EWM Phoenix 401 Progress puls MM FKW Operating Instructions Manual Download Page 1

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Operating instructions

Welding machine

Phoenix 401 Progress puls MM FKW
Phoenix 501 Progress puls MM FKW

099-005323-EW501

21.05.2014

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Summary of Contents for Phoenix 401 Progress puls MM FKW

Page 1: ...g machine Phoenix 401 Progress puls MM FKW Phoenix 501 Progress puls MM FKW 099 005323 EW501 21 05 2014 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for e...

Page 2: ...ment No other form of liability regardless of type shall be accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monit...

Page 3: ...ice documents spare parts and circuit diagrams 17 3 2 5 Calibration Validation 17 4 Machine description quick overview 18 4 1 Front view 18 4 2 Rear view 20 4 3 Inside view 22 4 4 Machine control Oper...

Page 4: ...e tack welding non latched 67 5 8 11 4 Example aluminium tack welding non latched special 67 5 8 11 5 Example aluminium welding latched special 68 5 8 11 6 Example visible seams latched super pulse 69...

Page 5: ...on 108 6 3 Maintenance work 108 6 4 Disposing of equipment 109 6 4 1 Manufacturer s declaration to the end user 109 6 5 Meeting the requirements of RoHS 109 7 Rectifying faults 110 7 1 Checklist for r...

Page 6: ...Contents Notes on the use of these operating instructions 6 099 005323 EW501 21 05 2014...

Page 7: ...l 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...

Page 8: ...ess Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exit the menu 4 s Time display example wait 4s...

Page 9: ...pment 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 av...

Page 10: ...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 all...

Page 11: ...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 sec...

Page 12: ...he 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...

Page 13: ...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 equipme...

Page 14: ...ft all lifting eyes simultaneously When using retrofitted craning frames etc always use at least two lifting points positioned as far apart as possible observe option description Avoid any jerky movem...

Page 15: ...ties 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 ambie...

Page 16: ...modelling capabilities for effortless gap bridging and positional welding 3 1 2 MIG MAG pulse welding Welding process for optimum welding results when joining stainless steel and aluminium thanks to c...

Page 17: ...d with the unit 3 2 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 hazar...

Page 18: ...05323 EW501 21 05 2014 4 Machine description quick overview 4 1 Front view NOTE The maximum possible machine configuration is given in the text description If necessary the optional connection may nee...

Page 19: ...o central connection torch MIG MAG cored wire welding Workpiece connection TIG welding Workpiece connection MMA welding Workpiece or electrode holder connection 14 Welding current cable polarity selec...

Page 20: ...Machine description quick overview Rear view 20 099 005323 EW501 21 05 2014 4 2 Rear view Figure 4 2...

Page 21: ...on the inside 4 Wire spool inspection window Check wire supply 5 Cooling air outlet 6 Bracket for shielding gas cylinder 7 Wheels fixed castors 8 PC interface serial D Sub connection socket 9 pole 9...

Page 22: ...Machine description quick overview Inside view 22 099 005323 EW501 21 05 2014 4 3 Inside view Figure 4 3...

Page 23: ...ew 099 005323 EW501 21 05 2014 23 Item Symbol Description 0 1 Welding torch function changeover switch special welding torch required Changing over programs or JOBs Infinite adjustment of welding perf...

Page 24: ...peed hold values 4 Push button parameter selection left power saving mode AMP Welding current Material thickness Wire feed speed Hold After welding the values used last are shown from the main program...

Page 25: ...c length correction selection of welding program rotary dial Correction of the arc length from 9 9 V to 9 9 V Selection of welding programs 0 to 15 not possible if accessory components such as program...

Page 26: ...max Correction of the arc length 9 9 V to 9 9 V 7 Signal light duration of main program PA Setting range 0 1 s to 20 0 s 0 1 s increments Used e g in connection with the super pulse function 8 Signal...

Page 27: ...ction 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 di...

Page 28: ...e 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 li...

Page 29: ...or KF 23E must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components The coolant must be checked for adequate frost protect...

Page 30: ...up as necessary Figure 5 1 Item Symbol Description 0 1 Coolant tank cap 2 Coolant filter sieve 3 Coolant tank 4 Min mark Minimum coolant level Unscrew and remove the coolant tank sealing cover Check f...

Page 31: ...etwork has to be suitable for operating devices according to protection class 1 5 6 1 Mains configuration NOTE The machine may be connected to a three phase system with four conductors and an earthed...

Page 32: ...ielding gas supply An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results In addition a blocked shielding gas...

