EWM M3.00 Operating Instructions Manual
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EWM M3.00 Operating Instructions Manual

EWM M3.00 Operating Instructions Manual

Phoenix expert drive 4
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Operating instructions
099-004801-EW501
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www.ewm-group.com
Wire feed unit
Phoenix Expert drive 4 M3.00
Observe additional system documents!
29.04.2013
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Summary of Contents for EWM M3.00

  • Page 1 Operating instructions Wire feed unit Phoenix Expert drive 4 M3.00 099-004801-EW501 Observe additional system documents! 29.04.2013 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
  • Page 2 © EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 General ............................8 Transport and installation ......................12 2.4.1 Ambient conditions .......................
  • Page 4 Resetting JOBs to status on delivery (Reset ALL) ............68 Vent coolant circuit ........................69 8 Technical data............................70 Phoenix Expert drive 4 M3.00 ...................... 70 9 Accessories ............................71 General accessories ........................71 Remote control/connecting and extension cable ................. 71 9.2.1...
  • Page 5 Wire feed rollers for steel wire ..................72 10.1.2 Wire feed rollers for aluminium wire ................72 10.1.3 Wire feed rollers for cored wire ..................72 10.1.4 Conversion sets ......................73 11 Appendix A ............................74 11.1 Overview of EWM branches ......................74 099-004801-EW501 29.04.2013...

  • Page 6: 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 7: Explanation Of Icons

    Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu) EXIT EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use...

  • Page 8: General

    Safety instructions General General DANGER Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •...
  • Page 9 Safety instructions General WARNING Risk of injury due to radiation or heat! Arc radiation results in injury to skin and eyes. Contact with hot workpieces and sparks results in burns. • Use welding shield or welding helmet with the appropriate safety level (depending on the application)! •...
  • Page 10 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 11 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.

  • Page 12: 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 13: Ambient Conditions

    Safety instructions Transport and installation 2.4.1 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 14: Intended Use

    Intended use Applications Intended use This machine has been manufactured according to the latest developments in technology and current regulations and standards. It must only be operated in line with the instructions on correct usage. WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly.

  • Page 15: Use And Operation Solely With The Following Machines

    A suitable power source (system component) is required in order to operate the wire feed unit! Phoenix Expert 351, 401, 451, 551  drive 200C  drive 300C  drive 4L M3.00  drive 4L M3.70  drive 4 M3.00  drive 4 M3.70  miniDrive 099-004801-EW501 29.04.2013...

  • Page 16: Documents Which Also Apply

    Intended use Documents which also apply Documents which also apply 3.3.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.3.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •...

  • Page 17: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description 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 18: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-2 Item Symbol Description Wire spool holder Wire feed unit Quick connect coupling (red) coolant return Strain relief Connector plug, welding current "+" Welding current connection on wire feed unit Quick connect coupling (blue) coolant supply 7-pole connection socket (digital)

  • Page 19: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 Item Symbol Description Wire speed rotary dial Infinitely adjustable setting of the wire speed from min. to max. (welding output, one-dial operation) “WF-min. / WF-max.” signal lights Max.

  • Page 20: 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 21: 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 22: Welding Torch Cooling System

    Design and function Welding torch cooling system Welding torch cooling system General 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 23: 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 NOTE Incorrectly installed welding current leads can cause faults in the arc (flickering). Install welding lead and hose package in parallel and as close together as possible. Keep the welding lead and hose packages of each welding machine separate, with an installation distance of at least 15 cm! Fully unroll welding current leads, torch hose packages and intermediate hose...

  • Page 24: Intermediate Hose Package Connection

    Design and function Notes on the installation of welding current leads 5.5.1 Intermediate hose package connection Figure 5-2 Item Symbol Description Power source Intermediate hose package 7-pole connection socket (digital) • Control lead for wire feed unit Connecting nipple G¼, shielding gas connection Quick connect coupling (blue) coolant supply Connector plug, welding current "+"...

