EWM Phoenix 355 Progress puls MM TKM Operating Instructions Manual
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EWM Phoenix 355 Progress puls MM TKM Operating Instructions Manual

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Operating instructions
Welding machine
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Phoenix 355 Progress puls MM TKM
099-005403-EW501
18.08.2016

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Summary of Contents for EWM Phoenix 355 Progress puls MM TKM

  • Page 1 Operating instructions Welding machine Phoenix 355 Progress puls MM TKM 099-005403-EW501 18.08.2016...

  • Page 2: General Instructions

    +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 Safety instructions .......................... 8 Transport and installation ......................12 3 Intended use ............................
  • Page 4 Contents Notes on the use of these operating instructions 5.3.6.4 Accessory components for operating point setting ........48 5.3.7 forceArc / forceArc puls ....................49 5.3.8 rootArc/rootArc puls ...................... 50 5.3.9 MIG/MAG functional sequences / operating modes ............. 51 5.3.9.1 Explanation of signs and functions ..............
  • Page 5 7.4.1 Automation interface ....................114 Vent coolant circuit ........................115 8 Technical data ............................ 116 Phoenix 355 Progress puls MM TKM ..................116 9 Accessories ............................117 General accessories ........................117 Options ............................117 Remote control/connecting and extension cable ............... 118 9.3.1...

  • Page 6: Safety Instructions

    Safety instructions Notes on the use of these operating instructions Safety instructions Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •...

  • Page 7: Explanation Of Icons

    Safety instructions Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release/tap/tip user must observe. Switch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Numerical value – adjustable Correct Menu entry Signal light lights up in green...

  • Page 8: Safety Instructions

    Safety instructions Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
  • Page 9 Safety instructions Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times. The protective equipment has to include: •...
  • Page 10 Safety instructions Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
  • Page 11 Safety instructions Safety instructions CAUTION Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •...

  • Page 12: Transport And Installation

    Safety instructions Transport and installation Transport and installation WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! • Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air! •...

  • Page 13: Intended Use

    In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product.

  • Page 14: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-005403-EW501 18.08.2016...
  • Page 15 Machine description – quick overview Front view Item Symbol Description Carrying handle Transport bar Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside. Wire spool inspection window Check wire supply Slide latch, lock for the protective cap...

  • Page 16: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-005403-EW501 18.08.2016...
  • Page 17 Machine description – quick overview Rear view Item Symbol Description Main switch, machine on/off Connecting nipple G¼, shielding gas connection ▼ Retrofitting option ▼ 19-pole mechanised welding interface (analogue) > see 5.7.1 chapter ▲ Retrofitting option ▲ Cooling air outlet External wire feed inlet Pre-cut casing inlet for external wire feed.

  • Page 18: Operating Elements In The Machine

    Machine description – quick overview Rear view 4.2.1 Operating elements in the machine Figure 4-3 Item Symbol Description Key button, automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse Welding torch function changeover switch (special welding torch required) Changing over programs or JOBs Infinite adjustment of welding performance.

  • Page 19: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 Item Symbol Description Functional sequence > see 4.3.1 chapter JOB- Welding task push-button (JOB) LIST Select the welding task from the welding task list (JOB-LIST). The list can be found inside the protective cap on the wire feeder and in the appendix to these operating instructions.
  • Page 20 Machine description – quick overview Machine control – Operating elements Item Symbol Description Select operating mode button --------- Non-latched ------- Latched -------- Signal light lights up in green: Special non-latched ---- Signal light lights up in red: MIG spot welding -------- Special latched Welding type push-button ------- Standard arc welding...

  • Page 21: Function Sequence

    Machine description – quick overview Machine control – Operating elements 4.3.1 Function sequence Figure 4-5 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. Signal light, gas pre-flow time Setting range 0.0 s to 20.0 s Signal light, start program (P...
  • Page 22 Machine description – quick overview Machine control – Operating elements Item Symbol Description Super- Signal lamp, super pulse function puls Lights up when the super pulse function is active. 099-005403-EW501 18.08.2016...

