EWM PHOENIX 301 CAR EXPERT PULS Operating Instructions Manual Download Page 1

 

 

EWM 

HIGHTEC WELDING GmbH 

Dr. Günter - Henle - Straße 8 • D-56271 Mündersbach 

Phone: +49 2680 181 0 • Fax: +49 2680 181 244 

www.ewm.de

 • 

[email protected]

 

 
 

GB

 

Operating instructions 

 

 

 

Compact welding machine for MIG brazing and 
MIG/MAG welding 

 

PHOENIX 301 CAR EXPERT PULS 
 

 

 

N. B. These operating instructions must be read before commissioning. 

Failure to do so may be dangerous. 

Machines may only be operated by personnel who are familiar with the appropriate safety 
regulations. 

 

 

The machines bear the conformity mark and thus comply with the 
•  EC Low Voltage Directive (73/23/EEC) 
•  EC EMC Directive (89/336/EEC) 

 

 

In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments 
with an increased electrical hazard. 

 

© 2006  Subject to alteration. 

Item No.: 099-004998-EWM01 

Revised: 25.09.06

Summary of Contents for PHOENIX 301 CAR EXPERT PULS

Page 1: ...t be read before commissioning Failure to do so may be dangerous Machines may only be operated by personnel who are familiar with the appropriate safety regulations The machines bear the conformity ma...

Page 2: ...unauthorized changes improper repairs and or unauthorized modifications which have not been expressly allowed by EWM this declaration will lose its validity Par la pr sente nous d clarons que la conce...

Page 3: ...ody future oriented advanced technology at the utmost level of quality Each of our products is carefully checked we guarantee that the material and processing of our products is faultless These operat...

Page 4: ...ields CE EWM HIGHTEC WELDING GMBH D 56271 M NDERSBACH TYP ART SNR PROJ GEPR FT CONTROL Name of Customer company Adress Post code Place Country Stamp Signature of EWM distibutor Date of purchase Name o...

Page 5: ...g task selection 19 5 2 3 1 Selecting manufacturer specific JOBs 19 5 2 3 2 Examples 20 5 3 Conventional operation 21 5 3 1 Definition of MIG MAG welding tasks 21 5 3 2 Selecting MIG MAG welding tasks...

Page 6: ...are 44 7 1 General 44 7 2 Cleaning 44 7 3 Repetition test 44 7 3 1 Test intervals and scope 45 7 3 2 Documentation of the test 45 7 3 3 Visual inspection 45 7 3 4 Measurement of protective conductor r...

Page 7: ...otective clothing e g gloves Protect eyes and face with protective visor Electric shocks can be fatal Do not touch any live parts in or on the machine The machine may only be connected to correctly ea...

Page 8: ...Before beginning welding work ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source N...

Page 9: ...ing cylinders do not throw or heat guard against them toppling over When moving by crane take off the gas cylinder from the welding machine 2 2 1 Ambient conditions This machine must not be operated i...

Page 10: ...oid jerky movements when raising or lowering the welding machine Wire spools are to be removed from the welding and wire feed units before they are lifted No equipment may be operated during lifting 2...

Page 11: ...cy 50 60Hz Mains fuse slow blow safety fuse 3 x 16A Mains connection lead H07RN F4G2 5 Max connected power 14 3kVA Recommended generator rating 19 3kVA Cos efficiency 0 99 89 Insulation class protecti...

Page 12: ...ine on off 3 Control Operating elements see chapter Function specification 4 Cooling air inlet 5 19 pole connection socket analogue For connecting analogue remote controls 6 Euro central connector wel...

Page 13: ...nnection 3 42V 4A Automatic cutout key button Wire feed motor supply voltage fuse press to reset a triggered fuse 4 7 pole connection socket digital For connecting digital accessory components remote...

Page 14: ...minal actual and hold values Panel thickness nominal value Wire speed A M Motor current 1 A A M Select other welding parameters on deeper programming levels 2 Button for welding programs for vehicles...

Page 15: ...llet weld 4 Raised edge weld 5 Tack weld 6 Plug weld 7 Slot weld 7 Prog 1 2 3 4 5 6 7 8 8 Fillet weld for tie rod 8 0 1 Key switch for protection against unauthorised use Position 1 changes possible P...

Page 16: ...actory setting Select operating mode button Non latched Latched Special non latched 2 Special latched 3 Earth fault signal light Safety shut down see Troubleshooting causes and remedies chapter Weldin...

Page 17: ...Switch over the welding programs using the rocker on the CAR CONTROL program torch Factory setting 1 Up Down Set welding performance using the rocker on the CAR CONTROL program torch via infinite sett...

Page 18: ...ription 0 1 Seam type program number display Displays the selected seam type or the selected welding program Torch trigger rocker Application specific operation Select seam types or welding programs 2...

Page 19: ...d two bodywork specific welding parameters panel thickness seam shape 5 2 2 MIG MAG welding data display To the left and right of the LCD display on the control there are 2 arrow keys on each side for...

Page 20: ...elevant program number for each brazing position can be found in the welding instructions for the specific vehicle Selecting this program means that all the optimum brazing or welding parameters are p...

Page 21: ...necessary 5 3 2 Selecting MIG MAG welding tasks The welding task is selected on the welding machine control LEDs display the welding parameter selection It is possible to change the basic welding para...

