine/torch cooling

Cooling capacity at 1 l/min

Max. flow rate

Max. coolant outlet pressure

Max. tank capacity

Welding lead

Dimensions L x W x H in mm

Weight

Wire feed speed

Standard roller installation

Drive type

Welding torch connection

EMC class

Constructed to standards

5 A/20.2 V to 400 A/36.0 V

5 A/14.3 V to 400 A/34.0 V

400 A

10 min. (60% DC

6 min. welding, 4 min. pause)

79 V

3 x 400 V (-25% to +20%)

50/60 Hz

3 x 32 A

H07RN-F4G6

17.5 kVA

18.5 kVA

25 kVA

0.99

H/IP 23

-25 °C to +40 °C

Fan/gas or water

1500 W

5 l/min

3.5 bar

12 l

70 mm²

1100 x 455 x 950

120 kg

0.5 m/min to 24 m/min

1.0 mm + 1.2 mm (for steel wire)

4-roller (37 mm)

Euro torch connector

A

IEC 60974-1, -2, -5, -10 / /

*Ambient temperature depends on coolant! Observe the coolant temperature range for the welding torch cooling!

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Technical data

Taurus 501 FKW

8.6 Taurus 501 FKW

Setting range for welding current

Setting range for welding voltage

Duty cycle at 40 °C

60%

100%

Load cycle

Open circuit voltage

Mains voltage (tolerances)

Frequency

Mains fuse (safety fuse, slow-blow)

Mains connection lead

Maximum connected load

Recommended generator rating cos

/efficiency

Insulation class/protection classification

Ambient temperature*

Machine/welding torch cooling

Cooling capacity at 1 l/min

Max. flow rate

Max. coolant outlet pressure

Max. tank capacity

Workpiece lead

Wire feed speed

Standard roller installation

Wire drive type

Wire spool diameter

Welding torch connection

EMC class

Dimensions L x W x H in mm

Weight

Constructed to standard

MIG/MAG

14.3 V

–39.0 V

5 A

–500 A

MMA

20.2 V

–40.0 V

500 A

430 A

10 min. (60% DC

6 min. welding, 4 min. pause)

79 V

3 x 400 V (-25% to +20%)

50/60 Hz

3 x 32 A

H07RN-F4G6

24.9 kVA 25.6 kVA

34.6 kVA

0.99/90%

H/IP 23

-25 °C to +40 °C

Fan/gas or water

1500 W

5 l/min

3.5 bar

12 l

95 mm²

0.5 m/min. to 24 m/min.

1.0 mm + 1.2 mm (for steel wire)

4 rolls (37 mm)

Standardized wire spools up to 300 mm

Euro torch connector

A

1100 x 455 x 950

124.5 kg

IEC 60974-1, -2, -5, -10

/

*Ambient temperature depends on coolant! Observe the coolant temperature range for the welding torch cooling!

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Accessories

General accessories

9

Accessories

Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer.

9.1

General accessories

Type Designation

AK300 Wire spool adapter K300

DMDIN TN 200B AR/MIX 35L Manometer pressure regulator

GH 2X1/4'' 2M

5POLE/CEE/32A/M

Gas hose

Machine plug

HOSE BRIDGE UNI

TYP 1

KF 23E-10

KF 23E-200

KF 37E-10

KF 37E-200

SPL

HC PL Hose cutter

9.2

Remote control / connection cable

Type Designation

R11 19POL

RG11 19POL 5M

RA5 19POL 5M

RA10 19POL 10M

RA20 19POL 20M

Tube bridge

Frost protection tester

Coolant (-10 °C), 9.3 l

Coolant (-10 °C), 200 litres

Coolant (-20 °C), 9.3 l

Coolant (-20 °C), 200 l

Sharpener for plastic liners

Remote control

Remote control

Remote control e.g. connection cable

Remote control e.g. connection cable

Remote control e.g. connection cable

Item no.

094-001803-00001

094-000009-00000

094-000010-00001

094-000207-00000

092-007843-00000

094-014499-00000

094-000530-00000

094-000530-00001

094-006256-00000

094-006256-00001

094-010427-00000

094-016585-00000

Item no.

090-008601-00502

090-008107-00000

092-001470-00005

092-001470-00010

092-001470-00020

9.3 Options

Type Designation Item no.

