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Maintenance, care and disposal

General

96

099-005183-EW501

17.12.2010

6

Maintenance, care and disposal

DANGER

Risk of injury from electric shock!
Cleaning machines that are not disconnected from the mains can lead to serious
injuries!
•  Disconnect the machine completely from the mains.
•  Remove the mains plug!
•  Wait for 4 minutes until the capacitors have discharged!

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, depending on the pollution
level of the environment and the length of time the unit is in use.

6.2

Maintenance work, intervals

6.2.1

Daily maintenance tasks

• Mains supply lead and its strain relief

• Welding current cables (check that they are fitted correctly and secured)

• Gas tubes and their switching equipment (solenoid valve)

• Gas cylinder securing elements

• Operating, message, safety and adjustment devices (Functional test)

• Other, general condition

6.2.2

Monthly maintenance tasks

• Casing damage (front, rear and side walls)

• Transport rollers and their securing elements

• Transport elements (strap, lifting lugs, handle)

• Selector switches, command devices, emergency stop devices, voltage reducing devices, message

and control lamps

• Check coolant tubes and their connections for impurities

• Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.

6.2.3

Annual 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 further information, please see the accompanying 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.

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Содержание Phoenix 335 Progress Puls FA KGE

Страница 1: ...ructions Welding machine GB Phoenix 335 Progress Puls FA KGE 099 005183 EW501 17 12 2010 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ewm warranty www...

Страница 2: ...ther 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 whethe...

Страница 3: ...8 4 2 Machine control Operating elements 20 4 2 1 Machine control Concealed operating elements 22 4 2 2 Operating elements in the machine 23 5 Design and function 24 5 1 General 24 5 2 Installation 25...

Страница 4: ...A 64 5 7 16 MIG MAG automatic cut out 64 5 7 17 Standard MIG MAG torch 65 5 7 18 MIG MAG special torches 65 5 7 18 1 Program and Up down operation 65 5 7 19 Remote control 66 5 7 20 R10 R20 R40 66 5 7...

Страница 5: ...Manufacturer s declaration to the end user 97 6 5 Meeting the requirements of RoHS 97 7 Rectifying faults 98 7 1 Error messages power source 99 7 2 Resetting JOBs welding tasks to the factory settings...

Страница 6: ...Contents 6 099 005183 EW501 17 12 2010...

Страница 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...

Страница 8: ...scription Press Do not press Turn Switch 0 1 Switch off machine 0 1 Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display example wait 4s press Inter...

Страница 9: ...s and burns on contact Even low voltages can cause you to get a shock and lead to accidents Do not touch any live parts in or on the machine Connection cables and leads must be free of faults Switchin...

Страница 10: ...ny easily flammable 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 workpie...

Страница 11: ...regular intervals that users are working in a safety conscious way Regular checks of the machine according to IEC 60974 4 Damage due to the use of non genuine parts The manufacturer s warranty becomes...

Страница 12: ...crane or suspended CAUTION Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up Tilt resistance is guaranteed up to an an...

Страница 13: ...s 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...

Страница 14: ...ootArc Stable soft short arc even with long welding leads ideal for simple reliable root welding without pool support easy gap bridging 3 1 3 forceArc Welding with a powerful forced arc deep fusion pe...

Страница 15: ...ted conversion work not specifically authorised by the manufacturer The original copy of the declaration of conformity is enclosed with the unit 3 2 3 Welding in environments with increased electrical...

Страница 16: ...01 17 12 2010 4 Machine description quick overview 4 1 Phoenix 335 Progress puls 4 1 1 Front view NOTE The maximum possible machine configuration is given in the text description If necessary the opti...

Страница 17: ...gue accessory components remote control welding torch control lead etc 12 Connection socket welding current MIG MAG cored wire welding Workpiece connection TIG welding Workpiece connection MMA welding...

Страница 18: ...Machine description quick overview Phoenix 335 Progress puls 18 099 005183 EW501 17 12 2010 4 1 2 Rear view Figure 4 2...

Страница 19: ...voltage supply 4 8 pole connection socket Cooling unit control lead 5 digital 7 pole connection socket digital For connecting digital accessory components documentation interface robot interface or re...

