EWM Phoenix 401 Progress puls FKG Operating Instructions Manual
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EWM Phoenix 401 Progress puls FKG Operating Instructions Manual

EWM Phoenix 401 Progress puls FKG Operating Instructions Manual

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Operating instructions
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099-005296-EW501
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Welding machine
Phoenix 401 Progress puls FKG
Phoenix 401 Progress puls FKW
Phoenix 501 Progress puls FKW
28.01.2013
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  • Page 1 Operating instructions Welding machine Phoenix 401 Progress puls FKG Phoenix 401 Progress puls FKW Phoenix 501 Progress puls FKW 099-005296-EW501 28.01.2013 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..........................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 ......................14 2.4.2 Ambient conditions .......................
  • Page 4 Contents Notes on the use of these operating instructions 5.8.3 Definition of MIG/MAG welding tasks ................42 5.8.4 Welding task selection ....................42 5.8.4.1 Basic welding parameters ................42 5.8.4.2 Operating mode.....................42 5.8.4.3 Welding type (MIG/MAG standard/pulse arc welding) ........42 5.8.4.4 Choke effect / dynamics ................43 5.8.4.5 Superpulses ....................43 5.8.4.6...
  • Page 5 Wire feed rollers for aluminium wire ................113 10.1.3 Wire feed rollers for cored wire .................. 113 10.1.4 Conversion sets......................114 11 Appendix A ............................115 11.1 JOB-List .............................115 12 Appendix B ............................116 12.1 Overview of EWM branches ......................116 099-005296-EW501 28.01.2013...
  • Page 6 Contents Notes on the use of these operating instructions 099-005296-EW501 28.01.2013...

  • 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 Press Do not press Turn Switch Switch off machine Switch on machine ENTER (enter the menu) NAVIGATION (Navigating in the menu) 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 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 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 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 DANGER Risk of injury during lifting by crane! When lifting the equipment by crane, serious injuries can be inflicted by falling equipment or add-on units. • Transport on all lifting lugs at the same time (see Fig.

  • 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 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 17: Documents Which Also Apply

    Intended use Documents which also apply Documents which also apply 3.2.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 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 NOTE Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted (see "Accessories"...
  • Page 19 Machine description – quick overview Front view Item Symbol Description Lifting lug Ready for operation signal light Signal light on when the machine is switched on and ready for operation 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...

  • Page 20: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-005296-EW501 28.01.2013...
  • 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 4-3 099-005296-EW501 28.01.2013...
  • Page 23 Machine description – quick overview Inside view Item Symbol Description Welding torch function changeover switch (special welding torch required) Programm Changing over programs or JOBs Infinite adjustment of welding performance. Up / Down Wire spool holder Wire feed unit 099-005296-EW501 28.01.2013...

  • Page 24: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements M 3.72 Material Wire JOB- LIST Super- puls VOLT PROG HOLD Progress m/min Figure 4-4 099-005296-EW501 28.01.2013...
  • Page 25 Machine description – quick overview Machine control – Operating elements Item Symbol Description Lid (see chap. "Machine control – concealed operating elements") Button, Parameter selection left Welding current Material thickness Wire speed After each completed welding process, the last parameter values used for the HOLD welding process are shown on the display in the main program;...

  • Page 26: Machine Control - Concealed Operating Elements

    Machine description – quick overview Machine control – Operating elements 4.4.1 Machine control – Concealed operating elements 11 12 M 3.71 Material Wire JOB- LIST Super- puls 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.
  • Page 27 Machine description – quick overview Machine control – Operating elements Item Symbol Description Super- Signal lamp, super pulse function puls Lights up when the super pulse function is active. Signal light, JOB-List Material Illuminates upon display or selection of the JOB number Wire Key button, JOB-List JOB-...

  • Page 28: 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 29: 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 30: Welding Torch Cooling System

    Design and function Welding torch cooling system Welding torch cooling system 5.5.1 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 31: Adding Coolant

    Design and function Welding torch cooling system 5.5.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. NOTE After the initial filling, wait for at least one minute when the machine is switched on so that the tube package is filled with coolant completely and without bubbles.

