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

EWM Phoenix 401 Progress puls HP MM FKW Operating Instructions Manual

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Operating instructions
Welding machine
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Phoenix 401 Progress puls HP MM FKW
Phoenix 501 Progress puls HP MM FKW
099-005404-EW501
Observe additional system documents!
16.01.2017

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Summary of Contents for EWM Phoenix 401 Progress puls HP MM FKW

  • Page 1 Operating instructions Welding machine Phoenix 401 Progress puls HP MM FKW Phoenix 501 Progress puls HP MM FKW 099-005404-EW501 Observe additional system documents! 16.01.2017...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 Part of the complete documentation ....................8 Safety instructions ..........................
  • Page 4 Contents Notes on the use of these operating instructions 5.4.4.4 Burn-back ...................... 41 5.4.5 MIG/MAG operating point ..................... 42 5.4.5.1 Operating point setting via welding current, material thickness or wire feed speed ..................... 42 5.4.5.2 Arc length correction setting ................42 5.4.5.3 Accessory components for operating point setting ........
  • Page 5 Wire feed rollers for aluminium wire ................110 10.1.3 Wire feed rollers for cored wire .................. 110 10.1.4 Wire guide ........................111 11 Appendix A ............................112 11.1 JOB-List ............................. 112 12 Appendix B ............................119 12.1 Overview of EWM branches ...................... 119 099-005404-EW501 16.01.2017...

  • Page 6: For Your Safety

    For your safety Notes on the use of these operating instructions For your safety 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. •...

  • Page 7: 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 keep pressed Switch Wrong Turn Numerical value – adjustable Correct Menu entry Signal light lights up in green...

  • Page 8: Part Of The Complete Documentation

    For your safety Part of the complete documentation Part of the complete documentation These operating instructions are 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 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 Fire hazard! Due to the high temperatures, sparks, glowing parts and hot slag that occur during welding, there is a risk of flames. • Be watchful of potential sources of fire in the working area! •...
  • Page 11 For your safety Safety instructions CAUTION 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 12: Transport And Installation

    For your safety Transport and installation Transport and installation 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! • Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air! •...

  • Page 13: Intended Use

    In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product.

  • Page 14: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. Figure 4-1 Item Symbol Description Lifting lug Ready for operation signal light Signal light on when the machine is switched on and ready for operation 099-005404-EW501...
  • Page 15 Machine description – quick overview Front view Item Symbol Description Main switch, machine on/off Carrying handle Cooling air inlet Automatic cut-out of coolant pump key button press to reset a triggered fuse Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply Wheels, guide castors Coolant tank...

  • Page 16: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-005404-EW501 16.01.2017...
  • Page 17 Machine description – quick overview Inside 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 18: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-3 Item Symbol Description Welding torch function changeover switch (special welding torch required) Changing over programs or JOBs Infinite adjustment of welding performance. Wire spool holder Wire feed unit 099-005404-EW501 16.01.2017...

  • Page 19: 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 4.4.1 chapter JOB- Welding task push-button (JOB) LIST Select the welding task from the welding task list (JOB-LIST). The list can be found inside the protective cap on the wire feeder and in the appendix to these operating instructions.
  • Page 20 Machine description – quick overview Machine control – Operating elements Item Symbol Description Select operating mode button --------- Non-latched ------- Latched -------- Signal light lights up in green: Special non-latched ---- Signal light lights up in red: MIG spot welding -------- Special latched Welding type push-button -------- Standard arc welding...

  • Page 21: Function Sequence

    Machine description – quick overview Machine control – Operating elements 4.4.1 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 22: Design And Function

    Design and function Transport and installation Design and function 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 23: Ambient Conditions

    Design and function Transport and installation 5.1.2 Ambient conditions T he 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 24: Welding Torch Cooling System

    Design and function Transport and installation 5.1.5 Welding torch cooling system Insufficient frost protection in the welding torch coolant! Depending on the ambient conditions, different liquids are used for cooling the welding torch > see 5.1.5.1 chapter. Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components.

  • Page 25: Adding Coolant

    Design and function Transport and installation 5.1.5.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. Figure 5-1 Item Symbol Description Coolant tank cap Coolant filter sieve Coolant tank "Min" mark Minimum coolant level • Unscrew and remove the coolant tank sealing cover.

  • Page 26: 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 27: Stray Welding Currents

    Design and function Transport and installation 5.1.6.1 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 28: Mains Configuration

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.1.7.1 Mains configuration The machine may be connected to: • a three-phase system with four conductors and an earthed neutral conductor • a three-phase system with three conductors of which any one can be earthed, e.g.

