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

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Operating instructions
Welding machine
Phoenix 355 Progress puls HP MM TKM
EN
099-005403-EW501
Observe additional system documents!
10.2.2022

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Summary of Contents for EWM Phoenix 355 Progress puls HP MM TKM

  • Page 1 Operating instructions Welding machine Phoenix 355 Progress puls HP MM TKM 099-005403-EW501 Observe additional system documents! 10.2.2022...
  • 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.

  • Page 3: Table Of Contents

    Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................7 Notes on using these operating instructions ................7 Explanation of icons ....................... 8 Safety instructions ........................9 Transport and installation ....................12 3 Intended use ..........................
  • Page 4 Contents Notes on using these operating instructions 5.3.7.1 Accessory components for operating point setting ....... 44 5.3.7.2 Arc length ....................44 5.3.7.3 Arc dynamics (choke effect) ..............44 5.3.7.4 superPuls ....................44 5.3.7.5 Burn-back ....................45 5.3.8 Conventional MIG/MAG Welding (GMAW non synergic) ........46 5.3.8.1 Setting the operating point (welding output)..........
  • Page 5 Contents Notes on using these operating instructions 5.10 PC interface ......................... 84 5.10.1 Connection ......................84 5.11 Special parameters (advanced settings) ................84 5.11.1 Selecting, changing and saving parameters ............85 5.11.2 Reset to factory settings ..................87 5.11.3 Special parameters in detail ................. 87 5.11.3.1 Ramp time for wire inching (P1) ............
  • Page 6 Contents Notes on using these operating instructions 9.1.1 Coolant - type blueCool ..................109 9.1.2 Coolant - type KF ....................109 Transport system ....................... 109 Options ..........................109 General accessories ......................110 Remote control/connecting and extension cable ............... 110 9.5.1 7-pole connection ....................

  • Page 7: For Your Safety

    For your safety Notes on using these operating instructions For your safety Notes on using 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

    For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the u- Activate and release / Tap / Tip ser must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Correct / Valid...

  • Page 9: 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 10 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
  • Page 11 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...

  • Page 12: Transport And Installation

    For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.
  • Page 13 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.

  • Page 14: Intended Use

    3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration.

  • Page 15: Service Documents (Spare Parts And Circuit Diagrams)

    Intended use Documents which also apply 3.3.4 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 16: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-005403-EW501 10.2.2022...
  • Page 17 Machine description – quick overview Front view Item Symbol Description Carrying handle Machine control > see 4.3 chapter 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Park socket, polarity selection plug Retainer for the polarity selection plug in MMA mode or for transport.

  • Page 18: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-2 Item Symbol Description Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, there are added information stickers on the inside of the flap for the operation and maintenance of the machine.

  • Page 19: Operating Elements In The Machine

    Machine description – quick overview Inside view 4.2.1 Operating elements in the machine Figure 4-3 Item Symbol Description Key button, automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse Welding torch function changeover switch (special welding torch required) ---- Changing over programs or JOBs ---- Infinite adjustment of welding performance.
  • Page 20 Machine description – quick overview Inside view 099-005403-EW501 10.2.2022...

  • Page 21: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 Item Symbol Description Functional sequence > see 4.3.1 chapter Welding task push-button (JOB) JOB- LIST Select the welding task from the welding task list (JOB-LIST). The list can be found in- side the protective cap on the wire feeder and in the appendix to these operating in- structions.
  • Page 22 Machine description – quick overview Machine control – Operating elements Item Symbol Description Operating modes push-button (functional sequences) > see 5.3.12 chapter -------- Non-latched ------ Latched -------- Signal light turns green: Special non-latched ---- Signal light turns red: MIG spots -------- Special latched Welding type push-button --------- Standard arc welding...

  • Page 23: Function Sequence

    Machine description – quick overview Machine control – Operating elements 4.3.1 Function sequence Figure 4-5 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. Signal light, gas pre-flow time Setting range 0.0 s to 20.0 s Signal light, start program (P...