  • Page 23: Design And Function

    Design and function Transport and installation Design and function WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •...

  • Page 24: Machine Cooling

    Design and function Transport and installation 5.1.2 Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage. • Observe the ambient conditions! • Keep the cooling air inlet and outlet clear! • Observe the minimum distance of 0.5 m from obstacles! 5.1.3 Workpiece lead, general CAUTION...

  • Page 25: Welding Torch Holder

    Design and function Transport and installation 5.1.5 Welding torch holder The item described in the following is part of the machine´s scope of delivery. Figure 5-2 Item Symbol Description Crossmember of the transport handle Torch holder Fan-type lock washers Fixing screws (x 4) •...

  • Page 26: Welding Torch Cooling System

    Design and function Transport and installation 5.1.6 Welding torch cooling system 5.1.6.1 Cooling module connection Figure 5-3 Item Symbol Description 4-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead Cooling module • Insert and lock the 4-pole supply plug on the cooling unit into the 4-pole connection socket on the welding machine.

  • Page 27: Notes On The Installation Of Welding Current Leads

    Design and function Transport and installation 5.1.7 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.

  • Page 28: Stray Welding Currents

    Design and function Transport and installation Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders. Figure 5-6 5.1.7.1 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and...

  • Page 29: Mains Connection

    Design and function Transport and installation 5.1.8 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only operate machine using a socket that has correctly fitted protective earth. • The mains voltage indicated on the rating plate must match the supply voltage.

  • Page 30: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Transport and installation 5.1.9 Shielding gas supply (shielding gas cylinder for welding machine) WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! •...

  • Page 31: Shielding Gas Hose Connection

    Design and function Transport and installation 5.1.9.2 Shielding gas hose connection Figure 5-10 Item Symbol Description Connecting nipple G¼, shielding gas connection • Connect crown nut of the shielding gas line to the G¼“ connecting nipple. 099-005403-EW501 18.08.2016...

  • Page 32: Gas Test - Setting The Shielding Gas Volume

    Design and function Transport and installation Gas test – setting the shielding gas volume 5.1.9.3 If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to form. Adjust the shielding gas quantity to suit the welding task! •...

  • Page 33: Welding Data Display

    Design and function Welding data display Welding data display To the left and right of the control displays are the "Parameter selection" buttons ( ). They are used to select welding parameters to be displayed. Each press of the button advances the display to the next parameter (LEDs next to the button indicate the selection).

  • Page 34: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.3.1 Welding torch and workpiece line connection On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used! •...

  • Page 35: Welding Torch And Workpiece Line Connection

    Design and function MIG/MAG welding 5.3.2 Welding torch and workpiece line connection On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used! •...
  • Page 36 Design and function MIG/MAG welding Figure 5-12 Item Symbol Description Welding torch Welding torch hose package Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated 19-pole connection socket (analogue) Connection for welding torch control lead Welding current cable, polarity selection Welding current to central connection/torch.

  • Page 37: Wire Feed

    Design and function MIG/MAG welding 5.3.3 Wire feed CAUTION Risk of injury due to moving parts! The wire feeders 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! •...

  • Page 38: Inserting The Wire Spool

    Design and function MIG/MAG welding 5.3.3.2 Inserting the wire spool CAUTION Risk of injury due to incorrectly secured wire spool. If the wire spool is not secured properly, it may come loose from the wire spool support and fall to the ground, causing damage to the machine and injuries. •...

  • Page 39: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.3.3.3 Changing the wire feed rollers Figure 5-14 Item Symbol Description Tommy The tommy is used to secure the closure brackets of the wire feed rollers. Closure bracket The closure brackets are used to secure the wire feed rollers. Feed roll tensioner Fixing the clamping unit and setting the pressure.
  • Page 40 Design and function MIG/MAG welding Unsatisfactory welding results due to faulty wire feeding! The wire feed rolls must be suitable for the diameter of the wire and the material. The wire feed rolls are colour-coded to facilitate distinction (see the Wire feed roll overview table). When working with a wire diameter of >...