  • Page 29: Pressure Regulator Connection

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.2.1 Pressure regulator connection Figure 5-7 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve • Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out any dirt.

  • Page 30: Shielding Gas Volume Settings

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.2.2 Shielding gas volume settings CAUTION Electric shocks! When setting the shielding gas quantity, high voltage ignition pulses or open circuit voltage are applied at the welding torch; these can lead to electric shocks and burning on contact.

  • Page 31: Welding Data Display

    Design and function Welding data display Welding data display To the left and right of the control displays are the "Parameter selection" buttons ( ). They are used to select welding parameters to be displayed. Each press of the button advances the display to the next parameter (LEDs next to the button indicate the selection).

  • Page 32: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.4.1 Welding torch and workpiece line connection Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •...
  • Page 33 Design and function MIG/MAG welding Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity. In this case, the welding current lead should be connected to the "-" welding current socket, and the workpiece lead should be connected to the "+" welding current socket. Observe the information from the electrode manufacturer! Figure 5-12 Item Symbol...

  • Page 34: 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 35: Inserting The Wire Spool

    Design and function MIG/MAG welding 5.4.2.2 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 36: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.4.2.3 Changing the wire feed rollers Figure 5-14 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 37 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 38: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.4.2.4 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 injury including injuries to the face and eyes! •...

  • Page 39: Spool Brake Setting

    Design and function MIG/MAG welding A prerequisite for the automatic inching process is the correct preparation of the wire guide, especially in the capillary and wire guide tube area > see 5.4.1 chapter. • The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll tensioner setting nuts depending on the welding consumable used.

  • Page 40: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.4.3 Definition of MIG/MAG welding tasks This machine series offers user-friendly operation and a multitude of features. • Various welding tasks (JOBs) consisting of welding procedure, material type, wire diameter and shielding gas type have been predefined > see 11.1 chapter. •...

  • Page 41: Superpuls

    (PB). This function is e.g. used for thin sheet welding to reduce the heat input in a controlled manner or for positional welding without the need for weaving. The combination of superPuls and other EWM welding processes offers a multitude of possibilities. For example, to enable the welding of vertical-up welds without the "Christmas tree" technique, when selecting program 1 >...

  • Page 42: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.4.5 MIG/MAG operating point The operating point (welding power) is specified using the MIG/MAG one-knob operation principle, i.e. the user can specify either the welding current, the wire feed speed or the material thickness to define the operating point.

  • Page 43: Forcearc / Forcearc Puls

    Design and function MIG/MAG welding 5.4.6 forceArc / forceArc puls Low-heat, directionally stable and powerful high-performance arc with deep fusion penetration for the upper power range Unalloyed, low-alloy and high-alloy steels as well as high-tensile fine-grained steels. Figure 5-24 • Smaller included angle due to deep penetration and directionally stable arc •...

  • Page 44: Rootarc/Rootarc Puls

    Design and function MIG/MAG welding 5.4.7 rootArc/rootArc puls Short arc with perfect weld modelling capabilities for effortless gap bridging, especially for positional welding Figure 5-25 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion •...

  • Page 45: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.4.8 MIG/MAG functional sequences / operating modes 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). 5.4.8.1 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 46 Design and function MIG/MAG welding Non-latched mode Figure 5-26 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 47 Design and function MIG/MAG welding Non-latched operation with superpulse 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 flows. •...
  • Page 48 Design and function MIG/MAG welding Special, non-latched Figure 5-28 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 49 Design and function MIG/MAG welding Spot welding Figure 5-29 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 50 Design and function MIG/MAG welding Special, non-latched with superpulse Figure 5-30 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 51 Design and function MIG/MAG welding Latched mode Figure 5-31 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 Latched mode with superpulse Figure 5-32 Step 1: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 53 Design and function MIG/MAG welding Latched with changing welding method (process switching) To activate or set the function > see 5.4.15 chapter. Figure 5-33 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 Latched special Figure 5-34 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 55 Design and function MIG/MAG welding Special latched with changing welding method by tapping (process switching) To activate or set the function > see 5.4.15 chapter. Figure 5-35 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
  • Page 56 Design and function MIG/MAG welding Special latched with changing welding method (process switching) To activate or set the function > see 5.4.15 chapter. Figure 5-36 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) •...
  • Page 57 Design and function MIG/MAG welding Special, latched 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 is flowing (start program P for the time t START...

  • Page 58: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Design and function MIG/MAG welding 5.4.9 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 59: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.4.10 MIG/MAG program sequence ("Program steps" mode) Certain materials, such as aluminium, require special functions in order to be able to weld them safely and at high quality. The latched special operating mode is used here with the following programs: •...

