EWM Taurus 351 Basic FKG, Taurus 401 Basic FKG, Taurus 351 Basic FKW, Taurus 401 Basic FKW, Taurus 501 Basic FKW Operating Instructions Manual
Operating instructions
EN
Welding machine
Taurus 351 Basic FKG
Taurus 401 Basic FKG
Taurus 351 Basic FKW
Taurus 401 Basic FKW
Taurus 501 Basic FKW
099-005425-EW501
14.07.2016
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the location where the machine is operated.
• Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
• Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
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-Straße 8
56271 Mündersbach
Germany
The copyright to this document remains the property of the manufacturer.
Copying, 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
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1 Contents
1 Contents .................................................................................................................................................. 3
2 Safety instructions ................................................................................................................................. 6
2.1 Notes on the use of these operating instructions .......................................................................... 6
2.2 Explanation of icons ....................................................................................................................... 7
2.3 Safety instructions .......................................................................................................................... 8
2.4 Transport and installation ............................................................................................................ 12
3 Intended use ......................................................................................................................................... 13
3.1 Documents which also apply ....................................................................................................... 13
3.1.1 Warranty ....................................................................................................................... 13
3.1.2 Declaration of Conformity ............................................................................................. 13
3.1.3 Welding in environments with increased electrical hazards ......................................... 13
3.1.4 Service documents (spare parts and circuit diagrams) ................................................ 13
3.1.5 Calibration/Validation ................................................................................................... 13
4 Machine description – quick overview .............................................................................................. 14
4.1 Front view .................................................................................................................................... 14
4.2 Rear view ..................................................................................................................................... 16
4.3 Inside view ................................................................................................................................... 18
4.4 Machine control – Operating elements ........................................................................................ 19
5 Design and function ............................................................................................................................. 21
5.1 Transport and installation ............................................................................................................ 21
5.1.1 Lifting by crane ............................................................................................................. 21
5.1.2 Ambient conditions ....................................................................................................... 22
5.1.2.1 In operation ................................................................................................... 22
5.1.2.2 Transport and storage ................................................................................... 22
5.1.3 Machine cooling ............................................................................................................ 22
5.1.4 Workpiece lead, general ............................................................................................... 22
5.1.5 Welding torch cooling system ....................................................................................... 23
5.1.5.1 Approved coolants overview ......................................................................... 23
5.1.5.2 Maximal hose package length ...................................................................... 23
5.1.5.3 Adding coolant .............................................................................................. 24
5.1.6 Notes on the installation of welding current leads ........................................................ 25
5.1.7 Stray welding currents .................................................................................................. 26
5.1.8 Mains connection .......................................................................................................... 27
5.1.8.1 Mains configuration ....................................................................................... 27
5.1.9 Shielding gas supply (shielding gas cylinder for welding machine) ............................. 28
5.1.9.1 Pressure regulator connection ...................................................................... 28
5.1.9.2 Shielding gas hose connection ..................................................................... 29
5.1.9.3 Gas test – setting the shielding gas volume ................................................. 30
5.1.9.4 Rinse hose package function ........................................................................ 30
5.2 Welding data display .................................................................................................................... 31
5.3 MIG/MAG welding ........................................................................................................................ 32
5.3.1 Welding torch and workpiece line connection .............................................................. 32
5.3.2 Wire feed ...................................................................................................................... 35
5.3.2.1 Open the protective flap of the wire feeder ................................................... 35
5.3.2.2 Inserting the wire spool ................................................................................. 36
5.3.2.3 Changing the wire feed rollers ...................................................................... 37
5.3.2.4 Inching the wire electrode ............................................................................. 39
5.3.2.5 Spool brake setting ....................................................................................... 40
5.3.3 Welding task selection .................................................................................................. 41
5.3.3.1 Accessory components for operating point setting ....................................... 41
5.3.4 Further welding parameters ......................................................................................... 42
5.3.5 MIG/MAG functional sequences / operating modes ..................................................... 43
5.3.5.1 Explanation of signs and functions ............................................................... 43
5.3.6 Standard MIG/MAG torch ............................................................................................. 45
5.3.7 MIG/MAG special-torches ............................................................................................ 45
5.4 MMA welding ............................................................................................................................... 46
Contents
Notes on the use of these operating instructions
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5.4.1 Connecting the electrode holder and workpiece lead .................................................. 47
5.4.2 Welding task selection .................................................................................................. 48
5.4.3 Arcforce......................................................................................................................... 48
5.4.4 Hotstart ......................................................................................................................... 48
5.4.5 Antistick......................................................................................................................... 48
5.4.6 Air arc gouging .............................................................................................................. 49
5.4.6.1 Connection .................................................................................................... 49
5.4.7 Welding task selection .................................................................................................. 50
5.5 Remote control ............................................................................................................................. 51
5.6 Special parameters (advanced settings) ...................................................................................... 51
5.6.1 Selecting, changing and saving parameters................................................................. 51
5.6.1.1 Reset to factory settings ................................................................................ 53
5.6.1.2 Special parameters in detail .......................................................................... 53
5.7 Machine configuration menu ........................................................................................................ 54
5.7.1 Selecting, changing and saving parameters................................................................. 54
5.7.2 Power-saving mode (Standby) ..................................................................................... 55
5.7.3 Aligning the cable resistance ........................................................................................ 55
6 Maintenance, care and disposal ......................................................................................................... 57
6.1 General......................................................................................................................................... 57
6.2 Cleaning ....................................................................................................................................... 57
6.3 Maintenance work, intervals ........................................................................................................ 58
6.3.1 Daily maintenance tasks ............................................................................................... 58
6.3.1.1 Visual inspection ........................................................................................... 58
6.3.1.2 Functional test ............................................................................................... 58
6.3.2 Monthly maintenance tasks .......................................................................................... 58
6.3.2.1 Visual inspection ........................................................................................... 58
6.3.2.2 Functional test ............................................................................................... 58
6.3.3 Annual test (inspection and testing during operation) .................................................. 59
6.4 Disposing of equipment ................................................................................................................ 59
6.4.1 Manufacturer's declaration to the end user .................................................................. 59
6.5 Meeting the requirements of RoHS .............................................................................................. 59
7 Rectifying faults.................................................................................................................................... 60
7.1 Checklist for rectifying faults ........................................................................................................ 60
7.2 Error messages (power source) ................................................................................................... 61
7.3 Welding parameter calibration ..................................................................................................... 63
7.4 Vent coolant circuit ....................................................................................................................... 64
8 Technical data....................................................................................................................................... 65
8.1 Taurus 351 FKG ........................................................................................................................... 65
8.2 Taurus 401 FKG ........................................................................................................................... 66
8.3 Taurus 351 FKW .......................................................................................................................... 67
8.4 Taurus 401 FKW .......................................................................................................................... 68
8.5 Taurus 501 FKW .......................................................................................................................... 69
9 Accessories .......................................................................................................................................... 70
9.1 General accessories .................................................................................................................... 70
9.2 Remote control / connection cable ............................................................................................... 70
9.3 Options ......................................................................................................................................... 70
10 Replaceable parts ................................................................................................................................. 71
10.1 Wire feed rollers ........................................................................................................................... 71
10.1.1 Wire feed rollers for steel wire ...................................................................................... 71
10.1.2 Wire feed rollers for aluminium wire ............................................................................. 72
10.1.3 Wire feed rollers for cored wire ..................................................................................... 72
10.1.4 Wire guide ..................................................................................................................... 72
11 Appendix A ............................................................................................................................................ 73
11.1 Setting instructions ....................................................................................................................... 73
12 Appendix B ............................................................................................................................................ 74
12.1 Overview of EWM branches......................................................................................................... 74
Contents
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Safety instructions
Notes on the use of these operating instructions
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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.