  • 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: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.8.1 Welding torch and workpiece line connection NOTE Fault with the wire guide! On delivery, the central connector (Euro) is fitted with a capillary tube for welding torches with spiral guides. Conversion is necessary if a welding torch with a plastic core is used! Welding torch with plastic core: •...

  • Page 35: Mig/Mag Standard Welding

    Design and function MIG/MAG welding 5.8.1.1 MIG/MAG standard welding Figure 5-3 Item Symbol Description Workpiece "-" welding current connection socket • MIG/MAG welding: Workpiece connection Welding torch Welding torch hose package 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Euro torch connector Integrated welding current, shielding gas and torch trigger...

  • Page 36: Mig/Mag Cored Wire Welding

    Design and function MIG/MAG welding 5.8.1.2 MIG/MAG cored wire welding Figure 5-4 Item Symbol Description Workpiece Connection socket, "+" welding current • MIG/MAG cored wire welding: Workpiece connection Welding torch Welding torch hose package 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Euro torch connector Integrated welding current, shielding gas and torch trigger...

  • Page 37: Wire Feed

    Design and function MIG/MAG welding 5.8.2 Wire feed 5.8.2.1 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 38: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.8.2.3 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 39: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.8.2.4 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 40 Design and function MIG/MAG welding Figure 5-7 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 41: Spool Brake Setting

    Design and function MIG/MAG welding 5.8.2.5 Spool brake setting Figure 5-8 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 42: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.8.3 Definition of MIG/MAG welding tasks This range of machines feature simple operation with a very wide range of functions. • Various JOBs (i.e. welding tasks consisting of welding process, material type, wire diameter and shielding gas type) have been pre-defined (see appendix for a list of JOBs).

  • Page 43: Choke Effect / Dynamics

    Design and function MIG/MAG welding 5.8.4.4 Choke effect / dynamics DY N m /m in Figure 5-9 Display Setting/selection Dynamics setting 40: Arc harder and narrower -40: Arc softer and wider 5.8.4.5 Superpulses m /m in Figure 5-10 Display Setting/selection Selects super pulses Switches function on or off.

  • Page 44: Burn-Back

    Design and function MIG/MAG welding 5.8.4.6 Burn-back m /m in Figure 5-11 Display Setting/selection menu burn back Set burn back Parameter setting (setting range 0 to 499) Back-burn set too high: large drops developing on the wire electrode result in poor ignition properties or the wire electrode sticking to the welding nozzle.

  • Page 45: Selecting The Display Unit

    Design and function MIG/MAG welding 5.8.5.1 Selecting the display unit VOLT PROG HOLD Figure 5-12 The operating point (welding performance) can be displayed as the welding current, material thickness or wire speed. Operating Action Result element Switching the display between: Welding current Material thickness Wire speed...

  • Page 46: Mig/Mag Welding Data Display

    Design and function MIG/MAG welding 5.8.6 MIG/MAG 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 47: Forcearc

    Design and function MIG/MAG welding 5.8.7 forceArc Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range. Figure 5-14 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 48: Rootarc

    Design and function MIG/MAG welding 5.8.8 rootArc Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding. Figure 5-15 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion • Un-alloyed and low-alloy steels •...

  • Page 49: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.8.9 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). 5.8.9.1 Explanation of signs and functions Symbol Meaning...
  • Page 50 Design and function MIG/MAG welding Non-latched mode Figure 5-16 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 5-17 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 flows. •...
  • Page 52 Design and function MIG/MAG welding Special, non-latched START 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 53 Design and function MIG/MAG welding Spot welding START Figure 5-19 NOTE 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 START Figure 5-20 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 5-21 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 mode with superpulse 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 flows. •...
  • Page 57 Design and function MIG/MAG welding Latched mode with alternating welding process Figure 5-23 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 58 Design and function MIG/MAG welding Latched special START Figure 5-24 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 Latched special with welding process alternation NOTE This function can be activated using the PC300.NET software. • Refer to the software operating instructions. START Figure 5-25 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
  • Page 60 Design and function MIG/MAG welding Latched special with alternating welding process NOTE This function can be activated using the PC300.NET software. • Refer to the software operating instructions. START Figure 5-26 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 START Figure 5-27 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: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Design and function MIG/MAG welding 5.8.11 Conventional MIG/MAG Welding (GMAW non synergic) • With wire-feed speeds less than 8 m/min select JOB 188. • With wire-feed speeds over 8 m/min select JOB 187. You can only change the JOB number when no welding current is flowing. Operating Action Result...