Страница 20: ...trol Operating elements 20 099 005183 EW501 17 12 2010 4 2 Machine control Operating elements sec sec sec sec sec sec DYN sec sec Super puls HOLD AMP VOLT PROG m min DYN S Wire Gas Material JOB LIST M...

Страница 21: ...rmance for selecting the JOB welding task and for setting other welding parameters 5 Select operating mode button Non latched Latched Signal light lights up in green Special non latched Signal light l...

Страница 22: ...e 0 0 s to 20 0 s 0 1 s increments 6 Signal light main program PA Wire speed WF min to WF max Correction of the arc length 9 9 V to 9 9 V 7 DYN Signal light dynamics Setting range 40 to 40 8 sec Signa...

Страница 23: ...nching the Wire Electrode chapter 19 Gas test rinse button Gas test For setting the shielding gas quantity Rinse For rinsing longer tube packages See also Shielding Gas Supply chapter 4 2 2 Operating...

Страница 24: ...units are equipped with moving parts which can trap hands hair clothing or tools and thus injure persons Do not reach into rotating or moving parts or drive components Keep casing covers closed durin...

Страница 25: ...be replaced if faulty or if lost 5 2 Installation WARNING Risk of accident due to improper transport of machines that may not be lifted Do not lift or suspend the machine The machine can fall down and...

Страница 26: ...orking area is adequately ventilated Do not obstruct the air inlets and outlets of the machine Do not allow metal parts dust or other objects to get into the machine 5 4 Workpiece lead general CAUTION...

Страница 27: ...ctions The resulting network has to be suitable for operating devices according to protection class 1 5 5 1 Mains configuration NOTE The machine may be connected to a three phase system with four cond...

Страница 28: ...ling unit 2 1 3 Figure 5 3 Item Symbol Description 0 1 4 pole connection socket Cooling unit voltage supply 2 8 pole connection socket Cooling unit control lead 3 Cooling module Insert and lock the 8...

Страница 29: ...s steel Use a plastic core to weld or braze soft high alloy wire electrodes or aluminium materials Preparation for connecting welding torches with a plastic core Push forward the capillary tube on the...

Страница 30: ...ts polarity selection for MIG MAG welding 5 Standard applications Connection for welding current connection socket welding current connection socket 6 MIG MAG welding Workpiece connection 7 Workpiece...

Страница 31: ...ng torch control lead 5 Connection socket welding current 6 Connection socket welding current 7 Workpiece Insert the central plug for the welding torch into the central connector and screw together wi...

Страница 32: ...2 Inserting the wire spool NOTE Standard D300 pin reels can be used Adapters see accessories are required when using standardised basket coils DIN 8559 2 1 Figure 5 6 Item Symbol Description 0 1 Carr...

Страница 33: ...re 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 Nut rollers with for steel wires and other hard wires use U N...

Страница 34: ...units are equipped with moving parts which can trap hands hair clothing or tools and thus injure persons Do not reach into rotating or moving parts or drive components Keep casing covers closed durin...

Страница 35: ...ng torch CAUTION Extensive wear due to incorrect contact pressure Incorrect contact pressure will cause extensive wear of the wire feed rollers With the adjusting nuts of the pressure units set the co...

Страница 36: ...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...

Страница 37: ...min Figure 5 10 Display Setting selection Dynamics setting 40 Arc harder and narrower 40 Arc softer and wider 5 7 7 5 Superpulses m min Figure 5 11 Display Setting selection Selects super pulses Switc...

Страница 38: ...MIG MAG one dial operation i e the user need only specify the operating point by setting the required wire speed for example and the digital system will calculate the optimum values for welding curre...

Страница 39: ...e or reduce welding performance via the wire speed parameter Display example 10 5 m min 5 7 8 3 Arc length correction setting The arc length can be corrected as follows Operating element Action Result...

Страница 40: ...next parameter LEDs next to the button indicate the selection After the last parameter is reached the system starts again from the beginning HOLD AMP VOLT PROG Figure 5 14 The display shows Nominal v...

Страница 41: ...cross sections are adequate Fully unroll welding current cables torche tube packages and if applicable intermediate tube packages Avoid loops Use welding torches preferably water cooled that are suita...

Страница 42: ...also be changed if required 5 7 12 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 We...

Страница 43: ...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...

Страница 44: ...speed Arc 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 sp...

Страница 45: ...re 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 main pro...

Страница 46: ...es after the 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...