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.
Safety instructions
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/tip
Switch off machine
Release
Switch on machine
Press and keep pressed
Switch
Wrong
Turn
Correct
Numerical value – adjustable
Menu entry
Signal light lights up in green
Navigating the menu
Signal light flashes green
Exit menu
Signal light lights up in red
Time representation (e.g.: wait
4 s/activate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use
Safety instructions
Safety instructions
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2.3 Safety instructions
WARNING
Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
• Carefully read the safety instructions in this manual!
• Observe the accident prevention regulations and any regional regulations!
• Inform persons in the working area that they must comply with the regulations!
WARNING
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low
voltages can cause a shock and lead to accidents.
• Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
• Always place torches and electrode holders on an insulated surface!
• Wear the full personal protective equipment (depending on the application)!
• The machine may only be opened by qualified personnel!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a
technical specialist may interconnect the sources as per standard IEC 60974-9:2010:
Installation and use and German Accident Prevention Regulation BVG D1 (formerly VBG
15) or country-specific regulations.
Before commencing arc welding, a test must verify that the equipment cannot exceed
the maximum permitted open circuit voltage.
• Only qualified personnel may connect the machine.
• When taking individual power sources out of operation, all mains and welding current leads
must be safely disconnected from the welding system as a whole. (Hazard due to reverse
polarity voltage!)
• Do not interconnect welding machines with pole reversing switch (PWS series) or machines
for AC welding since a minor error in operation can cause the welding voltages to be
combined, which is not permitted.
Safety instructions
Safety instructions
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WARNING
Risk of injury due to improper clothing!
During arc welding, radiation, heat and voltage are sources of risk that cannot be
avoided. The user has to be equipped with the complete personal protective equipment
at all times. The protective equipment has to include:
• Respiratory protection against hazardous substances and mixtures (fumes and vapours);
otherwise implement suitable measures such as extraction facilities.
• Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and
heat.
• Dry welding clothing (shoes, gloves and body protection) to protect against warm
environments with conditions comparable to ambient temperatures of 100 °C or higher and
arcing and work on live components.
• Hearing protection against harming noise.
WARNING
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!
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!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during
welding, there is a risk of flames.
• Be watchful of potential sources of fire in the working area!
• Do not carry any easily inflammable objects, e.g. matches or lighters.
• Ensure suitable fire extinguishers are available in the working area!
• Thoroughly remove any residue of flammable materials from the workpiece prior to starting
to weld.
• Only further process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!
Safety instructions
Safety instructions
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CAUTION
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!
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!
Obligations of the operator!
The respective national directives and laws must be complied with when operating the machine!
• Implementation of national legislation relating to framework directive 89/391/EEC on the
introduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
• In particular, directive 89/655/EEC concerning the minimum safety and health requirements for
the use of work equipment by workers at work.
• The regulations applicable to occupational safety and accident prevention in the country
concerned.
• Setting up and operating the machine as per IEC 60974.-9.
• Brief the user on safety-conscious work practices on a regular basis.
• Regularly inspect the machine as per IEC 60974.-4.
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.
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.
Safety instructions
Safety instructions
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CAUTION
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 6.3 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).
According to IEC 60974-10, welding machines are divided into two classes of
electromagnetic compatibility (the EMC class can be found in the Technical
data) > see 8 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 system
• 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
Safety instructions
Transport and installation
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2.4 Transport and installation
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!
• Observe the instructions from the gas manufacturer and any relevant regulations
concerning the use of compressed air!
• Do not attach any element to the shielding gas cylinder valve!
• Prevent the shielding gas cylinder from heating up.
CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
• Disconnect all supply lines before transport!
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 IEC 60974-1).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
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!
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.
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!
Intended use
Documents which also apply
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. 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 its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
Arc welding machine for gas-shielded metal-arc welding and MMA welding as secondary process. It may
be possible to expand the range of functions by using accessories (see the documentation in the relevant
chapter).
3.1 Documents which also apply
3.1.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.1.2 Declaration of Conformity
The labelled machine complies with the following EC directives in terms of its design and
construction:
• Low Voltage Directive (LVD)
• Electromagnetic Compatibility Directive (EMC)
• Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which
have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the
specific declaration of conformity is included with every product.
3.1.3 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.
3.1.4 Service documents (spare parts and circuit diagrams)
WARNING
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.
3.1.5 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
Machine description – quick overview
Front view
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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.
Figure 4-1
Machine description – quick overview
Front view
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Item
Symbol
Description 0
1 Lifting lug
2 Ready for operation signal light
Signal light on when the machine is switched on and ready for operation
3 Main switch, machine on/off
4 Carrying handle
5
Cooling air inlet
6
Automatic cut-out of coolant pump key button
press to reset a triggered fuse
7 Quick connect coupling (red)
coolant return
8 Quick connect coupling (blue)
coolant supply
9 Wheels, guide castors
10 Coolant tank
11 Coolant tank cap
12 Connection socket, “-” welding current
• ----------- MIG/MAG welding: workpiece connection
• ----------- MIG/MAG cored wire welding: welding current connection for the
welding torch
• ----------- MMA welding: electrode holder connection
13 Connection socket, “+” welding current
• ----------- MIG/MAG welding: welding current connection for the welding torch
• ----------- MIG/MAG cored wire welding: workpiece connection
• ----------- MMA welding: workpiece connection
14 Welding current cable, polarity selection
Welding current to the central connector/torch, enables polarity selection.
