EWM PHOENIX 333 PROGRESS PULS forceArc Operating Instructions Manual Download Page 92

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Accessories, options

Options

Item No.: 099-005073-EWM01

10.4

Options

Type Designation

Item

no.

MIG PP 24D POTI G 8M

MIG welding torch, gas, push/pull

094-003419-00000

MIG 36 2U/D G 3M

MIG welding torch, gas, Up/Down

094-007791-00000

POWERCONTROL 36
U/DLED G 3M

MIG welding torch, gas, Up/Down, with display

094-007790-00000

MIG PP 401D W 8M

MIG welding torch, water cooled, push/pull

094-003420-00000

MIG PP 401D POTI W 8M

MIG welding torch, water cooled, push/pull

094-003418-00000

MIG 452W 4M19PB2UD HF
EZA

MIG welding torch, water flex., 2xU/D

094-011056-00304

MIG 452W 4M19PBPC HF
EZA

MIG welding torch, POWERCONTROL, water flex.

094-011056-00404

ON SET KRAN HOR

Optional retrofitting of PHOENIX horizontal traverse
suspension

092-001832-00000

ON SET CRANE HOR/VER

Optional retrofit kit for horizontal/vertical crane
suspension

092-002355-00000

ON A INTERFACE

Option retrofit for analog mech. welding interface
PHOENIX PROGRESS

092-001779-00000

ON WHEELS PHOENIX
303/330/333

Optional retrofit wheel set for PHOENIX
303/330/333 machine series

092-002387-00000

10.5

Computer communication

Type Designation

Item

no.

PC300.NET

PC300.Net welding parameter software set incl.
cable and SECINT X10 USB interface

090-008265-00000

CD-ROM PC300.NET

PC300.Net Update on CD-ROM

092-008172-00001

WELDQAS1 Mobil

Stationary welding data monitoring and docu set for
one welding machine

090-008214-00000

WELDQAS2 Mobil

Mobile welding data monitoring and docu set for two
welding machines

090-008217-00000

FRV5-L 7POL

Extension/connecting cable

092-000201-00003

FRV10-L 7POL

Extension/connecting cable

092-000201-00000

FRV20-L 7POL

Extension/connecting cable

092-000201-00001

PC INTX10 SET

Q-DOC 9000 documentation interface

090-008093-00000

PCV10-L 10M 9POL

Cable between PC/interface

094-001206-00002

Summary of Contents for PHOENIX 333 PROGRESS PULS forceArc

Page 1: ...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 mar...

Page 2: ...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 3: ...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 4: ...ial thickness welding current wire speed 26 5 2 3 3 Arc length correction setting 26 5 2 3 4 Wire burn back 27 5 2 3 5 Accessory components for operating point setting 27 5 2 4 MIG MAG welding data di...

Page 5: ...P9 54 5 2 11 14 Single or dual operation P10 setting 54 5 2 11 15 Latched special tapping time setting P11 54 5 2 11 16 JOB list switching P12 55 5 2 11 17 Creating user defined JOB lists 55 5 2 11 18...

Page 6: ...lding gas supply 80 6 10 1 Connecting the shielding gas supply 80 6 10 2 Gas test 81 6 10 3 Rinse tube package function 81 6 10 4 Setting the shielding gas quantity 81 7 Maintenance and testing 82 7 1...

Page 7: ...conveyors 91 10 3 3 Wire feed rollers for cored wire 91 10 3 4 Conversion sets 91 10 4 Options 92 10 5 Computer communication 92 11 Circuit diagrams 93 11 1 PHOENIX 333 PROGRESS KG 93 12 Appendix A 9...

Page 8: ...Contents For your safety 8 Item No 099 005073 EWM01...

Page 9: ...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 10: ...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...

Page 11: ...any risk of explosion exists The following conditions must be observed during operation Temperature range of the ambient air During welding 10 C to 40 C For transport and storage 25 C to 55 C Using th...

Page 12: ...ch are graded as follows depending on their importance Please note Technical features which users must observe Warning Working and operating procedures which must be followed precisely to avoid damagi...

