EWM Phoenix 351 Expert puls FDW Operating Instructions Manual Download Page 103

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Technical data

Phoenix 401 Expert puls FDW

099-004833-EW501

22.04.2013

103

8 Technical

data

NOTE

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

8.1

Phoenix 401 Expert puls FDW

TIG MMA

MIG/MAG

Setting range for welding current

5 A–400 A

Setting range for welding voltage

10.2 V–26.0 V

20.2 V–36.0 V

14.3 V–34.0 V

Duty cycle at 40 °C (100% DC)

400 A

Load alternation

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 35 A

Mains connection lead

H07RN-F4G4

Maximum connected load

13.1 kVA

18.2 kVA

17.2 kVA

Recommended generator rating

25 kVA

cos



0.99

Insulation class/protection classification

H/IP 23

Ambient temperature

-20 °C to +40 °C

Machine/torch cooling

Fan/water

Cooling capacity at 1 l/min

1500 W

Maximum flow rate

5 l/min

Maximum coolant outlet pressure

3.5 bar

Maximum tank capacity

12 l

Coolant

Ex works: KF 23E (-10 °C to +40 °C) or

KF 37E (-20 °C to +10 °C)

Welding lead

70 mm²

Dimensions L x W x H in mm

1100 x 455 x 1000

Weight in kg

118

EMC class

Constructed to standard

IEC 60974-1, -2, -10

Summary of Contents for Phoenix 351 Expert puls FDW

Page 1: ...g machine Phoenix 351 401 451 551 Expert puls FDW 099 004833 EW501 Observe additional system documents 22 04 2013 GB Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group com ...

Page 2: ...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 materia...

Page 3: ...on Validation 17 4 Machine description quick overview 18 4 1 Front view 18 4 2 Rear view 20 4 3 Machine control Operating elements 22 5 Design and function 24 5 1 General 24 5 2 Installation 25 5 3 Machine cooling 25 5 4 Workpiece lead general 25 5 5 Notes on the installation of welding current leads 26 5 6 Welding torch cooling system 27 5 6 1 General 27 5 6 2 List of coolants 27 5 6 3 Adding coo...

Page 4: ...2 Connection for workpiece lead 69 5 11 3 Welding task selection 70 5 11 3 1 M3 19 welding machine control and M3 00 wire feed unit control 70 5 11 3 2 M3 19 welding machine control and M3 70 wire feed unit control 71 5 11 4 TIG welding data display 72 5 11 5 TIG arc ignition 72 5 11 5 1 Liftarc ignition 72 5 11 6 Pulses function sequences 73 5 11 6 1 Explanation of signs and functions 73 5 11 7 T...

Page 5: ...ctional test 95 6 2 3 Annual test inspection and testing during operation 95 6 3 Maintenance work 95 6 4 Disposing of equipment 96 6 4 1 Manufacturer s declaration to the end user 96 6 5 Meeting the requirements of RoHS 96 7 Rectifying faults 97 7 1 Checklist for rectifying faults 97 7 2 Error messages power source 98 7 2 1 Interface for automated welding 99 7 3 Resetting JOBs welding tasks to the...

Page 6: ...ol in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading with a general warning symbol The risk is explained using a symbol on the edge of the page CAUTION Working and operating procedures which must be followed precisely to avoid damaging or destroying t...

Page 7: ...escription Press Do not press Turn Switch Switch off machine Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display example wait 4s press Interruption in the menu display other setting options possible Tool not required do not use Tool required use l 0 l 0 ...

Page 8: ...ipment sensitive to radiation accordingly The correct functioning of pacemakers may be affected obtain advice from a doctor if necessary Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repaired or modified by specialist skilled persons The warranty becomes null and void in the event of unauthorised interference Appoint only skil...

Page 9: ...e objects such as matches or lighters Keep appropriate fire extinguishing equipment to hand in the working area Thoroughly remove any residue of flammable substances from the workpiece before starting welding Only continue work on welded workpieces once they have cooled down Do not allow to come into contact with flammable material Connect welding leads correctly Danger when coupling multiple powe...

Page 10: ...g currents Stray welding currents can destroy protective earth conductors damage equipment and electronic devices and cause overheating of components leading to fire Make sure all welding leads are securely connected and check regularly Always ensure a proper and secure electrical connection to the workpiece Set up attach or suspend all conductive power source components like casing transport vehi...

Page 11: ...The user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the user must consider the following see also EN 60974 10 Appendix A Mains control signal and telecommunication lines Radios and televisions Computers and other control systems Safety equipment The health of neighbouring persons especi...

Page 12: ... during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to EN 60974 A2 Set up and transport the machine on level solid ground Secure add on parts using suitable equipment Replace damaged wheels and their fixing elements Fix external wire feed units during transport avoid uncontrolled rotation Damage due to supply lines not being disconnected During transport supply...

Page 13: ...elding gas cylinders tool boxes wire feed units etc Avoid jerky movements when raising or lowering Use shackles and load hooks of the appropriate size m i n 1 m m i n 1 m 75 Fig Lifting 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 li...

Page 14: ...ities of dust acid corrosive gases or substances may damage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambient conditions Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Keep the cooling air inlet and outlet clear Observe the minimum distan...