• ----------- MIG/MAG: Connection socket for “+” welding current
• ----------- Self-shielding cored wire
15 Welding torch connection (Euro or Dinse torch connector)
Welding current, shielding gas and torch trigger integrated
16 19-pole connection socket (analogue)
For connecting analogue remote controls
17 Machine control > see 4.4 chapter
Machine description – quick overview
Rear view
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4.2 Rear view
Figure 4-2
Machine description – quick overview
Rear view
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Item
Symbol
Description 0
1 Slide latch, lock for the protective cap
2 Securing elements for shielding gas cylinder (strap/chain)
3 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.
4 Wire spool inspection window
Check wire supply
5
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
Key button, Automatic cutout
Wire feed motor supply voltage fuse
(press to reset a triggered fuse)
11
Mains connection cable > see 5.1.8 chapter
Machine description – quick overview
Inside view
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4.3 Inside view
Figure 4-3
Item
Symbol
Description 0
1 Wire spool holder
2 Wire feed unit
Machine description – quick overview
Machine control – Operating elements
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4.4 Machine control – Operating elements
Figure 4-4
Item
Symbol
Description 0
1 Button, welding process
J1 --------- MIG/MAG welding
J2 --------- MMA welding
J3 --------- Air arc gouging
2 Display, left
Welding current, wire feed speed
3 Status displays
AMP ----- "Welding current display" signal light
---------- "Wire feed speed display" signal light
4 Display, welding process
J1 --------- MIG/MAG welding
J2 --------- MMA welding
J3 --------- Gouging
5 Welding parameter setting, rotary dial
For setting the welding performance, for selecting the JOB (welding task) and for
setting other welding parameters.
6 Select operating mode button
--------- Non-latched
-------- Latched
Machine description – quick overview
Machine control – Operating elements
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Item
Symbol
Description 0
7 Push-button, throttling effect (arc dynamics)
---- Arc is harder and more narrow
---- Arc is softer and wider
8 Rotary dial, welding voltage
Adjustment of the welding voltage from min. to max.
(twin-knob operation: wire speed/welding voltage)
9 Push-button, parameter selection right/power-saving mode
VOLT --- Welding voltage
kW ------- Welding power display
--------- Gas flow rate (option)
Enter power-saving mode by pressing the push-button for long interval.
10 Display, right
Welding voltage, welding performance, motor current (wire feed mechanism) during
wire inching, shielding gas flow rate (option)
11 Push-button gas test / rinse hose package > see 5.1.9.4 chapter
12 Push-button, wire inching
Potential- and gas-free inching of the wire electrode through the hose package to the
welding torch > see 5.3.2.4 chapter.
Design and function
Transport and installation
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5 Design and function
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!
5.1 Transport and installation
5.1.1 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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5.1.2 Ambient conditions
T he 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.
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)!
5.1.2.1 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
5.1.2.2 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
5.1.3 Machine cooling
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!
5.1.4 Workpiece lead, general
CAUTION
Risk of burning due to incorrect welding current connection!
If the welding current plugs (machine connections) are not locked or if the workpiece
connection is contaminated (paint, corrosion), these connections and leads can heat up
and cause burns when touched!
• Check welding current connections on a daily basis and lock by turning to the right when
necessary.
• Clean workpiece connection thoroughly and secure properly. Do not use structural parts of
the workpiece as welding current return lead!
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5.1.5 Welding torch cooling system
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch > see 5.1.5.1 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!
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.
Dispose of the coolant in accordance with local regulations and the material safety data sheets
(German waste code number: 70104).
May not be disposed of in household waste.
Prevent entry into sewers.
Absorb with liquid-binding material (sand, gravel, acid-binding agents, universal binding agents,
sawdust).
5.1.5.1 Approved coolants overview
Coolant
Temperature range
KF 23E (Standard)
-10 °C to +40 °C
KF 37E
-20 °C to +10 °C
5.1.5.2 Maximal hose package length
Pump 3.5 bar
Pump 4.5 bar
Machines with or without separate wire feeder
30 m
60 m
Compact machines with additional intermediate
drive (example. miniDrive)
20 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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5.1.5.3 Adding coolant
The unit is supplied ex works with a minimum level of coolant.
Figure 5-1
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 chapter.
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5.1.6 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).
Figure 5-2
Use an individual welding lead to the workpiece for each welding machine!
Figure 5-3
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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 5-4
5.1.7 Stray welding currents
WARNING
Risk of injury due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage machines and
electronic devices and cause overheating of components, leading to fire.
• Check that all welding current connections are firmly secured and electrical connections are
in perfect condition.
• Set up, attach or suspend all conductive power source components such as casing,
transport vehicles and crane frames so they are insulated.
• Do not place any other electronic devices such as drills or angle grinders 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.
Figure 5-5
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5.1.8 Mains connection
DANGER
Hazards caused by improper mains connection!
An improper mains connection can cause injuries or damage property!
• Only operate machine using a socket that has correctly fitted protective earth.
• The mains voltage indicated on the rating plate must match the supply voltage.
• If a new mains plug must be fitted, only an electrician may do so as per the relevant
national legislation or regulations.
• Mains plug, socket and lead must be checked by an electrician on a regular basis.
• When operating the generator, always ensure it is earthed as stipulated in the operating
instructions. The network created must be suitable for operating machines according to
protection class I.
5.1.8.1 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 5-6
Legend
Item
Designation
Colour code
L1
Outer conductor 1
brown
L2
Outer conductor 2
black
L3
Outer conductor 3
grey
N
Neutral conductor
blue
PE
Protective conductor
green-yellow
• Insert mains plug of the switched-off machine into the appropriate socket.
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5.1.9 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!
• Place shielding gas cylinder into the designated holder and secure with
fastening elements (chain/belt)!
• Attach the fastening elements within the upper half of the shielding gas
cylinder!
• The fastening elements must tightly enclose the shielding gas cylinder!
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.
5.1.9.1 Pressure regulator connection
Figure 5-7
Item
Symbol
Description 0
1 Pressure regulator
2 Shielding gas cylinder
3 Output side of the pressure regulator
4 Cylinder valve
• Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow
out any dirt.