Страница 47: ...tact 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 parameter...

Страница 48: ...ed 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 trigg...

Страница 49: ...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...

Страница 50: ...d 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 wit...

Страница 51: ...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 the main...

Страница 52: ...ing start program PSTART 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 tor...

Страница 53: ...cycle Release torch trigger Slope 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 p...

Страница 54: ...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 parameters c...

Страница 55: ...g point welding 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 AMP Welding curre...

Страница 56: ...lude the parameters wire speed operating point arc length correction slope times program duration etc t I PSTART PA PB PA PEND Figure 5 27 In every JOB separate settings can be made for the ignition p...

Страница 57: ...rom PSTART to PA 0 0s to 20 0s 5 PA Wire speed absolute 0 1 m min to 40 m min 6 Dynamics 40 to 40 7 Duration spot time and superpulse 0 01s to 20 0s 8 PB Wire speed relative Arc length correction rela...

Страница 58: ...t I PA PEND PSTART Figure 5 30 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...

Страница 59: ...ing 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 Meaning explanation Setting range Sett...

Страница 60: ...start Arc length correction 9 9V to 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 th...

Страница 61: ...t software EXPERT machine series Can also be changed using M3 1x see chapter MIG MAG parameter overview M3 1x Non latched latched mode with alternating welding process Non latched latched special with...

Страница 62: ...elding parameters for the main programs using the following components Program changeover Program Operating mode Welding process Superpulse Wire speed Voltage correction Dynamics P0 Yes 1 Yes 2 M3 71...

Страница 63: ...A3 PA3 PA4 PA5 Figure 5 35 Example 3 Aluminium welding of different sheet metal thicknesses non latched or latched special PA0 PA1 PA8 PA9 t I Figure 5 36 NOTE Up to 16 programs PA0 to PA15 can be def...

Страница 64: ...t 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 DYN is on sec sec sec sec sec sec DYN sec sec Super puls m min S...

Страница 65: ...anual for the relevant welding torch The following special torches can be used together with this welding machine UP DOWN welding torch with one rocker for setting the wire speed or to change up to 10...

Страница 66: ...330 x 180 x 95 270 x 150 x 75 Weight in kg 0 86 2 3 1 4 The remote controls are designed specifically for use with welding machines in the Phoenix Progress alpha Q Taurus Synergic S range and offer va...

Страница 67: ...min m min Figure 5 38 NOTE ENTER Enter the menu Switch off machine at the main switch Press and hold the left parameter selection button and switch the machine on again at the same time NAVIGATION Nav...

Страница 68: ...ff Ex works 1 correction operation on Main program PA flashing Program changeover with standard torch 0 no program changeover Ex works 1 special latched 2 specific latched special n cycle active Lat a...

Страница 69: ...works 1 program selection possible 5 7 21 2 Reset to factory settings NOTE All special parameters saved by the user will be overwritten by the factory settings Displays Operating element Action Result...

Страница 70: ...ge 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 depends on the position of t...

Страница 71: ...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 voltage must be...

Страница 72: ...ess button and hold down for approx 4 s Left Current limit value of the wire feed speed correction VOLT PROG 4 s Right Current limit value of the voltage correction m min Set limit value for the wire...

Страница 73: ...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 unit contr...

Страница 74: ...sec can switch to other programs Programs PA1 to PA9 are possible 3rd cycle Press and hold torch trigger Slope to end program PEND from PAN The program can be stopped at any time by pressing the torc...

Страница 75: ...with key switches optional see Key switches chapter must be configured as masters P10 1 The wire feed configured as the master is active after the welding machine is switched on There are no other fun...

Страница 76: ...nfigure special parameter P12 to P12 2 or P12 1 Operating element Action Result Display JOB LIST 1 x Select JOB list m min Select the source JOB Wait for around 3 seconds until the JOB has been transf...

Страница 77: ...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 switch position 0 or...

Страница 78: ...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...

Страница 79: ...ge 3 Central connection for welding torch Euro Integrated welding current shielding gas and torch trigger 4 19 pole connection socket analogue For connecting analogue remote controls Welding current c...

Страница 80: ...torch used insert the torch control lead plug into either the 7 pole connection socket digital or the 19 pole connection socket and lock in place Welding current lead insert polarity selection into t...