  • Page 41: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.3.3.4 Inching the wire electrode CAUTION Risk of injury due to welding wire escaping from the welding torch! The welding wire can escape from the welding torch at high speed and cause bodily injury including injuries to the face and eyes! •...

  • Page 42: Spool Brake Setting

    Design and function MIG/MAG welding A prerequisite for the automatic inching process is the correct preparation of the wire guide, especially in the capillary and wire guide tube area > see 5.3.1 chapter. • The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll tensioner setting nuts depending on the welding consumable used.

  • Page 43: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.3.4 Definition of MIG/MAG welding tasks This machine series offers user-friendly operation and a multitude of features. • Various welding tasks (JOBs) consisting of welding procedure, material type, wire diameter and shielding gas type have been predefined > see 11.1 chapter. •...

  • Page 44: Choke Effect / Dynamics

    Design and function MIG/MAG welding 5.3.5.2 Choke effect / dynamics Setting range: Arc hard and narrow, deeper fusion penetration. -40: Arc soft and wide. EXIT ENTER Figure 5-19 099-005403-EW501 18.08.2016...

  • Page 45: Superpuls

    (PB). This function is e.g. used for thin sheet welding to reduce the heat input in a controlled manner or for positional welding without the need for weaving. The combination of superPuls and other EWM welding processes offers a multitude of possibilities. For example, to enable the welding of vertical-up welds without the "Christmas tree" technique, when selecting program 1 the relevant superPuls variant (depending on the material) is activated as well.

  • Page 46: Burn-Back

    Design and function MIG/MAG welding 5.3.5.4 Burn-back EXIT ENTER Figure 5-21 Display Setting/selection menu burn back Set burn back 099-005403-EW501 18.08.2016...

  • Page 47: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.3.6 MIG/MAG operating point The operating point (welding output) is specified using the principle of 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 current and voltage (operating point).

  • Page 48: Operating Point Setting Using Material Thickness

    Design and function MIG/MAG welding 5.3.6.2 Operating point setting using material thickness Plate thickness details in welding programs generally refer to fillet welds in the PB welding position. They should be regarded as guideline values and may differ in other welding positions. Application example Aluminium is to be welded.

  • Page 49: Forcearc / Forcearc Puls

    Design and function MIG/MAG welding 5.3.7 forceArc / forceArc puls Low-heat, directionally stable and powerful high-performance arc with deep fusion penetration for the upper power range Unalloyed, low-alloy and high-alloy steels as well as high-tensile fine-grained steels. Figure 5-26 • Smaller included angle due to deep penetration and directionally stable arc •...

  • Page 50: Rootarc/Rootarc Puls

    Design and function MIG/MAG welding 5.3.8 rootArc/rootArc puls Short arc with perfect weld modelling capabilities for effortless gap bridging, especially for positional welding Figure 5-27 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion •...