Page 13: ...ltage 103V Mains voltage tolerances 3 x 400V 25 to 20 3 x 415V 25 to 15 Frequency 50 60Hz Mains fuse safety fuse slow blow 3 x 16A Mains connection lead H07RN F4G2 5 Max connected power 13 0kVA Recomm...

Page 14: ...Machine description PHOENIX 333 PROGRESS KG 14 Item No 099 005073 EWM01 4 Machine description 4 1 PHOENIX 333 PROGRESS KG 4 1 1 Front view 6 7 4 3 2 1 10 5 9 11 12 13 8 Figure 4 1...

Page 15: ...7 7 pole connection socket digital For connecting digital accessory components remote control welding torch control lead etc 8 19 pole connection socket analogue For connecting analogue accessory comp...

Page 16: ...Machine description PHOENIX 333 PROGRESS KG 16 Item No 099 005073 EWM01 4 1 2 Rear view 6 7 4 3 2 1 10 5 9 11 8 Figure 4 2...

Page 17: ...onents documentation interface robot interface or remote control etc 5 G connecting nipple Shielding gas connection on the pressure reducer 6 4 pole connection socket Cooling unit voltage supply 7 8 p...

Page 18: ...Machine description PHOENIX 333 PROGRESS KG 18 Item No 099 005073 EWM01 4 1 3 Inside view 2 3 1 Figure 4 3...

Page 19: ...changeover switch This changeover switch is only effective on the POWERCONTROL POWERCONTROL 2 welding torch Programm Programm Change over welding programs using POWERCONTROL 2 program torch 1 Up Down...

Page 20: ...values 1 HOLD AMP HOLD After each completed welding process the last parameter values used for the welding process are shown on the display in the main program the signal light is on 2 LCD display 3 d...

Page 21: ...rogram number rotary dial Arc length correction from 9 9 V to 9 9 V Setting the program number 0 15 not possible if accessory components such as program torches is connected 8 LCD display 3 digit righ...

Page 22: ...m PA Wire speed setting range WF min to WF max Setting range for arc length correction 9 9 V to 9 9 V 7 DYN LED Dynamics Setting range 40 to 40 8 sec LED Duration of main program PA Absolute setting r...

Page 23: ...D Joblist Illuminates upon display or selection of the job number 17 JOBLIST key button Selection of the welding task JOB from the JOB list 18 Wire inching button See also Commissioning Inching the Wi...

Page 24: ...ameters such as gas pre flow free burning etc for numerous applications and these can be changed if required The parameters and functions described here can also be programmed by PC using the PHOENIX...

Page 25: ...rs button until on off Sup appears on the display on off Sup m min Switches function on or off on off Sup Super puls The signal light indicates when the function has been activated 5 2 2 6 Wire burn b...

Page 26: ...rent Material thickness Wire speed No change Example application You need to weld aluminium material AlMg gas Ar 100 wire diameter 1 2 mm in other words JOB 183 you do not have any specifications and...

Page 27: ...ace See RINTX11 operating instructions 5 2 4 MIG MAG welding data display To the left of the LCD display on the control there is an arrow button for selecting the welding parameters to be displayed Th...

Page 28: ...ry 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 if requir...

Page 29: ...ck time expires Gas post flow time elapses 5 2 5 3 Non latched operation with superpulse t I t t 1 2 PA PB Figure 5 6 Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows Wire f...

Page 30: ...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 31: ...feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART spot time starts Slope on main program PA After the...

Page 32: ...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 33: ...ire 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...

Page 34: ...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 35: ...een the process PA stored in the JOB and the opposite process PB at the specified times t2 and t3 2nd cycle If a standard process is stored in the JOB this means that there is a permanent alternation...

Page 36: ...earliest after the set time tSTART elapses and at the latest when the torch trigger is released Tapping1 can be used to change over to the reduced main program PB Repeated tapping will switch back to...

