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Contents

Notes on the use of these operating instructions

099-005320-EW501

22.05.2014

Contents

Contents .................................................................................................................................................. 3

Safety instructions ................................................................................................................................. 5

2.1

Notes on the use of these operating instructions .......................................................................... 5

2.2

Explanation of icons ....................................................................................................................... 6

2.3

General .......................................................................................................................................... 7

2.4

Transport and installation ............................................................................................................ 11

2.4.1

Ambient conditions ....................................................................................................... 12

2.4.1.1

In operation ................................................................................................... 12

2.4.1.2

Transport and storage ................................................................................... 12

Intended use ......................................................................................................................................... 13

3.1

Applications .................................................................................................................................. 13

3.1.1

MIG/MAG standard welding ......................................................................................... 13

3.1.1.1

forceArc ......................................................................................................... 13

3.1.1.2

rootArc ........................................................................................................... 13

3.1.2

MIG/MAG pulse welding ............................................................................................... 13

3.1.2.1

forceArc puls ................................................................................................. 13

3.1.2.2

rootArc puls ................................................................................................... 13

3.1.3

TIG (Liftarc) welding ..................................................................................................... 13

3.1.4

MMA welding ................................................................................................................ 13

3.1.4.1

Air arc gouging .............................................................................................. 13

3.2

Use and operation solely with the following machines ................................................................ 14

3.3

Documents which also apply ....................................................................................................... 15

3.3.1

Warranty ....................................................................................................................... 15

3.3.2

Declaration of Conformity ............................................................................................. 15

3.3.3

Welding in environments with increased electrical hazards ......................................... 15

3.3.4

Service documents (spare parts and circuit diagrams) ................................................ 15

3.3.5

Calibration/Validation ................................................................................................... 15

Machine description

– quick overview .............................................................................................. 16

4.1

Front view .................................................................................................................................... 16

4.2

Rear view ..................................................................................................................................... 18

Design and function ............................................................................................................................. 20

5.1

General ........................................................................................................................................ 20

5.2

Installation .................................................................................................................................... 21

5.3

Machine cooling ........................................................................................................................... 21

5.4

Workpiece lead, general .............................................................................................................. 21

5.5

Notes on the installation of welding current leads ....................................................................... 22

5.6

Welding torch cooling system ...................................................................................................... 24

5.6.1

Cooling module connection .......................................................................................... 24

5.7

Mains connection ......................................................................................................................... 25

5.7.1

Mains configuration ...................................................................................................... 25

5.8

Connecting the intermediate hose package to the power source ............................................... 26

5.8.1

Intermediate hose package strain relief ....................................................................... 26

5.8.2

Intermediate hose package connection ....................................................................... 27

5.9

Shielding gas supply (shielding gas cylinder for welding machine) ............................................. 28

5.10

Matching the cable resistance ..................................................................................................... 29

5.11

MIG/MAG welding ........................................................................................................................ 31

5.11.1

Connection for workpiece lead ..................................................................................... 31

5.12

TIG welding .................................................................................................................................. 32

5.12.1

Welding torch connection ............................................................................................. 32

5.12.2

Connection for workpiece lead ..................................................................................... 32

5.13

MMA welding ............................................................................................................................... 33

5.13.1

Connecting the electrode holder and workpiece lead .................................................. 33

5.14

Welding torch holder .................................................................................................................... 34

5.15

Remote control ............................................................................................................................. 35

5.16

Interfaces ..................................................................................................................................... 35

5.16.1

Automation interface .................................................................................................... 36

Содержание Phoenix 355 Progress puls MM TDM

Страница 1: ...MM TDM Phoenix 405 Progress puls MM TDM Phoenix 505 Progress puls MM TDM 099 005320 EW501 Observe additional system documents 22 05 2014 Register now For your benefit Jetzt Registrieren und Profitier...

Страница 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...

Страница 3: ...ts spare parts and circuit diagrams 15 3 3 5 Calibration Validation 15 4 Machine description quick overview 16 4 1 Front view 16 4 2 Rear view 18 5 Design and function 20 5 1 General 20 5 2 Installati...

Страница 4: ...Manufacturer s declaration to the end user 40 6 5 Meeting the requirements of RoHS 40 7 Rectifying faults 41 7 1 Checklist for rectifying faults 41 7 2 Error messages power source 42 7 3 Resetting JOB...

Страница 5: ...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 6: ...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...

