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Design and function

Notes on the installation of welding current leads

099-005504-EW501

20.11.2015

5.5

Notes on the installation of welding current leads

Incorrectly installed welding current leads can cause faults 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 interferences

Always keep leads as short as possible! For optimum welding results max. 30 m (welding lead +
intermediate hose p torch lead).

Figure 5-1

Содержание Phoenix 401 Progress puls LP MM FKW

Страница 1: ...lding machine Phoenix 401 Progress puls LP MM FKW Phoenix 501 Progress puls LP MM FKW 099 005504 EW501 20 11 2015 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For deta...

Страница 2: ...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 m...

Страница 3: ...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 Operating elements...

Страница 4: ...Up down operation 62 5 10 14 2Switching between Push Pull and intermediate drive 62 5 11 TIG welding 63 5 11 1 Welding torch and workpiece line connection 63 5 11 2 Welding task selection 64 5 11 2 1...

Страница 5: ...elding tasks to the factory settings 96 7 3 1 Resetting a single JOB 96 7 3 2 Resetting all JOBs 97 7 4 General operating problems 97 7 4 1 Interface for automated welding 97 7 5 Vent coolant circuit...

Страница 6: ...Contents Notes on the use of these operating instructions 6 099 005504 EW501 20 11 2015...

Страница 7: ...e hazard is also highlighted using a symbol in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information i...

Страница 8: ...sers must observe Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu 4 s...

Страница 9: ...t 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...

Страница 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...

Страница 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...

Страница 12: ...ard 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 foll...

Страница 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...

Страница 14: ...ting 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 Av...

Страница 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...

Страница 16: ...welding Welding process for optimum welding results when joining unalloyed low allow and high alloy steels and aluminium thanks to controlled droplet transfer and targeted adapted heat input 3 1 2 1 f...

Страница 17: ...is enclosed 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 elect...

Страница 18: ...ick overview 4 1 Front view Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling Figure 4 1 Item Symbol Description 0 1 Lifting lug 2 Rea...

Страница 19: ...Workpiece connection MMA welding Workpiece or electrode holder connection 14 Welding current cable polarity selection Welding current to Euro torch connector torch for polarity selection MIG MAG Conne...

Страница 20: ...Machine description quick overview Rear view 20 099 005504 EW501 20 11 2015 4 2 Rear view Figure 4 2...

Страница 21: ...tion 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 Connecting nipple G shielding gas...

Страница 22: ...Machine description quick overview Inside view 22 099 005504 EW501 20 11 2015 4 3 Inside view Figure 4 3...

Страница 23: ...ew 099 005504 EW501 20 11 2015 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...

Страница 24: ...The list can be found inside the protective cap of the wire feed mechanism and in the appendix to these operating instructions 2 Display left Welding current material thickness wire speed hold values...

Страница 25: ...arc dynamics Arc is harder and more narrow Arc is softer and wider 9 Arc length correction selection of welding program rotary dial Correction of the arc length from 9 9 V to 9 9 V Selection of weldi...

Страница 26: ...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...

Страница 27: ...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...

Страница 28: ...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 parall...

Страница 29: ...20 11 2015 29 Use an individual welding lead to the workpiece for each welding machine Figure 5 2 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Alw...

Страница 30: ...protection tester Replace coolant as necessary if frost protection is inadequate The disposal of coolant must be carried out according to official regulations and observing the relevant safety data s...

Страница 31: ...the filter sieve insert close sealing cover again 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...

Страница 32: ...uctions The resulting network has to be suitable for operating devices according to protection class 1 5 7 1 Mains configuration The machine may be connected to a three phase system with four conducto...

Страница 33: ...shielding 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 g...

Страница 34: ...package Shielding gas flows continuously until the Gas Test button is pressed again 5 8 2 1 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diam...

Страница 35: ...t parameter LEDs next to the button indicate the selection After the last parameter is reached the system starts again from the beginning Figure 5 7 The display shows Nominal values before welding Act...

Страница 36: ...llary tube Depending on the wire electrode diameter or type either a steel liner or liner with the correct inner diameter must be inserted in the torch Recommendation Use a steel liner when welding ha...

Страница 37: ...connection socket MIG MAG welding Workpiece connection 3 Welding torch 4 Welding torch hose package 5 19 pole connection socket analogue For connecting analogue accessory components remote control wel...

Страница 38: ...g 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 with add...

Страница 39: ...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...