Page 15: ... MAG standard welding Metal arc welding using a wire electrode whereby gas from an external source surrounds the arc and the molten pool to protect them from the atmosphere 3 1 2 1 forceArc Welding with a powerful forced arc deep fusion penetration and virtually spatter free weld seams of the highest quality 3 1 2 2 rootArc Stable soft short arc even with long welding leads ideal for simple reliab...

Page 16: ...22 04 2013 3 2 Use and operation solely with the following machines NOTE A suitable wire feed unit system component is required in order to operate the welding machine Phoenix Expert 351 401 451 551 drive 200C drive 300C drive 4L M3 00 drive 4L M3 70 drive 4 M3 00 drive 4 M3 70 miniDrive ...

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

Page 18: ...Machine description quick overview Front view 18 099 004833 EW501 22 04 2013 4 Machine description quick overview 4 1 Front view Figure 4 1 ...

Page 19: ...lant tank cap 9 Automatic cut out of coolant pump key button press to reset a triggered fuse 10 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 11 Connection socket welding current MIG MAG welding welding current connection for the welding torch MIG MAG cored w...

Page 20: ...Machine description quick overview Rear view 20 099 004833 EW501 22 04 2013 4 2 Rear view Figure 4 2 ...

Page 21: ...ing current Standard MIG MAG welding intermediate hose package 6 Connection socket welding current Connection for welding current plug from intermediate hose package MIG MAG flux cored wire welding TIG welding 7 Quick connect coupling red coolant return 8 Quick connect coupling blue coolant supply 9 Wheels fixed castors 10 Bracket for shielding gas cylinder 11 Cooling air outlet 12 Mains connectio...

Page 22: ... nominal actual and hold values Material thickness nominal value Wire speed nominal actual and hold values Operating hour counter Selection of further welding parameters in lower programming levels 2 Display 16 digit Display of all welding parameters and their values 3 Switching of the digital display Buttons right Welding voltage nominal actual values Motor current actual value JOB number After e...

Page 23: ...obs 0 8 mm wire diameter 0 9 mm wire diameter 1 0 mm wire diameter 1 2 mm wire diameter 1 6 mm or greater wire diameter depending on output Special job 1 fast selection of JOB 129 Special job 2 fast selection of JOB 130 Special job 3 fast selection of JOB 131 8 Key button Select material type Steel Chrome nickel Copper silicon Copper aluminium Aluminium magnesium Aluminium silicon 99 aluminium 9 K...

Page 24: ...ection If the welding current connections are not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by turning in clockwise direction if necessary Risk of injury due to moving parts The wire feeders are equipped with moving parts which can trap hands hair clothing or tools and thus injure persons Do not reach into rotating ...

Page 25: ...CAUTION Installation site The machine must not be operated in the open air and must only be set up and operated on a suitable stable and level base The operator must ensure that the ground is non slip and level and provide sufficient lighting for the place of work Safe operation of the machine must be guaranteed at all times 5 3 Machine cooling To obtain an optimal duty cycle from the power compon...

Page 26: ...ether as possible B Keep the welding lead and hose packages of each welding machine separate with an installation distance of at least 15 cm C Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops D Use an individual welding lead to the workpiece for each welding machine Connect the work clamp close to the welding point E Always keep leads as short as po...

Page 27: ...ust be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components The coolant must be checked for adequate frost protection with the TYP 1 frost protection tester see accessories Replace coolant as necessary if frost protection is inadequate NOTE The disposal of coolant must be carried out according to official regulations and obs...

Page 28: ... necessary Figure 5 2 Item Symbol Description 0 1 Coolant tank cap 2 Coolant filter sieve 3 Coolant tank 4 Min mark Minimum coolant level Unscrew and remove the coolant tank sealing cover Check filter sieve insert for dirt clean if necessary and reinsert into position Top up coolant to the filter sieve insert close sealing cover again NOTE The level of coolant must never fall below the min mark If...

Page 29: ...o be suitable for operating devices according to protection class 1 5 7 1 Mains configuration NOTE The machine may be connected to a three phase system with four conductors and an earthed neutral conductor a three phase system with three conductors of which any one can be earthed e g the outer conductor L1 L1 L3 L3 N L2 L2 PE PE Figure 5 3 Legend Item Designation Colour code L1 Outer conductor 1 b...

Page 30: ...lead should be connected to the welding current socket Observe the information from the electrode manufacturer Figure 5 4 Item Symbol Description 0 1 Wire feed unit 2 Intermediate hose package 3 Intermediate hose package strain relief 4 7 pole connection socket digital Wire feed unit connection 5 Connection socket welding current Standard MIG MAG welding intermediate hose package 6 Connection sock...

Page 31: ...dling and insufficient securing of shielding gas cylinders can cause serious injuries The fastening elements must tightly enclose the shielding gas cylinder Attach the fastening elements within the upper half of the shielding gas cylinder Do not attach any element to the shielding gas cylinder valve Observe the instructions from the gas manufacturer and any relevant regulations concerning the use ...

Page 32: ...egulator 2 Shielding gas cylinder 3 Output side of the pressure regulator 4 Cylinder valve Place the shielding gas cylinder into the relevant cylinder bracket Secure the shielding gas cylinder using a securing chain Tighten the pressure regulator screw connection on the gas bottle valve to be gas tight Tighten gas hose on pressure regulator to be gas tight 4 3 2 1 ...