Страница 7: ...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 8: ...accidents if these safety instructions are not observed Non observance of these safety instructions is potentially fatal Carefully read the safety information in this manual Observe the accident preve...

Страница 9: ...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...

Страница 10: ...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...

Страница 11: ...itable for transport by hand only The machine may not be lifted by crane or suspended CAUTION Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself d...

Страница 12: ...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...

Страница 13: ...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...

Страница 14: ...owing machines NOTE A suitable wire feed unit system component is required in order to operate the welding machine Wire feed unit Phoenix Progress drive 4 WE Phoenix Progress drive 4L WE Phoenix Progr...

Страница 15: ...d 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 hazar...

Страница 16: ...05320 EW501 22 05 2014 4 Machine description quick overview NOTE The maximum possible machine configuration is given in the text description If necessary the optional connection may need to be retrofi...

Страница 17: ...ine is switched on and ready for operation 3 Main switch machine on off 4 Cooling air inlet 5 Machine feet 6 Connection socket welding current MIG MAG cored wire welding Workpiece connection TIG weldi...

Страница 18: ...Machine description quick overview Rear view 18 099 005320 EW501 22 05 2014 4 2 Rear view Figure 4 2...

Страница 19: ...ing current Standard MIG MAG welding intermediate hose package 5 Connection socket welding current Connection for welding current plug from intermediate hose package MIG MAG flux cored wire welding TI...

Страница 20: ...act with non insulated connection sockets or connectors Always place torches and electrode holders on an insulated surface Risk of burns on the welding current connection If the welding current connec...

Страница 21: ...TION 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 an...

Страница 22: ...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 p...

Страница 23: ...5 2014 23 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 loop...

Страница 24: ...structions for the cooling unit Figure 5 4 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...

Страница 25: ...etwork 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...

Страница 26: ...tube package may be damaged if the strain relief is missing or incorrectly fitted The strain relief takes the strain from cables plugs and sockets Check the strain relief function by pulling in all d...

Страница 27: ...feed unit 2 Intermediate hose package 3 7 pole connection socket digital Wire feed unit connection 4 Connection socket welding current Standard MIG MAG welding intermediate hose package 5 Connection...

Страница 28: ...lding 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 su...

Страница 29: ...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...

Страница 30: ...hine combinations A second matching with the rL2 parameter has to be carried out if a second circuit is used on a welding system e g two wire feeders on one power source 3 Matching Measuring Carefully...

Страница 31: ...rent 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 10...

Страница 32: ...ed to the wire feeder Observe the operating instructions for the wire feeder system component 5 12 2 Connection for workpiece lead Figure 5 11 Item Symbol Description 0 1 Workpiece 2 Connection socket...

Страница 33: ...d surface 5 13 1 Connecting the electrode holder and workpiece lead Figure 5 12 Item Symbol Description 0 1 Workpiece 2 Electrode holder 3 Connection socket welding current 4 Connection socket welding...

Страница 34: ...is part of the machine s scope of delivery Figure 5 13 Item Symbol Description 0 1 Crossmember of the transport handle 2 Torch holder 3 Fan type lock washers 4 Fixing screws x 4 Use the mounting scre...

Страница 35: ...ntation of the accessory components 5 16 Interfaces DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repaired or modified by...

Страница 36: ...er 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...

Страница 37: ...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...

Страница 38: ...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...

Страница 39: ...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...

Страница 40: ...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...

Страница 41: ...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...

Страница 42: ...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...

Страница 43: ...end 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...

Страница 44: ...gle 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 fac...

Страница 45: ...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...

Страница 46: ...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...

Страница 47: ...0 300 A Load 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 20 A Mains...

Страница 48: ...ircuit 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 32 A Mains connection lead H07RN F4G4 Max connected load 13 1 kVA 17 2 kVA 18 2...

Страница 49: ...ion 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 32 A Mains connection lead H07R...

Страница 50: ...00502 9 2 Options Type Designation Item no ON Filter 355 405 505 50 Contamination filter for air inlet 092 002698 00000 ON AIF MOD 505 Automation interface 092 007891 00000 ON FC CS 405 505 Pedestal f...

Страница 51: ...ble 092 000201 00001 FRV 7POL 25M Extension connecting cable 092 000201 00007 9 6 General accessories Type Designation Item no 5POLE CEE 32A M Machine plug 094 000207 00000 DM AR MIX 35L MIN Manometer...

Страница 52: ...Appendix A Overview of EWM branches 52 099 005320 EW501 22 05 2014 10 Appendix A 10 1 Overview of EWM branches...

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