EWM Phoenix 401 Progress puls LP MM FKW Operating Instructions Manual
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EWM Phoenix 401 Progress puls LP MM FKW Operating Instructions Manual

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Operating instructions
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099-005504-EW501
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Welding machine
Phoenix 401 Progress puls LP MM FKW
Phoenix 501 Progress puls LP MM FKW
20.11.2015
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  • Page 1 Operating instructions Welding machine Phoenix 401 Progress puls LP MM FKW Phoenix 501 Progress puls LP MM FKW 099-005504-EW501 20.11.2015 Register now and benefit! Jetzt Registrieren und Profitieren! www.ewm-group.com...
  • Page 2 +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 ..........................7 Notes on the use of these operating instructions ................7 Explanation of icons ........................8 General ............................9 Transport and installation ......................13 2.4.1 Lifting by crane ......................
  • Page 4 Contents Notes on the use of these operating instructions 5.10.2.5 Spool brake setting ..................44 5.10.3 Definition of MIG/MAG welding tasks ................45 5.10.4 Welding task selection ....................45 5.10.4.1 Basic welding parameters ................45 5.10.4.2 Operating mode ..................... 45 5.10.4.3 Choke effect / dynamics ................
  • Page 5 Wire feed rollers for aluminium wire ................104 10.1.3 Wire feed rollers for cored wire .................. 104 10.1.4 Wire guide ........................104 11 Appendix A ............................105 11.1 JOB-List ............................. 105 12 Appendix B ............................106 12.1 Overview of EWM branches ...................... 106 099-005504-EW501 20.11.2015...
  • Page 6 Contents Notes on the use of these operating instructions 099-005504-EW501 20.11.2015...

  • Page 7: 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 8: Explanation Of Icons

    Safety instructions Explanation of icons Explanation of icons Symbol Description Special technical points which users must observe. Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine enter the menu ENTER Navigating in the menu NAVIGATION Exit the menu EXIT...

  • Page 9: General

    Safety instructions General General DANGER Electric shock! Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents. • Do not touch any live parts in or on the machine! •...
  • Page 10 Safety instructions General 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! Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning.
  • Page 11 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
  • Page 12 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes - See 8 Technical data chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.

  • Page 13: 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 14: Lifting By Crane

    Safety instructions Transport and installation 2.4.1 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. • Simultaneous lifting of system components such as power source wire feeder or cooling unit without suitable crane components is not allowed.

  • Page 15: Ambient Conditions

    Safety instructions Transport and installation 2.4.2 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 16: Intended Use

    Intended use Applications Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with proper usage and by trained or expert staff! •...

  • Page 17: Documents Which Also Apply

    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 designated machine conforms to EC Directives and standards in terms of its design and construction: •...

  • Page 18: 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 Ready for operation signal light Signal light on when the machine is switched on and ready for operation 099-005504-EW501...
  • Page 19 Machine description – quick overview Front view Item Symbol Description Main switch, machine on/off Carrying handle Cooling air inlet Automatic cut-out of coolant pump key button press to reset a triggered fuse Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply Wheels, guide castors Coolant tank...

  • Page 20: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-005504-EW501 20.11.2015...
  • Page 21 Machine description – quick overview Rear view Item Symbol Description Slide latch, lock for the protective cap Securing elements for shielding gas cylinder (strap/chain) 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.

  • Page 22: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-3 099-005504-EW501 20.11.2015...
  • Page 23 Machine description – quick overview Inside view Item Symbol Description Welding torch function changeover switch (special welding torch required) Changing over programs or JOBs Infinite adjustment of welding performance. Wire spool holder Wire feed unit 099-005504-EW501 20.11.2015...

  • Page 24: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 Item Symbol Description Push-button, welding task selection (JOB) SP1/2/3 Special JOBs (Phoenix Expert only). Pressing the push-button longer: special JOB selection. Pressing the push-button briefly: switching between special JOBs.
  • Page 25 Machine description – quick overview Machine control – Operating elements Item Symbol Description Rotary knob, welding parameter setting • Setting the welding task (JOB). With machines of the Phoenix Expert series, welding tasks are selected at the power source control. •...