• 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.
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5.1.9.2 Shielding gas hose connection
Figure 5-8
Item
Symbol
Description 0
1 Connecting nipple G¼, shielding gas connection
• Connect crown nut of the shielding gas line to the G¼“ connecting nipple.
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5.1.9.3 Gas test – setting the shielding gas volume
• Slowly open the gas cylinder valve.
• Open the pressure regulator.
• Switch on the power source at the main switch.
• Set the relevant gas quantity for the application on the pressure regulator.
• You can activate the gas test on the machine control (see Control operating instructions) or by
pressing the "Gas test/rinse hose package " push-button briefly (welding voltage and wire feed
motor remain switched off – no unintentional ignition of the arc). Some welding systems have several
push-buttons to set the shielding gas. The push-button is generally found near a wire feeder.
Shielding gas flows for around 25 seconds or until the button is pressed again.
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!
Setting instructions
Welding process
Recommended shielding gas quantity
MAG welding
Wire diameter x 11.5 = l/min
MIG brazing
Wire diameter x 11.5 = l/min
MIG welding (aluminium)
Wire diameter x 13.5 = l/min (100 % argon)
TIG
Gas nozzle diameter in mm corresponds to l/min gas throughput
Helium-rich gas mixtures require a higher gas volume!
The table below can be used to correct the gas volume calculated where necessary:
Shielding gas
Factor
75% Ar/25% He
1.14
50% Ar/50% He
1.35
25% Ar/75% He
1.75
100% He
3.16
5.1.9.4 Rinse hose package function
EXIT
5s
5s
Figure 5-9
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5.2 Welding data display
Figure 5-10
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" ( ) push-
button 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
Nominal values
Actual values
Hold values
Welding current
Wire feed speed
Welding voltage
Welding performance
MMA welding
Parameter
Nominal values
Actual values
Hold values
Welding current
Welding voltage
Welding performance
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5.3 MIG/MAG welding
5.3.1 Welding torch and workpiece line connection
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 5.1.5.2 chapter.
• When using a gas-cooled welding torch, use a hose bridge to establish the coolant
circuit > see 9 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 > see 9 chapter 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 > see 9 chapter and sharpen.
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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 5-11
Item
Symbol
Description 0
1 Workpiece
2 "-" welding current connection socket
• ----------- MIG/MAG welding: Workpiece connection
3 Welding torch
4 Welding torch hose package
5 19-pole connection socket (analogue)
For connecting analogue accessory components (remote control, welding torch control
lead, etc.)
6 Welding torch connection (Euro or Dinse torch connector)
Welding current, shielding gas and torch trigger integrated
7 Welding current cable, polarity selection
Welding current to central connection/torch. Permits polarity selection for MIG/MAG
welding.
• ----------- Standard applications > Connection for "+" welding current connection socket
8 Quick connect coupling (red)
coolant return
9 Quick connect coupling (blue)
coolant supply
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• 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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5.3.2 Wire feed
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!
• Check wire guide at regular intervals!
• Keep all casing covers or protective caps closed during operation!
5.3.2.1 Open the protective flap of the wire feeder
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.
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5.3.2.2 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 support
and fall to the ground, causing damage to the machine and injuries.
• Make sure to correctly fasten the wire spool to the wire spool support.
• Before you start working, always check the wire spool is securely fastened.
Standard D300 wire spool holder can be used. Adapters > see 9 chapter are required when using
standardised basket coils (DIN 8559).
Figure 5-12
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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5.3.2.3 Changing the wire feed rollers
Figure 5-13
Item
Symbol
Description 0
1 Tommy
The tommy is used to secure the closure brackets of the wire feed rollers.
2 Closure bracket
The closure brackets are used to secure the wire feed rollers.
3 Feed roll tensioner
Fixing the clamping unit and setting the pressure.
4 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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Unsatisfactory welding results due to faulty wire feeding!
The wire feed rolls must be suitable for the diameter of the wire and the material. The wire feed
rolls are colour-coded to facilitate distinction (see the Wire feed roll overview table). When
working with a wire diameter of > 1.6 mm the drive has to be converted for the wire feed kit ON
WF 2,0-3,2MM EFEED > see 10 chapter.
Wire feed roller overview table
Material
Diameter
Colour code
Groove form
mm
inch
Steel
Stainless
steel
Brazing
0.6
.023
monochrome
light pink
V-groove
0.8
.030
white
0.9/1.0
.035/.040
blue
1.2
045
red
1.4
052
green
1.6
060
black
2.0
.080
grey
2.4
.095
brown
2.8
.110
Light
green
3.2
.125
purple
Aluminium
0.8
.030
bichrome
white
yellow
U-groove
0.9/1.0
.035/.040
blue
1.2
.045
red
1.6
.060
black
2.0
.080
grey
2.4
.095
brown
2.8
.110
Light
green
3.2
.125
purple
Flux cored
wire
0.8
.030
bichrome
white
orange
V-groove,
knurled
0.9
1.0
.035
.040
blue
1.2
.045
red
1.4
.052
green
1.6
.060
black
2.0
.080
grey
2.4
.095
brown
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5.3.2.4 Inching the wire electrode
CAUTION
Risk of injury due to welding wire escaping from the welding torch!
The welding wire can escape from the welding torch at high speed and cause bodily
injury including injuries to the face and eyes!
• Never direct the welding torch towards your own body or towards other persons!
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.
Figure 5-14
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).
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A prerequisite for the automatic inching process is the correct preparation of the wire guide,
especially in the capillary and wire guide tube area > see 5.3.1 chapter.
• 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
Figure 5-15
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.
5.3.2.5 Spool brake setting
Figure 5-16
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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5.3.3 Welding task selection
Figure 5-17
5.3.3.1 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 chapter
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5.3.4 Further welding parameters
NAVIGATION
B
A
A
A
A
A
A
B
B
B
B
ENTER EXIT
3 s
l
0
Figure 5-18
Display
Setting/selection
Dynamic correction
• Increase value > harder arc
• Decrease value > softer arc
Gas pre-flow time
Gas post-flow time
Correct wire burn-back
If too high a value is set, a large ball will form at the tip of the wire electrode (bad reignition) or the wire electrode sticks to the contact tip. If too low a value is set, the wire
electrode sticks to the weld pool.