  • Page 51: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.3.9 MIG/MAG functional sequences / operating modes There are optimum pre-sets for welding parameters such as gas pre-flow and burn back, etc. for numerous applications (although these can also be changed if required). 5.3.9.1 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 52 Design and function MIG/MAG welding Non-latched mode Figure 5-28 Step 1 • Press and hold torch trigger. • Shielding 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. •...
  • Page 53 Design and function MIG/MAG welding Non-latched operation with superpulse Figure 5-29 Step 1 • Press and hold torch trigger. • Shielding 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. •...
  • Page 54 Design and function MIG/MAG welding Special, non-latched Figure 5-30 Step 1 • Press and hold torch trigger • Shielding 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 is flowing (start program P for the time t START...
  • Page 55 Design and function MIG/MAG welding Spot welding Figure 5-31 The ignition time t must be added to the spot time t start 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" •...
  • Page 56 Design and function MIG/MAG welding Special, non-latched with superpulse Figure 5-32 Step 1 • Press and hold torch trigger • Shielding 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 is flowing (start program P for the time t START...
  • Page 57 Design and function MIG/MAG welding Latched mode Figure 5-33 Step 1 • Press and hold torch trigger • Shielding 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. •...
  • Page 58 Design and function MIG/MAG welding Latched mode with superpulse Figure 5-34 Step 1: • Press and hold torch trigger • Shielding 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. •...
  • Page 59 Design and function MIG/MAG welding Latched with changing welding method (process switching) For machine versions with pulsed arc welding procedures only. To activate or set the function > see 5.3.16 chapter. Figure 5-35 1st cycle: • Press and hold torch trigger •...
  • Page 60 Design and function MIG/MAG welding Latched special Figure 5-36 Step 1 • Press and hold torch trigger • Shielding 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 is flowing (start program P START Step 2...
  • Page 61 Design and function MIG/MAG welding Special latched with changing welding method by tapping (process switching) For machine versions with pulsed arc welding procedures only. To activate or set the function > see 5.3.16 chapter. Figure 5-37 1st cycle • Press and hold torch trigger. •...
  • Page 62 Design and function MIG/MAG welding Special latched with changing welding method (process switching) For machine versions with pulsed arc welding procedures only. Figure 5-38 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed"...
  • Page 63 Design and function MIG/MAG welding Special, latched with superpulse Figure 5-39 Step 1 • Press and hold torch trigger • Shielding 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 is flowing (start program P for the time t START...

  • Page 64: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Design and function MIG/MAG welding 5.3.10 Conventional MIG/MAG Welding (GMAW non synergic) It is only possible to change the JOB number when no welding current is flowing. • With wire-feed speeds less than 8 m/min select JOB 188. • With wire-feed speeds over 8 m/min select JOB 187. EXIT Figure 5-40 5.3.10.1 Setting the operating point (welding output)

  • Page 65: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.3.11 MIG/MAG program sequence ("Program steps" mode) Certain materials, such as aluminium, require special functions in order to be able to weld them safely and at high quality. The latched special operating mode is used here with the following programs: •...

  • Page 66: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.3.11.2 MIG/MAG overview of parameters , and P are set as relative programs ex faxtory. They relate to percentages of the wire START feed value of the main program P . These programs can also be set in an absolute manner, if desired (see Setting of special parameter P21).

  • Page 67: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.3.11.3 Example, tack welding (non-latched) Figure 5-47 Basic parameters Parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 68: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.3.11.5 Example, aluminium welding (latched special) Figure 5-49 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 length 2 to 500 "P "...

  • Page 69: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.3.11.6 Example, visible seams (latched super pulse) Figure 5-50 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 length 2 to 500 "P "...

  • Page 70: Main Program A Mode

    Design and function MIG/MAG welding 5.3.12 Main program A mode Different welding tasks or positions on a workpiece demand various welding performances (operating points) or welding programs. The following parameters are stored in each of the up to 16 programs: •...
  • Page 71 Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-51 Example 2: Welding different positions on a workpiece (latched) Figure 5-52 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-53 Up to 16 programs (P...

  • Page 72: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.3.12.1 Selecting parameters (program A) Changes to the welding parameters can only be made when the key switch is in position "1". Figure 5-54 Select program number. 5.3.13 MIG/MAG automatic cut-out The welding machine ends the ignition process or the welding process with an •...

  • Page 73: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.3.14 Standard MIG/MAG torch The MIG welding torch trigger is essentially used to start and stop the welding process. Operating elements Functions • Torch trigger Start/stop welding Other functions are also possible by tapping the torch trigger, depending on the machine type and control configuration >...