  • Page 63: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.8.12 MIG/MAG program sequence ("Program steps" mode) NOTE This function can only be enabled with the PC300.NET software. • (See operating instructions for the software) Certain materials, such as aluminium, require special functions in order to be able to weld them safely and at high quality.

  • Page 64: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.8.12.2 MIG/MAG overview of parameters NOTE In the factory setting, P , and P are "relative programs". They relate to START percentages of the wire feed value from the main program P Super- puls Figure 5-29 Basic Parameters Item Meaning / Explanation...

  • Page 65: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.8.12.3 Example, tack welding (non-latched) Figure 5-30 Basic parameters Parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 66: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.8.12.5 Example, aluminium welding (latched special) START Figure 5-32 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: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.8.12.6 Example, visible seams (latched super pulse) START Figure 5-33 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 PROC.SP.

  • Page 68: Welding Process Changeover

    Design and function MIG/MAG welding 5.8.12.7 Welding process changeover NOTE This function can only be enabled with the PC300.NET software. • (See operating instructions for the software) START Figure 5-34 Program Setting option Relates to Setting Pulse arc welding process on/off All special, non-latched 1 (= on) START...

  • Page 69: Main Program A Mode

    Design and function MIG/MAG welding 5.8.13 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 70 Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-35 Example 2: Welding different positions on a workpiece (latched) Figure 5-36 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-37 NOTE...

  • Page 71: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.8.13.1 Selecting parameters (program A) NOTE 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.

  • Page 72: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.8.14 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: •...

  • Page 73: Remote Control

    Design and function Remote control 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 74: Advanced Settings

    Design and function Remote control 5.9.1 Advanced settings The special parameters cannot be viewed directly since they are normally only set and stored once. The machine control offers the following special functions: 5.9.1.1 Selecting, changing and saving parameters VOLT A M P PROG HOLD m /m in...
  • Page 75 Design and function Remote control 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 POWERCONTROL torch display mode 0 = normal display (factory setting) program number/JOB or...

  • Page 76: Reset To Factory Settings

    Design and function Remote control Display Setting/selection Block JOB mode 0 = Block JOB mode not enabled (Ex works) 1 = Block JOB mode enabled Program selection with standard torch trigger 0 = no program selection (Ex works) 1 = program selection possible 5.9.1.2 Reset to factory settings NOTE...

  • Page 77: The Special Parameters In Detail

    Design and function Remote control 5.9.1.3 The 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 78 Design and function Remote control 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 79 Design and function Remote control Operating Action Result Display (examples) element Left Right VOLT Press button until "PROG" LED comes PROG Left: Wire feed speed Right: Program number VOLT Press button and hold down for approx. PROG Left: Current limit value of the wire feed speed correction Right: Current limit value of the...
  • Page 80 Design and function Remote control 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". • Cycle 3: absolute program 3 is run until the "t3"...
  • Page 81 Design and function Remote control 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 82 Design and function Remote control "Single or dual operation" (P10) setting NOTE If the system is fitted with two wire feeds, no further accessory components may be operated on the 7-pole connection socket (digital)! This relates to digital remote controls, robot interfaces, documentation interfaces, welding torches with digital control lead connection, etc.
  • Page 83 Design and function Remote control Creating user-defined JOB lists A consecutive memory range where accessories such as the POWERCONTROL 2 torch can be used to switch between JOBs will be created. • Set special parameter P12 to "2". • Set "Program or Up/Down function" changeover switch to "Up/Down" position. •...
  • Page 84 Design and function Remote control Block JOB mode (P16) The following accessory components support block JOB mode: • R20 remote control and MT U/D welding torch 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 85: Switching Between Push/Pull And Intermediate Drive

    Design and function Remote control 5.9.1.4 Switching between Push/Pull and intermediate drive DANGER 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 86: Tig Welding

    Design and function TIG welding 5.10 TIG welding 5.10.1 Welding torch and workpiece line connection Figure 5-44 Item Symbol Description Workpiece Connection socket, "+" welding current • TIG welding: Workpiece connection Welding torch Welding torch hose package 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Euro torch connector...