  • Page 24: Welding Data Display

    Machine description – quick overview Machine control – Operating elements 4.3.2 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 25: Design And Function

    Design and function General Design and function General WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •...

  • Page 26: Transport And Installation

    Design and function Transport and installation Transport and installation WARNING Risk of accident due to improper transport of machines that must not be lifted! Do not lift or suspend the machine! The machine can drop and cause injuries! The handles, straps or brackets are suitable for transport by hand only! •...

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

    Design and function Transport and installation 5.2.4 Notes on the installation of welding current leads • Incorrectly installed welding current leads can cause faults in the arc (flickering). • Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel.

  • Page 28: Stray Welding Currents

    Design and function Transport and installation 5.2.5 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. •...

  • Page 29: Mains Connection

    Design and function Transport and installation 5.2.6 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 nati- onal regulations! •...

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

    Design and function Transport and installation 5.2.7 Shielding gas supply (shielding gas cylinder for welding machine) WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! •...

  • Page 31: Shielding Gas Hose Connection

    Design and function Transport and installation 5.2.7.2 Shielding gas hose connection Figure 5-7 Item Symbol Description Connection thread - G¼" Shielding gas connection (inlet) • Screw the gas hose connection to the shielding gas connection (inlet) on the machine gas-tight. 5.2.7.3 Shielding gas volume settings If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause...

  • Page 32: Gas Test

    Design and function Transport and installation 5.2.7.4 Gas test Figure 5-8 5.2.7.5 Purge hose package 300s Figure 5-9 5.2.8 Welding torch cooling system 5.2.8.1 Cooling unit connection Figure 5-10 Item Symbol Description Cooling module 4-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead 099-005403-EW501...

  • Page 33: Welding Torch Holder

    Design and function Transport and installation • Insert and lock the 4-pole supply plug on the cooling unit into the 4-pole connection socket on the welding machine. • Insert and lock the 8-pole control lead plug on the cooling unit into the 8-pole connection socket on the welding machine.

  • Page 34: Protective Flap, Welding Machine Control

    Design and function Transport and installation 5.2.10 Protective flap, welding machine control Figure 5-12 Item Symbol Description Protective cap Bracket, protective cap • Push the right-hand bracket of the protective cap to the right and remove the protective cap. 5.2.11 Dirt filter These accessory components can be retrofitted as an option >...

  • Page 35: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.3.1 Assemble the wire guide The Euro torch connector is factory-fitted with a guide tube for welding torches with steel liner. Conver- sion is necessary if a welding torch with a steel liner is used! •...

  • Page 36: Welding Torch And Workpiece Line Connection

    Design and function MIG/MAG welding 5.3.2 Welding torch and workpiece line connection Figure 5-15 Item Symbol Description Welding torch Polarity selector plug, welding current cable Internal welding current cable for central connection/welding torch. • ---------- Connection socket for “+” welding current Workpiece •...

  • Page 37: Inserting The Wire Spool

    Design and function MIG/MAG welding 5.3.3.1 Inserting the wire spool CAUTION Risk of injury due to incorrectly secured wire spool. If the wire spool is not secured properly, it may come loose from the wire spool support and fall to the ground, causing damage to the machine and injuries. •...

  • Page 38: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.3.3.2 Changing the wire feed rollers Figure 5-18 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 39 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 40: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.3.3.3 Inching the wire electrode CAUTION Risk of injury due to welding wire escaping from the welding torch! The welding wire can escape from the welding torch at high speed and cause bodily in- jury including injuries to the face and eyes! •...

  • Page 41: Spool Brake Setting

    Design and function MIG/MAG welding • The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll ten- sioner setting nuts depending on the welding consumable used. A table with the setting values can be found on a sticker near the wire drive.