  • Page 60: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.4.10.2 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 61: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.4.10.3 Example, tack welding (non-latched) Figure 5-43 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 62: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.4.10.5 Example, aluminium welding (latched special) Figure 5-45 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 63: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.4.10.6 Example, visible seams (latched super pulse) Figure 5-46 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 64: Main Program A Mode

    Design and function MIG/MAG welding 5.4.11 Main program A mode Different welding tasks or positions on a workpiece demand various welding performances (operating points) or welding programs. The following parameters are stored in each of the up to 16 programs: •...
  • Page 65 Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-47 Example 2: Welding different positions on a workpiece (latched) Figure 5-48 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-49 Up to 16 programs (P...

  • Page 66: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.4.11.1 Selecting parameters (program A) Changes to the welding parameters can only be made when the key switch is in position "1". Figure 5-50 Select program number. 5.4.12 MIG/MAG automatic cut-out The welding machine ends the ignition process or the welding process with an •...

  • Page 67: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.4.13 Standard MIG/MAG torch The MIG welding torch trigger is essentially used to start and stop the welding process. Operating elements Functions • Torch trigger Start/stop welding Other functions are also possible by tapping the torch trigger, depending on the machine type and control configuration >...

  • Page 68: Expert Menu (Mig/Mag)

    Design and function MIG/MAG welding 5.4.15 Expert menu (MIG/MAG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of parameters shown may be limited, e.g. if a function is deactivated. 5.4.16 Selection ENTER (Enter the menu) •...
  • Page 69 Design and function MIG/MAG welding Display Setting/selection Correct wire burn-back If too high a value is set, a large ball will form at the tip of the wire electrode (bad re- ignition) or the wire electrode sticks to the contact tip. If too low a value is set, the wire electrode sticks to the weld pool.

  • Page 70: Tig Welding

    Design and function TIG welding TIG welding 5.5.1 Welding torch and workpiece line connection Figure 5-53 Item Symbol Description Workpiece Connection socket, "+" welding current • TIG welding: Workpiece connection Welding torch Welding torch hose package Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Welding current cable, polarity selection Welding current to the central connector/torch, enables polarity selection.

  • Page 71: Welding Task Selection

    Design and function TIG welding 5.5.2 Welding task selection EXIT 5.5.3 Welding current setting Figure 5-54 5.5.4 TIG arc ignition 5.5.4.1 Liftarc Figure 5-55 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 72: Function Sequences/Operating Modes

    Design and function TIG welding 5.5.5 Function sequences/operating modes 5.5.5.1 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 73 Design and function TIG welding Non-latched mode Figure 5-56 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 74 Design and function TIG welding Latched mode Figure 5-58 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 75: Tig Automatic Cut-Out

    Design and function TIG welding Latched special Figure 5-59 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 76: Tig Program Sequence ("Program Steps" Mode)

    Design and function TIG welding 5.5.7 TIG program sequence ("Program steps" mode) Figure 5-60 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 to P 0 s to 20 s...

  • Page 77: Mma Welding

    Design and function MMA welding 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 78: Welding Task Selection

    Design and function MMA welding 5.6.2 Welding task selection EXIT Figure 5-62 5.6.3 Welding current setting Figure 5-63 5.6.4 Arcforce Figure 5-64 Setting: • Negative values: rutile electrode types • Values at zero: basic electrode types • Positive values: cellulose electrode types 5.6.5 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current.

  • Page 79: Antistick

    Design and function MMA welding 5.6.6 Antistick Anti-stick prevents the electrode from annealing. If the electrode sticks in spite of the Arcforce device, the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating. Check the welding current setting and correct according to the welding task! Figure 5-66 5.6.7...

  • Page 80: 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! Interfaces for automation WARNING Do not carry out any unauthorised repairs or modifications!

  • Page 81: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.8.2 Remote control connection socket, 19-pole Figure 5-68 Signal form Short description Output Connection for PE cable screen Output Reference voltage for potentiometer 10 V (max. 10 mA) Control voltage specification (0 V–10 V) – wire feed speed Input Output Reference potential (0 V)

  • Page 82: Pc Interface

    Design and function PC interface PC interface 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 83: Selecting, Changing And Saving Parameters

    Design and function Special parameters (advanced settings) 5.11.1 Selecting, changing and saving parameters ENTER (Enter the menu) • Switch off machine at the main switch. • Press and hold the "left parameter selection" button and switch the machine on again at the same time.
  • Page 84 Design and function Special parameters (advanced settings) Display Setting/selection Enable special jobs SP1 to SP3 0 = ------- no enabling (Ex works) 1 = ------- enabling of Sp1-3 Correction operation, threshold value setting 0 = ------- correction operation switched off (Ex works) 1 = ------- correction operation on "Main program (PA)"...
  • Page 85 Design and function Special parameters (advanced settings) Display Setting/selection Predefined pulse arc welding process in the PA program 0 = -------- Predefined pulse arc welding process in the PA program is disabled. 1 = -------- If the superPuls and welding process switching functions are available and activated, the pulse arc welding process is always executed in the main program PA (ex factory).

