EWM Phoenix 401 Expert 2.0 puls MM FKG Operating Instructions Manual Download Page 11 | Manualshive

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For your safety

Transport and installation

099-005549-EW501

12.11.2018

11

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!

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Summary of Contents for Phoenix 401 Expert 2.0 puls MM FKG

Page 1: ...Operating instructions EN Welding machine Phoenix 401 Expert 2 0 puls MM FKG Phoenix 401 Expert 2 0 puls MM FKW 099 005549 EW501 Observe additional system documents 12 11 2018...

Page 2: ...uthorised sales partners can be found at www ewm group com en specialist dealers Liability relating to the operation of this equipment is restricted solely to the function of the equipment No other fo...

Page 3: ...cooling system 19 5 1 5 1 Approved coolants overview 19 5 1 5 2 Maximal hose package length 20 5 1 5 3 Adding coolant 20 5 1 6 Notes on the installation of welding current leads 21 5 1 7 Stray weldin...

Page 4: ...Disposing of equipment 40 7 Rectifying faults 41 7 1 Checklist for rectifying faults 41 7 2 Vent coolant circuit 43 8 Technical data 44 8 1 Phoenix 401 FKG 44 8 2 Phoenix 401 FKW 45 9 Accessories 46 9...

Page 5: ...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...

Page 6: ...lete documentation These operating instructions are part of the complete documentation and valid only in combination with all other parts of these instructions Read and observe the operating instructi...

Page 7: ...en 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 int...

Page 8: ...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 c...

Page 9: ...d 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 sh...

Page 10: ...ions 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...

Page 11: ...2018 11 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...

Page 12: ...lift arc MMA welding Gouging forceArc rootArc coldArc pipeSolution forceArc puls rootArc puls coldArc puls alpha Q puls MM Phoenix puls MM Taurus Synergic S MM possible not possible 3 2 Documents whi...

Page 13: ...ll 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 pa...

Page 14: ...d quick connect coupling of coolant supply and return are only fitted in machines with water cooling Figure 4 1 Item Symbol Description 0 1 Lifting lug see 5 1 1 chapter 2 Ready for operation signal l...

Page 15: ...Please observe the connection description for the corresponding welding procedure see 5 chapter 14 Connection socket welding current How to connect the accessories depends on the welding procedure Ple...

Page 16: ...tton automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse 3 PC interface serial D Sub connection socket 9 pole 4 Cooling air outlet 5 Bracket for shielding gas cylinder...

Page 17: ...JOBs Infinite adjustment of welding performance 2 Push button gas test rinse hose package see 5 1 9 chapter 3 Push button wire inching Potential and gas free inching of the wire electrode through the...

Page 18: ...part 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...

Page 19: ...nsufficient 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 protectio...

Page 20: ...e Wire feeder miniDrive Welding torch Max Compact 25 m 82 ft 5 m 16 ft 30 m 98 ft 20 m 65 ft 5 m 16 ft Decompact 25 m 82 ft 5 m 16 ft 15 m 49 ft 10 m 32 ft 5 m 16 ft Pump Pmax 4 5 bar 0 45 MPa Power s...

Page 21: ...imum 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 2 chapter 5 1 6 Notes on the installatio...

Page 22: ...rs 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 co...

Page 23: ...ccording 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 co...

Page 24: ...1 Pressure regulator connection Figure 5 7 Item Symbol Description 0 1 Pressure regulator 2 Output side of the pressure regulator 3 Shielding gas cylinder 4 Cylinder valve Before connecting the press...

Page 25: ...r 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 ni...

Page 26: ...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 wel...

Page 27: ...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...

Page 28: ...sing standardised basket coils DIN 8559 see 9 chapter Figure 5 10 Item Symbol Description 0 1 Carrier pin For fixing the wire spool 2 Knurled nut For fixing the wire spool Loosen knurled nut from spoo...

Page 29: ...xing 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 Fol...

Page 30: ...hite 0 8 0 9 1 0 030 035 040 bicolour white blue 1 0 1 2 040 045 blue red 1 4 052 monochrome 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 bicolou...

Page 31: ...e inching push button 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 Depending...

Page 32: ...g Version 2 right hand mounting Figure 5 13 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...

Page 33: ...t coupling red coolant return 8 Quick connect coupling blue coolant supply Insert the central plug for the welding torch into the central connector and screw together with crown nut Insert the cable p...

Page 34: ...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 sock...

Page 35: ...source will ignore the external interrupt equipment and will not shut down Remove jumper 1 on the corresponding control board to be done only by qualified service personnel These accessory components...

Page 36: ...put signal to reference potential 0 V pin E R Input Activation of control voltage specification for arc length correction S3 For activation put signal to reference potential 0 V pin E U V Output Suppl...

Page 37: ...re Set all welding parameters on the PC and simply transfer to one or more welding machines accessory set consisting of software interface connection leads Manage up to 510 JOBs Exchange JOBs with the...

Page 38: ...ght 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...

Page 39: ...ly tighten if necessary Remove any spatter Clean the wire feed rollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks Visual inspection Casing damage front rear...

Page 40: ...r on wheels indicates that the equipment must be collected separately This machine has to be disposed of or recycled in accordance with the waste separation systems in use According to German law law...

Page 41: ...lding torch equipment Adjust contact tip to wire diameter and material and replace if necessary Adjust wire guide to material in use blow through and replace if necessary Contact tip blocked Clean spr...

Page 42: ...rc Unsuitable or worn welding torch equipment Adjust contact tip to wire diameter and material and replace if necessary Adjust wire guide to material in use blow through and replace if necessary Mater...

Page 43: ...nt 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 i...

Page 44: ...H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 4 25 C up to 40 C Machine cooling Torch cooling Fan AF Gas Wire feed speed 0 5 m min up to 25m mi...

Page 45: ...ine cooling Torch cooling Fan AF Gas or water Cooling capacity 1500 W max Flow rate 5 l min max Pump pressure 3 5 bar max Tank content 12 5 l Wire feed speed 0 5 m min up to 25m min Factory installed...

Page 46: ...090 008088 00000 R50 7POL Remote control all welding machine functions can be set directly at the workplace 090 008776 00000 FRV 7POL 0 5 m Extension connecting cable 092 000201 00004 FRV 7POL 1 m Ext...

Page 47: ...ct 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 ON HS XX1 Mou...

Page 48: ...ve 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 I...

Page 49: ...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 groov...

Page 50: ...x A Searching for a dealer 50 099 005549 EW501 12 11 2018 11 Appendix A 11 1 Searching for a dealer Sales service parteners www ewm group com en specialist dealers More than 400 EWM sales partners wor...

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