Praxair PHOENIX 401 BASIC PULS forceArc Operating Instructions Manual
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Praxair PHOENIX 401 BASIC PULS forceArc Operating Instructions Manual

Praxair PHOENIX 401 BASIC PULS forceArc Operating Instructions Manual

Machines for mig/mag and mma welding
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GB Operating instructions
Machines for MIG/MAG and MMA welding
PHOENIX 401 BASIC PULS forceArc;
PHOENIX BASIC DRIVE 4 / 4L
N. B. These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machines may only be operated by personnel who are familiar with the appropriate safety
regulations.
The machines bear the conformity mark and thus comply with the
•
EC Low Voltage Directive (73/23/EEC)
•
EC EMC Directive (89/336/EEC)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.
© 2006
Subject to alteration.
Item No.: 099-004838-PRA01
Dated: 10.04.06

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  • Page 1 GB Operating instructions Machines for MIG/MAG and MMA welding PHOENIX 401 BASIC PULS forceArc; PHOENIX BASIC DRIVE 4 / 4L N. B. These operating instructions must be read before commissioning. Failure to do so may be dangerous. Machines may only be operated by personnel who are familiar with the appropriate safety regulations.
  • Page 2 Declaración de Conformidad CE EU - Conformity declaration Déclaration de Comformidité UE Declaraçao de Conformidade CE Nombre del Fabricante: PRAXAIR SOLDADURA, S.L. Name of manufacturer: C/ Orense, 11 - 9ª planta Nom du fabricant: 28020 MADRID Nome do fabricante: Dirección del Fabricante:...
  • Page 3 Estimado Cliente, ¡Enhorabuena! Usted acaba de elegir un producto de calidad de PRAXAIR SOLDADURA. Con los equipos de PRAXAIR se consiguen unos resultados de la máxima perfección, gracias a su calidad SUPERIOR. ¡Nosotros desarrollamos y producimos calidad! Desde los componentes individuales hasta el producto final, conservamos la exclusiva responsabilidad sobre nuestros equipos.
  • Page 4 Datos del Equipo y de la Empresa Rogamos introduzca los datos del equipo PRAXAIR así como los de su empresa en los campos correspondientes TYP: SNR: ART: PROJ: GEPRÜFT/CONTROL: Nombre de Cliente / Compañía Nombre de Cliente / Compañía Dirección Dirección...

  • Page 5: Table Of Contents

    Contents 1 Contents..............................5 2 Safety instructions ..........................7 3 Technical data ............................10 PHOENIX 401 BASIC PULS forceArc ..................10 PHOENIX BASIC DRIVE 4 / 4L....................11 4 Machine description ..........................12 PHOENIX 401 BASIC PULS forceArc ..................12 4.1.1...
  • Page 6 9 Accessories, options ...........................57 General accessories ........................57 Remote control / connection cable....................57 Options ............................57 Computer communication ......................57 Welding data documentation......................57 10 Circuit diagrams ...........................58 10.1 PHOENIX 401 BASIC PULS forceArc ..................58 10.2 PHOENIX BASIC DRIVE 4 / 4L ....................60 Item No.: 099-004838-PRA01...

  • Page 7: Safety Instructions

    Safety instructions PHOENIX 401 BASIC PULS forceArc Safety instructions Item No.: 099-004838-PRA01...
  • Page 8 Safety instructions PHOENIX 401 BASIC PULS forceArc Item No.: 099-004838-PRA01...
  • Page 9 Safety instructions PHOENIX 401 BASIC PULS forceArc Item No.: 099-004838-PRA01...

  • Page 10: Technical Data

    Technical data PHOENIX 401 BASIC PULS forceArc Technical data PHOENIX 401 BASIC PULS forceArc PHOENIX 401 PULSE forceArc Setting range: Welding current / voltage 5 A / 10.2 V – 400 A / 26.0 V 5 A / 20.2 V – 400 A / 36.0 V 5 A / 14.3 V –...

  • Page 11: Phoenix Basic Drive 4 / 4L

    Technical data PHOENIX BASIC DRIVE 4 / 4L PHOENIX BASIC DRIVE 4 / 4L PHOENIX DRIVE 4 DRIVE 4L Supply voltage 42 VAC / 60 VDC 500 A Max. welding current at 60% DC 0.5 m/min to 24 m/min Wire feed speed Standard WF roller fitting 1.0 + 1.2 mm (for steel wire) 4-roller (37 mm)

  • Page 12: Machine Description

    Machine description PHOENIX 401 BASIC PULS forceArc Machine description PHOENIX 401 BASIC PULS forceArc 4.1.1 Front view Figure 4-1 Item No.: 099-004838-PRA01...
  • Page 13 Machine description PHOENIX 401 BASIC PULS forceArc Item Symbol Description Wire feed unit Lifting lug Carrying handle Main switch, machine on/off Cooling air inlet “Automatic cut-out of coolant pump” key button (press to reset a triggered fuse) Conveyor rolls, guide castors...