  • Page 74: Expert Menu (Mig/Mag)

    Design and function MIG/MAG welding 5.3.16 Expert menu (MIG/MAG) The expert menu includes functions and parameters which are either not set on the machine control, or which do not require regular setting. 5.3.16.1 Selection ENTER (Enter the menu) • Keep the "welding parameters" push-button pressed for 3 s. NAVIGATION (Navigate the menu) •...
  • Page 75 Design and function MIG/MAG welding Display Setting/selection Correct wire burn-back If too high a value is set, a large ball will form at the tip of the wire electrode (bad re- ignition) or the wire electrode sticks to the contact tip. If too low a value is set, the wire electrode sticks to the weld pool.

  • Page 76: Tig Welding

    Design and function TIG welding TIG welding 5.4.1 Welding torch and workpiece line connection Figure 5-57 Item Symbol Description Welding torch Welding torch hose package Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Welding current cable, polarity selection Welding current to the central connector/torch, enables polarity selection.

  • Page 77: Welding Task Selection

    Design and function TIG welding 5.4.2 Welding task selection EXIT Figure 5-58 5.4.3 Welding current setting Figure 5-59 5.4.4 TIG arc ignition 5.4.4.1 Liftarc Figure 5-60 The arc is ignited on contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger (liftarc current flowing, regardless of the main current set).

  • Page 78: Function Sequences/Operating Modes

    Design and function TIG welding 5.4.5 Function sequences/operating modes 5.4.5.1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger (press briefly and release) Shielding gas flowing Welding output Gas pre-flows Gas post-flows Non-latched Special, non-latched Latched Special, latched...
  • Page 79 Design and function TIG welding Non-latched mode Figure 5-61 Selection • Select non-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 •...
  • Page 80 Design and function TIG welding Latched mode Figure 5-63 Selection • Select 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 •...

  • Page 81: Tig Automatic Cut-Out

    Design and function TIG welding Latched special Figure 5-64 Selection • Select 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 at pre-selected setting in start program "P ".

  • Page 82: Tig Program Sequence ("Program Steps" Mode)

    Design and function TIG welding 5.4.7 TIG program sequence ("Program steps" mode) Figure 5-65 Basic parameters Item Meaning/explanation Setting range Gas pre-flow time 0 s to 0.9 s START 0% to 200% Ignition current Duration (start program) 0 s to 20 s Slope duration from P to P 0 s to 20 s...

  • Page 83: Mma Welding

    Design and function MMA welding MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •...

  • Page 84: Welding Task Selection

    Design and function MMA welding 5.5.2 Welding task selection EXIT Figure 5-67 5.5.3 Arcforce Figure 5-68 099-005403-EW501 18.08.2016...

  • Page 85: Hotstart

    Design and function MMA welding 5.5.4 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current Welding current Time Figure 5-69 For hotstart parameter settings, > see 5.5.6 chapter 5.5.5 Antistick Anti-stick prevents the electrode from annealing.

  • Page 86: Remote Control

    Design and function Remote control Remote control The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...

  • Page 87: Automation Interface

    Design and function Interfaces for automation 5.7.1 Automation interface These accessory components can be retrofitted as an option > see 9 chapter. Input / Description Diagram output Output Connection for cable shielding Output IGRO Current flows signal I>0 (maximum load 20 (open mA / 15 V) collector)

  • Page 88: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.7.2 Remote control connection socket, 19-pole Figure 5-72 Signal form Short description Output Connection for PE cable screen Output Reference voltage for potentiometer 10 V (max. 10 mA) Control voltage specification (0 V–10 V) – wire feed speed Input Output Reference potential (0 V)

  • Page 89: Rint X12 Robot Interface

    Design and function PC interface 5.7.3 RINT X12 robot interface The standard digital interface for mechanised applications
 (optional, retrofitting on the machine or external fitting by the customer) Functions and signals: • Digital inputs: start/stop, operating modes, JOB and program selection, inching, gas test •...