Страница 40: ...ixing the clamping unit and setting the pressure 4 Clamping unit 5 Wire feed roller see the Wire feed roller overview table Rotate the tommy by 90 clockwise or anti clockwise tommy locks into place Fo...

Страница 41: ...code Groove form mm inch Steel Stainless steel Brazing 0 6 023 monochrome light pink V groove 0 8 030 white 0 9 1 0 035 040 blue 1 2 045 red 1 4 052 green 1 6 060 black 2 0 080 grey 2 4 095 brown 2 8...

Страница 42: ...intervals 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 hi...

Страница 43: ...elding torch outlet A prerequisite for the automatic inching process is the correct preparation of the wire guide especially in the capillary and wire guide tube area The contact pressure has to be ad...

Страница 44: ...ol 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 Tighten the spo...

Страница 45: ...eeder control The special JOBs are selected by pressing the welding task selection push button for a longer period The special JOBs are switched by pressing the push button briefly 5 10 4 Welding task...

Страница 46: ...d function MIG MAG welding 46 099 005504 EW501 20 11 2015 5 10 4 3 Choke effect dynamics EXIT ENTER 3 s Figure 5 14 Display Setting selection Dynamics setting 40 Arc harder and narrower 40 Arc softer...

Страница 47: ...rrent 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 Mat...

Страница 48: ...ents for operating point setting The operating point can also be set with various accessory components such as remote controls special torches PC software robot and industrial bus interfaces optional...

Страница 49: ...i Ar 91 99 251 12 0 252 12 0 253 6 0 You can make use of these properties after selecting the forceArc process See 5 10 4 Welding task selection chapter As with pulse arc welding it is important to ma...

Страница 50: ...t formation 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...

Страница 51: ...ng Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I Welding output Wire electrode is being conveyed Wire creep Wire burn back Gas pre flows...

Страница 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...

Страница 53: ...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...

Страница 54: ...e 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 Wi...

Страница 55: ...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...

Страница 56: ...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 program PA St...

Страница 57: ...ith the following programs Start program PSTART reduction of cool points at the start of the seam Main program PA continuous welding Reduced main program PB targeted heat reduction End program PEND mi...

Страница 58: ...welding 58 099 005504 EW501 20 11 2015 5 10 10 1Example tack welding non latched Figure 5 24 5 10 10 2Example aluminium tack welding non latched special Figure 5 25 5 10 10 3Example aluminium welding...

Страница 59: ...ents Program switching JOB switching Program Operating mode Welding process Wire speed Voltage correction Dynamics M3 7x Wire feeder control Yes Yes P0 Yes Yes Yes P1 15 Yes R20 Remote control Yes No...

Страница 60: ...igure 5 28 Example 3 Aluminium welding of different sheet metal thicknesses non latched or latched special Figure 5 29 Up to 16 programs PA0 to PA15 can be defined An operating point wire speed arc le...

Страница 61: ...m number Display example Program 1 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 Dynamic program sequence parameter S...

Страница 62: ...torch function changeover switch special welding torch required Changing over programs or JOBs Infinite adjustment of welding performance 5 10 14 2Switching between Push Pull and intermediate drive DA...

Страница 63: ...ity 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...

Страница 64: ...is set Setpoint setting 5 11 3 TIG arc ignition 5 11 3 1 Liftarc ignition Figure 5 32 The arc is ignited on contact with the workpiece a Carefully place the torch gas nozzle and tungsten electrode tip...

Страница 65: ...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 Special non latched...

Страница 66: ...cial non latched Figure 5 34 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...

Страница 67: ...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...

Страница 68: ...n 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...

Страница 69: ...ated surface 5 12 1 Connecting the electrode holder and workpiece lead Figure 5 37 Item Symbol Description 0 1 Workpiece 2 Electrode holder 3 Connection socket welding current 4 Connection socket weld...

Страница 70: ...ing element Action Result Display Select arcforcing welding parameter LED for the button is on Arcforcing setting for electrode types Setting range 40 to 40 Negative values Rutile Values around zero B...

Страница 71: ...lease note the relevant documentation of the accessory components 5 14 Interfaces for automation DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage...

Страница 72: ...n 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 10...

Страница 73: ...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...

Страница 74: ...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 using the SECINT X...

Страница 75: ...5 17 Special parameters advanced settings Special parameters P1 to Pn are applied for customer specific configuration of machine functions This allows the user maximum flexibility in optimising their...

