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Summary of Contents for EWM Phoenix 404 Progress puls TGD
- Page 1 Operating instructions Welding machine Phoenix 404 Progress puls TGD Observe additional system documents! 099-008717-EW501 24.03.2011 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
- Page 2 © EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer.
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Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents..............................3 2 Safety instructions..........................5 Notes on the use of these operating instructions ................5 Explanation of icons........................6 General ............................7 Transport and installation ......................11 Ambient conditions........................12 2.5.1 In operation........................ - Page 4 7.3.2 Resetting all JOBs ......................33 8 Technical data............................34 Phoenix 404 Progress........................34 9 Accessories, options ...........................35 System components........................35 Transport systems........................35 Remote control / connection cable....................35 General accessories ........................35 Computer communication ......................35 10 Appendix A............................36 10.1 Overview of EWM branches......................36 099-008717-EW501 24.03.2011...
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Page 5: 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 6: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine Switch on machine ENTER (enter the menu) NAVIGATION (Navigating in the menu) EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use... -
Page 7: General
Safety instructions General General DANGER 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 8 Safety instructions General WARNING 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 9 Safety instructions General CAUTION Damage due to the use of non-genuine 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 10 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): 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 11: Transport And Installation
Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •... -
Page 12: Ambient Conditions
Safety instructions Ambient conditions Ambient conditions CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 13: Intended Use
Intended use Use and operation solely with the following machines Intended use This machine has been manufactured according to the latest developments in technology and current regulations and standards. It must only be operated in line with the instructions on correct usage. WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not... -
Page 14: Documents Which Also Apply
Intended use Documents which also apply Documents which also apply 3.3.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.3.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 15: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Carrying handle Main switch, machine on/off Connection socket, “+” welding current • MIG/MAG welding: welding current connection for the welding torch •... -
Page 16: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Connection socket, 7-pole Connection for peripheral devices with digital interface Key button, Automatic cutout Wire feed motor supply voltage fuse (press to reset a triggered fuse) Cooling air outlet Cooling air inlet Connection socket, "+"... -
Page 17: Design And Function
Design and function General Design and function General CAUTION Insulate the arc welder from welding voltage! Not all active parts of the welding current circuit can be shielded from direct contact. To avoid any associated risks it is vital for the welder to adhere to the relevant safety regulations. -
Page 18: Installation
Design and function Installation Installation WARNING Risk of accident due to improper transport of machines that may not be lifted! Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only! •... -
Page 19: Mains Connection
Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations (any phase sequence for three-phase machines)! -
Page 20: Connecting The Intermediate Tube Package To The Power Source
Design and function Connecting the intermediate tube package to the power source Connecting the intermediate tube package to the power source 5.6.1 Intermediate tube package strain relief CAUTION Missing or incorrectly fitted strain relief! Connection sockets or connection plugs on the machine, or the intermediate tube package, may be damaged if the strain relief is missing or incorrectly fitted. -
Page 21: Intermediate Tube Package Connection
Design and function Connecting the intermediate tube package to the power source 5.6.2 Intermediate tube package connection NOTE Note the polarity of the welding current! 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 "+"... -
Page 22: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Connecting the intermediate tube package to the power source 5.6.3 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 23: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.7.1 Connection for workpiece lead NOTE Note the polarity of the welding current! 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 "+"... -
Page 24: Remote Control
Design and function R 40 5.7.2 Remote control CAUTION Using protective dust caps! 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. -
Page 25: 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 26: Shielding Gas Supply
Design and function Shielding gas supply 5.10 Shielding gas supply 5.10.1 Gas test • Slowly open the gas cylinder valve. • Open the pressure reducer. • Switch on the power source at the main switch. • Initiate gas test function on the machine control. •... -
Page 27: Interfaces
Design and function Interfaces 5.11 Interfaces CAUTION Damage due to the use of non-genuine 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 28: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! •... -
Page 29: Maintenance Work
Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922. •... -
Page 30: Rectifying Faults
Rectifying faults Customer checklist 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 31: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) NOTE 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. •... -
Page 32: 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 NOTE All customised welding parameters that are stored will be replaced by the factory settings. 7.3.1 Resetting a single JOB JOB- JOB- LIST LIST m /m in... -
Page 33: Resetting All Jobs
Rectifying faults Resetting JOBs (welding tasks) to the factory settings 7.3.2 Resetting all JOBs JOB- JOB- LIST LIST m /m in 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. 099-008717-EW501 24.03.2011... -
Page 34: Technical Data
Technical data Phoenix 404 Progress Technical data Phoenix 404 Progress NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Setting range: Welding current/voltage 5 A/20.2 V to 400 A/36 V 5 A/10.2 V to 400 A/26 V MIG/MAG 5 A/14.2 V to 400 A/34 V Duty cycle at 40 °C ambient temperature... -
Page 35: Accessories, Options
Accessories, options System components Accessories, options NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. System components Type Designation Item no. Phoenix Progress drive 4L RE Wire feed unit, water, Euro central connector, opens 090-008602-00502 on the right Transport systems... -
Page 36: Overview Of Ewm Branches
50259 Pulheim · Germany · Tel: +49 2234 697-047 · Fax: -048 www.ewm-group.com/handel · nl-koeln@ewm-group.com Sales and Service International EWM HIGHTEC WELDING GmbH EWM HIGHTEC WELDING Sales s.r.o. / Prodejní a poradenské centrum Fichtenweg 1 Tyršova 2106 4810 Gmunden · Austria · Tel: +43 7612 778 02-0 · Fax: -20 256 01 Benešov u Prahy ·...
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