  • Page 90: Access Control

    Design and function Access control Access control The key switch is only available for machines which are fitted with the "OW KL XX5" option ex works. To protect against unauthorised or unintentional adjustment of the welding parameters on the machine, the control input can be locked with the aid of a key switch.

  • Page 91: Selecting, Changing And Saving Parameters

    Design and function Special parameters (advanced settings) 5.10.1 Selecting, changing and saving parameters 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.
  • Page 92 Design and function Special parameters (advanced settings) Display Setting/selection Enable special jobs SP1 to SP3 0 = ------- no enabling (Ex works) 1 = ------- enabling of Sp1-3 Correction operation, threshold value setting 0 = ------- correction operation switched off (Ex works) 1 = ------- correction operation on "Main program (PA)"...

  • Page 93: Reset To Factory Settings

    Design and function Special parameters (advanced settings) Display Setting/selection Predefined pulse arc welding process in the PA program 0 = -------- Predefined pulse arc welding process in the PA program is disabled. 1 = -------- If the superPuls and welding process switching functions are available and activated, the pulse arc welding process is always executed in the main program PA (ex factory).

  • Page 94: Special Parameters In Detail

    Design and function Special parameters (advanced settings) 5.10.1.2 Special parameters in detail Ramp time for wire inching (P1) The wire inching starts with a speed 1.0 m/min for 2 secs. It is subsequently increased to a ramp function to 6.0 m/min. The ramp time can be set between two ranges. During wire inching, the speed can be changed by means of the welding parameter setting rotary dial.
  • Page 95 Design and function Special parameters (advanced settings) Correction operation, threshold value setting (P7) The correction operation is switched on 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 separately for each program.
  • Page 96 Design and function Special parameters (advanced settings) EXIT Figure 5-75 • If the user is inactive for about 5 seconds, the pre-set values will be applied and the display switches back to the program display. • Key switch back to position "0"! 099-005403-EW501 18.08.2016...
  • Page 97 Design and function Special parameters (advanced settings) Switching programs with the standard torch trigger (P8) Special latched (latched absolute program sequence) • Cycle 1: absolute program 1 is run • Cycle 2: absolute program 2 is run after completion of "tstart". •...
  • Page 98 Design and function Special parameters (advanced settings) The number of programs (P ) corresponds to the cycle number specified under N cycle. 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". •...
  • Page 99 Design and function Special parameters (advanced settings) "Single or dual operation" (P10) setting If the system is fitted with two wire feeds, no further accessory components may be operated on the 7-pole connection socket (digital)! This relates to digital remote controls, robot interfaces, documentation interfaces, welding torches with digital control lead connection, etc.
  • Page 100 Design and function Special parameters (advanced settings) Creating user-defined JOB lists A consecutive memory range where accessories such as the POWERCONTROL 2 torch can be used to switch between JOBs will be created. • Set special parameter P12 to "2". •...
  • Page 101 Design and function Special parameters (advanced settings) Lower and upper limits of the remote JOB changeover process (P13, P14) The highest and lowest JOB numbers which can be selected using accessory components, such as the PowerControl 2 torch. Avoids an accidental changeover into undesirable or undefined JOBs. Hold function (P15) Hold function active (P15 = 1) •...
  • Page 102 Design and function Special parameters (advanced settings) Selecting programs with the standard torch trigger (P17) Allows you to select a program or switch a program before starting welding. You switch to the next program by tapping the torch trigger. Once the last enabled program is reached, you start again at the beginning.

  • Page 103: Machine Configuration Menu

    Design and function Machine configuration menu Predefined absolute value for relative programs (P21) Start program (P ), down-slope program (P ) and end program (P ) can be set relative to the main START program (P ) or in an absolute manner, as desired. Function active (P21 = 1) •...
  • Page 104 Design and function Machine configuration menu ENTER EXIT NAVIGATION Figure 5-78 Display Setting/selection Lead resistance 1 Lead resistance for the first welding circuit 0 mΩ–60 mΩ (8 mΩ ex works). Lead resistance 2 Lead resistance for the second welding circuit 0 mΩ–60 mΩ (8 mΩ ex works). Only qualified service personnel may change the parameters! Only qualified service personnel may change the parameters! Time-controlled power-saving mode >...