  • Page 14: Rear View

    Machine description PHOENIX 401 BASIC PULS forceArc 4.1.2 Rear view The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted (see "Accessories" chapter). Figure 4-2 Item No.: 099-004838-PRA01...
  • Page 15 Machine description PHOENIX 401 BASIC PULS forceArc Item Symbol Description Lifting lug "Automatic cutout" key button Wire feed motor supply voltage fuse (press to reset a triggered fuse) 42V/4A 19-pole connection socket (analogue) Wire feed unit control lead connection PC interface, serial (D-SUB connection socket, 9-pole) PC INT Connector plug, welding current "+"...

  • Page 16: Phoenix Basic Drive 4L

    Machine description PHOENIX BASIC DRIVE 4L PHOENIX BASIC DRIVE 4L 4.2.1 Front view Figure 4-3 Item No.: 099-004838-PRA01...
  • Page 17 Machine description PHOENIX BASIC DRIVE 4L Item Symbol Description Slide latch, lock for the protective cap Label "Wire feed parts subject to wear" "JOB list" sticker Cover for wire delivery unit and operating elements Carrying handle with integrated lifting lug Wire spool casing Control / Operating elements (see chapter Function specification) Spool holder...

  • Page 18: Rear View

    Machine description PHOENIX BASIC DRIVE 4L 4.2.2 Rear view Figure 4-4 Item No.: 099-004838-PRA01...
  • Page 19 Machine description PHOENIX BASIC DRIVE 4L Item Symbol Description Intermediate tube package strain relief 19-pole connection socket (analogue) Wire feed unit control lead connection Connecting nipple G¼, shielding gas connection Rapid-action closure coupling, red (coolant return) Rapid-action closure coupling, blue (coolant supply) Connector plug, welding current "+"...

  • Page 20: Functional Characteristics

    Functional characteristics Machine control – Operating elements Functional characteristics Machine control – Operating elements 5.1.1 Wire feed machine control Figure 5-1 Item Symbol Description “Parameter selection ” (left) Welding current (nominal, actual and hold values) HOLD Material thickness (nominal value) Wire speed (actual, nominal and hold values) After each completed welding process, the last parameter values HOLD...
  • Page 21 Functional characteristics Machine control – Operating elements Item Symbol Description "Select welding parameters" button MIG/MAG standard welding MIG/MAG pulse arc welding "Arc length correction / program number" rotary dial • Arc length correction from -9.9 V to +9.9 V • Setting the program number 0-15 (not possible if accessory components such as program torches is connected) LCD display, 3-digit (right)

  • Page 22: Covered Operating Elements

    Functional characteristics Machine control – Operating elements 5.1.1.1 Covered operating elements Figure 5-2 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. LED "Gas pre-flow time" Setting range 0.0 sec to 20.0 sec LED "start program (P )"...
  • Page 23 Functional characteristics Machine control – Operating elements Item Symbol Description LED “Joblist” Illuminates upon display or selection of the job number “JOBLIST” key button Selection of the welding task (JOB) from the JOB list “Wire inching” button See also “Commissioning/Inching the Wire Electrode” chapter “Gas test / rinse”...

  • Page 24: Job List

    Functional characteristics Machine control – Operating elements 5.1.1.2 JOB list Figure 5-3 Item No.: 099-004838-PRA01...

  • Page 25: Operating Elements In The Machine

    Functional characteristics Machine control – Operating elements 5.1.2 Operating elements in the machine Programm Up / Down Figure 5-4 Item Symbol Description “Gas test” button The welding voltage and wire feed remain off when testing and setting the gas flow. Pressing the key button once causes shielding gas to flow for approx.

  • Page 26: Mig/Mag Welding

    Functional characteristics MIG/MAG welding MIG/MAG welding 5.2.1 Definition of MIG/MAG welding tasks The PHOENIX product range has been designed so that it is very easy and quick to operate, but still provides all the functions one could ever need. For the most common applications, 128 JOBs (welding tasks) have been pre-programmed. The JOB (welding task) is defined using the four basic welding parameters of welding process, material type, wire diameter and gas type.

  • Page 27: Choke Effect / Dynamics

    Functional characteristics MIG/MAG welding 5.2.2.4 Choke effect / dynamics Operating Action Result Display element -40 to +40 Select dynamics welding parameter Press until LED “Dynamic” comes on. -40 to +40 Dynamics setting on the rotary dial “Wire speed/welding parameters” m/min 5.2.2.5 Superpulses Operating...