  • Page 86: Reset To Factory Settings

    Design and function Special parameters (advanced settings) 5.11.1.1 Reset to factory settings All special parameters saved by the user will be overwritten by the factory settings! Figure 5-70 5.11.1.2 Special parameters in detail Ramp time for wire inching (P1) The wire inching starts with a speed 1.0 m/min for 2 secs. It is subsequently increased to a ramp function to 6.0 m/min.
  • Page 87 Design and function Special parameters (advanced settings) • Main program "P " Enabling special JOBs SP1 to SP3 (P6) Phoenix Expert machine series: The welding task is set at the power source control; refer to the relevant system documentation. If required, the predefined special welding tasks SP1 = JOB 129 / SP2 = JOB130 / SP3 = JOB 131 only can be selected at the wire feeder control.
  • Page 88 Design and function Special parameters (advanced settings) Setting the correction range: • Activate the “correction operation” special parameter (P7=1) and save. > see 5.11.1 chapter • Key switch to position "1". • Set the correction range as follows: EXIT Figure 5-72 •...
  • Page 89 Design and function Special parameters (advanced settings) Switching programs with the standard torch trigger (P8) Special latched (latched absolute program sequence) • Cycle 1: absolute program 1 is run • Cycle 2: absolute program 2 is run after completion of "tstart". •...
  • Page 90 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 91 Design and function Special parameters (advanced settings) JOB list switching (P12) Value Designation Explanation Task-oriented The JOB numbers are sorted by welding wires and shielding gases. JOB list JOB numbers may be skipped during selection where relevant. Actual JOB list JOB numbers correspond to the actual memory cells.
  • Page 92 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 93 Design and function Special parameters (advanced settings) 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 94: Machine Configuration Menu

    Design and function Machine configuration menu Electronic gas flow control, type (P22) Active only in machines with integrated gas flow control (option ex works). Adjustment may only be carried out by authorised service personnel (basic setting = 1). Program settings for relative programs (P23) The start, down-slope and end program relative programs can be set individually or combined for the P0- P15 operating points.
  • Page 95 Design and function Machine configuration menu ENTER EXIT NAVIGATION Figure 5-76 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 96: Aligning The Cable Resistance

    Design and function Aligning the cable resistance 5.13 Aligning the cable resistance The resistance value of cables can either be set directly or it can be aligned using the power source. The factory setting of the power sources is 8 mΩ. This value correponds to a 5 m earth cable, a 1.5 m intermediate hose package and a 3 m water-cooled welding torch.

  • Page 97: 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 98: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal General DANGER Incorrect maintenance and testing! The machine may be cleaned, repaired and tested by skilled and qualified personnel only. A qualified person is one who, due to their training, knowledge and experience, can detect any hazards and possible consequential damage when checking the machine, and can take the necessary safety measures.

  • Page 99: Daily Maintenance Tasks

    For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed.

  • Page 100: Disposing Of Equipment

    In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives on the Declaration of Conformity on your machine).

  • Page 101: 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 102: Error Messages (Power Source)

    Rectifying faults Error messages (power source) Error messages (power source) 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 103: Resetting Jobs (Welding Tasks) To The Factory Settings

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings Error Category Possible cause Remedy (Err) Software update required Inform Service. Legend for categories (reset error) a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a push-button: Welding machine control Push-button RC1 / RC2...

  • Page 104: Resetting All Jobs

    Rectifying faults General operating problems 7.3.2 Resetting all JOBs JOBs 1–128 and 170–256 will be reset. Custom JOBs 129–169 are maintained. ENTER ENTER EXIT Figure 7-2 Display Setting/selection RESET to factory settings The RESET will be done after pressing the button. The menu will be ended when no changes are done after 3 sec.

  • Page 105: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-3 099-005404-EW501...

  • Page 106: Technical Data

    Technical data Phoenix 401 Progress FKW Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 401 Progress FKW MIG/MAG Setting range for welding current 5 A–400 A Setting range for welding voltage 14-3 V–34.0 V 10.2 V–26.0 V 20.2 V–36.0 V Duty cycle at 40 °C...