  • Page 26: Design And Function

    Design and function General Design and function General 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 27: Installation

    Design and function Installation CAUTION Damage due to incorrect connection! Accessory components and the power source itself can be damaged by incorrect connection! • Only insert and lock accessory components into the relevant connection socket when the machine is switched off. •...

  • Page 28: Notes On The Installation Of Welding Current Leads

    Design and function Notes on the installation of welding current leads 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 29 Design and function Notes on the installation of welding current leads Use an individual welding lead to the workpiece for each welding machine! Figure 5-2 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.

  • Page 30: Welding Torch Cooling System

    Design and function Welding torch cooling system Welding torch cooling system CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! • Only use the coolant described in this manual (overview of coolants). •...

  • Page 31: Adding Coolant

    Design and function Welding torch cooling system 5.6.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. Figure 5-4 Item Symbol Description Coolant tank cap Coolant filter sieve Coolant tank "Min" mark Minimum coolant level •...

  • Page 32: 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! •...

  • Page 33: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) 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 34: Gas Test

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.8.1 Gas test • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. • Initiate gas test function on the machine control. •...

  • Page 35: 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 36: Mig/Mag Welding

    Design and function MIG/MAG welding 5.10 MIG/MAG welding 5.10.1 Welding torch and workpiece line connection CAUTION 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 37 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 5-8 Item Symbol...
  • Page 38 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 39: Wire Feed

    Design and function MIG/MAG welding 5.10.2 Wire feed 5.10.2.1 Open the protective flap of the wire feeder CAUTION To perform the following steps, the protective flap of the wire feeder needs to be opened. Make sure to close the protective flap again before starting to work. •...

  • Page 40: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.10.2.3 Changing the wire feed rollers Figure 5-10 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 41 Design and function MIG/MAG welding Unsatisfactory welding results due to faulty wire feeding! The wire feed rollers must be suitable for the diameter of the wire and the material. The wire feed rollers are colour-coded to facilitate distinction (see the Wire feed roller overview table). Wire feed roller overview table Material Diameter...

  • Page 42: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.10.2.4 Inching the wire electrode 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 43 Design and function MIG/MAG welding Figure 5-11 Item Symbol Description Welding wire Wire feed nipple Guide tube Adjusting nut • Extend and lay out the torch hose package. • Carefully unwind the welding wire from the wire spool and insert through the wire feed nipples up to the wire feed rollers.

  • Page 44: Spool Brake Setting

    Design and function MIG/MAG welding 5.10.2.5 Spool brake setting Figure 5-13 Item Symbol Description Allen screw Securing the wire spool retainer and adjustment of the spool brake • Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect. Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation! 099-005504-EW501...

  • Page 45: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.10.3 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 . •...

  • Page 46: Choke Effect / Dynamics

    Design and function MIG/MAG welding 5.10.4.3 Choke effect / dynamics EXIT ENTER Figure 5-14 Display Setting/selection Dynamics setting 40: Arc harder and narrower -40: Arc softer and wider 099-005504-EW501 20.11.2015...

  • Page 47: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.10.5 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: Arc Length Correction Setting

    Design and function MIG/MAG welding 5.10.5.3 Arc length correction setting The arc length can be corrected as follows. Operating Action Result Display element "Arc length correction" setting (Display example: -0.9V, setting range -9.9 V to +9.9 V) 5.10.5.4 Accessory components for operating point setting The operating point can also be set with various accessory components such as •...