  • Page 25: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.6.1 Welding torch connection CAUTION Equipment damage due to improperly connected coolant lines! If the coolant lines are not connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •...
  • Page 26 Design and function MIG/MAG welding Figure 5-3 Item Symbol Description Welding torch Welding torch hose package 7-pole connection socket (digital) For connecting digital accessory components (remote control, welding torch control lead, etc.) Euro torch connector Integrated welding current, shielding gas and torch trigger Quick connect coupling (red) coolant return Quick connect coupling (blue)

  • Page 27: Wire Feed

    Design and function MIG/MAG welding 5.6.2 Wire feed 5.6.2.1 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 28: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.6.2.3 Changing the wire feed rollers NOTE Unsatisfactory welding results due to faulty wire feeding! Wire feed rollers must be suitable for the diameter of the wire and the material. • Check the roller label to verify that the rollers are suitable for the wire diameter. Turn or change if necessary! •...

  • Page 29: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.6.2.4 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 30 Design and function MIG/MAG welding Figure 5-6 Item Symbol Description Pressure unit Clamping unit Knurled nut Pressure roller Wire feed nipple Guide tube Drive rollers "Undetachable" knurled screws Wire feed nipple with wire stabiliser • Extend and lay out the torch hose package. •...

  • Page 31: Spool Brake Setting

    Design and function MIG/MAG welding 5.6.2.5 Spool brake setting Figure 5-7 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. NOTE Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation!

  • Page 32: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.6.3 Definition of MIG/MAG welding tasks You can select the welding task (JOB) in two ways: • Select the required welding task using the four basic parameters (welding process, material, wire diameter and shielding gas). This combination will result in a JOB number stored in the control. The JOB number can be displayed, if required.
  • Page 33 Design and function MIG/MAG welding Operating Action Result element Select welding process The signal light indicates the selection. Select material type The signal light indicates the selection. Select wire diameter The signal light indicates the selection. Select gas type The signal light indicates the selection. Select operating mode Select welding type Switch superpulses on or off...

  • Page 34: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.6.5 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 35: Operating Point Setting Using Material Thickness

    Design and function MIG/MAG welding 5.6.5.2 Operating point setting using material thickness In the situations given below, only the wire speed is given to represent the operating point. Operating Action Result Display Element Operating point is set using the wire speed Parameter selected previously set is displayed...

  • Page 36: Forcearc

    Design and function MIG/MAG welding 5.6.6 forceArc Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range. Figure 5-10 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 37: Rootarc

    Design and function MIG/MAG welding 5.6.7 rootArc Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding. Figure 5-11 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion • Un-alloyed and low-alloy steels •...

  • Page 38: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.6.8 MIG/MAG functional sequences / operating modes NOTE 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). 5.6.8.1 Explanation of signs and functions Symbol Meaning...
  • Page 39 Design and function MIG/MAG welding Non-latched mode Figure 5-12 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 40 Design and function MIG/MAG welding Non-latched operation with superpulse Figure 5-13 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 41 Design and function MIG/MAG welding Latched mode Figure 5-14 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 42 Design and function MIG/MAG welding Latched mode with superpulse Figure 5-15 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 43 Design and function MIG/MAG welding Latched with changing welding method (process switching) Figure 5-16 1st cycle: • 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 44 Design and function MIG/MAG welding Latched special Figure 5-17 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 45 Design and function MIG/MAG welding Special, latched with superpulse 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 is flowing (start program P for the time t START...
  • Page 46 Design and function MIG/MAG welding Figure 5-19 1st cycle • 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 2nd cycle...
  • Page 47 Design and function MIG/MAG welding Special latched with changing welding method by tapping (process switching) Figure 5-20 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" •...

  • Page 48: Mig/Mag Automatic Cut-Out

    Design and function MIG/MAG welding Special latched with changing welding method (process switching) Figure 5-21 1st cycle • 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 49: 5.6.10 Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.6.10 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 5.6.11 MIG/MAG special-torches Function specifications and more indepth information can be found in the operating manual for the relevant welding torch! The following special torches can be used together with this welding machine: •...

  • Page 50: 5.6.12 Mig/Mag Push/Pull Welding Torch

    Design and function MIG/MAG welding 5.6.12 MIG/MAG Push/Pull welding torch The most important requirement for the greatest degree of efficiency and weld seam quality is the smooth conveyance of the wire electrode. This is particularly problematic when: • Longer tube packages are used, •...

  • Page 51: Tig Welding

    Design and function TIG welding TIG welding 5.7.1 Welding torch connection NOTE TIG welding torches to be connected to a Euro torch connector are available in two versions: • TIG combi welding torches are connected to the Euro torch connector of the wire feeder and to the (-) welding current plug of the power source.

