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Design and function

Notes on the installation of welding current leads

099-004846-EW501

8.01.2014

5.4

Notes on the installation of welding current leads

NOTE

Incorrectly installed welding current leads can cause faults in the arc (flickering).

Install welding lead and hose package in parallel and as close together as possible.

Keep the welding lead and hose packages of each welding machine separate, with an
installation distance of at least 15 cm!

Fully unroll welding current leads, torch hose packages and intermediate hose
packages. Avoid loops!

Use an individual welding lead to the workpiece for each welding machine!
Connect the work clamp close to the welding point.

Always keep leads as short as possible!

Figure 5-1

Item Symbol

Description

Welding machine

Wire feed unit

Workpiece

Содержание Phoenix Expert drive 4L M3.70

Страница 1: ...feed unit Phoenix Expert drive 4L M3 70 099 004846 EW501 Observe additional system documents 8 01 2014 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for ew...

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: ...ments spare parts and circuit diagrams 16 3 3 5 Calibration Validation 16 4 Machine description quick overview 17 4 1 Front view 17 4 2 Rear view 18 4 3 Inside view 19 4 4 Machine control Operating el...

Страница 4: ...u MIG MAG 51 5 7 15 1 Selection 51 5 8 TIG welding 53 5 8 1 Welding torch connection 53 5 8 2 Welding task selection 54 5 8 3 TIG arc ignition 55 5 8 3 1 Liftarc ignition 55 5 8 4 TIG automatic cut ou...

Страница 5: ...Resetting a single JOB 85 7 3 2 Resetting all JOBs 86 7 4 Vent coolant circuit 87 8 Technical data 88 8 1 Phoenix Expert drive 4L 88 9 Accessories 89 9 1 General accessories 89 9 2 Remote control con...

Страница 6: ...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 7: ...ss 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 8: ...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 Switching off alone is not sufficient Place welding torch a...

Страница 9: ...any 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 workp...

Страница 10: ...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 11: ...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 12: ...table 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 du...

Страница 13: ...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 14: ...odelling 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 co...

Страница 15: ...04846 EW501 8 01 2014 15 3 2 Use and operation solely with the following machines NOTE A suitable power source system component is required in order to operate the wire feed unit Phoenix Expert 351 40...

Страница 16: ...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 17: ...ll be located on the inside 4 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and torch trigger integrated 5 Slide latch lock for the protective cap 6 7 pole conne...

Страница 18: ...ol lead for wire feed unit 2 Connecting nipple G shielding gas connection 3 Quick connect coupling red coolant return 4 Connector plug welding current Welding current connection on wire feed unit 5 Qu...

Страница 19: ...or wire feed unit 4 Wire feed unit 5 Welding torch function changeover switch special welding torch required Changing over programs or JOBs Infinite adjustment of welding performance 6 Protective cap...

Страница 20: ...Machine description quick overview Machine control Operating elements 20 099 004846 EW501 8 01 2014 4 4 Machine control Operating elements Figure 4 4...

Страница 21: ...welding performance 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 lights up in red MIG sp...

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

Страница 23: ...se function Lights up when the super pulse function is active 16 Button special job Select the special jobs SP1 to SP3 JOB 129 to 131 17 Wire inching button See also Inching the Wire Electrode chapter...

Страница 24: ...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 25: ...erated on that connection The cap must be replaced if faulty or if lost NOTE Observe documentation of other system components when connecting 5 2 Installation WARNING Risk of accident due to improper...

Страница 26: ...t be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components The coolant must be checked for adequate frost protection with the T...

Страница 27: ...s close together as possible B Keep the welding lead and hose packages of each welding machine separate with an installation distance of at least 15 cm C Fully unroll welding current leads torch hose...

Страница 28: ...kage strain relief Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right Push the welding current cable socket onto the welding current conn...

Страница 29: ...ge function Operating Element Action Result 5 s Select rinse hose package Shielding gas flows continuously until the Gas Test button is pressed again 5 6 3 Setting the shielding gas quantity Welding p...

Страница 30: ...iral guide or plastic core with the correct inner diameter has to be inserted in the torch Recommendation Use a spiral guide to weld hard unalloyed wire electrodes steel Use a plastic core to weld or...

Страница 31: ...ad etc 5 Quick connect coupling blue coolant supply 6 Quick connect coupling red coolant return Insert the central plug for the welding torch into the central connector and screw together with crown n...

Страница 32: ...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 33: ...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 groove rollers with for steel wires and other hard wires use U...

