EWM Phoenix 351-551 Operating Instructions Manual Download

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Operating instructions

Welding machine

Phoenix 351-551 Progress puls MM FDW

099-005325-EW501

Observe additional system documents!

05.12.2014

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Summary of Contents for Phoenix 351-551

Page 1: ...achine Phoenix 351 551 Progress puls MM FDW 099 005325 EW501 Observe additional system documents 05 12 2014 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warranty www ewm group com ...

Page 2: ...pment 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 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 i...

Page 3: ... of Conformity 17 3 3 3 Welding in environments with increased electrical hazards 17 3 3 4 Service documents spare parts and circuit diagrams 17 3 3 5 Calibration Validation 17 4 Machine description quick overview 18 4 1 Front view 18 4 2 Rear view 20 4 3 Rear view 20 5 Design and function 22 5 1 General 22 5 2 Installation 23 5 3 Machine cooling 23 5 4 Workpiece lead general 23 5 5 Notes on the i...

Page 4: ...during operation 43 6 3 Disposing of equipment 44 6 3 1 Manufacturer s declaration to the end user 44 6 4 Meeting the requirements of RoHS 44 7 Rectifying faults 45 7 1 Checklist for rectifying faults 45 7 2 Error messages power source 46 7 3 Resetting JOBs welding tasks to the factory settings 48 7 3 1 Resetting a single JOB 48 7 3 2 Resetting all JOBs 49 7 4 General operating problems 49 7 4 1 I...

Page 5: ...Contents Notes on the use of these operating instructions 099 005325 EW501 05 12 2014 5 ...

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: ...Wrong Press 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 press Interruption in the menu display other setting options possible Tool not required do not use Tool required use ...

Page 8: ... equipment 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 ...

Page 9: ... 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 power sources Coupling multiple power sources in parallel or in series has to be carried o...

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: ...dard 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 e...

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: ...fting eyes always lift 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 movements Ensure that the load is distributed evenly Use chain hoists and chain slings of the same length only Stay outside the danger zone underneath the machine Observe the regulation...

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: ...lled drop transfer and targeted adapted heat input 3 1 2 1 forceArc puls Effective addition to the forceArc arc perfect for welding final passes in all performance classes and all positions 3 1 2 2 rootArc puls The perfect enhancement for focused heat input for the higher performance range 3 1 3 TIG Liftarc welding TIG welding process with arc ignition by means of workpiece contact 3 1 4 MMA weldi...

Page 16: ...se 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 Progress 351 451 551 351 551 D 351 551 2DV miniDrive drive 200C drive 300C drive 4 drive 4 HS drive 4L drive 4L RE drive 4D drive 4X drive 4X LP ...

Page 17: ...mity is enclosed 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 r...

Page 18: ...Machine description quick overview Front view 18 099 005325 EW501 05 12 2014 4 Machine description quick overview 4 1 Front view Figure 4 1 ...

Page 19: ...in the relevant standard See 8 Technical data chapter The voltage reduction device is only active on VRD machine versions 3 Ready for operation signal light Signal light on when the machine is switched on and ready for operation 4 Main switch machine on off 5 Carrying handle 6 Cooling air inlet 7 Wheels guide castors 8 Coolant tank 9 Coolant tank cap 10 Automatic cut out of coolant pump key button...

Page 20: ...ew 20 099 005325 EW501 05 12 2014 4 2 Rear view NOTE The maximum possible machine configuration is given in the text description If necessary the optional connection may need to be retrofitted See 9 Accessories chapter 4 3 Rear view Figure 4 2 ...

Page 21: ...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 connection cable See ...

Page 22: ...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 23: ...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 24: ...s in the arc flickering Lay the workpiece lead and hose package of power sources without HF igniter MIG MAG for as long and as close as possible in parallel Lay the workpiece lead and hose package of power sources with HF igniter TIG for as long as possible in parallel with a distance of 20 cm to avoid HF sparkover Always keep a distance of at least 20 cm to leads of other power sources to avoid i...

Page 25: ...12 2014 25 NOTE Use an individual welding lead to the workpiece for each welding machine Figure 5 2 NOTE Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Always keep leads as short as possible Lay any excess cable lengths in meanders Figure 5 3 ...

Page 26: ...protection tester Replace coolant as necessary if frost protection is inadequate NOTE The disposal of coolant must be carried out according to official regulations and observing the relevant safety data sheets German waste code number 70104 Coolant must not be disposed of together with household waste Coolant must not be discharged into the sewerage system Recommended cleaning agent water if neces...

Page 27: ...e filter sieve insert close sealing cover again NOTE After the initial filling wait for at least one minute when the machine is switched on so that the hose package is filled with coolant completely and without bubbles With frequent changes of torch and during the initial filling process the cooling unit tank should be topped up as necessary The level of coolant must never fall below the min mark ...

Page 28: ...tions The resulting network has to 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 Figure 5 5 Legend Item Designation Colour code L1 Outer conduc...

Page 29: ...lead should be connected to the welding current socket Observe the information from the electrode manufacturer Figure 5 6 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 30: ...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 31: ...re regulator 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 ...

Page 32: ...3 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 means of re adjusting the cable resistance It is recommended to match the electric cable resistance after replacing accessories such as torches or intermediate hose packages In case a second wire fee...

