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Summary of Contents for EWM Phoenix 401 Expert 2.0 puls MM FKG
- Page 1 Operating instructions Welding machine Phoenix 401 Expert 2.0 puls MM FKG Phoenix 401 Expert 2.0 puls MM FKW 099-005549-EW501 Observe additional system documents! 12.11.2018...
- Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.
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Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................5 Part of the complete documentation ....................6 Safety instructions .......................... - Page 4 Contents Notes on the use of these operating instructions 5.6.4 BUSINT X11 Industrial bus interface ................36 PC interface ..........................37 Access control ..........................37 6 Maintenance, care and disposal ......................38 General............................38 6.1.1 Cleaning ........................38 6.1.2 Dirt filter......................... 38 Maintenance work, intervals ......................
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Page 5: For Your Safety
For your safety Notes on the use of these operating instructions For your safety 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. •... -
Page 6: Part Of The Complete Documentation
For your safety Part of the complete documentation Symbol Description Symbol Description Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use Part of the complete documentation These operating instructions are part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system. -
Page 7: Safety Instructions
For your safety 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 8 For your safety Safety instructions WARNING Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure when heated. • Move containers with inflammable or explosive liquids away from the working area! • Never heat explosive liquids, dusts or gases by welding or cutting! Fire hazard! Due to the high temperatures, sparks, glowing parts and hot slag that occur during welding, there is a risk of flames.
- Page 9 For your safety Safety instructions CAUTION According to IEC 60974-10, welding machines are divided into two classes of electromagnetic compatibility (the EMC class can be found in the Technical data) > see 8 chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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Page 10: Transport And Installation
For your safety Transport and installation 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 11 For your safety Transport and installation Protective dust caps protect the connection sockets and therefore the machine against dirt and damage. • The protective dust cap must be fitted if there is no accessory component being operated on that connection. •...
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Page 12: Intended Use
3.2.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.2.2 Declaration of Conformity The labelled product complies with the following EC directives in terms of its design and construction: •... -
Page 13: Service Documents (Spare Parts And Circuit Diagrams)
Intended use Documents which also apply 3.2.4 Service documents (spare parts and circuit diagrams) WARNING Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. -
Page 14: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview 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 Lifting lug > see 5.1.1 chapter Ready for operation signal light Signal light on when the machine is switched on and ready for operation Main switch, machine on/off... - Page 15 Machine description – quick overview Front view Item Symbol Description Welding current cable, polarity selection Welding current to Euro torch connector/torch, for polarity selection • ----------- MIG/MAG: Connection socket for “+” welding current • ----------- Self-shielding flux cored wire/TIG: Connection socket, “-” welding current •...
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Page 16: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Securing elements for shielding gas cylinder (strap/chain) Key button, automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse PC interface, serial (D-Sub connection socket, 9-pole) Cooling air outlet Bracket for shielding gas cylinder Wheels, fixed castors... -
Page 17: Inside View
Machine description – quick overview Inside view Item Symbol Description 7-pole connection socket (digital) For connecting digital accessory components (documentation interface, robot interface or remote control, etc.). Inside view Figure 4-3 Item Symbol Description Welding torch function changeover switch (special welding torch required) --- Changing over programs or JOBs --- Infinite adjustment of welding performance. -
Page 18: Design And Function
Design and function Transport and installation Design and function Transport and installation 5.1.1 Lifting by crane WARNING Risk of injury during lifting by crane When lifting the machine by crane, persons may be severely injured by falling machines or mount-on components. •... -
Page 19: Machine Cooling
Design and function Transport and installation 5.1.3 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! 5.1.4 Workpiece lead, general CAUTION... -
Page 20: Maximal Hose Package Length
All information relates to the total hose package length of the complete welding system and presents exemplary configurations (of components of the EWM product portfolio with standard lengths). A straight kink-free installation is to be ensured, taking into account the max. delivery height. -
Page 21: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation • Unscrew and remove the coolant tank sealing cover. • Check filter sieve insert for dirt, clean if necessary and reinsert into position. • Top up coolant to the filter sieve insert, close sealing cover again. If the cooling system is empty or only insufficiently filled with coolant, the coolant pump is automatically switched off after approx. -
Page 22: 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 5-4 5.1.7 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and... -
Page 23: 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! • The connection (mains plug or cable), the repair or voltage adjustment of the device must be carried out by a qualified electrician in accordance with the respective local laws or national regulations! •... -
Page 24: Pressure Regulator Connection
Design and function Transport and installation 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 supply may result in the welding torch being destroyed. •... -
Page 25: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.2.1 Welding torch and workpiece line connection Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •... - Page 26 Design and function MIG/MAG welding Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity. In this case, the welding current 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 5-9 Item Symbol...