Страница 81: ...sing the Wire speed rotary dial Operating element Action Result Displays m min Welding current is set Setpoint setting 5 8 4 TIG arc ignition 5 8 4 1 Liftarc ignition a b c Figure 5 44 The arc is igni...

Страница 82: ...nd functions Symbol 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 Specia...

Страница 83: ...on latched t t I 1 2 PA PEND PSTART Figure 5 46 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 W...

Страница 84: ...ed 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 torch trig...

Страница 85: ...gram 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 Repeated tapping wi...

Страница 86: ...reduced main program Welding current 1 to 100 8 Duration reduced main program 0 01 s to 20 0 s 9 Slope duration from PA to PEND 0 s to 20 s 10 PEND end program Welding current 1 to 100 11 Duration en...

Страница 87: ...selection plug Retainer for the polarity selection plug in MMA mode or for transport 5 Electrode holder Insert cable plug of the electrode holder into either the or welding current connection socket a...

Страница 88: ...Result Display JOB LIST 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 9 3 Welding current setting The welding current i...

Страница 89: ...ks 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 Check the welding current setting and...

Страница 90: ...rs in the holders provided for them and secure with fixing devices Avoid heating the shielding gas cylinder CAUTION Faults in the shielding gas supply An unhindered shielding gas supply from the shiel...

Страница 91: ...n gas hose on pressure reducer to be gas tight 5 10 2 Gas test Slowly open the gas cylinder valve Open the pressure reducer Switch on the power source at the main switch Initiate gas test function on...

Страница 92: ...TIG Gas nozzle diameter in mm corresponds to l min gas throughput Helium rich gas mixtures require a higher gas volume The table below can be used to correct the gas volume calculated where necessary...

Страница 93: ...ce is switched on 5 11 1 Automation interface NOTE These accessory components can be retrofitted as an option see Accessories chapter Pin Input output Description Diagram A Output PE Connection for ca...

Страница 94: ...sing 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 be...

Страница 95: ...witch In key switch position 1 all functions and parameters can be set without restriction In key switch position 0 the following functions and parameters cannot be changed Job switching function weld...

Страница 96: ...ing elements Operating message safety and adjustment devices Functional test Other general condition 6 2 2 Monthly maintenance tasks Casing damage front rear and side walls Transport rollers and their...

Страница 97: ...provisions guideline 2002 96 EG of the European Parliament and the Council of January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be co...

Страница 98: ...ng wire electrodes chapter Check settings and correct if necessary a Worn wire rolls Check and replace if necessary a Wire feed motor without supply voltage automatic cutout triggered by overloading R...

Страница 99: ...olant level Top up the coolant Leak in the coolant circuit rectify the leak and top up the coolant Coolant pump is not working check excess current release on air cooling unit Err 5 x Error WF unit WF...

Страница 100: ...customised welding parameters that are stored will be replaced by the factory settings 7 2 1 Resetting a single JOB JOB LIST JOB LIST m min Figure 7 1 Display Setting selection Reset to factory settin...

Страница 101: ...r 3 sec 7 3 General operating problems 7 3 1 Interface for mechanised welding WARNING No function of the external shut down devices emergency stop switch If the emergency stop circuit has been realise...

Страница 102: ...d 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 16 A Mains connection...

Страница 103: ...ion 090 008087 00000 RA5 19POL 5M Remote control e g connection cable 092 001470 00005 RA10 19POL 10M Remote control e g connection cable 092 001470 00010 RA20 19POL 20M Remote control e g connection...

Страница 104: ...6 2 0 2 4 Drive rollers 37 mm cored wire 092 000836 00000 ROE 2DR4R 2 8 3 2 Drive rollers 37 mm cored wire 092 000837 00000 ROE 2GR4R Counterpressure rollers knurled 37mm 092 000838 00000 9 4 4 Conve...

Страница 105: ...olid Wire 1 34 98 42 106 190 189 188 131 130 129 126 187 127 128 3 35 99 43 107 254 179 4 36 100 44 108 255 180 5 37 101 45 109 256 181 6 8 9 10 CuSi L ten Brazing CuAl L ten Brazing 114 115 116 117 1...

Страница 106: ...Appendix B Overview of EWM branches 106 099 005183 EW501 17 12 2010 11 Appendix B 11 1 Overview of EWM branches...

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