  • Page 42: Definition Of Mig/Mag Welding Tasks

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

  • Page 43: Operating Mode

    Design and function MIG/MAG welding 5.3.5.2 Operating mode The operating mode determines the process sequence controlled by the welding torch. Detailed descripti- ons of the operating modes > see 5.3.12 chapter. Figure 5-23 5.3.6 Welding type Different forms of MIG/MAG processes are collectively referred to as welding type. Standard (welding with standard arc) Depending on the set combination of wire feed speed and arc voltage, the arc types short arc, transitional arc or spray arc can be used for welding.

  • Page 44: Accessory Components For Operating Point Setting

    Design and function MIG/MAG welding 5.3.7.1 Accessory components for operating point setting The operating point can be set at various accessory components as well, such as remote control, special welding torches or robot and industrial bus interfaces (optional interface for automated welding required, not available for all machines of this series).

  • Page 45: Burn-Back

    Design and function MIG/MAG welding Display Setting/selection Switch on Switching on machine function Switch off Switching off machine function 5.3.7.5 Burn-back The wire burn-back parameter prevents the sticking of the wire electrode in the weld pool or at the contact tip at the end of the welding process.

  • Page 46: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Design and function MIG/MAG welding 5.3.8 Conventional MIG/MAG Welding (GMAW non synergic) It is only possible to change the JOB number when no welding current is flowing. Wire feed speed and welding voltage can be configured independently in two performance ranges: •...

  • Page 47: Welding Power (Operating Point)

    Design and function MIG/MAG welding 5.3.9 Welding power (operating point) The welding power is adjusted according to the principle of one-knob operation. The user can set their operating point optionally as wire feed speed, welding current or material thickness. The optimum welding voltage for the operating point is calculated and set by the welding machine.

  • Page 48: Forcearc / Forcearc Puls

    Design and function MIG/MAG welding 5.3.10 forceArc / forceArc puls Heat-reduced, directionally-stable and powerful arc with deep fusion penetration for the upper power range. Figure 5-34 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 49: Operating Modes (Functional Sequences)

    Design and function MIG/MAG welding 5.3.12 Operating modes (functional sequences) There are optimum pre-sets for welding parameters such as gas pre-flow and burn back, etc. for numerous applications (although these can also be changed if required). 5.3.12.1 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 50 Design and function MIG/MAG welding Non-latched mode Figure 5-36 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 51 Design and function MIG/MAG welding Non-latched operation with superpulse Figure 5-37 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 52 Design and function MIG/MAG welding Special, non-latched Figure 5-38 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 53 Design and function MIG/MAG welding Spot welding Figure 5-39 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 54 Design and function MIG/MAG welding Special, non-latched with superpulse Figure 5-40 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P for the time t START...
  • Page 55 Design and function MIG/MAG welding Latched mode Figure 5-41 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 mode with superpulse Figure 5-42 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 57 Design and function MIG/MAG welding Latched with changing welding method (process switching) To activate or set the function > see 5.3.17 chapter. Figure 5-43 1st cycle: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed"...
  • Page 58 Design and function MIG/MAG welding Latched special Figure 5-44 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 59 Design and function MIG/MAG welding Special latched with changing welding method by tapping (process switching) To activate or set the function > see 5.3.17 chapter. Figure 5-45 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
  • Page 60 Design and function MIG/MAG welding Special latched with changing welding method (process switching) To activate or set the function > see 5.3.17 chapter. Figure 5-46 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) •...
  • Page 61 Design and function MIG/MAG welding Special, latched with superpulse Figure 5-47 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 62: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.3.13 MIG/MAG program sequence ("Program steps" mode) Certain materials, aluminium for example, require special functions for reliable and high-quality welding. In this case, the special latched mode is used with the following programs: • Start program P (avoidance of cold welds at start of seam) START •...

  • Page 63: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.3.13.2 MIG/MAG overview of parameters , and P are set as relative programs ex faxtory. They relate to percentages of the wire START feed value of the main program P . These programs can also be set in an absolute manner, if desired (see Setting of special parameter P21).