  • Page 52: Welding Task Selection

    Design and function TIG welding • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the welding current plug of the combi welding torch into the (-) welding current connection socket and lock into place by turning to the right (only in case of a separate welding current connection).

  • Page 53: Tig Arc Ignition

    Design and function TIG welding 5.7.4 TIG arc ignition 5.7.4.1 Liftarc ignition Figure 5-26 The arc is ignited on contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger (liftarc current flowing, regardless of the main current set).
  • Page 54 Design and function TIG welding Non-latched mode Figure 5-27 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 55 Design and function TIG welding Latched mode Figure 5-29 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 56 Design and function TIG welding Latched special Figure 5-30 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 57: Mma Welding

    Design and function MMA welding MMA welding 5.8.1 Welding task selection 8 9 10 m /m in Figure 5-31 Operating Action Result Display element The various welding processes are run through The nominal values until the signal light for the required welding for the welding process comes on.

  • Page 58: 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) 5.9.1 Gas test • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. •...

  • Page 59: Remote Control

    Design and function Remote control 5.10 Remote control CAUTION Using protective dust caps! Protective dust caps protect the connection sockets and therefore the machine against dirt and damage. • The protective dust cap must be fitted if there is no accessory component being operated on that connection.

  • Page 60: 5.11.1 Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.11.1 Remote control connection socket, 19-pole Figure 5-32 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 61: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! •...

  • Page 62: Monthly Maintenance Tasks

    Maintenance, care and disposal Maintenance work 6.2.2 Monthly maintenance tasks 6.2.2.1 Visual inspection • Casing damage (front, rear and side walls) • Wheels and their securing elements • Transport elements (strap, lifting lugs, handle) • Check coolant tubes and their connections for impurities 6.2.2.2 Functional test •...

  • Page 63: Disposing Of Equipment

    Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922. •...

  • Page 64: 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 65: Error Messages (Power Source)

    Error 5 Wire feeder, speedometer Check the wire feeder (Wi.Spe) error speedometer is not issuing a signal, M3.00 defective > inform Service Error 6 Shielding gas error Check shielding gas supply (for machines (gas) with shielding gas monitoring) Error 7 Secondary excess voltage Inverter error >...
  • Page 66 Rectifying faults Error messages (power source) Legend for categories (error reset) a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a key button: Welding machine control Key button RC1 / RC2 Expert CarExpert / Progress (M3.11)

  • Page 67: Display Machine Control Software Version

    Rectifying faults Display machine control software version Display machine control software version NOTE The query of the software versions only serves to inform the authorised service staff! ENTER EXIT Figure 7-1 Display Setting/selection List of the software Start of the automated process Software versions display ------- = System bus ID/printed circuit board...

  • Page 68: Resetting Jobs To Status On Delivery (Reset All)

    Rectifying faults Display machine control software version 7.3.1 Resetting JOBs to status on delivery (Reset ALL) NOTE JOBs 1–128 and 170–256 will be reset. Custom JOBs 129–169 are maintained. Operating Action Result Display element Select “Special Mode” Program steps Special Mode Res.

  • Page 69: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit NOTE 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 7-2 099-004801-EW501...

  • Page 70: Technical Data

    Technical data Phoenix Expert drive 4 M3.00 Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix Expert drive 4 M3.00 Supply voltage 42 VAC/60 VDC Max. welding current at 60% DC 550 A Max.

  • Page 71: Accessories

    Accessories General accessories Accessories NOTE 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 HOSE BRIDGE Tube bridge 092-007843-00000 Remote control/connecting and extension cable 9.2.1 7-pole connection...

  • Page 72: 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 73: 10.1.4 Conversion Sets

    Replaceable parts Wire feed rollers 10.1.4 Conversion sets Type Designation Item no. URUE VERZ>UNVERZ FE/AL Conversion kit, 37mm, 4-roller drive on non-toothed 092-000845-00000 rollers (steel/aluminium) URUE AL 4ZR4R 0,8+1,0 Conversion kit, 37mm, 4-roller drive for aluminium 092-000867-00000 URUE AL 4ZR4R 1,0+1,2 Conversion kit, 37mm, 4-roller drive for aluminium 092-000846-00000 URUE AL 4ZR4R 1,2+1,6...

  • Page 74: Overview Of Ewm Branches

    Appendix A Overview of EWM branches Appendix A 11.1 Overview of EWM branches 099-004801-EW501 29.04.2013...

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