EWM Phoenix 355 Expert 2.0 puls MM TKM Operating Instructions Manual
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Summary of Contents for EWM Phoenix 355 Expert 2.0 puls MM TKM
- Page 1 Operating instructions Welding machine Phoenix 355 Expert 2.0 puls MM TKM 099-005445-EW501 Observe additional system documents! 22.9.2022...
- 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.
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Page 3: Table Of Contents
Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use .......................... - Page 4 Disposing of equipment ......................42 7 Rectifying faults..........................43 Checklist for rectifying faults ....................43 8 Technical data..........................45 Phoenix 355 Expert 2.0 puls MM TKM ................45 9 Accessories ..........................46 Welding torch cooling system ....................46 9.1.1 Coolant - type blueCool ..................46 9.1.2...
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Page 5: 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 6: Explanation Of Icons
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn... -
Page 7: Safety Instructions
For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 8 For your safety Safety instructions WARNING 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 9 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! •...
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Page 10: 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 11 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.
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Page 12: Intended Use
3.2.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.2.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 13: Part Of The Complete Documentation
Intended use Documents which also apply 3.2.6 Part of the complete documentation This document is part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system. -
Page 14: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-005445-EW501 22.9.2022... - Page 15 Machine description – quick overview Front view Item Symbol Description Carrying handle Machine control (see the relevant control operating instructions) 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.
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Page 16: 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 17: 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 18: Design And Function
Design and function Transport and installation Design and function 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 19: Machine Cooling
Design and function Transport and installation Transport and storage Storage in a closed room, temperature range of the ambient air: • -30 °C to +70 °C (-22 °F to 158 °F) Relative humidity • up to 90 % at 20 °C (68 °F) Ambient temperature dependent on coolant! Observe the coolant temperature range of the torch coo- ling 5.1.2... -
Page 20: Welding Torch Holder
Design and function Transport and installation 5.1.4 Welding torch holder The item described in the following is part of the machine´s scope of delivery. Figure 5-1 Item Symbol Description Crossmember of the transport handle Torch holder Fixing screws (x 4) Fan-type lock washers •... -
Page 21: Welding Torch Cooling System
Design and function Transport and installation 5.1.5 Welding torch cooling system 5.1.5.1 Cooling unit connection Figure 5-2 Item Symbol Description Cooling module 4-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead • Insert and lock the 4-pole supply plug on the cooling unit into the 4-pole connection socket on the welding machine. -
Page 22: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.6 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 23: Stray Welding Currents
Design and function Transport and installation 5.1.7 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. •... -
Page 24: Mains Connection
Design and function Transport and installation 5.1.8 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • The connection (mains plug or cable), the repair or voltage adjustment of the device must be carried out by a qualified electrician in accordance with the respective local laws or nati- onal regulations! •... -
Page 25: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Transport and installation 5.1.9 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 26: Shielding Gas Hose Connection
Design and function Transport and installation 5.1.9.2 Shielding gas hose connection Figure 5-9 Item Symbol Description Shielding gas cylinder / pressure regulator Connection thread - G¼" Shielding gas connection (inlet) • Screw the gas hose connection to the shielding gas connection (inlet) on the machine gas-tight. 5.1.9.3 Gas test –... -
Page 27: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.2.1 Welding torch and workpiece line connection On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used! •... -
Page 28: Wire Feed
Design and function MIG/MAG welding • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the plug on the workpiece lead into the "-" welding current connection socket and lock. •... -
Page 29: Changing The Wire Feed Rollers
Design and function MIG/MAG welding Item Symbol Description Knurled nut For fixing the wire spool • Unlock and open protective flap. • Loosen knurled nut from spool holder. • Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore. •... - Page 30 Design and function MIG/MAG welding Item Symbol Description Closure bracket The closure brackets are used to secure the wire feed rollers. Feed roll tensioner Fixing the clamping unit and setting the pressure. Clamping unit Wire feed roller see the Wire feed roller overview table •...
- Page 31 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 >...
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Page 32: Inching The Wire Electrode
Design and function MIG/MAG welding 5.2.2.3 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 33: 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 34: Tig Welding
Design and function TIG welding TIG welding 5.3.1 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! 5.3.2 Welding torch and workpiece line connection... -
Page 35: Mma Welding
Design and function MMA welding MMA welding 5.4.1 Connecting the electrode holder and workpiece lead CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. •... -
Page 36: Connection
Design and function Interfaces for automation 5.6.1 Connection Equipment damage or faults may occur if the PC is connected incorrectly! Not using the SECINT X10USB interface results in equipment damage or faults in signal trans- mission. The PC may be destroyed due to high frequency ignition pulses. •... -
Page 37: Remote Control Connection Socket, 19-Pole
Design and function Interfaces for automation Input / Name Figure Output Output PE ------- Connection for cable screen Output IGRO ---- Current flows signal I>0 (maximum load 20 mA / (open collec- 15 V) 0 V = welding current flows tor) Input Not-Aus - Emergency stop for higher level shut-down of the... -
Page 38: Rint X12 Robot Interface
Design and function Access control 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 Welding power start/stop (S1) Input... -
Page 39: 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 40: Explanation Of Icons
Maintenance, care and disposal Explanation of icons Explanation of icons Personnel Welder / operator Qualified person (authorised service personnel) Tests Visual inspection Functional test Period, interval One-shift operation Multi-shift operation Every 8 hours Daily Weekly Monthly Every 6 months Annually Maintenance schedule Maintenance step Only personnel designated as inspectors or repairers due to their trai-... - Page 41 Maintenance, care and disposal 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. • Transport elements (strap, lifting eyes, handle, wheels, parking brake) corresponding safety elements (if necessary fuse caps) are present and flawless? •...
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Page 42: 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 43: 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 dea- ler. - Page 44 Rectifying faults Checklist for rectifying faults Wire feed problems Wire feed roll holder is worn (wire feed rolls must be firmly seated on their holders and must not have any play) Replace wire feed roll holder (092-002960-E0000) > see 10 chapter ...
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Page 45: Technical Data
Technical data Phoenix 355 Expert 2.0 puls MM TKM Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 355 Expert 2.0 puls MM TKM MIG/MAG Welding current (I 5 A to 350 A... -
Page 46: 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 47: 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 48: 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 Extended-Set WiFi... -
Page 49: 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 50: 10.1.3 Wire Feed Rollers For Cored Wire
Replaceable parts Wire feed rollers 10.1.3 Wire feed rollers for cored wire Type Designation Item no. FUEL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00008 WHITE/ORANGE flux cored wire 092-002848-00010 FUEL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for BLUE/ORANGE flux cored wire... -
Page 51: Appendix
Appendix Searching for a dealer Appendix 11.1 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005445-EW501 22.9.2022...
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