Page 33: ...nt 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 1 2 3 Figure 5 6 Item Symbol Description 0 1 Connection socket welding current MIG MAG cored wire welding Workpiece connection 2 welding current connection socket MIG MAG welding Workpiece connection 3 Workpiece I...

Page 34: ... the operating point defined single dial operation via wire speed rotary dial Additional parameters can be modified as required in the configuration menu on the control or using the PC300 NET welding parameter software 5 10 3 Welding task selection NOTE Selection of a welding task involves the interaction of the controls on the welding machine and the wire feed unit After the basic settings are ma...

Page 35: ...ect gas type The signal light indicates the selection Select operating mode Select welding type 1 x Switch superpulses on or off The signal light indicates the selection Operating point is set using the wire speed previously set Arc length correction setting Dynamic correction choke effect rotary switch Dynamic correction or choke effect setting in 9 stages hard narrow to soft wide arc 0 5 1 1 5 2...

Page 36: ...Design and function MIG MAG welding 36 099 004833 EW501 22 04 2013 5 10 3 2 M3 19 welding machine control and M3 70 wire feed unit control Superpuls m min m min DYN Super puls Figure 5 8 ...

Page 37: ...ng mode The LED displays the selected operating mode Non latched operation Latched operation Green Special non latched mode Red Spot operating mode Special latched mode n x Select welding type The signal light indicates the selection Standard MIG MAG welding Pulse arc MIG MAG welding 1 x Switch superpulses on or off The signal light indicates the selection Operating point is set using the wire spe...

Page 38: ...e electrode sticks in the gas nozzle Back burn set too low Wire electrode sticks in the weld pool Welding machine Operating element Action Result Display 1 x Select program sequence mode Program steps n x Select RUECK parameter using the Up and Down buttons left RUECK 2 500 n x Adjust the selected parameter using the Up and Down buttons right RUECK 2 500 3 x Machine returns to Display mode Wire fe...

Page 39: ...ng point welding performance can be displayed as the welding current material thickness or wire speed On the welding machine using control M3 19 Operating element Action Result n x Switching the display between Welding current Material thickness Wire speed On the wire feed unit using control M3 70 Operating element Action Result n x Switching the display between Welding current Material thickness ...

Page 40: ...hickness parameter is described as an example below Operating element Action Result Display Increase or reduce welding performance via the panel thickness parameter Display example 5 0 mm 5 10 4 3 Arc length correction setting NOTE The settings are made on the wire feed unit control M3 00 The Arc length correction setting option is provided for adjusting the arc length for any specific welding tas...

Page 41: ...ndividual machines and their functions 5 10 5 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 selecting the welding parameter to be displayed The button is used to scroll through the parameters from the bottom upwards and the button is used to scroll downwards from the top As soon as changes have been made to the settings...

Page 42: ...n also be changed if required 5 10 6 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I Welding output Wire electrode is being conveyed Wire creep Wire burn back Gas pre flows Gas post flows Non latched Special non latched Latched Special latched t Time PSTART Ignition program PA Main pro...

Page 43: ...ng gas is expelled gas pre flows Wire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Change over to pre selected wire speed Step 2 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses ...

Page 44: ...s after the wire electrode makes contact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 2 Release torch trigger Super pulse function is ended WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas...

Page 45: ...uns at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART for the time tstart Slope to main program PA Step 2 Release torch trigger Slope to end program PEND for the time tend WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses t t t I 1 2 PA PEND PSTART ...

Page 46: ...e makes contact with the workpiece welding current is flowing start program PSTART spot time starts Slope to main program PA After the set spot time elapses slope goes to end program PEND Wire feed motor stop welding Arc is extinguished after the pre selected wire burn back time elapses Gas post flow time elapses 2nd cycle Release torch trigger Releasing the torch trigger step 2 interrupts the wel...

Page 47: ...ng current is flowing start program PSTART for the time tstart Slope on main program PA Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 2 Release torch trigger Super pulse function is ended Slope to end program PEND for the time tend WF motor stops Arc is extinguished aft...

Page 48: ...t 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 t t t I 1 2 3 4 ...

Page 49: ...ontact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 2 Release torch trigger no effect Step 3 Press torch trigger no effect Step 4 Release torch trigger Super pulse function is ended WF motor stops Arc is extinguished after the p...

Page 50: ...ndard process is stored in the JOB this means that there is a permanent alternation between the processes starting with the standard process and followed by the pulse process The same applies if the situation is reversed 2nd cycle Release torch trigger no effect 3rd cycle Press torch trigger no effect 4th cycle Release torch trigger Super pulse function is ended WF motor stops Arc is extinguished ...

Page 51: ...s and at the latest when the torch trigger is released Tapping1 can be used to change over to the reduced main program PB Repeated tapping will switch back to the main program PA Step 3 Press and hold torch trigger Slope to end program PEND Step 4 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses NOTE 1 Prevent tap...

Page 52: ... torch trigger is released Tapping pressing the torch trigger for less than 0 3 sec changes over the welding process PB If a standard process has been defined in the main program tapping changes to the pulse process and tapping again will return to the standard process etc 3rd cycle Press and hold torch trigger Slope to end program PEND 4th cycle Release torch trigger WF motor stops Arc is extingu...