Страница 34: ...pool to the welding torch Remove the pressure rollers from the wire feeder if no welding torch is fitted Check wire guide at regular intervals Keep all casing covers or protective caps closed during o...

Страница 35: ...arefully 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 pipe Press the clamping eleme...

Страница 36: ...escription 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 NOTE Tighten the sp...

Страница 37: ...d process parameters are calculated by the system depending on the operating point defined single dial operation via wire speed rotary dial Additional parameters can be modified as required in the con...

Страница 38: ...operating mode The LED displays the selected operating mode Non latched operation Latched operation Green Special non latched mode Red Spot operating mode Special latched mode n x Select welding type...

Страница 39: ...rode sticks in the gas nozzle Back burn set too low Wire electrode sticks in the weld pool Welding machine Operating element Action Result Display 1 x Select program sequence mode Program steps n x Se...

Страница 40: ...x Switching the display between Welding current Material thickness Wire speed On the wire feed unit using control M3 70 Operating element Action Result n x Switching the display between Welding curre...

Страница 41: ...perating instructions for the machine in question for a more detailed description of the individual machines and their functions 5 7 6 MIG MAG welding data display To the left and right of the control...

Страница 42: ...lding 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 Welding current display of...

Страница 43: ...99 251 12 0 252 12 0 253 6 0 You can make use of these properties after selecting the forceArc process see the Selecting a MIG MAG welding task chapter As with pulse arc welding it is important to ma...

Страница 44: ...ormation 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 CO2...

Страница 45: ...m steps mode NOTE Changes to the welding parameters can only be made when the key switch is in position 1 5 7 10 1 Selecting the program sequence parameters using wire feed unit control M3 70 Operatin...

Страница 46: ...n 0 0s to 20 0s 4 Slope duration from 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 r...

Страница 47: ...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 is on Set dynamic Setting range 40 to 40 40 Arc hard and narrow 40 Ar...

Страница 48: ...torches P8 chapter Change over between pulse and standard welding in the special latched operating mode Switching between wire feed units in dual operation mode see chapter M3 70 M3 71 machine contro...

Страница 49: ...ed wire conveyors In addition to a pushing wire feed PUSH in the power source wire feed case a pulling wire feed PULL is used in the torch The two feed motors are synchronised by a current regulator W...

Страница 50: ...terference 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 confo...

Страница 51: ...ing 5 7 15 1 Selection NOTE ENTER Enter the menu Keep the welding parameters push button pressed for 3 s NAVIGATION Navigate the menu Select parameters by pressing the welding parameters push button S...

Страница 52: ...cial latched you can switch to the next program by tapping the torch trigger in the main program see the special parameters description 1 No JOB dependent program limit 2 9 JOB dependent program limit...

Страница 53: ...ted 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 F...

Страница 54: ...to quick connect coupling red coolant return and supply line blue to quick connect coupling blue coolant supply 5 8 2 Welding task selection NOTE Selection of a welding task involves the interaction...

Страница 55: ...duce a gap of approx 2 3 mm between the electrode tip and the workpiece The arc ignites and the welding current is increased depending on the operating mode set to the ignition or main current set c L...

Страница 56: ...the welding current is increased depending on the operating mode set to the ignition or main current set c Lift off the torch and swivel to the normal position Ending the welding process Release or pr...

Страница 57: ...ial non latched Figure 5 22 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 wit...

Страница 58: ...ing 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 ef...

Страница 59: ...ting in start program PSTART Step 2 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 to...

Страница 60: ...e run through until the signal light for the required welding process comes on The nominal values for the welding current and welding voltage are displayed Welding current is set Setpoint setting 5 9...

Страница 61: ...t arcforce welding parameter LED for the button is on Arcforcing setting for electrode types Setting range 40 to 40 Negative values Rutile Values around zero Basic Positive values Cellulose 5 9 1 3 Ho...

Страница 62: ...e 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 skilled persons for repair work tra...

Страница 63: ...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 64: ...l parameters can deviate between the machine controls used in the welding system also see the relevant standard operating instructions If required the special parameters can be reset to the factory se...

Страница 65: ...2 1 Selecting changing and saving parameters ENTER EXIT HOLD AM P m min NAVIGATION m min l 0 VOLT PROG kW Figure 5 28 Display Setting selection Ramp time for wire inching 0 normal inching 10s ramp tim...

Страница 66: ...e active Lat and sp lat tapping start 0 no latched tapping start Ex works 1 latched tapping start possible One or two wire feed operation 0 single operation Ex works 1 dual operation this unit is the...

Страница 67: ...gram is disabled 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 or in an absolute manner as...