Page 22: ...t is set using the wire speed previously set Selected parameter Application example The material AlSi must be welded using 100 argon Wire diameter 1 2mm material thickness 5mm Let s say you don t have...

Page 23: ...onds factory setting there is an automatic cut out There are optimum pre sets for welding parameters such as gas pre flow and free burn etc for numerous applications although these can also be changed...

Page 24: ...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 mai...

Page 25: ...creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters change at t...

Page 26: ...gas pre flows Wire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART for the time tstart Slope to ma...

Page 27: ...pot time t2 The start and spot times are set in the Program steps mode menu Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows Wire feed motor runs at creep speed Arc ignites...

Page 28: ...es contact with the workpiece welding current is flowing start program PSTART for the time tstart Slope on main program PA Start the super pulse function beginning with main program PA The welding par...

Page 29: ...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...

Page 30: ...lectrode makes contact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program...

Page 31: ...earliest after the set time tSTART elapses and at the latest when the torch trigger is released Tapping 1 can be used to change over to the reduced main program PB Repeated tapping will switch back to...

Page 32: ...ding current is flowing start program PSTART for the time tstart Step 2 Release torch trigger Slope on main program PA Start the super pulse function beginning with main program PA The welding paramet...

Page 33: ...nt of the welding parameters on the machine the control input can be locked with the aid of a key switch In key switch position 1 all functions and parameters can be set without restriction In key swi...

Page 34: ...for more information on crane work 6 4 Mains connection The operating voltage shown on the rating plate must match the mains voltage For mains fuse protection please refer to the Technical Data chapt...

Page 35: ...relevant measures to equip the torch for MIG brazing and MIG welding CuSi CuAl or AlSi AlMg and for MAG welding SG 2 3 are described below 6 7 1 1 Preparing the welding torch for MIG brazing and MIG...

Page 36: ...Teflon or plastic core for MIG brazing or MIG welding Extend and lay out the tube package Remove the existing wire or Teflon core if necessary Insert the Teflon core with spring forwards onto the cent...

Page 37: ...that it is flush with the clamping nut thread on the central connection Screw the guide spiral and holding nipple handtight using a clamping nut Press the guide spiral from the torch head into the to...

Page 38: ...oller is as short as possible The Teflon core and the guide pipe must not be deformed Deburr the Teflon core and the guide pipe Figure 6 3 Item Symbol Description 0 1 Euro central connector welding to...

Page 39: ...ire spool retainer the following working steps are to be carried out for every spool change and before every adjustment of the spool brake Figure 6 4 Item Symbol Description 0 1 Securing and braking u...

Page 40: ...ng 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 6 7 5 Changing...

Page 41: ...ckage Unfasten pressure units and fold out clamping units and counter pressure rollers will automatically flip upwards Unwind welding wire carefully from the wire spool and insert through the wire inl...

Page 42: ...n 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 spool brake only to...

Page 43: ...lding gas connections must be gastight Place the shielding gas cylinder in the cylinder holder and secure it from tipping over using the safety strap Before connecting the pressure reducer to the gas...

Page 44: ...moisture free compressed air Electronics Do not blast electronic components or circuit boards with compressed air but instead use suction from a vacuum cleaner for cleaning purposes 7 3 Repetition te...

Page 45: ...achine must be marked if the test is successful e g with a test plate This plate must include the date of the next repetition test 7 3 3 Visual inspection Given below are the main points in the full t...

Page 46: ...r the frequency response measurement please refer to DIN EN 61010 1 Appendix A Measuring Circuit A1 For these measurements the welding machine must be switched on and supplying open circuit voltage 1...

Page 47: ...servicing When placing an order please quote the type designation and item number as well as the type serial number and item number of the relevant equipment We hereby confirm that the servicing and...

Page 48: ...eled bins indicates the requirement to separate this waste Help to protect the environment and ensure that this equipment when you no longer want to use it is disposed of in the relevant system of sep...

Page 49: ...t manufactured by other companies e g motors pumps fans torches etc Non reproducible software errors and parts subject to mechanical aging are excluded from the warranty e g WF rollers wheels solenoid...

Page 50: ...that are damaged due to accidents misuse improper operation incorrect installation use of force disregard of the specifications and operating instructions inadequate maintenance see chapter Maintenanc...

Page 51: ...the machine to cool down main switch to 1 Error 4 Water x Coolant level low Top up the coolant Leak in the coolant circuit rectify the leak and top up the coolant Coolant pump is not working check exc...

Page 52: ...A 1 L 2 A 1 L 3 Q1 L2 L3 L1 T1 T2 T3 M 3 2 0 A2 X2 1 X2 2 X2 3 X2 4 X2 L fter X3 1 X3 2 X3 3 X3 4 X3 5 X3 6 X3 7 X3 8 Inverter prim r X3 X1 1 X1 2 X1 3 X1 4 X1 5 X1 6 X1 7 X1 8 X1 9 X1 10 X1 11 X1 12...

Page 53: ...1 23 X1 24 X1 25 X1 1 X1 2 X1 3 X1 4 X1 5 X1 6 X1 7 X1 8 X1 9 X1 26 X1 Frontplatte X5 Gas Schalter X5 12 X5 11 X5 10 X5 9 X5 8 X5 7 X5 6 X5 5 X5 4 X5 3 X5 2 X5 1 X11 Systembus 15polig D Sub X13 System...

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