Page 33: ...package Shielding gas flows continuously until the Gas Test button is pressed again 5 7 3 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diamete...

Page 34: ...hard high alloy wire electrodes CrNi Use a plastic core to weld or braze soft wire electrodes high alloy wire electrodes or aluminium materials Preparation for connecting welding torches with a plasti...

Page 35: ...e For connecting analogue accessory components remote control welding torch control lead etc 6 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and torch trigger in...

Page 36: ...k Welding current lead insert polarity selection into the welding current connection socket and lock Insert the welding torch control cable into the 19 pole connection socket and lock MIG MAG torches...

Page 37: ...analogue For connecting analogue accessory components remote control welding torch control lead etc 6 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and torch tr...

Page 38: ...o the welding current connection socket and lock Insert the welding torch control cable into the 19 pole connection socket and lock MIG MAG torches with additional control cables only Lock connecting...

Page 39: ...y come loose from the wire spool holder and fall to the ground causing damage to the machine and injuries Securely fasten the wire spool to the wire spool holder using the knurled nut Before you start...

Page 40: ...and the material Check the roller label to verify that the rollers are suitable for the wire diameter Turn or change if necessary use V groove rollers with for steel wires and other hard wires use U...

Page 41: ...tervals Keep all casing covers or protective caps closed during operation Risk of injury due to welding wire escaping from the welding torch The welding wire can escape from the welding torch at high...

Page 42: ...pwards 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 p...

Page 43: ...Description 0 1 Allen screw Securing the wire spool retainer and adjustment of the spool brake Tighten the Allen screw 8 mm in the clockwise direction to increase the braking effect NOTE Tighten the s...

Page 44: ...300 NET welding parameter software 5 8 4 Welding task selection 5 8 4 1 Basic welding parameters Select JOB welding task with JOB list The JOB list sticker can be found on the inside of the protective...

Page 45: ...welds without weaving superPuls in combination with EWM welding processes offers many possibilities Welding performance can be represented as average value ex works or solely as program A value If th...

Page 46: ...Display Setting selection menu burn back Set burn back Parameter setting setting range 0 to 499 Back burn set too high large drops developing on the wire electrode result in poor ignition properties...

Page 47: ...current material thickness or wire speed Operating element Action Result n x Switching the display between Welding current Material thickness Wire speed Application example Aluminium is to be welded M...

Page 48: ...e operating instructions for the machine in question for a more detailed description of the individual machines and their functions 5 8 6 MIG MAG welding data display To the left and right of the cont...

Page 49: ...99 251 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 ma...

Page 50: ...ormation and secure sidewall fusion Un alloyed and low alloy steels Manual and automated applications rootArc welding up to Wire mm 0 6 0 8 0 9 1 1 2 1 6 Material Gas JOB JOB JOB JOB JOB JOB Steel CO2...

Page 51: ...also be changed if required 5 8 9 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 Wel...

Page 52: ...g 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 S...

Page 53: ...c 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 the specified t...

Page 54: ...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 main program PA Step...

Page 55: ...wire electrode 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...

Page 56: ...orkpiece 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 parameters change at the...

Page 57: ...runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Change over to pre selected WF speed main program PA Step 2 Release torch trigger no ef...

Page 58: ...ntact 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 reduce...

Page 59: ...arting 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 60: ...me 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 the main program PA Step...

Page 61: ...2nd cycle Release torch trigger Slope on main program PA The 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 Ta...

Page 62: ...ope on main program PA Start the process alternation starting with process PA The welding processes alternate between the process PA stored in the JOB and the opposite process PB at the specified time...

Page 63: ...g 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 parameters change at the spec...

Page 64: ...elding output The operating point welding performance is set using the wire feed speed and the welding voltage Operating element Action Result n x Switch the display between Welding current display of...

Page 65: ...geted heat reduction The programs include the parameters wire speed operating point arc length correction slope times program duration etc Figure 5 29 In every JOB separate settings can be made for th...

Page 66: ...pre flow time 0 0s to 20 0s 2 2 PSTART Wire speed relative Arc length correction 1 to 200 9 9V to 9 9V 3 3 Duration 0 0s to 20 0s 4 4 Slope duration from PSTART to PA 0 0s to 20 0s 5 5 PA Wire speed...

Page 67: ...ecial Figure 5 32 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 5...

Page 68: ...tion 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 Meaning explanation Setting range Setting the wir...

Page 69: ...tion 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 Sl...