  • Page 64: Example, Aluminium Tack Welding (Non-Latched Special)

    Design and function MIG/MAG welding 5.3.13.4 Example, aluminium tack welding (non-latched special) Figure 5-52 Basic parameters Welding parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20.0s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 65: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.3.13.5 Example, aluminium welding (latched special) Figure 5-53 Basic parameters Welding parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20.0s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 66: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.3.13.6 Example, visible seams (latched super pulse) Figure 5-54 Basic parameters Welding parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20.0s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 67: Main Program A Mode

    Design and function MIG/MAG welding 5.3.14 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 68: Selecting Parameters (Program A)

    Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-55 Example 2: Welding different positions on a workpiece (latched) Figure 5-56 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-57 Up to 16 programs (P...

  • Page 69: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.3.15 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 Additional functions such as program switching (before or after welding) are possible by tapping the torch trigger (depending on machine type and control configuration).

  • Page 70: Expert Menu (Mig/Mag)

    Design and function MIG/MAG welding 5.3.17 Expert menu (MIG/MAG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa- rameters shown may be limited, e.g. if a function is deactivated. 5.3.17.1 Selection Figure 5-60 Display Setting/selection Burn-back time >...

  • Page 71: Programme Limit

    Design and function MMA welding Display Setting/selection Pulse arc welding process (program P The pulse arc welding process can be activated in the end program (P ) with the spe- cial non-latched and special latched operating modes. -------Function activated. -------Function deactivated. Ignition type (MIG/MAG) Application: Low-spatter ignition, e.g.

  • Page 72: Welding Task Selection

    Design and function MMA welding • Insert the polarity selection plug in the park socket and lock in place by turning to the right. • Insert the electrode holder plug and workpiece lead into the welding current socket depending on ap- plication and lock in place by turning to the right.

  • Page 73: Hotstart

    Design and function MMA welding 5.4.5 Hotstart The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent metal at the beginning of the welding process. The ignition takes place here with increased current (hot start current) over a certain time (hot start time).

  • Page 74: Tig Welding

    Design and function TIG welding TIG welding 5.5.1 Preparing the TIG welding torch The TIG welding torch is to be equipped to suit the relevant welding task! • Fit suitable tungsten electrodes and • an appropriate shielding gas nozzle. • Observe the operating instructions for the TIG welding torch! 5.5.2 Welding torch and workpiece line connection...

  • Page 75: Welding Current Setting

    Design and function TIG welding 5.5.4 Welding current setting Figure 5-70 5.5.5 Arc ignition 5.5.5.1 Liftarc Figure 5-71 The arc ignites through contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip against the workpiece (lift arc current flows independent of the set main current) b) Angle the torch above the torch gas nozzle until the distance between electrode tip and workpiece is approx.

  • Page 76: Operating Modes (Functional Sequences)

    Design and function TIG welding 5.5.6 Operating modes (functional sequences) 5.5.6.1 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...
  • Page 77 Design and function TIG welding Non-latched mode Figure 5-72 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 78 Design and function TIG welding Latched mode Figure 5-74 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 79 Design and function TIG welding Latched special Figure 5-75 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 80: Tig Program Sequence ("Program Steps" Mode)

    Design and function Access control 5.5.7 TIG program sequence ("Program steps" mode) Figure 5-76 Basic parameters Item Meaning/explanation Setting range Gas pre-flow time 0 s to 0.9 s START 0% to 200% Start current Duration (start program) 0 s to 20 s Slope duration from P to P 0 s to 20 s...

  • Page 81: Remote Control

    Design and function Remote control Remote control The remote controls are operated via the 19-pole remote control connection socket (analogue) or the 7-pole remote control connection socket (digital), depending on the model. Read and observe the documentation to all system and accessory components! Power-saving mode (Standby) You can activate the power-saving mode by either pressing the push-button >...

  • Page 82: Automation Interface

    Design and function Interfaces for automation 5.9.1 Automation interface WARNING No function of the external interrupt equipment (emergency stop switch)! If the emergency stop circuit has been set up using an external interrupt equipment connected to the interface for automated welding, the machine must be configured for this setup.