Страница 76: ...099 005504 EW501 20 11 2015 ENTER EXIT NAVIGATION l 0 AMP Hold Prog VOLT kW Figure 5 41 Display Setting selection Ramp time for wire inching 0 normal inching 10s ramp time 1 fast inching 3s ramp time...

Страница 77: ...ch 0 no program changeover Ex works 1 special latched 2 specific latched special n cycle active Lat and sp lat tapping start 0 no latched tapping start Ex works 1 latched tapping start possible One or...

Страница 78: ...ys executed in the main program 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...

Страница 79: ...be switched when the changeover switch is in the program position Programs can be switched by means of a connected remote control or special welding torch If a special welding torch or a remote contr...

Страница 80: ...am 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 volta...

Страница 81: ...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...

Страница 82: ...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...

Страница 83: ...flow time elapses Latched special latched tap start P9 In latched tap start operating mode it is possible to switch straight to the second step by tapping the torch trigger it is not necessary for cu...

Страница 84: ...e As for the actual JOB list JOB changeover is also possible with accessory components such as the PowerControl 2 torch Creating user defined JOB lists A consecutive memory range where accessories suc...

Страница 85: ...on By repeating the last two steps the same source JOB can be copied to multiple target JOBs If the control does not register any user activity for longer than 5 seconds the parameter display is shown...

Страница 86: ...the welding parameters manually Selection of JOB 0 can be prevented via the key switch or with the block program 0 parameter P2 Key switch position 0 or special parameter P2 0 JOB 0 is blocked Key sw...

Страница 87: ...ion of the pulsed arc welding process in the PA program P20 For machine versions with pulsed arc welding procedures only Function active P20 1 If the superPuls and welding process switching functions...

Страница 88: ...rotary knob EXIT Exit the menu Press the parameter selection right push button switch machine off and on again ENTER EXIT NAVIGATION l 0 l 0 Prog VOLT kW M3 7x B D LP M3 7x A C HP Figure 5 45 Display...

Страница 89: ...ding 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 realigning...

Страница 90: ...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 seconds A short circuit current will flow briefl...

Страница 91: ...se quote the machine type serial number and item number of the machine as well as the type designation and item number of the spare part 6 1 General When used in the specified environmental conditions...

Страница 92: ...ch must be disposed of Do not dispose of in household waste Observe the local regulations regarding disposal 6 3 1 Manufacturer s declaration to the end user According to European provisions guideline...

Страница 93: ...pool brake See 5 10 2 5 Spool brake setting chapter Check settings and correct if necessary Setting pressure units See 5 10 2 4 Inching the wire electrode chapter Check settings and correct if necessa...

Страница 94: ...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 ex...

Страница 95: ...heck 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 con...

Страница 96: ...mised welding parameters that are stored will be replaced by the factory settings 7 3 1 Resetting a single JOB EXIT RESET ENTER 3 s 3 s 3 s Figure 7 1 Display Setting selection RESET to factory settin...

Страница 97: ...e 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 e...

Страница 98: ...nt circuit 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 i...

Страница 99: ...d load 17 5 kVA 13 5 kVA 18 5 kVA Recommended generator rating 25 0 kVA cos efficiency 0 99 90 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine welding torch...

Страница 100: ...r rating 34 6 kVA cos efficiency 0 99 90 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine welding torch cooling Fan gas or water Cooling capacity at 1 l min...

Страница 101: ...008088 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 Extens...

Страница 102: ...hines without pivot support 092 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 commun...

Страница 103: ...azing 092 002770 00008 FE 4R 1 0 MM 0 04 INCH BLUE Drive roll set 37 mm 4 rolls V groove for steel stainless steel and brazing 092 002770 00010 FE 4R 1 2 MM 0 045 INCH RED Drive roll set 37 mm 4 rolls...

Страница 104: ...nurled for flux cored wire 092 002848 00008 FUEL 4R 1 0 MM 0 04 INCH BLUE ORANGE Drive roll set 37 mm 4 rolls V groove knurled for flux cored wire 092 002848 00010 FUEL 4R 1 2 MM 0 045 INCH RED ORANGE...

Страница 105: ...Appendix A JOB List 099 005504 EW501 20 11 2015 105 11 Appendix A 11 1 JOB List Figure 11 1...

Страница 106: ...Appendix B Overview of EWM branches 106 099 005504 EW501 20 11 2015 12 Appendix B 12 1 Overview of EWM branches...

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