Page 70: ...mponents Program switching JOB switching Program Operating mode Welding process superPuls Wire speed Voltage correction Dynamics M3 7x Wire feeder control Yes Yes P0 Yes Yes Yes P1 15 Yes R20 Remote c...

Page 71: ...ure 5 36 Example 3 Aluminium welding of different sheet metal thicknesses non latched or latched special Figure 5 37 NOTE Up to 16 programs PA0 to PA15 can be defined An operating point wire speed arc...

Page 72: ...m 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 Dyn...

Page 73: ...ion before starting welding see chapter entitled Selecting programs with the standard torch trigger P17 Change over between pulse and standard welding in the special latched operating mode Switching b...

Page 74: ...nterference Appoint only skilled persons for repair work trained service personnel CAUTION Test Before re commissioning it is essential that an inspection and test during operation is carried out conf...

Page 75: ...setting 5 8 16 1 Selection NOTE ENTER Enter the menu Keep the welding parameters push button pressed for 3 s NAVIGATION Navigate the menu Select parameters by pressing the welding parameters push butt...

Page 76: ...ecial latched you can switch to the next program by tapping the torch trigger in the main program see the special parameters description 1 No JOB dependent program limit 2 9 JOB dependent program limi...

Page 77: ...ty selection TIG Connection socket for welding current 7 Quick connect coupling red coolant return 8 Quick connect coupling blue coolant supply Insert the central plug for the welding torch into the c...

Page 78: ...s set Setpoint setting 5 9 4 TIG arc ignition 5 9 4 1 Liftarc ignition Figure 5 41 The arc is ignited on contact with the workpiece a Carefully place the torch gas nozzle and tungsten electrode tip on...

Page 79: ...ymbol 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...

Page 80: ...cial non latched Figure 5 43 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 wi...

Page 81: ...ting 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 torch trigger no e...

Page 82: ...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 Repeated tapping will switch back t...

Page 83: ...0 s to 20 s 5 PA main program Welding current absolute 5 A to 550 A 6 Duration PA 0 01 s to 20 0 s 7 PB reduced main program Welding current 1 to 100 8 Duration reduced main program 0 01 s to 20 0 s...

Page 84: ...d surface 5 10 1 Connecting the electrode holder and workpiece lead Figure 5 47 Item Symbol Description 0 1 Workpiece 2 Electrode holder 3 Connection socket welding current 4 Connection socket welding...

Page 85: ...e machine adopts the required setting after approx 3 seconds 5 10 3 Welding current setting The welding current is normally set using the Wire speed rotary dial Operating element Action Result Display...

Page 86: ...e from annealing If the electrode sticks in spite of the Arcforce device the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating...

Page 87: ...l Please note the relevant documentation of the accessory components 5 12 Interfaces for automation DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment dama...

Page 88: ...ion jumper 1 must be unplugged on PCB M320 1 in the welding machine Contact open welding current off F Output 0 V Reference potential G P Output I 0 Power relay contact galvanically isolated max 15 V...

Page 89: ...ification 0 V 10 V wire feed speed E Output Reference potential 0 V F S Input Welding power start stop S1 G Input Control voltage specification 0 V 10 V arc length correction P Input Activation of con...

Page 90: ...e of products Only insert and lock accessory components into the relevant connection socket when the machine is switched off Equipment damage or faults may occur if the PC is connected incorrectly Not...

Page 91: ...settings Special parameters P1 to Pn are applied for customer specific configuration of machine functions This allows the user maximum flexibility in optimising their requirements These settings are...

Page 92: ...014 5 15 1 Selecting changing and saving parameters ENTER EXIT NAVIGATION l 0 AMP Hold Prog VOLT kW Figure 5 52 Display Setting selection Ramp time for wire inching 0 normal inching 10s ramp time 1 fa...

Page 93: ...le active Lat and sp lat tapping start 0 no latched tapping start Ex works 1 latched tapping start possible One or two wire feed operation 0 single operation Ex works 1 dual operation this unit is the...

Page 94: ...am PA ex factory Predefined absolute value for relative programs Start program PSTART down slope program PB and end program PEND can be set relative to the main program PA or in an absolute manner as...

Page 95: ...pulse Up down operation Change up down setting and up down symbol Program limit P4 Program selection can be limited with the special parameter P4 The setting is adopted for all JOBs Program selection...

Page 96: ...m can only be carried out with these values To allow the welder also to perform wire and voltage correction in program mode the correction mode must be switched on and limit values for wire and voltag...