Page 37: ...slope on main program PA is given at the earliest after the set time tSTART elapses and at the latest when the torch trigger is released Tapping pressing the torch trigger for less than 0 3 sec chang...

Page 38: ...elding 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 param...

Page 39: ...tarting with process PA The welding processes alternate between the process PA stored in the JOB and the opposite process PB at the specified times t2 and t3 If a standard process is stored in the JOB...

Page 40: ...e parameters wire speed operating point arc length correction slope times program duration etc t I PSTART PA PB PA PEND Figure 5 17 Pulse arc welding machines In every JOB separate settings can be mad...

Page 41: ...0 0s to 20 0s 4 Slope duration from PSTART to PA 0 0s to 20 0s 5 Wire speed relative Wire speed absolute 1 to 200 0 1 m min to 40 m min 6 Dynamics 40 to 40 7 Duration spot time and superpulse 0 01s to...

Page 42: ...2 6 4 Example aluminium tack welding non latched special t I PA PEND PSTART Figure 5 20 Basic parameters Welding parameter Meaning explanation Setting range GASstr Gas pre flow time 0 0s to 20 0s GASe...

Page 43: ...t flow time 0 0s to 20 0s RUECK Wire burn back length 2 to 500 PSTART start program DVstart Wire speed 0 to 200 ustart Arc length correction 9 9V to 9 9V tstart Duration 0 0s to 20s PA main program Se...

Page 44: ...0cm PSTART start program DVstart Wire speed 0 to 200 ustart Arc length correction 9 9V to 9 9V tstart Duration 0 0s to 20s PA main program tS1 Slope duration from PSTART to PA 0 0s to 20s Setting the...

Page 45: ...changeover to the pulse arc process and vice versa Changes using PC300 Net software EXPERT machine series Can also be changed using M3 1x see chapter MIG MAG parameter overview M3 1x Non latched latch...

Page 46: ...e of the WF value of main program PA switching between relative and absolute wire feed values see chapter WF Speed Switching absolute relative The user can change the welding parameters for the main p...

Page 47: ...welding of different sheet metal thicknesses non latched or latched special PA0 PA1 PA8 PA9 t I Figure 5 25 This mode can be used to define 16 different programs PA0 to PA15 for one program sequence T...

Page 48: ...ments Functions Torch trigger Start stop welding It is also possible to change over between welding programs by tapping the torch trigger depending on the machine control configuration see Program cha...

Page 49: ...ion on Main program PA flashing 0 P82 Program changeover with standard torch 0 no program changeover 1 special latched 2 specific latched special n cycle active 0 P9 Lat and sp lat tapping start 0 no...

Page 50: ...lding machine t1 on Switch welding machine off and back on again to activate the changes 5 2 11 4 Ramp time for wire inching P1 The wire inching starts with a speed 1 0 m min for 2 secs It is subseque...

Page 51: ...n and off for all JOBs and their programs at the same time A correction operation is specified for wire speed DV and welding voltage correction Ukorr for each JOB The correction value is saved separat...

Page 52: ...s DV 10 U 5 0 V were entered 7 5 DV 4 prog no 5 2 11 11Program changeover with standard torch P8 Special latched In Latched absolute program sequence the machine starts at the first cycle with absolut...

Page 53: ...tes after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART from PA1 2nd cycle Release torch trigger Slope to main program PA1 The slope to main progr...

Page 54: ...the 7 pole connection socket digital This relates to digital remote controls robot interfaces documentation interfaces welding torches with digital control lead connection etc No second wire feed may...

Page 55: ...he assignment of the welding tasks to the JOB numbers will change The JOB list sticker is no longer valid In the appendix you will find pictures of both JOB lists See JOB list sticker chapter All JOB...

Page 56: ...JOBs If the control does not register any user activity for longer than 5 seconds the parameter display is shown once more and the copy process is complete 5 2 11 19Lower and upper limits of the remot...

Page 57: ...mally set using the Wire speed rotary dial m min Welding current is set The welding current and voltage change depending on the setting 5 3 3 TIG arc ignition 5 3 3 1 Liftarc a b c Figure 5 29 The arc...