Page 53: ...ate 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 this means that there is a permanent alternation between the processes starting with the standard process and followed by the pulse process The same applies if the situation is reversed 3rd cycle Press the torch trigger Super pulse function is ended S...

Page 54: ...ith main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 3 Press the torch trigger Super pulse function is ended Slope in the end program PEND for the time tend Step 4 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses 5 10 6 2 MIG MAG auto...

Page 55: ...dewall fusion Un alloyed and low alloy steels Manual and automated applications rootArc welding up to Wire Ø mm 0 6 0 8 0 9 1 1 2 1 6 Material Gas JOB JOB JOB JOB JOB JOB Steel CO2 x x x x x x 204 6 0 205 5 0 x x Ar 80 90 x x x x x x 206 6 0 207 5 0 x x NOTE Unstable arc Welding current cables that are not fully unrolled can cause faults in the arc flickering Fully unroll welding current cables to...

Page 56: ...x 251 12 0 252 12 0 253 6 0 You can make use of these properties after selecting the forceArc process see the Selecting a MIG MAG welding task chapter As with pulse arc welding it is important to make sure of a good welding current connection Keep welding current cables as short as possible and ensure that cable cross sections are adequate Fully unroll welding current cables torche hose packages a...

Page 57: ...ion etc Figure 5 24 In every JOB separate settings can be made for the ignition program reduced main program and end program as to whether or not to alternate with the pulse process These properties are stored on the welding machine with the JOB This means that in the factory settings the pulse process is active during the end program in all forceArc JOBs NOTE This function can only be enabled wit...

Page 58: ...e arc welding machines only 1 active 0 not active PEND end program tSe Slope duration from PA to PEND 0 0s to 20 0s DVend r Wire feed speed relative 1 to 200 DVend a Wire feed speed absolute 0 1m min to 40m min Uend Arc length correction 9 9V to 9 9V tend Duration superpulse 0 0s to 20 0s Basic parameters Display Meaning explanation Setting range RUECK Wire burn back length 2 to 500 GASend Gas pos...

Page 59: ... 5 27 Basic parameters Welding parameter Meaning explanation Setting range GASstr Gas pre flow time 0 0s to 20 0s GASend Gas post flow time 0 0s to 20 0s RUECK Wire burn back length 2 to 500 PSTART start program Welding parameter Meaning explanation Setting range DVstart Wire speed 0 to 200 Ustart Arc length correction 9 9V to 9 9V tstart Duration 0 0s to 20s PA main program Welding parameter Mean...

Page 60: ...ng range DVstart Wire speed 0 to 200 ustart Arc length correction 9 9V to 9 9V tstart Duration 0 0s to 20s PA main program Welding parameter Meaning explanation Setting range Setting the wire speed PB reduced main program Welding parameter Meaning explanation Setting range DV3 Wire speed 0 to 200 U3 Arc length correction 9 9V to 9 9V PEND end crater program Welding parameter Meaning explanation Se...

Page 61: ...9 9V tstart Duration 0 0s to 20s PA main program Welding parameter Meaning explanation Setting range tS1 Slope duration from PSTART to PA 0 0s to 20s DV3 Setting the wire speed 0 to 200 t2 Duration 0 1s to 20s tS3 Slope duration from PB to PA 0 0s to 20s PB reduced main program Welding parameter Meaning explanation Setting range tS2 Slope duration from PA to PB 0 0s to 20s DV3 Wire speed 0 to 200 ...

Page 62: ...rsa Non latched latched operation with changing welding processes Special non latched latched operation with changing welding processes Special latched operation with welding process switching PSTART Pulsed arc welding process on off All special non latched modes All special latched modes PEND Pulsed arc welding process on off activated for all forceArc JOBs ex factory All special non latched mode...

Page 63: ... parameters using the following components Program switching Program Operating mode Welding method superPuls Wire speed Voltage correction Dynamics M3 19 Welding machine control No P0 No Yes No P1 15 Yes M3 00 Wire feeder control Yes 5 P0 Yes 2 No Yes 1 Yes 1 Yes 1 P1 15 No No M3 70 Wire feeder control Yes P0 Yes Yes 1 Yes 3 P1 15 Yes R20 Remote control Yes 3 P0 No Yes 1 No P1 9 No R40 Remote cont...

Page 64: ...of different sheet metal thicknesses non latched or latched special Figure 5 33 NOTE Up to 16 programs PA0 to PA15 can be defined An operating point wire speed arc length correction dynamics choke effect can be defined permanently in each program Program P0 is an exception the settings for operating points are made manually here Changes to the welding parameters are saved immediately t I PA0 PA1 P...

Page 65: ...Change welding data display over to program display LED PROG is on Select program number Display example Program 1 n x Select program sequence parameter Main program PA LED is on Set wire speed Absolute value Set arc length correction Display example 0 8 V correction Setting range 9 9 V to 9 9 V 1 x Select Dynamic program sequence parameter LED is on Set dynamic Setting range 40 to 40 40 Arc hard ...