  • Page 49: Forcearc / Forcearc Puls

    Design and function MIG/MAG welding 5.10.6 forceArc / forceArc puls Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range. Figure 5-16 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 50: Rootarc/Rootarc Puls

    Design and function MIG/MAG welding 5.10.7 rootArc/rootArc puls Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding. Figure 5-17 • 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 5.10.8 MIG/MAG functional sequences / operating modes 5.10.9 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 Wire electrode is being conveyed Wire creep Wire burn-back Gas pre-flows...
  • Page 52 Design and function MIG/MAG welding Non-latched mode Figure 5-18 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 Special, non-latched Figure 5-19 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 54 Design and function MIG/MAG welding Spot welding Figure 5-20 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 55 Design and function MIG/MAG welding Latched mode Figure 5-21 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 56 Design and function MIG/MAG welding Latched special Figure 5-22 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 57: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.10.10 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 58: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.10.10.1 Example, tack welding (non-latched) Figure 5-24 5.10.10.2 Example, aluminium tack welding (non-latched special) Figure 5-25 5.10.10.3 Example, aluminium welding (latched special) Figure 5-26 099-005504-EW501 20.11.2015...

  • Page 59: Main Program A Mode

    Design and function MIG/MAG welding 5.10.11 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 60 Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-27 Example 2: Welding different positions on a workpiece (latched) Figure 5-28 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-29 Up to 16 programs (P...

  • Page 61: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.10.11.1 Selecting parameters (program A) Changes to the welding parameters can only be made when the key switch is in position "1". Operating Action Result Display element Change welding data display over to program display. (LED Prog is on) Select program number.

  • Page 62: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.10.13 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- See 5.17 Special parameters (advanced settings) chapter: •...

  • Page 63: Tig Welding

    Design and function TIG welding 5.11 TIG welding 5.11.1 Welding torch and workpiece line connection Figure 5-31 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 64: Welding Task Selection

    Design and function TIG welding 5.11.2 Welding task selection • Select JOB 127 (TIG welding task). It is only possible to change the JOB number when no welding current is flowing. Operating Action Result Display element Select JOB number input Set the JOB number The machine adopts the required setting after approx.

  • Page 65: Function Sequences/Operating Modes

    Design and function TIG welding 5.11.4 Function sequences/operating modes 5.11.4.1 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 66 Design and function TIG welding Non-latched mode Figure 5-33 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 67 Design and function TIG welding Latched mode Figure 5-35 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 68: Tig Automatic Cut-Out

    Design and function TIG welding Latched special Figure 5-36 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 69: Mma Welding

    Design and function MMA welding 5.12 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 70: Welding Task Selection

    Design and function MMA welding 5.12.2 Welding task selection • Select JOB 128 (MMA welding task). It is only possible to change the JOB number when no welding current is flowing. Operating Action Result Display element Select JOB number input Set the JOB number The machine adopts the required setting after approx.

  • Page 71: Remote Control

    Design and function Remote control 5.13 Remote control 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 72: Automation Interface

    Design and function Interfaces for automation 5.14.1 Automation interface These accessory components can be retrofitted as an option - See 9 Accessories 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 73: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.14.2 Remote control connection socket, 19-pole Figure 5-40 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 74: Rint X12 Robot Interface

    Design and function PC Interfaces 5.14.3 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 75: Protecting Welding Parameters From Unauthorised Access

    Design and function Protecting welding parameters from unauthorised access 5.16 Protecting welding parameters from unauthorised access 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 76 Design and function Special parameters (advanced settings) ENTER EXIT VOLT Prog Hold NAVIGATION Figure 5-41 Display Setting/selection Ramp time for wire inching 0 = normal inching (10s ramp time) 1 = fast inching (3s ramp time) (Ex works) Block program "0" 0 = P0 enabled (Ex works) 1 = P0 blocked 099-005504-EW501...
  • Page 77 Design and function Special parameters (advanced settings) Display Setting/selection Display mode for Up/Down welding torch with one-digit 7-segment display (two keys) 0 = normal display (ex works) program number/JOB or welding performance/welding voltage correction is shown 1 = alternating display display switches between program number and welding method Program limitation Programs 1 to max.