Page 58: ...mally preset for a multiplicity of applications can be adapted if required see chapter TIG Program sequence Program Steps mode In every operation mode the Superpulse function can be used 5 3 4 1 Expla...

Page 59: ...Special non latched t t I 1 2 PA PEND PSTART Figure 5 31 Selection Select non latched special mode Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows The arc is ignited using...

Page 60: ...latched operating mode Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows The arc is ignited using liftarc Welding current flows with pre selected setting Step 2 Release torc...

Page 61: ...on main program PA is given at the earliest after the set time tSTART elapses and at the latest when the torch trigger is released Tapping can be used to switch to the reduced main program PB Repeate...

Page 62: ...ire speed rotary dial m min Welding current is set The welding current and voltage change depending on the setting 5 4 3 Arcforcing Operating element Action Result Display X x Select arcforcing weldin...

Page 63: ...R Input Not Aus Emergency stop for higher level shut down of the power source To use this function jumper 1 must be unplugged on PCB M320 1 in the welding machine Contact open welding current off F O...

Page 64: ...ing on the machine or externally by the customer As examples Binzel APD system Dinse wire feed systems 5 5 5 PC Interfaces PC 300 welding parameter software Create all welding parameters quickly on th...

Page 65: ...hed off The remote control is detected automatically when the welding machine is switched on 5 6 1 R10 manual remote control Figure 5 34 Item Symbol Description 0 1 0 5 1 1 5 2 2 5 3 3 5 4 5 6 7 8 9 1...

Page 66: ...n with welding programs key switch set to 0 3 Display for showing the current program number 4 Program switching Up button Select program number up 5 Program switching Down button Select program numbe...

Page 67: ...min Set the JOB number to be reset Confirm JOB reset If not pressed within approx 3 seconds the machine switches to the last parameters displayed and the JOB reset process is cancelled 5 7 2 Resettin...

Page 68: ...relevant machine Set up the machine so that there is sufficient room to adjust the operating elements When lifting the wire feed unit the wire spool should be removed please see the operating instruc...

Page 69: ...from the intermediate tube package with the rapid action closure coupling marked in red on the cooling unit Insert and lock the 8 pole control lead plug on the cooling unit into the 8 pole connection...

Page 70: ...ing pages entitled For Your Safety We can only guarantee the perfect functioning of our machines when used with our range of accessory components 6 7 1 Welding torch connection We can only guarantee c...

Page 71: ...elevant wire diameter and wire type Welding torch with insulatated liner A capillary tube must be installed in the central connection Welding torch with Teflon or plastic core The capillary tube must...

Page 72: ...MAG welding Workpiece connection MMA welding Workpiece or electrode holder connection 1 TIG welding Welding current connection for welding torch Connection socket welding current MMA welding Workpiec...

Page 73: ...Figure 6 4 Item Symbol Description 0 1 Securing and braking unit 2 Allen screw Securing the wire spool retainer and adjustment of the spool brake 3 Spool holder retainer Loosen the Allen screw of the...

Page 74: ...or 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 6 7 5 Ch...

Page 75: ...upwards Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide...

Page 76: ...it was previously tightened a renewed tightening of the pin reel will be necessary see chapter Fixing of the pin reel adjustment of the pretensioning 6 8 TIG welding Warning Risk from electrical curre...

Page 77: ...rew together with crown nut Insert central plug of the welding torch into the central connector and screw together with crown nut Lock connecting nipples of the cooling water tubes into place in the c...

Page 78: ...different methods and if a welding torch and an electrode holder remain connected to the machine the open circuit welding voltage is applied simultaneously on all cables The torch and the electrode ho...

Page 79: ...on MMA welding Workpiece or electrode holder connection 2 TIG welding Welding current connection for welding torch Insert cable plug of the electrode holder into either the or welding current connecti...

Page 80: ...Before connecting the pressure reducer to the gas cylinder open the cylinder valve briefly to blow out any dirt Place the shielding gas cylinder into the relevant cylinder bracket Secure the shieldin...