  • Page 83: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.9.2 Remote control connection socket, 19-pole Figure 5-77 Signal form Short description Output Connection for PE cable screen Output Reference voltage for potentiometer 10 V (max. 10 mA) Input Control voltage specification (0 V–10 V) – wire feed speed Output Reference potential (0 V) Input...

  • Page 84: Pc Interface

    Design and function PC interface 5.10 PC interface Welding parameter software Set all welding parameters on the PC and simply transfer to one or more welding machines (accessory, set consisting of software, interface, connection leads) • Data exchange between power source and PC •...

  • Page 85: Selecting, Changing And Saving Parameters

    Design and function Special parameters (advanced settings) 5.11.1 Selecting, changing and saving parameters Figure 5-79 Display Setting/selection Wire inching / wire return ramp time 0 = --------normal inching (10 s ramp time) 1 = --------fast inching (3 s ramp time) (ex works) Block program "0"...
  • Page 86 Design and function Special parameters (advanced settings) Display Setting/selection Lat. and sp. lat. tapping start 0 = ------- no latched tapping start (Ex works) 1 = ------- latched tapping start possible One or two-wire feed operation 0 = ------- single operation (Ex works) 1 = ------- dual operation, this unit is the "master"...

  • Page 87: Reset To Factory Settings

    Design and function Special parameters (advanced settings) Display Setting/selection Program settings for relative programs 0 = --------Combined setting of relative programs possible (ex works). 1 = --------Individual setting of relative programs possible (ex works). Correction or nominal voltage display 0 = --------Correction voltage display (ex works). 1 = --------Absolute nominal voltage display.

  • Page 88: Program "0", Releasing The Program Block (P2)

    Design and function Special parameters (advanced settings) 5.11.3.2 Program "0", releasing the program block (P2) The program P0 (manual setting) is blocked. Only operation with P1-P15 is possible, irrespective of the key switch position. 5.11.3.3 Display mode for Up/Down welding torch with one-digit 7-segment display (P3) Normal display: •...

  • Page 89: Correction Operation, Threshold Value Setting (P7)

    Design and function Special parameters (advanced settings) 5.11.3.6 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 cor- rection 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 90: Switching Programs With The Standard Torch Trigger (P8)

    Design and function Special parameters (advanced settings) 5.11.3.7 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 91: Latched/Special-Latched Tap Start (P9)

    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 92: Job List Switching (P12)

    Design and function Special parameters (advanced settings) 5.11.3.11 JOB list switching (P12) Name Explanation Task-based JOB numbers are sorted by welding wires and shielding gases. When JOB list selecting, the JOB numbers may be skipped. JOB numbers correspond to the actual memory cells. Every job can Real JOB list be selected, there will be no memory cells if the selection will be skip- ped.

  • Page 93: Lower And Upper Limits Of The Remote Job Changeover Process (P13, P14)

    Design and function Special parameters (advanced settings) By repeating the last two steps, the same source JOB can be copied to multiple target JOBs. If the control does not register any user activity for longer than 5 seconds, the parameter display is shown once more and the copy process is complete.

  • Page 94: Selecting Programs With The Standard Torch Trigger (P17)

    Design and function Special parameters (advanced settings) 5.11.3.15 Selecting programs with the standard torch trigger (P17) Allows you to select a program or switch a program before starting welding. You switch to the next program by tapping the torch trigger. Once the last enabled program is reached, you start again at the beginning.

  • Page 95: Correction Or Nominal Voltage Display (P24)

    Design and function Special parameters (advanced settings) 5.11.3.22 Correction or nominal voltage display (P24) When setting the arc correction using the right-hand rotary knob the display will either show the correction voltage +- 9.9 V (ex works) or the absolute nominal voltage. 5.11.3.23 JOB selection in Expert mode (P25) The special parameter P25 can be used to specify whether the special JOBs SP1/2/3 or the welding job selection according to the JOB list can be selected on the wire feeder.