  • Page 87: Welding Task Selection

    Design and function TIG welding 5.10.2 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 JOB- LIST comes on...

  • Page 88: Function Sequences/Operating Modes

    Design and function TIG welding 5.10.5 Function sequences/operating modes 5.10.5.1 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 89 Design and function TIG welding Non-latched mode Figure 5-46 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 90 Design and function TIG welding Latched mode Figure 5-48 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 91: Tig Automatic Cut-Out

    Design and function TIG welding Latched special START Figure 5-49 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 92: Tig Program Sequence ("Program Steps" Mode)

    Design and function TIG welding 5.10.7 TIG program sequence ("Program steps" mode) 5.10.7.1 TIG parameter overview Super- puls Figure 5-50 Basic parameters Item Meaning/explanation Setting range Gas pre-flow time 0 s to 0.9 s START 0% to 200% Ignition current Duration (start program) 0 s to 20 s Slope duration from P...

  • Page 93: Mma Welding

    Design and function MMA welding 5.11 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 94: Welding Task Selection

    Design and function MMA welding 5.11.2 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 JOB- LIST comes on...

  • Page 95: Hotstart

    Design and function MMA welding 5.11.5 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current Welding current Time Figure 5-52 For hotstart parameter settings, see "parameter overview" chapter 5.11.6 Antistick Anti-stick prevents the electrode from annealing.

  • Page 96: Interfaces

    Design and function Interfaces 5.12 Interfaces 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 97: Rint X12 Robot Interface

    Design and function Interfaces 5.12.2 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 98: Protecting Welding Parameters From Unauthorised Access

    Design and function Protecting welding parameters from unauthorised access 5.13 Protecting welding parameters from unauthorised access 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. In key switch position 1 all functions and parameters can be set without restriction.

  • Page 99: 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 100: 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 101: 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 102: 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 103: Error Messages (Power Source)

    Rectifying faults Error messages (power source) Error messages (power source) NOTE 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 104 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 105: 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 7.3.1 Resetting a single JOB NOTE All customised welding parameters that are stored will be replaced by the factory settings. JOB- JOB- LIST LIST m /m in...

  • Page 106: Resetting All Jobs

    Rectifying faults General operating problems 7.3.2 Resetting all JOBs NOTE JOBs 1–128 and 170–256 will be reset. Custom JOBs 129–169 are maintained. JOB- JOB- LIST LIST m /m in 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 107: 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)! blau / blue ca.

  • Page 108: Technical Data

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

  • Page 109: Phoenix 401 Progress Fkw

    Technical data Phoenix 401 Progress FKW Phoenix 401 Progress FKW Setting range for welding current/voltage: 5 A/10.2 V to 400 A/26.0 V 5 A/20.2 V to 400 A/36.0 V MIG/MAG 5 A/14.3 V to 400 A/34.0 V Duty cycle at 40 °C 100% 400 A ∧...

  • Page 110: 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 10.2 V–30.0 V 14.3 V–39.0 V 20.2 V–40.0 V Duty cycle 40 °C 25 °C 40 °C 25 °C 40 °C 25 °C...

  • Page 111: 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 TYP 1 Frost protection tester 094-014499-00000 KF 23E-10 Coolant (-10 °C), 9.3 l...

  • Page 112: 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 113: 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 114: 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 115: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List 094-015723-00500 Wire Material Job-Nr. CO 100 / C1 SG2/3 G3/4 Si1 Ar80-90 / M2 Figure 11-1 099-005296-EW501 28.01.2013...

  • Page 116: Overview Of Ewm Branches

    · info@ewm-automation.de www.ewm-ransbach-baumbach.de · info@ewm-ransbach-baumbach.de Sales and Service International EWM HIGHTEC WELDING GmbH EWM HIGHTEC WELDING Sales s.r.o. / Prodejní a poradenské centrum Fichtenweg 1 Tyršova 2106 4810 Gmunden · Austria · Tel: +43 7612 778 02-0 · Fax: -20 256 01 Benešov u Prahy ·...

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