Page 81: ...y 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 throug...

Page 82: ...ng on the amount of dust blow out using oil and moisture free compressed air Electronics Do not blast electronic components or circuit boards with compressed air but instead use suction from a vacuum...

Page 83: ...lding current sockets The voltmeter must display mean values and have an internal resistance 1 M In the case of step switch controlled devices set the maximum output voltage step switch Adjust the pot...

Page 84: ...uctor current 5mA 2 Leakage current from the welding sockets separately to PE 10mA 7 3 7 Measurement of protective conductor resistance Measure between the plug earthed contact and accessible live par...

Page 85: ...g 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 maintenance instructio...

Page 86: ...eeled 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 se...

Page 87: ...ll additional parts used by EWM but manufactured by other companies e g motors pumps fans torches etc Non reproducible software errors and parts subject to mechanical ageing are excluded from the warr...

Page 88: ...remote control remote control extension cable coolant etc The warranty does not apply to products that are damaged due to accidents misuse improper operation incorrect installation use of force disre...

Page 89: ...heck the mains voltages and compare with the welding machine connection see Technical data chapter 1 Error 3 Temp x Welding machine excess temperature Allow the machine to cool down main switch to 1 E...

Page 90: ...MM 4M KL Workpiece cable clamp 092 000003 00000 MIG 40 G 3M MIG welding torch gas 094 003415 00000 MIG 452 W 4M HDH MIG welding torch water flex 094 011056 00104 EH50 4M Electrode holder 092 000004 00...

Page 91: ...s 37mm 4 roller cored wire 092 000834 00000 ROE 2DR4R 1 0 1 2 1 4 1 6 Drive rollers 37mm 4 roller cored wire 092 000835 00000 ROE 2DR4R 1 4 1 6 2 0 2 4 Drive rollers 37mm 4 roller cored wire 092 00083...

Page 92: ...tal vertical crane suspension 092 002355 00000 ON A INTERFACE Option retrofit for analog mech welding interface PHOENIX PROGRESS 092 001779 00000 ON WHEELS PHOENIX 303 330 333 Optional retrofit wheel...

Page 93: ...Not Aus R ckseite 1 PE5 PE X1 10 X1 11 X1 12 X1 13 X1 14 X1 15 X1 16 X1 17 X1 18 X1 1 X1 2 X1 3 X1 4 X1 5 X1 6 X1 7 X1 8 X1 9 X2 1 X2 2 X2 3 X2 4 X PE 1 X PE 2 X4 1 X4 2 X4 3 X4 4 X10 1 X10 2 D Sub 15...

Page 94: ...2 8 X2 9 X2 10 X2 11 X2 12 X2 13 X2 14 X2 15 X2 16 X2 17 X2 18 Push Pull M 3 7 0 1 X18 Peripherie1 X18 1 X18 2 X18 3 X18 4 X18 5 X18 6 X18 7 X18 8 X16 1 X16 2 ext Motorversorgung X16 A4 X20 1 X20 2 Ko...

Page 95: ...V RS 12V TXD RXD RSGND 42V X1 7 X1 6 X1 5 X1 4 X1 3 X1 2 X1 1 Schirm 0V RS 12V RSGND 42V X2 7 X2 6 X2 5 X2 4 X2 3 X2 2 X2 1 RXD TXD VP5 2D 2x2n2F A7 I 13 2 F 9 1 1 PE 1 F hlerspannung 2 F hlerspannung...

Page 96: ...he event of unau thorised modifications improperly con ducted repairs non observance of the deadlines for the repetition test and or non permitted conversion work not specifically authorised by EWM Pa...

Page 97: ...draht Flux Cored Wire Massivdraht Solid Wire F lldraht Flux Cored Wire CrNi CrNi Ar91 99 Ar He Ar80 90 Ar80 90 Ar91 99 Ar80 90 Ar80 90 Ar91 99 Ar91 99 Ar98 2 Ar92 8 Ar100 Ar91 99 Ar100 Ar100 AlMg AlSi...

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