• Increase value > increase wire burn-back
• Decrease value > decrease wire burn-back
Wire creep
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5.3.5 MIG/MAG functional sequences / operating modes
5.3.5.1 Explanation of signs and functions
Symbol
Meaning
Press torch trigger
Release torch trigger
Tap torch trigger (press briefly and release)
Shielding gas flowing
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 5-19
Step 1
• Press and hold torch trigger.
• Shielding gas is expelled (gas pre-flows).
• Wire feed motor runs at “creep speed”.
• Arc ignites after the wire electrode makes contact with the workpiece; welding current flows.
• 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 5-20
Step 1
• Press and hold torch trigger
• Shielding gas is expelled (gas pre-flows)
• Wire feed motor runs at “creep speed”.
• Arc ignites after the wire electrode makes contact with the workpiece; welding current flows.
• Change over to pre-selected WF speed (main program PA).
Step 2
• Release torch trigger (no effect)
Step 3
• Press torch trigger (no effect)
Step 4
• Release torch trigger
• WF motor stops.
• Arc is extinguished after the preselected wire burn-back time expires.
• Gas post-flow time elapses.
5.3.6 Standard MIG/MAG torch
The MIG welding torch trigger is essentially used to start and stop the welding process.
Operating elements
Functions
Torch trigger
• Start/stop welding
5.3.7 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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5.4 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.
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5.4.1 Connecting the electrode holder and workpiece lead
Figure 5-21
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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5.4.2 Welding task selection
Figure 5-22
5.4.3 Arcforce
Figure 5-23
Setting:
• Negative values: rutile electrode types
• Values at zero: basic electrode types
• Positive values: cellulose electrode types
5.4.4 Hotstart
The hotstart device improves the ignition of the stick electrodes using an increased ignition current.
a) = Hotstart time
b) = Hotstart current
I = Welding current
t = Time
Figure 5-24
5.4.5 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 5-25
Design and function
MMA welding
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5.4.6 Air arc gouging
5.4.6.1 Connection
Read and observe the documentation to all system and accessory components!
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.
Figure 5-26
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.
Design and function
MMA welding
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5.4.7 Welding task selection
Figure 5-27
Design and function
Remote control
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5.5 Remote control
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).
5.6 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 5.6.1.1 chapter.
5.6.1 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).
Design and function
Special parameters (advanced settings)
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Enter
+
l
0
Exit
Figure 5-28
Display
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)
Remote control encoding (Frc)
0 ---------- Automatic remote control detection (ex works)
2 ---------- Remote control encoding for accessory components with a single rotary knob
only
9 ---------- Remote control encoding for accessory components with a single pair of
buttons or a rocker only
1, 3–8 --- No remote control encoding
10–15 --- No remote control encoding
Design and function
Special parameters (advanced settings)
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5.6.1.1 Reset to factory settings
All special parameters saved by the user will be overwritten by the factory settings!
RESET
+
l0l
0
Figure 5-29
Display
Setting/selection
Initialisation complete
All customised welding parameters haven been overwritten by the factory settings.
5.6.1.2 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.
Electronic gas flow control, type (P22)
Active only in machines with integrated gas flow control (option ex works).
Adjustment may only be carried out by authorised service personnel (basic setting = 1).
Design and function
Machine configuration menu
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5.7 Machine configuration menu
5.7.1 Selecting, changing and saving parameters
ENTER (Enter the menu)
• Switch off the machine at the main switch.
• Press and hold down 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 "Push-button, parameter selection right" push-button (switch machine off and on
again).
Enter
Exit
+
l0l
0
Figure 5-30
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-controlled power-saving mode > see 5.7.2 chapter
• ---------- 5 min.–60 min. = time until activation of power-saving mode when inactive.
• ---------- off = switched off
Service menu
Modifications to the service menu may only be carried out by authorised maintenance
staff!
Design and function
Machine configuration menu
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5.7.2 Power-saving mode (Standby)
You can activate the power-saving mode by either pressing the push-button > see 5.7 chapter for a
prolonged time or by setting a parameter in the machine configuration menu (time-controlled powersaving mode ) > see 5.7 chapter.
When power-saving mode is activated, the 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.
5.7.3 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.
2
4
1
l0l
0
50mm
+
3
B
A
Figure 5-31
Design and function
Machine configuration menu
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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.
Maintenance, care and disposal
General
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6 Maintenance, care and disposal
6.1 General
DANGER
Incorrect maintenance and testing!
The machine may be cleaned, repaired and tested by skilled and qualified personnel
only. A qualified person is one who, due to their training, knowledge and experience,
can detect any hazards and possible consequential damage when checking the
machine, and can take the necessary safety measures.
• Observe the maintenance instructions > see 6.3 chapter!
• The machine may only be put into operation again once the testing has been successful.
Risk of injury due to electrical voltage after switching off!
Working on an open machine can lead to fatal injuries!
Capacitors are loaded with electrical voltage during operation. Voltage remains present
for up to four minutes after the mains plug is removed.
1. Switch off machine.
2. Remove the mains plug.
3. Wait for at last 4 minutes until the capacitors have discharged!
WARNING
Cleaning, testing and repair!
Cleaning, testing and repairing of the welding machine may only be carried out by
competent, qualified personnel. A qualified person is one who, because of his or her
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.
• In the event of failure of any one of the following tests, the machine must not be operated
again until it has been repaired and a new test has been carried out.
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.
Under the specified ambient conditions and normal working conditions this machine is essentially
maintenance-free and requires just a minimum of care.
Contamination of the machine may impair service life and duty cycle. The cleaning intervals depend on
the ambient conditions and the resulting contamination of the machine. The minimum interval is every six
months.
6.2 Cleaning
• Clean the outer surfaces with a moist cloth (no aggressive cleaning agents).
• Purge the machine venting channel and cooling fins (if present) with oil- and water-free compressed
air. Compressed air may overspeed and destroy the machine fans. Never direct the compressed air
directly at the machine fans. Mechanically block the fans, if required.
• Check the coolant for contaminants and replace, if necessary.
Maintenance, care and disposal
Maintenance work, intervals
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6.3 Maintenance work, intervals
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.
6.3.1 Daily maintenance tasks
6.3.1.1 Visual inspection
• Mains supply lead and its strain relief
• Gas cylinder securing elements
• Check hose package and power connections for exterior damage and replace or have repaired by
specialist staff as necessary!
• Gas tubes and their switching equipment (solenoid valve)
• Check that all connections and wearing parts are hand-tight and tighten if necessary.