Page 33: ...chine combinations In case of welding systems with a second power circuit if two wire feeders are to be operated from a single power source for example a second adjustment with parameter rL2 must be performed 3 Adjustment measurement Applying slight pressure put the welding torch in place with the contact tip on a clean purged location on the workpiece and then press the torch trigger for approx 2...

Page 34: ...rrent 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 Figure 5 9 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 Inse...

Page 35: ...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 Figure 5 10 Item Symbol Description 0 1 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and torch trigger integrated 2 Quick connect coupling red coolant ...

Page 36: ...te welding current connection If fitted 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 12 2 Connection for workpiece lead Figure 5 11 Item Symbol Description 0 1 Connection socket welding current TIG welding Workpiece c...

Page 37: ...ated tongs to remove spent stick electrodes or to move welded workpieces and Always put the electrode holder down on an insulated surface 5 13 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 12 Item Symbol Description 0 1 Connection socket welding current 2 Connection socket wel...

Page 38: ... 2014 Insert cable plug 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 socket and lock by turning to the right ...

Page 39: ...ntrols spare parts and replacement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the machine is switched off NOTE The remote controls are operated on the 7 pole remote control connection socket digital Please note the relevant documentation of the accessory components 5 16 Interfaces for automation DANGER Do not carry out an...

Page 40: ...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 100 mA H Output Uist Welding voltage measured against pin F 0 10 V 0 V 0 V 10 V 100 V L Input Str Stp Start 15 V Stop 0 V 1 M Output 15 V Voltage supply max 75 mA N Output 15 V Voltage supply max 25 mA S Output ...

Page 41: ...sert 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 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 th...

Page 42: ... the type designation and item number of the spare part 6 1 General When used in the specified environmental conditions and under normal operating conditions this machine is largely maintenance free and requires a minimum of care There are some points which should be observed to guarantee fault free operation of your welding machine Among these are regular cleaning and checking as described below ...

Page 43: ...nnual test inspection and testing during operation NOTE The welding machine may only be tested by competent capable personsl A capable person is one who because of his training knowledge and experience is able to recognise the dangers that can occur while testing welding power sources as well as possible subsequent damage and who is able to implement the required safety procedures For more informa...

Page 44: ...ided 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 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 h...

Page 45: ...he material and process gas in use is a fundamental requirement for perfect operation Legend Symbol Description Fault Cause Remedy Coolant error no coolant flowing Insufficient coolant flow Check coolant level and refill if necessary Air in the coolant circuit Vent coolant circuit Functional errors Machine control without displaying the signal lights after switching on Phase failure check mains co...

Page 46: ...Spe x Wire feeder speedometer error Check the wire feeder speedometer is not issuing a signal M3 51 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 Separate the connection between the...

Page 47: ... drive Error 56 no Pha x Mains phase failure Check mains voltages Legend 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 RC2 RC1 RC2 Expert CarExpert Progress M3 11 not possible alpha Q Concept Basic Basic S Synergic Synergic S Progress M3 71 Picomig 305 ...

Page 48: ...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 factory settings The RESET will be done after pressing the button The menu will be ended when no changes are done after 3 sec JOB number example The shown JOB will be set to ex works ...

Page 49: ...l 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 emergency stop circuit has been realised using an external interrupt equipment via the interface for automated welding the machine must be configured for this setup If this is not observed the power...

Page 50: ... 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 which is located as deep as possible inside the system close to the coolant tank Figure 7 3 ...

Page 51: ...20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 3 x 25 A Mains connection lead H07RN F4G6 Maximum connected load 10 9 kVA 15 4 kVA 14 3 kVA Recommended generator rating 20 8 kVA cosϕ Efficiency 0 99 88 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine torch cooling Fan water Cooling capacity at 1 l min 1500 W Maximum flow rate 5 l min Maximum coolan...

Page 52: ... A Mains connection lead H07RN F4G6 Maximum connected load 13 5 kVA 18 5 kVA 17 5 kVA Recommended generator rating 25 kVA cosϕ Efficiency 0 99 90 Insulation class protection classification H IP 23 Ambient temperature 25 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 Welding le...

Page 53: ... x 32 A Mains connection lead H07RN F4G6 Maximum connected load 19 3 kVA 25 6 kVA 24 9 kVA Recommended generator rating 34 6 kVA cosϕ efficiency 0 99 90 Insulation class protection classification H IP 23 Ambient temperature 25 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 Wor...

Page 54: ...ains fuse safety fuse slow blow 3 x 32 A Mains connection lead H07RN F4G6 MaximumconnectedloadMIG MAG 21 1 kVA 29 2 kVA Maximum connected load TIG 16 3 kVA 22 6 kVA MaximumconnectedloadMMA 22 0 kVA 29 5 kVA Recommended generator rating 29 7 kVA 39 8 kVA cosϕ Efficiency 0 99 90 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine torch cooling Fan water Coolin...

Page 55: ...er 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 DMDIN TN 200B AR MIX 35L Manometer pressure regulator 094 000009 00000 5POLE CEE 32A M Machine plug 094 000207 00000 HOSE BRIDGE UNI Tube bridge 092 007843 00000 9 3 Options Type Designatio...

Page 56: ...nnecting cable 092 000201 00003 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 FRV 7POL 5 m Extension connecting c...

Page 57: ...Appendix A Overview of EWM branches 099 005325 EW501 05 12 2014 57 10 Appendix A 10 1 Overview of EWM branches ...

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