  • Page 96: Machine Configuration Menu

    Design and function Machine configuration menu 5.12 Machine configuration menu Figure 5-86 Display Setting/selection Lead resistance 1 Lead resistance for the first welding circuit 0 mΩ–60 mΩ (8 mΩ ex works). Lead resistance 2 Lead resistance for the second welding circuit 0 mΩ–60 mΩ (8 mΩ ex works). Only qualified service personnel may change the parameters! Only qualified service personnel may change the parameters! Time-based power-saving mode >...

  • Page 97: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.12.1 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 inter- mediate hose package and a 3 m water-cooled welding torch.

  • Page 98: Power-Saving Mode (Standby)

    Design and function Power-saving mode (Standby) 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 99: 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 100: Explanation Of Icons

    Maintenance, care and disposal Explanation of icons Explanation of icons Person Welder / operator Service staff / expert, qualified person Test Visual inspection Functional check Period, interval One-shift operation Multi-shift operation every 8 hours Daily Weekly Monthly Every 6 months Annually 099-005403-EW501 10.2.2022...

  • Page 101: Maintenance Schedule

    Maintenance, care and disposal Maintenance schedule Maintenance schedule Maintenance step Only personnel designated as inspectors or repairers due to their trai- ning are allowed to carry out the relevant work step! Non-applicable in- spection points are omitted. • Check and clean the welding torch. Deposits in the welding torch may cause short circuits, impair the welding result and lead to welding torch damage! •...

  • Page 102: Disposing Of Equipment

    Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html.

  • Page 103: Rectifying Faults

    Rectifying faults Error messages (power source) 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 dea- ler.
  • Page 104 Rectifying faults Error messages (power source) Category Possible cause Remedy ID number allocation error Correct ID numbers (2DV) Detection of wire feeder 2 Check cable connections Error in open circuit voltage Inform Service. reduction (VRD) Overcurrent detection on wire Check ease of wire feeding feeder Error in tachometer generator Check the connection and particularly the ta-...

  • Page 105: Checklist For Rectifying Faults

    Rectifying faults Checklist for rectifying faults Checklist for rectifying faults The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation! Legend Symbol Description Fault/Cause  Remedy  Functional errors  Mains fuse triggers - unsuitable mains fuse Set up recommended mains fuse >...

  • Page 106: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit Figure 7-1 • Switch off the machine and fill the coolant tank to the maximum level. • Unlock the quick-connect coupling with a suitable tool (connection open). 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 7-2 •...

  • Page 107: 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. 7.4.1 Resetting a single JOB ENTER RESET EXIT Figure 7-3 7.4.2 Resetting all JOBs...

  • Page 108: Technical Data

    Technical data Phoenix 355 Progress puls MM TKM Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 355 Progress puls MM TKM MIG/MAG Welding current (I 5 A to 350 A Welding voltage according to stan- 14,3 V to 31,5 V 10,2 V to 24,0 V 20,2 V to 34,0 V...

  • Page 109: Accessories

    Accessories Welding torch cooling system Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Welding torch cooling system Type Designation Item no. cool50 U40 Cooling module 090-008598-00502 cool50-2 U42 Cooling unit with reinforced pump 090-008797-00502 HOSE BRIDGE UNI Tube bridge...

  • Page 110: General Accessories

    Accessories General accessories 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 16A 5POLE/CEE Mains plug 094-000712-00000 DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 G1 G1/4 R 3M Gas hose 094-000010-00003 Sharpener for liner...

  • Page 111: Networking / Xnet

    Accessories Networking / Xnet Networking / Xnet Type Designation Item no. Xnet LAN Gateway LAN gateway in external casing 090-008833-00502 Xnet WiFi Gateway WiFi gateway in external casing 090-008834-00502 Xnet Extended-Set LAN Xnet retrofit set LAN: One machine licence, a LAN 091-008833-00001 gateway and a network cable (10 m) Xnet retrofit set WiFi: One machine licence, one...