• Check correct mounting of the wire spool.
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
• Other, general condition
6.3.1.2 Functional test
• Operating, message, safety and adjustment devices (Functional test)
• Welding current cables (check that they are fitted correctly and secured)
• Gas tubes and their switching equipment (solenoid valve)
• Gas cylinder securing elements
• Check correct mounting of the wire spool.
• 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).
6.3.2 Monthly maintenance tasks
6.3.2.1 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
6.3.2.2 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.
• Check coolant tubes and their connections for impurities
• Check and clean the welding torch. Deposits in the torch can cause short circuits and have a negative
impact on the welding result, ultimately causing damage to the torch.
Maintenance, care and disposal
Disposing of equipment
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6.3.3 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.
6.4 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!
6.4.1 Manufacturer's declaration to the end user
• According to European provisions (guideline 2012/19/EU of the European Parliament and the Council
of Juli, 4th 2021), 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.
6.5 Meeting the requirements of RoHS
We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and
that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives
on the Declaration of Conformity on your machine).
Rectifying faults
Checklist for rectifying faults
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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 > see 7.4 chapter
Wire feed problems
Contact tip blocked
Clean, spray with anti-spatter spray and replace if necessary
Setting the spool brake > see 5.3.2.5 chapter
Check settings and correct if necessary
Setting pressure units > see 5.3.2.4 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
All machine control signal lights are illuminated after switching on
No machine control signal light is illuminated after switching on
No welding power
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
Rectifying faults
Error messages (power source)
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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
(Err)
Category
Possible cause
Remedy
a)
b)
c)
1 - - x Mains overvoltage
Check the mains voltages and compare with
the welding machine connection voltages
2 - - x Mains undervoltage
3 x -
-
Welding machine excess
temperature
Allow the machine to cool down (mains
switch to "1")
4 x x - Low coolant level
Top up the coolant
Leak in the coolant circuit >
repair the leak and top up the coolant
Coolant pump is not working > check excess
current trigger on air cooling unit
5 x - - Wire feeder/tachometer error
Check the wire feeder
Speedometer is not emitting a signal,
M3.51 defective > inform Service.
6 x - - Shielding gas error
Check shielding gas supply (for machines
with shielding gas monitoring)
7 - - x Secondary overvoltage
Inverter error > inform Service
8 - -
x
Earth fault between welding
wire and earth line
Separate the connection between welding
wire and casing or an earthed object
9 x -
-
Fast cut-out
Triggered by BUSINT X11 or
RINT X12
Rectify error on robot
10 - x
-
Arc interruption
Triggered by BUSINT X11 or
RINT X12
Check wire feeding
11 - x
-
Ignition error after 5 s
Triggered by BUSINT X11 or
RINT X12
Check wire feeding
13 x - - Emergency stop deactivation
Check the emergency stop circuit at the
interface for automated welding
14 - x
-
Wire feeder not detected.
Control cable not connected.
Check cable connections.
Incorrect ID numbers
assigned during operation
with multiple wire feeders.
Check ID number assignation
15 - x
-
Wire feeder 2 not detected.
Control cable not connected.
Check cable connections.
16 - -
x
VRD (open circuit voltage
reduction error).
Inform Service.
17 - x
x
Excess current detection on
wire feeder
Check wire feeding
18 - x
x
No speedometer signal from
second wire feeder (slave
drive)
Check the connection and particularly the
speedometer for the second wire feeder
(slave drive).
56 - - x Mains phase failure
Check mains voltages
Rectifying faults
Error messages (power source)
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Error
(Err)
Category
Possible cause
Remedy
a)
b)
c)
59 - - x Machine incompatible
Check machine used
60 - - x Software update required
Inform Service.
Legend for categories (reset error)
a) The error message will disappear once the error has been rectified.
b) The error message can be reset by pressing a push-button:
Welding machine control
Push-button
RC1 / RC2
Expert
Expert 2.0
CarExpert / Progress (M3.11)
alpha Q / Concept / Basic / Basic S / Synergic /
Synergic S / Progress (M3.71) / Picomig 305
not possible
c) The error message can only be reset by switching the machine off and on again.
The shielding gas error (Err 6) can be reset by pressing the "Welding parameters" key button.
Rectifying faults
Welding parameter calibration
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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.
NAVIGATION
C
B
A
C
C
B
C
B
C
B
C
B
B
A
A
C
C
C
C
A
A
A
EXIT
ENTER
+
l
0
Figure 7-1
Rectifying faults
Vent coolant circuit
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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)!
Figure 7-2
Technical data
Taurus 351 FKG
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8 Technical data
Performance specifications and guarantee only in connection with original spare and
replacement parts!
8.1 Taurus 351 FKG
MIG/MAG
MMA
Setting range for welding current
5 A to 350 A
Setting range for welding voltage
14.3 V–31.5 V
20.2 V–34 V
Duty cycle at 40 °C
100% DC
350 A
Load cycle
10 min. (60% DC 6 min. welding, 4 min. pause)
Open circuit voltage
79 V
Mains voltage (tolerances)
3 x 400 V (-25% to +20%)
Frequency
50/60 Hz
Mains fuse (safety fuse, slow-blow)
3 x 25 A
Mains connection lead
H07RN-F4G6
Max. connected load
13.9 kVA
15.0 kVA
Recommended generator rating
20.3 kVA
cos/efficiency
0.99/90%
Ambient temperature
-25 °C to +40 °C
Machine cooling/torch cooling
Fan (AF)/gas
Workpiece lead
70 mm²
Insulation class/protection classification
H/IP 23
EMC class
A
Safety identification
/ /
Other standards used
IEC 60974-1, -5, -10
Wire spool diameter
Standardized wire spools up to 300 mm
Wire feed speed
0.5 m/min. to 25 m/min.