ON LB Wheels 160x40MM Retrofit option for locking brake for machine wheels 092-002110-00000

ON Holder Gas Bottle <50L Holding plate for gas cylinders smaller than 50 litres 092-002151-00000

ON Shock Protect

ON Hose/FR Mount

Ram protection retrofit option

Optional holder for tubes and remote control for machines without pivot support

092-002154-00000

092-002116-00000

ON Filter T/P

ON Tool Box

Retrofit option contamination filter for air inlet

Retrofit option tool box

092-002092-00000

092-002138-00000

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Replaceable parts

Wire feed rollers

10

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!

• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.

10.1 Wire feed rollers

10.1.1 Wire feed rollers for steel wire

Type Designation Item no.

092-002770-00006 FE 4R 0.6 MM/0.023 INCH

LIGHT PINK

FE 4R 0.8 MM/0.03 INCH

WHITE

FE 4R 1,0 MM/0.04 INCH

BLUE

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

092-002770-00008

092-002770-00010

FE 4R 1.2 MM/0.045 INCH

RED

FE 4R 1.4 MM/0.052 INCH

GREEN

FE 4R 1.6 MM/0.06 INCH

BLACK

FE 4R 2.0 MM/0.08 INCH

GREY

FE 4R 2.4 MM/0.095 INCH

BROWN

FE 4R 2.8 MM/0.11 INCH

LIGHT GREEN

FE 4R 3.2 MM/0.12 INCH

VIOLET

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing

092-002770-00012

092-002770-00014

092-002770-00016

092-002770-00020

092-002770-00024

092-002770-00028

092-002770-00032

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Replaceable parts

Wire feed rollers

10.1.2 Wire feed rollers for aluminium wire

Type Designation

Drive roll set, 37 mm, for aluminium AL 4R 0.8 MM/0.03 INCH

WHITE

AL 4R 1.0 MM/0.04 INCH

BLUE

AL 4R 1.2 MM/0.045 INCH

RED

AL 4R 1.6 MM/0.06 INCH

BLACK

Drive roll set, 37 mm, for aluminium

Drive roll set, 37 mm, for aluminium

Drive roll set, 37 mm, for aluminium

AL 4R 2.0 MM/0.08 INCH

GREY/YELLOW

AL 4R 2.4 MM/0.095 INCH

BROWN/YELLOW

AL 4R 2.8 MM/0.110 INCH

LIGHT GREEN/YELLOW

AL 4R 3.2 MM/0.125 INCH

VIOLET/YELLOW

Drive roll set, 37 mm, for aluminium

Drive roll set, 37 mm, for aluminium

Drive roll set, 37 mm, for aluminium

Drive roll set, 37 mm, for aluminium

10.1.3 Wire feed rollers for cored wire

Type Designation

FUEL 4R 0.8 MM/0.03 INCH

WHITE/ORANGE

FUEL 4R 1.0 MM/0.04 INCH

BLUE/ORANGE

FUEL 4R 1.2 MM/0.045 INCH

RED/ORANGE

FUEL 4R 1.4 MM/0.052 INCH

GREEN/ORANGE

FUEL 4R 1.6 MM/0.06 INCH

BLACK/ORANGE

FUEL 4R 2.0 MM/0.08 INCH

GREY/ORANGE

FUEL 4R 2.4 MM/0.095 INCH

BROWN/ORANGE

10.1.4 Wire guide

Type

SET DRAHTFUERUNG

ON WF 2,0-3,2MM EFEED

SET IG 4x4 1.6mm BL

GUIDE TUBE L105

CAPTUB L108 D1,6

CAPTUB L105 D2,0/2,4

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire

Item no.

092-002771-00008

092-002771-00010

092-002771-00012

092-002771-00016

092-002771-00020

092-002771-00024

092-002771-00028

092-002771-00032

Item no.

092-002848-00008

092-002848-00010

092-002848-00012

092-002848-00014

092-002848-00016

092-002848-00020

092-002848-00024

Designation

Wire guide set

Retrofitting option, wire guide for 2.0

–3.2 mm wires, eFeed drive

Inlet guide set

Guide tube

Capillary tube

Capillary tube

Item no.

092-002774-00000

092-019404-00000

092-002780-00000

094-006051-00000

094-006634-00000

094-021470-00000

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Appendix A

Setting instructions

11

Appendix A

11.1 Setting instructions

78

Figure 11-1

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12

Appendix B

12.1 Overview of EWM branches

Appendix B

Overview of EWM branches

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