Page 97: ...gram number 4 s Press button and hold down for approx 4 s Left Current limit value of the wire feed speed correction Right Current limit value of the voltage correction Set limit value for the wire fe...

Page 98: ...time has elapsed The program then switches automatically to absolute program 4 Accessory components such as remote controls or special torches may not be connected Program switching at the wire feed...

Page 99: ...latest when the torch trigger is released Tapping pressing briefly and releasing within 0 3 sec can switch to other programs Programs PA1 to PA9 are possible 3rd cycle Press and hold torch trigger Slo...

Page 100: ...witches optional see Protecting welding parameters from unauthorised access chapter must be configured as masters P10 1 The wire feed configured as the master is active after the welding machine is sw...

Page 101: ...ge is between 129 169 First configure special parameter P12 to P12 2 or P12 1 Operating element Action Result Display 1 x Select JOB list Select the source JOB Wait for around 3 seconds until the JOB...

Page 102: ...his JOB allows you to set the welding parameters manually Selection of JOB 0 can be prevented via the key switch or with the block program 0 parameter P2 See List of special parameters chapter Key swi...

Page 103: ...program PA ex factory Function inactive P20 0 Predefined execution of the pulsed arc welding process in the PA program is disabled Predefined absolute value for relative programs P21 Start program PST...

Page 104: ...sistance for the first welding circuit 0 m 60 m 8 m ex works Lead resistance 2 Lead resistance for the second welding circuit 0 m 60 m 8 m ex works Only qualified service personnel may change the para...

Page 105: ...m water cooled welding torch With other hose package lengths it is necessary to carry out a voltage correction to optimise welding properties The voltage correction value can be set close to zero by m...

Page 106: ...d area of the workpiece and push the torch trigger for approx 2 s A short circuit current temporarily flows which is used to determine and display the new cable resistance The value can be between 0 m...

Page 107: ...be observed to guarantee fault free operation of your welding machine Among these are regular cleaning and checking as described below depending on the pollution level of the environment and the leng...

Page 108: ...lding power sources as well as possible subsequent damage and who is able to implement the required safety procedures For further information please see the accompanying supplementary sheets Machine a...

Page 109: ...ded for this purpose According to German law law governing the distribution taking back and environmentally correct disposal of electric and electronic equipment ElektroG from 16 03 2005 used machines...

Page 110: ...ol 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...

Page 111: ...ire 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 shi...

Page 112: ...gend for categories error reset a The error message will disappear once the error has been rectified b The error message can be reset by pressing a key button Welding machine control Key button RC1 RC...

Page 113: ...ngle JOB NOTE All customised welding parameters that are stored will be replaced by the factory settings EXIT RESET ENTER 3 s 3 s 3 s JOB LIST JOB LIST Figure 7 1 Display Setting selection Reset to fa...

Page 114: ...be ended when no changes are done after 3 sec 7 4 General operating problems 7 4 1 Interface for automated welding WARNING No function of the external interrupt equipment emergency stop switch If the...

Page 115: ...circuit NOTE 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 whic...

Page 116: ...ection lead H07RN F4G6 Maximum connected load MIG MAG 17 5 kVA TIG 13 1 kVA MMA 18 5 kVA Recommended generator rating 25 0 kVA cos 0 99 Insulation class protection classification H IP 23 Ambient tempe...

Page 117: ...x connected load 19 3 kVA 24 9 kVA 25 6 kVA Recommended generator rating 34 6 kVA Cos 0 99 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine torch cooling Fan...

Page 118: ...088 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 5 m Extension...

Page 119: ...002116 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 9 4 Computer communication Type Designation Item no...

Page 120: ...092 000841 00000 FE 2DR4R 1 0 1 2 Drive rollers 37 mm steel 092 000842 00000 FE 2DR4R 1 2 1 6 Drive rollers 37 mm steel 092 000843 00000 FE AL 2GR4R Pressure rollers smooth 37mm 092 000844 00000 10 1...

Page 121: ...m 092 000846 00000 URUE AL 4ZR4R 1 2 1 6 Conversion kit 37mm 4 roller drive for aluminium 092 000847 00000 URUE AL 4ZR4R 2 4 3 2 Conversion kit 37mm 4 roller drive for aluminium 092 000868 00000 URUE...

Page 122: ...Appendix A JOB List 122 099 005323 EW501 21 05 2014 11 Appendix A 11 1 JOB List Figure 11 1...

Page 123: ...Appendix B Overview of EWM branches 099 005323 EW501 21 05 2014 123 12 Appendix B 12 1 Overview of EWM branches...

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