Standard roll installation
1.0 mm + 1.2 mm (for steel wire)
Drive type
4 rolls (37 mm)
Welding torch connection
Euro torch connector
Dimensions L x W x H
1085 x 450 x 1003 mm
42.7 x 17.7 x 39.5 inch
Weight
110 kg
242.5 lb
Technical data
Taurus 401 FKG
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8.2 Taurus 401 FKG
MIG/MAG
MMA
Setting range for welding current
5 A to 400 A
Setting range for welding voltage
14.3 V–34.0 V
20.2 V–36 V
Duty cycle at 40 °C
100% DC
400 A
Load cycle
10 min. (60% DC 6 min. welding, 4 min. pause)
Open circuit voltage
79 V
Mains voltage (tolerances)
3 x 400 V (-25% to +20%)
Frequency
50/60 Hz
Mains fuse (safety fuse, slow-blow)
3 x 32 A
Mains connection lead
H07RN-F4G6
Max. connected load
17.2 kVA
18.2 kVA
Recommended generator rating
24.6 kVA
cos/efficiency
0.99/90%
Ambient temperature
-25 °C to +40 °C
Machine cooling/torch cooling
Fan (AF)/gas
Workpiece lead
70 mm²
Insulation class/protection classification
H/IP 23
EMC class
A
Safety identification
/ /
Other standards used
IEC 60974-1, -5, -10
Wire spool diameter
Standardized wire spools up to 300 mm
Wire feed speed
0.5 m/min. to 25 m/min.
Standard roll installation
1.0 mm + 1.2 mm (for steel wire)
Drive type
4 rolls (37 mm)
Welding torch connection
Euro torch connector
Dimensions L x W x H
1085 x 450 x 1003 mm
42.7 x 17.7 x 39.5 inch
Weight
110 kg
242.5 lb
Technical data
Taurus 351 FKW
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8.3 Taurus 351 FKW
MIG/MAG
MMA
Setting range for welding current
5 A–350 A
Setting range for welding voltage
14.3 V–31.5 V
20.2 V–34.0 V
Duty cycle at 40 °C
100% DC
350 A
Load cycle
10 min. (60% DC 6 min. welding, 4 min. pause)
Open circuit voltage
79 V
Mains voltage (tolerances)
3 x 400 V (-25% to +20%)
Frequency
50/60 Hz
Mains fuse (safety fuse, slow-blow)
3 x 25 A
Mains connection lead
H07RN-F4G6
Max. connected load
14.3 kVA
15.4 kVA
Recommended generator rating
20.8 kVA
cos/efficiency
0.99/90%
Ambient temperature*
-25 °C to +40 °C
Machine cooling/torch cooling
Fan (AF)/gas or water
Workpiece lead
70 mm²
Insulation class/protection
classification
H/IP 23
EMC class
A
Safety identification
/ /
Cooling capacity at 1 l/min.
1500 W
Max. flow rate
5 l/min.
Max. coolant outlet pressure
3.5 bar
Tank capacity
12 l
Wire feed speed
0.5 m/min. to 25 m/min.
Standard roll installation
1.0 mm + 1.2 mm (for steel wire)
Wire drive type
4 rolls (37 mm)
Wire spool diameter
Standardized wire spools up to 300 mm
Welding torch connection
Euro torch connector
Dimensions L x W x H
1085 x 450 x 1003 mm
42.7 x 17.7 x 39.5 inch
Weight
121.5 kg
267.9 lb
*Ambient temperature depends on coolant! Observe the coolant temperature range for the
welding torch cooling!
Technical data
Taurus 401 FKW
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8.4 Taurus 401 FKW
MIG/MAG
MMA
Setting range for welding current
5 A–400 A
Setting range for welding voltage
14.3 V–34.0 V
20.2 V–36.0 V
Duty cycle at 40 °C
100% DC
400 A
Load cycle
10 min. (60% DC 6 min. welding, 4 min. pause)
Open circuit voltage
79 V
Mains voltage (tolerances)
3 x 400 V (-25% to +20%)
Frequency
50/60 Hz
Mains fuse (safety fuse, slow-blow)
3 x 32 A
Mains connection lead
H07RN-F4G6
Max. connected load
17.5 kVA
18.5 kVA
Recommended generator rating
25 kVA
cos/efficiency
0.99/90%
Ambient temperature*
-25 °C to +40 °C
Machine cooling/torch cooling
Fan (AF)/gas or water
Workpiece lead
70 mm²
Insulation class/protection classification
H/IP 23
EMC class
A
Safety identification
/ /
Other standards used
IEC 60974-1, -2, -5, -10
Cooling capacity at 1 l/min.
1500 W
Max. flow rate
5 l/min.
Max. coolant outlet pressure
3.5 bar
Tank capacity
12 l
Wire spool diameter
Standardized wire spools up to 300 mm
Wire feed speed
0.5 m/min. to 25 m/min.
Standard roll installation
1.0 mm + 1.2 mm (for steel wire)
Wire drive type
4 rolls (37 mm)
Welding torch connection
Euro torch connector
Dimensions L x W x H
1085 x 450 x 1003 mm
42.7 x 17.7 x 39.5 inch
Weight
121.5 kg
267.9 lb
*Ambient temperature depends on coolant! Observe the coolant temperature range for the
welding torch cooling!
Technical data
Taurus 501 FKW
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8.5 Taurus 501 FKW
MIG/MAG
MMA
Setting range for welding current
5 A–500 A
Setting range for welding voltage
14.3 V–39.0 V
20.2 V–40.0 V
Duty cycle at 40 °C
60% DC
500 A
100% DC
430 A
Load cycle
10 min. (60% DC 6 min. welding, 4 min. pause)
Open circuit voltage
79 V
Mains voltage (tolerances)
3 x 400 V (-25% to +20%)
Frequency
50/60 Hz
Mains fuse (safety fuse, slow-blow)
3 x 32 A
Mains connection lead
H07RN-F4G6
Max. connected load
24.6 kVA
25.2 kVA
Recommended generator rating
34.0 kVA
cos/efficiency
0.99/90%
Ambient temperature*
-25 °C to +40 °C
Machine cooling/torch cooling
Fan (AF)/gas or water
Workpiece lead
95 mm²
Insulation class/protection
classification
H/IP 23
EMC class
A
Safety identification
/ /
Other standards used
IEC 60974-1, -2, -5, -10
Cooling capacity at 1 l/min.
1500 W
Max. flow rate
5 l/min.
Max. coolant outlet pressure
3.5 bar
Tank capacity
12 l
Wire feed speed
0.5 m/min. to 25 m/min.
Standard roll installation
1.0 mm + 1.2 mm (for steel wire)
Wire drive type
4 rolls (37 mm)
Wire spool diameter
Standardized wire spools up to 300 mm
Welding torch connection
Euro torch connector
Dimensions L x W x H
1085 x 450 x 1003
42.7 x 17.7 x 39.5 inch
Weight
124.5 kg
274.5 lb
*Ambient temperature depends on coolant! Observe the coolant temperature range for the
welding torch cooling!
Accessories
General accessories
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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
Item no.