  • Page 28: Mig/Mag Functional Sequences / Operating Modes

    Functional characteristics MIG/MAG welding 5.2.3 MIG/MAG functional sequences / operating modes The following applies during the wire creep phase: If there is no welding current flowing after 5 seconds (factory setting), the ignition process is cancelled (ignition error). The following applies during the welding phase: If the arc is broken during the welding process and is not re-ignited within 5 seconds (factory setting), there is an automatic cut-out.

  • Page 29: Non-Latched Mode

    Functional characteristics MIG/MAG welding 5.2.3.2 Non-latched mode Figure 5-5 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 30: Non-Latched Operation With Superpulse

    Functional characteristics MIG/MAG welding 5.2.3.3 Non-latched operation with superpulse Figure 5-6 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 31: Special, Non-Latched

    Functional characteristics MIG/MAG welding 5.2.3.4 Special, non-latched START Figure 5-7 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 32: Spots

    Functional characteristics MIG/MAG welding 5.2.3.5 Spots START Figure 5-8 The start time t must also be calculated at spot time t . The start and spot times are set in start the "Program steps mode" menu. Step 1 • Press and hold torch trigger. •...

  • Page 33: Special, Non-Latched With Superpulse

    Functional characteristics MIG/MAG welding 5.2.3.6 Special, non-latched with superpulse START Figure 5-9 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 34: Latched Mode

    Functional characteristics MIG/MAG welding 5.2.3.7 Latched mode Figure 5-10 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 35: Latched Mode With Superpulse

    Functional characteristics MIG/MAG welding 5.2.3.8 Latched mode with superpulse Figure 5-11 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 36: Latched Special

    Functional characteristics MIG/MAG welding 5.2.3.9 Latched special START Figure 5-12 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 37: 5.2.3.10 Special, Latched With Superpulse

    Functional characteristics MIG/MAG welding 5.2.3.10 Special, latched with superpulse START Figure 5-13 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 38: Mig/Mag Automatic Cut-Out

    Functional characteristics MIG/MAG welding 5.2.4 MIG/MAG automatic cut-out If pressing the torch trigger does not ignite the arc or if the arc is interrupted by the torch being removed during the welding process, automatic cut-out occurs within 5 seconds. The welding machine ends the welding process immediately (open circuit voltage or welding current, wire feed and shielding gas are shut off).

  • Page 39: Special Parameter, "Drive 4 P Wire Feed Units

    Functional characteristics MIG/MAG welding 5.2.6 Special parameter, “DRIVE 4 P wire feed units” The special parameters cannot be viewed directly since they are normally only set and stored once. The machine control offers the following special functions: 5.2.6.1 Special parameters list Function Setting options Ex works...

  • Page 40: Reset To Factory Settings

    Functional characteristics MIG/MAG welding 5.2.6.3 Reset to factory settings It is possible to reset all special parameters back to the factory settings. Operating Action Result Display Element left right Switch off the welding machine VOLT Press and hold button PROG Switch on the welding machine Switch welding machine off and back on again to activate the changes...

  • Page 41: Correction Operation, Threshold Value Setting (P7)

    Functional characteristics MIG/MAG welding 5.2.6.10 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 42: Program Changeover With Standard Torch (P8)

    Functional characteristics MIG/MAG welding 5.2.6.11 Program changeover with standard torch (P8) In "Latched absolute program sequence", the machine starts at the first cycle with absolute program 1. Releasing the torch trigger (2nd cycle) switches over to absolute program 2 when the "tstart" ignition time expires.

  • Page 43: Interfaces

    Functional characteristics TIG welding 5.2.7 Interfaces Only the accessory components described in these operating instructions may be connected. Only plug accessory components into the relevant connection socket on the welding machine and lock it when the machine is switched off. The component is detected automatically when the welding machine is switched on.

  • Page 44: Tig Function Sequences / Operating Modes

    Functional characteristics TIG welding 5.3.2 TIG function sequences / operating modes The arc ignition takes place with Liftarc (see chapter "TIG Arc ignition"). After unsuccessful ignition or interruption of the welding procedure, the automatic cut-out takes place (see chapter "TIG Automatic cut-out"). The welding parameters are optimally preset for a multiplicity of applications (can be adapted if required (see chapter TIG Program sequence "Program-Steps mode").