  • Page 107: Phoenix 501 Progress Fkw

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

  • Page 108: Accessories

    Accessories General accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. AK300 Wire spool adapter K300 094-001803-00001 CA D200 Centering adapter for 5-kg spools 094-011803-00000 TYP 1 Frost protection tester...

  • Page 109: Computer Communication

    Accessories Computer communication Computer communication Type Designation Item no. PC300.Net PC300.Net welding parameter software kit incl. 090-008777-00000 cable and SECINT X10 USB interface FRV 7POL 5 m Extension/connecting cable 092-000201-00003 FRV 7POL 10 m Extension/connecting cable 092-000201-00000 FRV 7POL 20 m Extension/connecting cable 092-000201-00001 QDOC9000 V2.0...

  • Page 110: Replaceable Parts

    Replaceable parts Wire feed rollers Replaceable 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 111: Wire Guide

    Replaceable parts Wire feed rollers Type Designation Item no. FUEL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00010 BLUE/ORANGE flux cored wire FUEL 4R 1.2 MM/0.045 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00012 RED/ORANGE flux cored wire...

  • Page 112: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List JOB no. Processes Material Diameter [mm] Standard GMAW/pulse G3Si1/G4Si1 100% CO2 Standard GMAW/puls G3Si1/G4Si1 100% CO2 Standard GMAW/puls 100% CO2 G3Si1/G4Si1 Standard GMAW/puls 100% CO2 G3Si1/G4Si1 Standard GMAW/puls 100% CO2 G3Si1/G4Si1 Standard GMAW/puls G3Si1/G4Si1 Ar-82/CO2-18 (M21) Standard GMAW/puls...
  • Page 113 Appendix A JOB-List JOB no. Processes Material Diameter [mm] coldArc/coldArc puls Ar-97,5/CO2-2,5 (M12) CrNi 19 9/1.4316 coldArc/coldArc puls AlMg Ar-100 (I1) coldArc/coldArc puls Ar-100 (I1) AlMg coldArc/coldArc puls Ar-100 (I1) AlSi coldArc/coldArc puls AlSi Ar-100 (I1) coldArc/coldArc puls Ar-100 (I1) Al99 coldArc/coldArc puls Al99...
  • Page 114 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Brazing CuSi Ar-97,5/CO2-2,5 (M12) Brazing CuSi Ar-97,5/CO2-2,5 (M12) Brazing CuSi Ar-100 (I1) Brazing CuSi Ar-100 (I1) Brazing CuSi Ar-100 (I1) Brazing CuSi Ar-100 (I1) Brazing CuAl Ar-97,5/CO2-2,5 (M12) Brazing CuAl Ar-97,5/CO2-2,5 (M12) Brazing CuAl Ar-97,5/CO2-2,5 (M12)
  • Page 115 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Block 2/ JOB10 Block 3/ JOB1 Block 3/ JOB2 Block 3/ JOB3 Block 3/ JOB4 Block 3/ JOB5 Block 3/ JOB6 Block 3/ JOB7 Block 3/ JOB8 Block 3/ JOB9 Block 3/ JOB10 171* pipeSolution G3Si1/G4Si1...
  • Page 116 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Ar-82/CO2-18 (M21) Surfacing G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Ar-100 (I1) 220* coldArc - St/Al ZnAl coldArc - St/Al Ar-100 (I1) 221* ZnAl coldArc - St/Al...
  • Page 117 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Standard GMAW/puls Ar-70/He-30 (I3) NiCr 617 Standard GMAW/puls Ar-70/He-30 (I3) NiCr 617 Standard GMAW/puls Ar-70/He-30 (I3) NiCr 625 Standard GMAW/puls Ar-70/He-30 (I3) NiCr 625 Standard GMAW/puls Ar-70/He-30 (I3) NiCr 625 Standard GMAW/puls NiCr 625 Ar-67,95/He-30/H2-2 / CO2-0,05...
  • Page 118 Appendix A JOB-List JOB no. Processes Material Diameter [mm] forceArc/forceArc puls CrNi 22 9 3a/1.4462 Ar-97,5/CO2-2,5 (M12) forceArc/forceArc puls CrNi 25 20/1.4842 Ar-97,5/CO2-2,5 (M12) forceArc/forceArc puls CrNi 25 20/1.4842 Ar-97,5/CO2-2,5 (M12) forceArc/forceArc puls CrNi 22 12/1.4829 Ar-97,5/CO2-2,5 (M12) forceArc/forceArc puls CrNi 22 12/1.4829 Ar-97,5/CO2-2,5 (M12) coldArc/coldArc puls...

  • Page 119: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005404-EW501 16.01.2017...

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