  • Page 112: 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 113: 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 114: Appendix

    Appendix JOB-List Appendix 11.1 JOB-List Procedure Material Ø [mm] GMAW standard G3Si1 / G4Si1 CO2 100 (C1) GMAW standard G3Si1 / G4Si1 CO2 100 (C1) GMAW standard G3Si1 / G4Si1 CO2 100 (C1) GMAW standard G3Si1 / G4Si1 CO2 100 (C1) GMAW standard G3Si1 / G4Si1 CO2 100 (C1)
  • Page 115 Appendix JOB-List Procedure Material Ø [mm] Standard GMAW / pulse CrNi 22 9 3 / 1.4462 Ar-78 / He-20 / CO2-2 (M12) Standard GMAW / pulse CrNi 22 9 3 / 1.4462 Ar-78 / He-20 / CO2-2 (M12) Standard GMAW / pulse CrNi 22 9 3 / 1.4462 Ar-78 / He-20 / CO2-2 (M12)
  • Page 116 Appendix JOB-List Procedure Material Ø [mm] Standard GMAW / pulse Al99 Ar-100 (I1) Standard GMAW / pulse Al99 Ar-100 (I1) Standard GMAW / pulse Al99 Ar-70 / He-30 (I3) Standard GMAW / pulse Al99 Ar-70 / He-30 (I3) Standard GMAW / pulse Al99 Ar-70 / He-30 (I3) Standard GMAW / pulse...
  • Page 117 Appendix JOB-List Procedure Material Ø [mm] Free JOB Free JOB Free JOB Free JOB Free JOB Free JOB Free JOB Free JOB Block 1 / JOB1 Block 1 / JOB2 Block 1 / JOB3 Block 1 / JOB4 Block 1 / JOB5 Block 1 / JOB6 Block 1 / JOB7 Block 1 / JOB8...
  • Page 118 Appendix JOB-List Procedure Material Ø [mm] 173* pipeSolution / pulse G3Si1 / G4Si1 Ar-82 / CO2-18 (M21) 174* pipeSolution / pulse G3Si1 / G4Si1 Ar-82 / CO2-18 (M21) GMAW Highspeed G3Si1 / G4Si1 Ar-90 / CO2-10 (M20) GMAW Highspeed G3Si1 / G4Si1 Ar-90 / CO2-10 (M20) forceArc / forceArc puls G3Si1 / G4Si1...
  • Page 119 Appendix JOB-List Procedure Material Ø [mm] Flux cored wire metal FCW CrNi - Metal Ar-97,5 / CO2-2,5 (M12) Flux cored wire metal FCW CrNi - Metal Ar-97,5 / CO2-2,5 (M12) Flux cored wire rutile FCW CrNi - Rutile Ar-82 / CO2-18 (M21) Flux cored wire rutile FCW CrNi - Rutile Ar-82 / CO2-18 (M21)
  • Page 120 Appendix JOB-List Procedure Material Ø [mm] Standard GMAW / pulse CrNi 23 12 / 1.4332 Ar-97,5 / CO2-2,5 (M12) Standard GMAW / pulse CrNi 23 12 / 1.4332 Ar-97,5 / CO2-2,5 (M12) forceArc / forceArc puls FCW Steel - Metal Ar-82 / CO2-18 (M21) forceArc / forceArc puls FCW Steel - Metal...

  • Page 121: Parameter Overview - Setting Ranges

    Appendix Parameter overview – setting ranges Procedure Material Ø [mm] 330* coldArc / coldArc puls CrNi 18 8 / 1.4370 Ar-97,5 / CO2-2,5 (M12) 331* coldArc / coldArc puls CrNi 18 8 / 1.4370 Ar-97,5 / CO2-2,5 (M12) 332* coldArc / coldArc puls CrNi 18 8 / 1.4370 Ar-97,5 / CO2-2,5 (M12) 334*...

  • Page 122: Mma Welding

    Appendix MMA welding 11.4 MMA welding Name Display Setting range Arcforce 099-005403-EW501 10.2.2022...

  • Page 123: Searching For A Dealer

    Appendix Searching for a dealer 11.5 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005403-EW501 10.2.2022...

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