Страница 68: ...pulse Up down operation Change 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...

Страница 69: ...m 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 voltag...

Страница 70: ...ram 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 fee...

Страница 71: ...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 72: ...atest when the torch trigger is released Tapping pressing briefly and releasing within 0 3 sec can switch to other programs Programs PA1 to PA9 are possible 3rd cycle Press and hold torch trigger Slop...

Страница 73: ...nal differences between the wire feeds Latched special tapping time setting P11 The tapping time for changing over between the main program and reduced main program can be set in three levels 0 no tap...

Страница 74: ...is JOB allows you 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 swit...

Страница 75: ...rogram PA ex factory Function inactive P20 0 Predefined execution of the pulsed arc welding process in the PA program is disabled Predefined absolute value for relative programs P21 Start program PSTA...

Страница 76: ...resistance for the first welding circuit 0 m 60 m 8 m ex works Lead resistance 2 Lead resistance for the second welding circuit 0 m 60 m 8 m ex works Only qualified service personnel may change the pa...

Страница 77: ...ter 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...

Страница 78: ...area of the workpiece and push the torch trigger for approx 2 s A short circuit current temporarily flows which is used to determine and display the new cable resistance The value can be between 0 m...

Страница 79: ...e the torch from the hose package Never clamp the torch body in a vice or similar as this can cause the torch to be irreparably destroyed If damage occurs to the torch or to the hose package which can...

Страница 80: ...anying 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 reg...

Страница 81: ...ed 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 82: ...l 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 C...

Страница 83: ...re 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 shie...

Страница 84: ...error message can be reset by pressing a key button Welding machine control Key button RC1 RC2 Expert CarExpert Progress M3 11 alpha Q Concept Basic Basic S Synergic Synergic S Progress M3 71 Picomig...

Страница 85: ...JOB NOTE All customised welding parameters that are stored will be replaced by the factory settings EXIT RESET ENTER 3 s JOB LIST m min 3 s JOB LIST 3 s Figure 7 1 Display Setting selection Reset to...

Страница 86: ...ng all JOBs NOTE JOBs 1 128 and 170 256 will be reset Custom JOBs 129 169 are maintained ENTER 3 s EXIT RESET 3 s JOB LIST m min JOB LIST 3 s Figure 7 2 Display Setting selection Reset to factory sett...

Страница 87: ...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 88: ...VAC 60 VDC Max welding current at 60 DC 550 A Max welding current at 100 DC 420 A Wire feed speed 0 5 m min to 24 m min Factory fit roller equipment 1 0 1 2 mm for steel wire Drive 4 roller 37 mm Conn...

Страница 89: ...20 m Extension connecting cable 092 000201 00001 FRV 7POL 25M Extension connecting cable 092 000201 00007 9 2 2 19 pole connection Type Designation Item no R10 19POL Remote control 090 008087 00000 RG...

Страница 90: ...92 000841 00000 FE 2DR4R 1 0 1 2 Drive rollers 37 mm steel 092 000842 00000 FE 2DR4R 1 2 1 6 Drive rollers 37 mm steel 092 000843 00000 FE AL 2GR4R Pressure rollers smooth 37mm 092 000844 00000 10 1 2...

Страница 91: ...092 000846 00000 URUE AL 4ZR4R 1 2 1 6 Conversion kit 37mm 4 roller drive for aluminium 092 000847 00000 URUE AL 4ZR4R 2 4 3 2 Conversion kit 37mm 4 roller drive for aluminium 092 000868 00000 URUE R...

Страница 92: ...Appendix A JOB List 92 099 004846 EW501 8 01 2014 11 Appendix A 11 1 JOB List...

Страница 93: ...Appendix A JOB List 099 004846 EW501 8 01 2014 93...

Страница 94: ...Appendix A JOB List 94 099 004846 EW501 8 01 2014...

Страница 95: ...Appendix A JOB List 099 004846 EW501 8 01 2014 95...

Страница 96: ...Appendix A JOB List 96 099 004846 EW501 8 01 2014...

Страница 97: ...Appendix A JOB List 099 004846 EW501 8 01 2014 97...

Страница 98: ...Appendix A JOB List 98 099 004846 EW501 8 01 2014...

Страница 99: ...Appendix A JOB List 099 004846 EW501 8 01 2014 99...

Страница 100: ...Appendix A JOB List 100 099 004846 EW501 8 01 2014...

Страница 101: ...Appendix B Overview of EWM branches 099 004846 EW501 8 01 2014 101 12 Appendix B 12 1 Overview of EWM branches...

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