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Page 27: Wire Feed
Design and function MIG/MAG welding • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the plug on the workpiece lead into the "-" welding current connection socket and lock. •... - Page 28 Design and function MIG/MAG welding Standard D300 wire spool holder can be used. Adapters are required when using standardised basket coils (DIN 8559) > see 9 chapter. Figure 5-10 Item Symbol Description Carrier pin For fixing the wire spool Knurled nut For fixing the wire spool •...
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Page 29: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.2.2.3 Changing the wire feed rollers Figure 5-11 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 30: Inching The Wire Electrode
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 31 Design and function MIG/MAG welding Incorrect contact pressure will cause extensive wear of the wire feed rollers! • With the adjusting nuts of the pressure units set the contact pressure so that the wire electrode is conveyed but will still slip through if the wire spool jams. •...
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Page 32: 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 5.2.1 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 33: Tig Welding
Design and function TIG welding TIG welding 5.3.1 Welding torch and workpiece line connection Figure 5-15 Item Symbol Description Workpiece Connection socket, "+" welding current • TIG welding: Workpiece connection 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 34: Mma Welding
Design and function MMA welding MMA welding CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. • Use an insulated pair of tongs to remove the used stick electrode or to move welded workpieces. -
Page 35: Interfaces For Automation
Design and function Interfaces for automation Interfaces for automation WARNING Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. •... -
Page 36: Remote Control Connection Socket, 19-Pole
Design and function PC interface 5.6.2 Remote control connection socket, 19-pole Figure 5-17 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 37: Pc Interface
Design and function PC interface PC interface Equipment damage or faults may occur if the PC is connected incorrectly! Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission. The PC may be destroyed due to high frequency ignition pulses. •... -
Page 38: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed. -
Page 39: Maintenance Work, Intervals
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-005549-EW501 12.11.2018... -
Page 40: Disposing Of Equipment
• Information about returning used equipment or about collections can be obtained from the respective municipal administration office. • In addition to this, returns are also possible throughout Europe via EWM sales partners. 099-005549-EW501 12.11.2018... -
Page 41: 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 42 Rectifying faults Checklist for rectifying faults Functional errors All machine control signal lights are illuminated after switching on No machine control signal light is illuminated after switching on No welding power Phase failure > check mains connection (fuses) ...
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Page 43: 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 7-1 099-005549-EW501... -
Page 44: Technical Data
Technical data Phoenix 401 FKG Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 401 FKG MIG/MAG Welding current (I 5 A up to 400 A Welding voltage according to 14,3 V up to 34,0 V 10,2 V up to 26,0 V 20,2 V up to 36,0 V Standard (U... -
Page 45: Phoenix 401 Fkw
Technical data Phoenix 401 FKW Phoenix 401 FKW MIG/MAG Welding current (I 5 A up to 400 A Welding voltage according to 14,3 V up to 34,0 V 10,2 V up to 26,0 V 20,2 V up to 36,0 V Standard (U Duty cycle at 40°... -
Page 46: 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. AK300 Wire spool adapter K300 094-001803-00001 CA D200 Centering adapter for 5-kg spools 094-011803-00000 TYP 1 Frost protection tester... -
Page 47: Options
Accessories Options Options Type Designation Item no. ON A INTERFACE Option retrofit for analog mech. welding interface 092-001779-00000 Phoenix Progress ON LB Wheels 160x40MM Retrofit option for locking brake for machine wheels 092-002110-00000 ON Holder Gas Bottle <50L Holding plate for gas cylinders smaller than 50 litres 092-002151-00000 ON Shock Protect Ram protection retrofit option 092-002154-00000... -
Page 48: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts Performance specifications and guarantee only in connection with original spare and replacement parts! 10.1 Wire feed rollers 10.1.1 Wire feed rollers for steel wire Type Designation Item no. FE 4R 0.6 MM/0.023 INCH Drive roll set, 37 mm, 4 rolls, V-groove for steel, 092-002770-00006 LIGHT PINK... -
Page 49: 10.1.3 Wire Feed Rollers For Cored Wire
Replaceable parts Wire feed rollers 10.1.3 Wire feed rollers for cored wire Type Designation Item no. FUEL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00008 WHITE/ORANGE flux cored wire FUEL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00010 BLUE/ORANGE... -
Page 50: Searching For A Dealer
Appendix A Searching for a dealer Appendix A 11.1 Searching for a dealer Sales & service parteners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005549-EW501 12.11.2018...
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