  • Page 45: Non-Latched Mode

    Functional characteristics TIG welding 5.3.2.2 Non-latched mode Figure 5-17 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 46: Latched Mode

    Functional characteristics TIG welding 5.3.2.4 Latched mode Figure 5-19 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 47: Latched Special

    Functional characteristics TIG welding 5.3.2.5 Latched special START Figure 5-20 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 48: Mma Welding

    Functional characteristics MMA welding MMA welding 5.4.1 Arcforcing Operating Action Result Display element -40 to +40 Select arcforcing welding parameter Press until “Dynamic” LED comes on. -40 to +40 Arcforcing setting on the "Wire speed/welding parameters" rotary dial m/min 5.4.2 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current.

  • Page 49: Remote Control

    Functional characteristics Remote control Remote control Only the remote controls described in these operating instructions may be connected. Plug the remote control unit into the remote control connection socket on the welding machine or wire feed unit and lock it only when the machine is switched off. The remote control is detected automatically when the welding machine is switched on.

  • Page 50: Resetting Jobs (Welding Tasks) To The Factory Settings

    Functional characteristics Resetting JOBs (welding tasks) to the factory settings Resetting JOBs (welding tasks) to the factory settings 5.6.1 Resetting a single JOB Operating Action Result Display element Select JOB Reset 3 sec. Set the JOB number to be reset m/min Confirm JOB reset.

  • Page 51: Commissioning

    Commissioning General Commissioning General Warning – Risk from electrical current! Follow the safety instructions on the opening pages entitled “For your safety”. Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead, interfaces) may only be connected when the machine is switched off. Area of application –...

  • Page 52: Maintenance And Care

    Maintenance and care General Maintenance and care General Under the indicated environmental conditions and normal operating conditions, this machine is largely maintenance-free and requires minimum care. However, a number of points should be observed to guarantee fault-free operation of your welding machine. Among these are regular cleaning and checking as described below, depending on the level of contamination in the environment and the usage time of the welding machine.

  • Page 53: Test Intervals And Scope

    Maintenance and care Repetition Test conforming to E VDE 0544-207, conforming to the German Ordinance on Operational Safety 7.3.1 Test intervals and scope A quarterly partial test and an annual extensive test are to be carried out. The extensive test must also be carried out each time that repairs are made;...

  • Page 54: Measurement Of Insulation Resistance

    Maintenance and care Repetition Test conforming to E VDE 0544-207, conforming to the German Ordinance on Operational Safety 7.3.5 Measurement of insulation resistance The mains switch must be on before the insulation in the interior of the machine through to the transformer can be checked.

  • Page 55: Repair Work

    Maintenance and care Repair Work Repair Work 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. Return deliveries of defective equipment subject to warranty may only be made through your dealer.

  • Page 56: Operating Problems, Causes And Remedies

    Operating problems, causes and remedies Error messages (power source) Operating problems, causes and remedies Error messages (power source) All machines are subject to rigorous production and final checks. If, despite this, anything fails to work at any time, please check machine using the chart below. If none of the fault rectification procedures described leads to the correct functioning of the machine, please inform your authorised dealer.

  • Page 57: Accessories, Options

    Accessories, options General accessories Accessories, options General accessories Type Designation Item number KF 23E-10 Coolant (-10 °C), 10 litres 094-000530-00000 KF 37E-10 Coolant (-20 °C), 10 litres 094-006256-00000 DM1 32L/MIN Manometer pressure reducer 094-000009-00000 G1 G1/4 R 2M Gas hose 094-000010-00000 5POLE/CEE/32A/M Machine plug...

  • Page 58: Circuit Diagrams

    Circuit diagrams PHOENIX 401 BASIC PULS forceArc Circuit diagrams Original format circuit diagrams are located inside the machine. 10.1 PHOENIX 401 BASIC PULS forceArc X5/1 42VAC X5/2 0VAC X13/1 X13/2 X15/1 X15/2 X15/3 X15/4 X15/5 X15/6 X15/7 X15/8 X14/1 Motor+...
  • Page 59 Circuit diagrams PHOENIX 401 BASIC PULS forceArc X3/1 Lüfter X3/2 X3/3 X3/4 X3/5 X3/6 Lüfter X3/7 X3/8 Pumpe X3/9 X3/10 X3/11 X3/12 Figure 10-2 Item No.: 099-004838-PRA01...

  • Page 60: Phoenix Basic Drive 4 / 4L

    Circuit diagrams PHOENIX BASIC DRIVE 4 / 4L 10.2 PHOENIX BASIC DRIVE 4 / 4L X1/1 Tacho +5V X1/2 Tacho Signal X1/3 Tacho GND X2/1 Tacho Signal X2/2 Tacho GND Figure 10-3 Item No.: 099-004838-PRA01...

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