  • Page 105: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.11.2 Aligning the cable resistance The resistance value of cables can either be set directly or it can be aligned using the power source. The factory setting of the power sources is 8 mΩ. This value correponds to a 5 m earth cable, a 1.5 m intermediate hose package and a 3 m water-cooled welding torch.

  • Page 106: Power-Saving Mode (Standby)

    Design and function Machine configuration menu 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Trim the welding wire, so that it is flush with the contact tip. • Retract the welding wire a little (approx. 50 mm) on the wire feeder. There should now be no more welding wire in the contact tip.

  • Page 107: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal General DANGER Incorrect maintenance and testing! The machine may be cleaned, repaired and tested by skilled and qualified personnel only. A qualified person is one who, due to their training, knowledge and experience, can detect any hazards and possible consequential damage when checking the machine, and can take the necessary safety measures.

  • Page 108: Maintenance Work, Intervals

    Maintenance, care and disposal Maintenance work, intervals Maintenance work, intervals Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine.

  • Page 109: Annual Test (Inspection And Testing During Operation)

    In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives on the Declaration of Conformity on your machine).

  • Page 110: Rectifying Faults

    Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer.

  • Page 111: Error Messages (Power Source)

    Rectifying faults Error messages (power source) Error messages (power source) A welding machine error is indicated by an error code being displayed (see table) on the display on the machine control. In the event of a machine error, the power unit is shut down. The display of possible error numbers depends on the machine version (interfaces/functions).
  • Page 112 Rectifying faults Error messages (power source) Error Category Possible cause Remedy (Err) Machine incompatible Check machine used Software update required Inform Service. Legend for categories (reset error) a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a push-button: Welding machine control Push-button RC1 / RC2...

  • Page 113: Resetting Jobs (Welding Tasks) To The Factory Settings

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings Resetting JOBs (welding tasks) to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. 7.3.1 Resetting a single JOB ENTER ENTER EXIT Figure 7-1 Display Setting/selection...

  • Page 114: Resetting All Jobs

    Rectifying faults General operating problems 7.3.2 Resetting all JOBs JOBs 1–128 and 170–256 will be reset. Custom JOBs 129–169 are maintained. ENTER ENTER EXIT Figure 7-2 Display Setting/selection RESET to factory settings The RESET will be done after pressing the button. The menu will be ended when no changes are done after 3 sec.

  • Page 115: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant 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 is located as deep as possible inside the system (close to the coolant tank)! Figure 7-3 099-005403-EW501...

  • Page 116: Technical Data

    Technical data Phoenix 355 Progress puls MM TKM Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 355 Progress puls MM TKM MIG/MAG Setting range for welding current 5 A–350 A Setting range for welding voltage 14.3 V–31.5 V...

  • Page 117: Accessories

    Accessories General accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. Trolly 55-5 Transport cart, assembled 090-008632-00000 cool50 U40 Cooling module 090-008598-00502 voltConverter 230/400 Voltage converter 090-008800-00502 CA D200...

  • Page 118: Remote Control/Connecting And Extension Cable

    Accessories Remote control/connecting and extension cable Remote control/connecting and extension cable 9.3.1 7-pole connection Type Designation Item no. R40 7POL Remote control, 10 programs 090-008088-00000 R50 7POL Remote control, all welding machine functions can 090-008776-00000 be set directly at the workplace FRV 7POL 0.5 m Extension/connecting cable 092-000201-00004...

  • Page 119: Replaceable Parts

    Replaceable parts Wire feed rollers Replaceable parts The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...