Page 66: ...operating instructions for the wire feed unit 0 to 30 P1 DV2 2 0m m Wire speed 0 1m min to 20 0m min P1 U2 0 0V Arc length correction 9 9V to 9 9V P1 DYN2 0 Dynamics choke effect 40 to 40 P2 to P14 P2 to P14 P2 to P14 P15 DV2 2 0m m Wire speed 0 1m min to 20 0m min P15 U2 0 0 V Arc length correction 9 9V to 9 9V P15 DYN2 0 Dynamics choke effect 40 to 40 5 10 12 Standard MIG MAG torch The MIG weldi...

Page 67: ...h one rocker and three digit digital display to set and display the welding performance program 0 or to access and display up to 10 welding programs programs 0 9 POWERCONTROL 2 welding torch with four triggers and three digit digital display for setting and displaying the welding performance and voltage correction or for calling up programs and JOBs as well as for displaying the corresponding para...

Page 68: ...ZA version are connected to the Euro torch connector of the wire feeder only To do so the welding current lead of the intermediate hose package must be connected to the welding current connection at the rear of the unit 2 1 3 4 5 6 Figure 5 35 Item Symbol Description 0 1 Euro torch connector Integrated welding current shielding gas and torch trigger 2 Quick connect coupling red coolant return 3 Qu...

Page 69: ...arate welding current connection 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 5 11 2 Connection for workpiece lead Figure 5 36 Item Symbol Description 0 1 Connection socket welding current TIG welding Workpiece connecti...

Page 70: ...5 11 3 1 M3 19 welding machine control and M3 00 wire feed unit control 0 5 1 1 5 2 2 5 3 3 5 4 5 6 7 8 9 1011 12 13 14 15 16 18 20 22 24 m min Figure 5 37 Operating element Action Result Display n x The various welding processes are run through until the signal light for the required welding process comes on The nominal values for the welding current and welding voltage are displayed Welding curr...

Page 71: ...re feed unit control m min Figure 5 38 Operating element Action Result Display n x The various welding processes are run through until the signal light for the required welding process comes on The nominal values for the welding current and welding voltage are displayed Welding current is set Setpoint setting m min ...

Page 72: ...re welding During welding Parameter Nominal value Actual value Nominal value Welding current Tungsten electrode diameter Welding voltage JOB no Running time meter 5 11 5 TIG arc ignition 5 11 5 1 Liftarc ignition Figure 5 40 The arc is ignited on contact with the workpiece a Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger liftarc curre...

Page 73: ...ol Meaning Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I Welding output Gas pre flows Gas post flows Non latched Special non latched Latched Special latched t Time PSTART Ignition program PA Main program PB Reduced main program PEND End program tS1 Slope duration from PSTART to PA ...

Page 74: ...igure 5 42 Selection Select non latched special mode Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows The arc is ignited using liftarc Welding gas flows with pre selected setting in start program PSTART After the tstart ignition current time elapses the welding current rises with the set upslope time tS1 to the main program PA Step 2 Release torch trigger The welding cur...

Page 75: ...e Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows The arc is ignited using liftarc Welding current flows with pre selected setting Step 2 Release torch trigger no effect Step 3 Press torch trigger no effect Step 4 Release torch trigger Arc is extinguished Gas post flow time elapses t t I 1 2 3 4 PA ...

Page 76: ...t after the set time tSTART elapses and at the latest when the torch trigger is released Tapping can be used to switch to the reduced main program PB Repeated tapping will switch back to the main program PA Step 3 Press the torch trigger Slope to end program PEND Step 4 Release torch trigger Arc is extinguished Gas post flow time elapses 5 11 7 TIG automatic cut out NOTE The welding machine ends t...

Page 77: ... 0 s t2 Duration 0 01 s to 20 00 s tS3 Slope duration from PB to PA 0 00 s to 20 00 s Reduced main program PB Display Meaning explanation Setting range tS2 Slope duration from PA to PB 0 00 s to 20 00 s I3 Welding current 0 to 100 t3 Duration 0 01 s to 20 00 s End program PEND Display Meaning explanation Setting range tSe Slope duration from PA or PB to PEND down slope 0 0 s to 20 0 s Iend Welding...

Page 78: ...ed surface 5 12 1 Connecting the electrode holder and workpiece lead NOTE Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging Figure 5 46 Item Symbol Description 0 1 Connection socket welding current 2 Connection socket welding current 3 Electrode holder 4 Workpiece Insert cable plug of the electrode holder into either the or welding current connec...

Page 79: ...5 12 2 1 M3 19 welding machine control and M3 00 wire feed unit control 0 5 1 1 5 2 2 5 3 3 5 4 5 6 7 8 9 1011 12 13 14 15 16 18 20 22 24 m min Figure 5 47 Operating element Action Result Display n x The various welding processes are run through until the signal light for the required welding process comes on The nominal values for the welding current and welding voltage are displayed Welding curr...

Page 80: ...ent and welding voltage are displayed Welding current is set Setpoint setting 5 12 2 3 Setting using the stick electrode diameter The welding current can also be set using the stick electrode diameter The welder sets the stick electrode diameter being used and the control calculates the relevant welding current for the electrode Control element Action Result Display 1 x Switch to stick electrode d...

Page 81: ...nges have been made to the settings after welding display on hold values the display switches back to the nominal values Figure 5 49 Four welding parameters can be selected in the MMA welding process Welding current and electrode diameter left hand side and welding voltage and JOB no right hand side The parameters can be displayed before nominal values during actual values welding Parameter Before...

