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Functional characteristics

MIG/MAG welding

24

Item No.: 099-005073-EWM01

5.2

MIG/MAG welding

5.2.1

Definition of MIG/MAG welding tasks

The PHOENIX product range has been designed to be very simple and quick to operate, but still provide
all the functions one could ever need.

For the most common applications, 128 JOBs (welding tasks) have been pre-programmed. The JOB
(welding task) is defined using the four basic welding parameters of welding process, material type, wire
diameter and gas type.

The digital system calculates the process parameters required, such as the welding current, welding
voltage and pulse current according to the operating point specified.

All the user needs to do is select the required job number (material, wire diameter, gas combination)
using the job list (sticker on the casing cover on the wire feed unit) and enter this job number on the
machine control.

There are presets for other welding parameters such as gas pre-flow, free-burning, etc. for numerous
applications, and these can be changed if required.

The parameters and functions described here can also be programmed by PC using the PHOENIX PC
300.NET welding parameter software.

5.2.2

Selecting MIG/MAG welding tasks

5.2.2.1

Basic welding parameters
• Select JOB (welding task) using the JOB list.

On decompact welding systems, the "JOB list" sticker is located on the inside on the wire feed unit
cover; with compact machines it is on the right-hand power source cover.

It is only possible to change the JOB number when no welding current is flowing.

Operating
element

Action Result

Display

1 x

Select JOB number input

comes on

m/min

Set the JOB number

The machine adopts the required setting after
approx. 3 seconds

5.2.2.2

Operating mode

Operating
element

Action Result

Display

X x

Select operating mode
The signal light displays the selection.

No change

5.2.2.3

Welding type

Operating
element

Action Result

Display

X x

Select welding type
The signal light indicates the selection.

Standard

MIG/MAG

welding

Pulse arc MIG/MAG welding

(PULS

series

only)

No change

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Содержание PHOENIX 333 PROGRESS PULS forceArc

Страница 1: ...be read before commissioning Failure to do so may be dangerous Machines may only be operated by personnel who are familiar with the appropriate safety regulations The machines bear the conformity mar...

Страница 2: ...ody future oriented advanced technology at the utmost level of quality Each of our products is carefully checked we guarantee that the material and processing of our products is faultless These operat...

Страница 3: ...ields CE EWM HIGHTEC WELDING GMBH D 56271 M NDERSBACH TYP ART SNR PROJ GEPR FT CONTROL Name of Customer company Adress Post code Place Country Stamp Signature of EWM distibutor Date of purchase Name o...

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

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

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

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

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

Страница 9: ...otective clothing e g gloves Protect eyes and face with protective visor Electric shocks can be fatal Do not touch any live parts in or on the machine The machine may only be connected to correctly ea...

Страница 10: ...Before beginning welding work ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 28: ...ry setting there is an automatic cut out There are optimum pre sets for welding parameters such as gas pre flow and free burn etc for numerous applications although these can also be changed if requir...

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

Страница 30: ...gas pre flows Wire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART for the time tstart Slope to ma...

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

Страница 32: ...es contact with the workpiece welding current is flowing start program PSTART for the time tstart Slope on main program PA Start the super pulse function beginning with main program PA The welding par...

Страница 33: ...ire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Change over to pre selected WF speed main program PA Step 2 Release torch...

Страница 34: ...lectrode makes contact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program...

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

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

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

Страница 38: ...elding current is flowing start program PSTART for the time tstart Step 2 Release torch trigger Slope on main program PA Start the super pulse function beginning with main program PA The welding param...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 74: ...or fixing the wire spool Loosen knurled nut from spool holder Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore Fasten wire spool using knurled nut 6 7 5 Ch...

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

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

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

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

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

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

Страница 81: ...y MAG welding Wire diameter x 11 5 l min MIG brazing Wire diameter x 11 5 l min MIG welding aluminium Wire diameter x 13 5 l min 100 argon TIG Gas nozzle diameter in mm corresponds to l min gas throug...

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

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

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

Страница 85: ...g an order please quote the type designation and item number as well as the type serial number and item number of the relevant equipment We hereby confirm that the servicing and maintenance instructio...

Страница 86: ...eeled bins indicates the requirement to separate this waste Help to protect the environment and ensure that this equipment when you no longer want to use it is disposed of in the relevant system of se...

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

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

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

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

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

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

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

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

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

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

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

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