  • Page 120: Wire Feed Rollers For Aluminium Wire

    Replaceable parts Wire feed rollers 10.1.2 Wire feed rollers for aluminium wire Type Designation Item no. AL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, for aluminium 092-002771-00008 WHITE AL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, for aluminium 092-002771-00010 BLUE AL 4R 1.2 MM/0.045 INCH...

  • Page 121: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List JOB no. Processes Material Diameter [mm] Standard GMAW/pulse G3Si1/G4Si1 100% CO2 Standard GMAW/puls G3Si1/G4Si1 100% CO2 Standard GMAW/puls 100% CO2 G3Si1/G4Si1 Standard GMAW/puls 100% CO2 G3Si1/G4Si1 Standard GMAW/puls 100% CO2 G3Si1/G4Si1 Standard GMAW/puls G3Si1/G4Si1 Ar-82/CO2-18 (M21) Standard GMAW/puls...
  • Page 122 Appendix A JOB-List JOB no. Processes Material Diameter [mm] coldArc/coldArc puls CrNi 19 9/1.4316 Ar-97,5/CO2-2,5 (M12) coldArc/coldArc puls AlMg Ar-100 (I1) coldArc/coldArc puls Ar-100 (I1) AlMg coldArc/coldArc puls AlSi Ar-100 (I1) coldArc/coldArc puls AlSi Ar-100 (I1) coldArc/coldArc puls Ar-100 (I1) Al99 coldArc/coldArc puls Al99...
  • Page 123 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Brazing CuSi Ar-97,5/CO2-2,5 (M12) Brazing CuSi Ar-97,5/CO2-2,5 (M12) Brazing CuSi Ar-100 (I1) Brazing CuSi Ar-100 (I1) Brazing CuSi Ar-100 (I1) Brazing CuSi Ar-100 (I1) Brazing CuAl Ar-97,5/CO2-2,5 (M12) Brazing CuAl Ar-97,5/CO2-2,5 (M12) Brazing CuAl Ar-97,5/CO2-2,5 (M12)
  • Page 124 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Block 2/ JOB10 Block 3/ JOB1 Block 3/ JOB2 Block 3/ JOB3 Block 3/ JOB4 Block 3/ JOB5 Block 3/ JOB6 Block 3/ JOB7 Block 3/ JOB8 Block 3/ JOB9 Block 3/ JOB10 171* pipeSolution G3Si1/G4Si1...
  • Page 125 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Rutile/basic flux cored CrNi CO2-100 (C1) wire Ar-82/CO2-18 (M21) Surfacing G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Ar-100 (I1) 220* coldArc - St/Al ZnAl 221* coldArc - St/Al...
  • Page 126 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Metal flux-cored wire High tensile steels Ar-82/CO2-18 (M21) Ar-82/CO2-18 (M21) Basic flux-cored G3Si1/G4Si1 Standard GMAW/puls Ar-70/He-30 (I3) NiCr 617 Standard GMAW/puls NiCr 617 Ar-70/He-30 (I3) Standard GMAW/puls Ar-70/He-30 (I3) NiCr 625 Standard GMAW/puls Ar-70/He-30 (I3) NiCr 625...
  • Page 127 Appendix A JOB-List JOB no. Processes Material Diameter [mm] forceArc/forceArc puls CrNi 22 9 3a/1.4462 Ar-97,5/CO2-2,5 (M12) forceArc/forceArc puls CrNi 22 9 3a/1.4462 Ar-97,5/CO2-2,5 (M12) forceArc/forceArc puls CrNi 22 9 3a/1.4462 Ar-97,5/CO2-2,5 (M12) forceArc/forceArc puls CrNi 22 9 3a/1.4462 Ar-97,5/CO2-2,5 (M12) forceArc/forceArc puls CrNi 25 20/1.4842 Ar-97,5/CO2-2,5 (M12)

  • Page 128: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005403-EW501 18.08.2016...

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