Page 82: ...etting for the different electrode types Negative values Rutile Values around zero Basic Positive values Cellulose No change M3 70 Operating element Action Result Display Select arcforce welding parameter LED for the button is on Arcforcing setting for electrode types Setting range 40 to 40 Negative values Rutile Values around zero Basic Positive values Cellulose 0 1 1 2 2 3 3 4 4 DYN m min ...

Page 83: ...current and Hotstart time Control element Action Result Display 1 x Select Program sequence mode Program Steps n x Select the welding parameter using the key buttons Up and Down left n x Adjust the selected welding parameter using the key buttons Up and Down right 3 x Machine returns to Display mode Basic parameters Display Meaning explanation Setting range Ihot Hotstart current 0 to 200 thot Hots...

Page 84: ...elding current setting and correct according to the welding task Figure 5 51 Control element Action Result Display 1 x Select Program sequence mode Program Steps n x Select the welding parameters using the key buttons Up and Down left n x Adjust the selected welding parameter using the key buttons Up and Down right 3 x Machine returns to Display mode Basic parameters Display Meaning explanation Se...

Page 85: ... cause damage to the machines Observe the operating instructions for the welding machine or wire feed unit Switch off the welding machine before connecting NOTE Please note the relevant documentation of the accessory components The operation of the remote control and its settings are directly dependent on the configuration of the respective welding machine or wire feed unit The settings are define...

Page 86: ...tion interface Pin Input output Description Diagram A Output PE Connection for cable shielding D Output open collector IGRO Current flows signal I 0 maximum load 20 mA 15 V 0 V welding current flows E 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 87: ...is connected incorrectly Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission The PC may be destroyed due to high frequency ignition pulses Interface SECINT X10USB must be connected between the PC and the welding machine The connection must only be made using the cables supplied do not use any additional extension cables PC 300 welding parameter softwa...

Page 88: ...ber akt Prg Program number Mode Operating mode Schweiss Welding type Job Text Text information relating to the JOB can be edited using PC 300 Net software Wire Wire diameter Material Material type Gas Typ Gas type Verf Welding process 5 15 2 Organising JOBs Job Manager You can use the JOB manager to load copy or write back JOBs A JOB is the welding task defined by the four main welding parameters ...

Page 89: ...tons Up and Down right Copy to xxx 1 x JOB has been copied Copy to xxx 1 x Machine returns to Display mode 5 15 2 2 Loading special jobs SP1 to SP3 These jobs are the first 3 free JOBs which can be called up directly on the M3 1x control using the buttons SP1 to SP3 SP1 JOB129 SP2 JOB130 SP3 JOB131 Control element Action Result 3 s Select Special Jobs n x Select Special Job SP1 SP2 or SP3 3 s Mach...

Page 90: ...ected are displayed Calling up welding JOBs block JOB mode NOTE In this operating mode a total of 27 JOBs welding tasks divided into three blocks can be called up using the torch Only program 1 can be used in these JOBs Simultaneous operation with interfaces such as RINT X12 BUSINT X11 or DVINT X11 is not possible Operating elements Functions Torch trigger Welding on off Rocker Call up 27 JOBs wel...

Page 91: ...n each special JOB see table Setpoint values for wire speed arc correction dynamics and other parameters must first be stored in the JOB using the welding machine control or the PC300 Net software see also Organising JOBs chapter The Special JOB signal light flashes 5 15 2 5 Resetting an existing JOB to the factory setting Reset JOB If a pre programmed JOB has been changed accidentally it is possi...

Page 92: ... function off Hold Fkt 1 Hold Fkt 0 1 x Save change No change 1 x Exit Special Mode Last selected parameters are displayed 5 15 4 WF speed switching absolute relative Operating element Action Result Display 1 x Select Special Mode Program steps 1 x 2 x 1 x Special Mode Select function using the buttons Up and Down left Abs Fkt 0 Switch the function on and off using the Up and Down right buttons 1 ...

Page 93: ...Select Res All using the buttons Up and Down left Res All 1 1 x Save change No change 1 x Exit Special Mode Last selected parameters are displayed 5 16 Operating time counter The operating time is displayed in the format hhhh mm h Four digits for the hours two digits for the minute and a final h symbol On the welding machine control Operating element Action Result Display n x Press until signal li...

Page 94: ...ove the torch from the hose package Never clamp the torch body in a vice or similar as this can cause the torch to be irreparably destroyed If damage occurs to the torch or to the hose package which cannot be corrected as part of the maintenance work the entire torch must be returned to the manufacturer 6 2 1 Daily maintenance tasks Check that all connections and wearing parts are hand tight and t...

Page 95: ...mpanying supplementary sheets Machine and Company Data Maintenance and Testing Warranty A periodic test according to IEC 60974 4 Periodic inspection and test has to be carried out In addition to the regulations on testing given here the relevant local laws and regulations must also be observed 6 3 Maintenance work DANGER Do not carry out any unauthorised repairs or modifications To avoid injury an...

Page 96: ...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...