AK300
Wire spool adapter K300
094-001803-00001
DM 842 Ar/CO2 230bar 30l D
Pressure regulator with manometer
394-002910-00030
GH 2X1/4'' 2M
Gas hose
094-000010-00001
5POLE/CEE/32A/M
Machine plug
094-000207-00000
HOSE BRIDGE UNI
Tube bridge
092-007843-00000
TYP 1
Frost protection tester
094-014499-00000
KF 23E-10
Coolant (-10 °C), 9.3 l
094-000530-00000
KF 23E-200
Coolant (-10 °C), 200 litres
094-000530-00001
KF 37E-10
Coolant (-20 °C), 9.3 l
094-006256-00000
KF 37E-200
Coolant (-20 °C), 200 l
094-006256-00001
SPL
Sharpener for plastic liners
094-010427-00000
HC PL
Hose cutter
094-016585-00000
9.2 Remote control / connection cable
Type
Designation
Item no.
R11 19POL
Remote control
090-008601-00502
RG11 19POL 5M
Remote control
090-008107-00000
RA5 19POL 5M
Remote control e.g. connection cable
092-001470-00005
RA10 19POL 10M
Remote control e.g. connection cable
092-001470-00010
RA20 19POL 20M
Remote control e.g. connection cable
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
Ram protection retrofit option
092-002154-00000
ON Filter T/P
Retrofit option contamination filter for air inlet
092-002092-00000
ON Tool Box
Retrofit option tool box
092-002138-00000
Replaceable parts
Wire feed rollers
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10 Replaceable 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.
FE 4R 0.6 MM/0.023 INCH
LIGHT PINK
Drive roll set, 37 mm, 4 rolls, V-groove for steel,
stainless steel and brazing
092-002770-00006
FE 4R 0.8 MM/0.03 INCH
WHITE
Drive roll set, 37 mm, 4 rolls, V-groove for steel,
stainless steel and brazing
092-002770-00008
FE 4R 1,0 MM/0.04 INCH
BLUE
Drive roll set, 37 mm, 4 rolls, V-groove for steel,
stainless steel and brazing
092-002770-00010
FE 4R 1.2 MM/0.045 INCH
RED
Drive roll set, 37 mm, 4 rolls, V-groove for steel,
stainless steel and brazing
092-002770-00012
FE 4R 1.4 MM/0.052 INCH
GREEN
Drive roll set, 37 mm, 4 rolls, V-groove for steel,
stainless steel and brazing
092-002770-00014
FE 4R 1.6 MM/0.06 INCH
BLACK
Drive roll set, 37 mm, 4 rolls, V-groove for steel,
stainless steel and brazing
092-002770-00016
FE 4R 2.0 MM/0.08 INCH
GREY
Drive roll set, 37 mm, 4 rolls, V-groove for steel,
stainless steel and brazing
092-002770-00020
FE 4R 2.4 MM/0.095 INCH
BROWN
Drive roll set, 37 mm, 4 rolls, V-groove for steel,
stainless steel and brazing
092-002770-00024
FE 4R 2.8 MM/0.11 INCH
LIGHT GREEN
Drive roll set, 37 mm, 4 rolls, V-groove for steel,
stainless steel and brazing
092-002770-00028
FE 4R 3.2 MM/0.12 INCH
VIOLET
Drive roll set, 37 mm, 4 rolls, V-groove for steel,
stainless steel and brazing
092-002770-00032
Replaceable parts
Wire feed rollers
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10.1.2 Wire feed rollers for aluminium wire
Type
Designation
Item no.
AL 4R 0.8 MM/0.03 INCH
WHITE
Drive roll set, 37 mm, for aluminium
092-002771-00008
AL 4R 1.0 MM/0.04 INCH
BLUE
Drive roll set, 37 mm, for aluminium
092-002771-00010
AL 4R 1.2 MM/0.045 INCH
RED
Drive roll set, 37 mm, for aluminium
092-002771-00012
AL 4R 1.6 MM/0.06 INCH
BLACK
Drive roll set, 37 mm, for aluminium
092-002771-00016
AL 4R 2.0 MM/0.08 INCH
GREY/YELLOW
Drive roll set, 37 mm, for aluminium
092-002771-00020
AL 4R 2.4 MM/0.095 INCH
BROWN/YELLOW
Drive roll set, 37 mm, for aluminium
092-002771-00024
AL 4R 2.8 MM/0.110 INCH
LIGHT GREEN/YELLOW
Drive roll set, 37 mm, for aluminium
092-002771-00028
AL 4R 3.2 MM/0.125 INCH
VIOLET/YELLOW
Drive roll set, 37 mm, for aluminium
092-002771-00032
10.1.3 Wire feed rollers for cored wire
Type
Designation
Item no.
FUEL 4R 0.8 MM/0.03 INCH
WHITE/ORANGE
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for
flux cored wire
092-002848-00008
FUEL 4R 1.0 MM/0.04 INCH
BLUE/ORANGE
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for
flux cored wire
092-002848-00010
FUEL 4R 1.2 MM/0.045 INCH
RED/ORANGE
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for
flux cored wire
092-002848-00012
FUEL 4R 1.4 MM/0.052 INCH
GREEN/ORANGE
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for
flux cored wire
092-002848-00014
FUEL 4R 1.6 MM/0.06 INCH
BLACK/ORANGE
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for
flux cored wire
092-002848-00016
FUEL 4R 2.0 MM/0.08 INCH
GREY/ORANGE
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for
flux cored wire
092-002848-00020
FUEL 4R 2.4 MM/0.095 INCH
BROWN/ORANGE
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for
flux cored wire
092-002848-00024
10.1.4 Wire guide
Type
Designation
Item no.
SET DRAHTFUERUNG
Wire guide set
092-002774-00000
ON WF 2,0-3,2MM EFEED
Retrofitting option, wire guide for 2.0–3.2 mm wires,
eFeed drive
092-019404-00000
SET IG 4x4 1.6mm BL
Inlet guide set
092-002780-00000
GUIDE TUBE L105
Guide tube
094-006051-00000
CAPTUB L108 D1,6
Capillary tube
094-006634-00000
CAPTUB L105 D2,0/2,4
Capillary tube
094-021470-00000
Appendix A
Setting instructions
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11 Appendix A
11.1 Setting instructions
Figure 11-1
Appendix B
Overview of EWM branches
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12 Appendix B
12.1 Overview of EWM branches
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