  • Page 78: Reset To Factory Settings

    Design and function Special parameters (advanced settings) Display Setting/selection Mean value display for superPuls Function switched off. 1 = Function switched on (ex factory). Predefined pulse arc welding process in the PA program Predefined pulse arc welding process in the PA program is disabled. 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 79: Special Parameters In Detail

    Design and function Special parameters (advanced settings) 5.17.1.2 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 80 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 81 Design and function Special parameters (advanced settings) Operating Action Result Display (examples) element Left Right Press button until "PROG" LED comes Left: Wire feed speed Right: Program number Press button and hold down for approx. Left: Current limit value of the wire feed speed correction Right: Current limit value of the...
  • Page 82 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 83 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 84 Design and function Special parameters (advanced settings) Latched special tapping time setting (P11) The tapping time for changing over between the main program and reduced main program can be set in three levels. 0 = no tapping 1 = 320ms (factory setting) 2 = 640ms JOB list switching (P12) Value Designation...
  • Page 85 Design and function Special parameters (advanced settings) Copying JOBs, "Copy to" function The possible target range is between 129 - 169. • First configure special parameter P12 to P12 = 2 or P12 = 1! Operating Action Result Display element Select JOB list Select the source JOB Wait for around 3 seconds until the JOB has...
  • Page 86 Design and function Special parameters (advanced settings) Block JOB mode (P16) The following accessory components support block JOB mode: • Up/Down welding torch with one-digit 7-segment display (two keys) Program 0 is always active in JOB 0 and program 1 in all other JOBs In this operating mode, a total of 27 JOBs (welding tasks) divided into three blocks can be called up using accessory components.
  • Page 87 Design and function Special parameters (advanced settings) Mean value display for superPuls (P19) Function active (P19 = 1) • For superPuls, the performance mean value from program A (P ) and program B (P ) is shown on the display (ex factory). Function inactive (P19 = 0) •...

  • Page 88: Machine Configuration Menu

    Design and function Machine configuration menu 5.18 Machine configuration menu 5.18.1 Selecting, changing and saving parameters ENTER (Enter the menu) • Switch off the machine at the main switch. • Press and hold the "welding parameters" or "choke effect" (drive 4X LP) push-button and switch the machine on again at the same time.

  • Page 89: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.18.2 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 90: 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 91: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal DANGER Improper maintenance and testing The equipment may only be cleaned, repaired or tested by specialist, skilled persons! A skilled person is one who, due to training, knowledge and experience, is able to recognise the dangers that can occur during testing of this equipment as well as possible subsequent damage and who is able to implement the required safety procedures.

  • Page 92: Monthly Maintenance Tasks

    In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU).

  • Page 93: 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 94: Error Messages

    Rectifying faults Error messages Error messages 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 95 Rectifying faults Error messages Error Category Possible cause Remedy Error 18 No speedometer signal from Check the connection and particularly the (WF. Sl.) second wire feeder (slave speedometer of the second wire feeder drive) (slave drive). Error 56 Mains phase failure Check mains voltages (no Pha) Legend for categories (error reset)

  • Page 96: 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 RESET ENTER EXIT Figure 7-1 Display Setting/selection...

  • Page 97: 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. RESET 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 98: 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 7-3 099-005504-EW501...

  • Page 99: Technical Data

    Technical data Phoenix 401 Progress FKW Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 401 Progress FKW MIG/MAG Setting range for welding current 5 A–400 A Setting range for welding voltage 14.3 V–34.0 V 10.2 V–26.0 V 20.2 V–36.0 V Duty cycle at 40 °C...

  • Page 100: Phoenix 501 Progress Fkw

    Technical data Phoenix 501 Progress FKW Phoenix 501 Progress FKW MIG/MAG Setting range for welding current 5 A–500 A Setting range for welding voltage 14.3 V–39.0 V 10.2 V–30.0 V 20.2 V–40.0 V Duty cycle at 40 °C 500 A 100% 430 A ...

  • Page 101: 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 TYP 1 Frost protection tester 094-014499-00000 KF 23E-10 Coolant (-10 °C), 9.3 l 094-000530-00000...

  • Page 102: Options

    Accessories Options Options Type Designation Item no. 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 ON Hose/FR Mount Optional holder for tubes and remote control for...

  • Page 103: Replaceable Parts

    Replaceable parts Wire feed rollers Replaceable parts 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 104: 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 105: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List Figure 11-1 099-005504-EW501 20.11.2015...

  • Page 106: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005504-EW501 20.11.2015...

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