Page 97: ...ool brake see Setting the spool brake chapter Check settings and correct if necessary Setting pressure units see Inching wire electrodes chapter Check settings and correct if necessary Worn wire rolls Check and replace if necessary Wire feed motor without supply voltage automatic cutout triggered by overloading Reset triggered fuse rear of the power source by pressing the key button Kinked hose pa...

Page 98: ...Wire feeder speedometer error Check the wire feeder speedometer is not issuing a signal M3 00 defective inform Service Error 6 gas x Shielding gas error Check shielding gas supply for machines with shielding gas monitoring Error 7 Se Vol x Secondary excess voltage Inverter error inform Service Error 8 no PE x Earth fault between welding wire and earth line Phoenix 330 only Separate the connection ...

Page 99: ...ssage 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 7 2 1 Interface for automated welding WARNING No function of the external interrupt equipment emergency stop switch If the emergency stop circuit has been realised using an external interrupt equipment via the interface for automated welding the...

Page 100: ...factory settings NOTE JOBs 1 128 and 170 256 will be reset Custom JOBs 129 169 are maintained Operating element Action Result Display 1 x Select Special Mode Program steps 1 x 2 x 1 x Special Mode Select Res All using the buttons Up and Down left Res All 1 1 x Save change No change 1 x Exit Special Mode Last selected parameters are displayed A ...

Page 101: ...ting selection List of the software Start of the automated process Software versions display System bus ID printed circuit board 0 0 0 0 Version number System bus ID printed circuit board and version number are separated by a colon List of the software End of the list of software versions NOTE The printed circuit boards and software versions shown are displayed in an automated process and vary acc...

Page 102: ... 5 Vent coolant circuit NOTE 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 max 1 2 ca 5s 3 4 7 6 5 KLICK CLICK KLICK CLICK 092 007861 00000 blau blue l 0 l 0 l 0 ...

Page 103: ... 79 V Mains voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 35 A Mains connection lead H07RN F4G4 Maximum connected load 13 1 kVA 18 2 kVA 17 2 kVA Recommended generator rating 25 kVA cos 0 99 Insulation class protection classification H IP 23 Ambient temperature 20 C to 40 C Machine torch cooling Fan water Cooling capacity at 1 l min 1500 W Maximum fl...

Page 104: ...oltage 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 3 x 35 A Mains connection lead H07RN F4G6 MaximumconnectedloadMIG MAG 13 9 kVA 20 7 kVA 28 8 kVA Maximum connected load TIG 10 6 kVA 15 9 kVA 22 2 kVA MaximumconnectedloadMMA 15 0 kVA 21 6 kVA 29 2 kVA Recommended generator rating 20 3 kVA 29 1 kVA 39 4 kVA cos 0 99 Insulation class...

Page 105: ...00 094 001803 00001 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 DM1 35L MIN Manometer pressure regulator 094 000009 00000 5POLE CEE 32A M Machine plug 094 000207 00000 HOSE BRIDGE Tube bridge 092 007843 000...

Page 106: ...FRV 7POL 10 m Extension connecting cable 092 000201 00000 FRV 7POL 20 m Extension connecting cable 092 000201 00001 FRV 7POL 25M Extension connecting cable 092 000201 00007 9 5 Computer communication Type Designation Item no PC300 Net PC300 Net welding parameter software kit incl cable and SECINT X10 USB interface 090 008777 00000 CD PC300 Net update PC300 Net Update on CD ROM 092 008172 00001 FRV...

Page 107: ...AG MIG MAG SG2 3 91 99 Ar 1 6 Auftragsschweißen GMA Surfacing SG2 3 91 99 Ar 1 6 Metall Fülldraht Metal Flux Cored Wire SG2 3 91 99 Ar 1 6 Rutil Fülldraht Rutil Flux Cored Wire SG2 3 91 99 Ar 1 6 Basisch Fülldraht Basic Flux Cored Wire SG2 3 91 99 Ar 1 6 21 MIG MAG MIG MAG SG2 3 Ar He O 2 Ar He CO 2 15 30 He 0 8 Auftragsschweißen GMA Surfacing SG2 3 Ar He O 2 Ar He CO 2 15 30 He 0 8 Metall Fülldra...

Page 108: ...schweißen GMA Surfacing CrNi Ar He O 2 Ar He CO 2 15 30 He 1 6 Metall Fülldraht Metal Flux Cored Wire CrNi Ar He O 2 Ar He CO 2 15 30 He 1 6 Rutil Fülldraht Rutil Flux Cored Wire CrNi Ar He O 2 Ar He CO 2 15 30 He 1 6 Basisch Fülldraht Basic Flux Cored Wire CrNi Ar He O 2 Ar He CO 2 15 30 He 1 6 46 MIG MAG MIG MAG CrNi 1 5 H 2 0 8 Auftragsschweißen GMA Surfacing CrNi 1 5 H 2 0 8 Metall Fülldraht M...

Page 109: ... 0 MIG MAG MIG MAG AlMg Ar N 2 Ar He N 2 0 2 N2 1 0 76 MIG MAG MIG MAG AlMg 100 Ar 1 2 MIG MAG MIG MAG AlMg Ar N 2 Ar He N 2 0 2 N2 1 2 77 MIG MAG MIG MAG AlMg 100 Ar 1 6 MIG MAG MIG MAG AlMg Ar N 2 Ar He N 2 0 2 N2 1 6 78 MIG MAG MIG MAG AlMg Ar He 15 70 He 0 8 79 MIG MAG MIG MAG AlMg Ar He 15 70 He 1 0 80 MIG MAG MIG MAG AlMg Ar He 15 70 He 1 2 81 MIG MAG MIG MAG AlMg Ar He 15 70 He 1 6 82 MIG M...

Page 110: ...IG MAG MIG MAG CuSi 91 99 Ar 0 8 Auftragsschweißen GMA Surfacing CuSi Ar He O 2 Ar He CO 2 15 30 He 0 8 103 MIG MAG MIG MAG CuSi 91 99 Ar 1 0 Auftragsschweißen GMA Surfacing CuSi Ar He O 2 Ar He CO 2 15 30 He 1 0 104 MIG MAG MIG MAG CuSi 91 99 Ar 1 2 Auftragsschweißen GMA Surfacing CuSi Ar He O 2 Ar He CO 2 15 30 He 1 2 105 MIG MAG MIG MAG CuSi 91 99 Ar 1 6 Auftragsschweißen GMA Surfacing CuSi Ar ...

Page 111: ...MIG Löten MIG Brazing CuAl Ar He O 2 Ar He CO 2 15 30 He 1 6 122 MIG Löten MIG Brazing CuAl 100 Ar 0 8 MIG Löten MIG Brazing CuAl Ar He 15 70 He 0 8 123 MIG Löten MIG Brazing CuAl 100 Ar 1 0 MIG Löten MIG Brazing CuAl Ar He 15 70 He 1 0 124 MIG Löten MIG Brazing CuAl 100 Ar 1 2 MIG Löten MIG Brazing CuAl Ar He 15 70 He 1 2 125 MIG Löten MIG Brazing CuAl 100 Ar 1 6 MIG Löten MIG Brazing CuAl Ar He ...

Page 112: ...mm 157 Block 2 Job8 158 Block 2 Job9 159 Block 2 Job10 160 Block 3 Job1 161 Block 3 Job2 162 Block 3 Job3 163 Block 3 Job4 164 Block 3 Job5 165 Block 3 Job6 166 Block 3 Job7 167 Block 3 Job8 168 Block3 Job9 169 Block3 Job10 170 MIG MAG MIG MAG 171 coldArc Pipe SG2 3 CO 2 1 0 172 coldArc Pipe SG2 3 CO 2 1 2 173 coldArc Pipe SG2 3 80 90 Ar 1 0 174 coldArc Pipe SG2 3 80 90 Ar 1 2 175 coldArc SG2 3 80...

Page 113: ...m s 189 forceArc SG2 3 80 90 Ar 0 8 190 forceArc SG2 3 91 99 Ar 0 8 191 coldArc SG2 3 80 90 Ar 0 8 192 coldArc SG2 3 80 90 Ar 0 9 193 coldArc SG2 3 80 90 Ar 1 0 194 coldArc SG2 3 80 90 Ar 1 2 195 coldArc SG2 3 80 90 Ar 1 6 196 coldArc Löten AlSi 100 Ar 0 8 197 coldArc Löten AlSi 100 Ar 1 0 198 coldArc Löten AlSi 100 Ar 1 2 199 coldArc Löten AlSi 100 Ar 1 6 200 coldArc Löten Zn 100 Ar 0 8 201 coldA...

Page 114: ... 8 220 coldArc Misch Zn 100 Ar 1 0 221 coldArc Misch Zn 100 Ar 1 2 222 coldArc Misch Zn 100 Ar 1 6 223 coldArc Misch AlSi 100 Ar 0 8 224 coldArc Misch AlSi 100 Ar 1 0 225 coldArc Misch AlSi 100 Ar 1 2 226 coldArc Misch AlSi 100 Ar 1 6 227 Metall Fülldraht CrNi 91 99 Ar 0 8 228 Metall Fülldraht CrNi 91 99 Ar 1 0 229 Metall Fülldraht CrNi 91 99 Ar 1 2 230 Metall Fülldraht CrNi 91 99 Ar 1 6 231 Rutil...

Page 115: ...a meter mm Verfahren process Material material Gas gas Draht durch messer wire dia meter mm Verfahren process Material material Gas gas Draht durch messer wire dia meter mm 244 Rutil Basic Fülldraht SG2 3 80 90 Ar 1 6 245 forceArc Al99 100 Ar 1 2 246 forceArc Al99 100 Ar 1 6 247 forceArc AlMg 100 Ar 1 2 248 forceArc AlMg 100 Ar 1 6 249 forceArc AlSi 100 Ar 1 2 250 forceArc AlSi 100 Ar 1 6 251 forc...

Page 116: ...eadquarters EWM HIGHTEC WELDING GmbH Dr Günter Henle Straße 8 56271 Mündersbach Germany Tel 49 2680 181 0 Fax 244 www ewm group com info ewm group com Technology centre EWM HIGHTEC WELDING GmbH Forststr 7 13 56271 Mündersbach Germany Tel 49 2680 181 0 Fax 144 www ewm group com info ewm group com EWM HIGHTEC WELDING GmbH Dr Günter Henle Straße 8 56271 Mündersbach Germany Tel 49 2680 181 0 Fax 244 w...

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