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Summary of Contents for EWM Phoenix 355 Expert 2.0 puls MM TDM
- Page 1 Operating instructions Power source Phoenix 355 Expert 2.0 puls MM TDM Phoenix 405 Expert 2.0 puls MM TDM Phoenix 505 Expert 2.0 puls MM TDM 099-005352-EW501 Observe additional system documents! 13.01.2016...
- 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.
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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 ........................8 General ............................9 Transport and installation ......................13 2.4.1 Ambient conditions ....................... - Page 4 Options ............................47 Welding torch cooling system ...................... 47 Transport systems ........................47 Remote control / connection cable ....................47 9.5.1 7-pole connection ......................47 General accessories ........................47 10 Appendix A ............................48 10.1 Overview of EWM branches......................48 099-005352-EW501 13.01.2016...
- Page 5 Contents Notes on the use of these operating instructions 099-005352-EW501 13.01.2016...
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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 Safety instructions Notes on the use of these operating instructions WARNING Validity of the document! This document is part of the complete documentation and valid only in combination with the "Power source"operating instructions for the product being used! • Read and observe the operating instructions for all system components, especially the safety instructions! Figure 2-1 The illustration shows a general example of a welding system.
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Page 8: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the user Activate and release/tap/tip must observe. Switch off machine Release/do not activate Switch on machine Press and hold/switch Wrong Turn Correct Signal light off Menu entry Signal light on (e.g. -
Page 9: 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 10 Safety instructions General WARNING Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
- Page 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 8 Technical data chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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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: 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 15: Intended Use
3.1.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.1.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview The device configuration shown may differ in case of an additional ex works options or retrofitting options- See 9 Accessories chapter. Front view Figure 4-1 099-005352-EW501 13.01.2016... - Page 17 Machine description – quick overview Front view Item Symbol Description Carrying handle Ready for operation signal light Signal light on when the machine is switched on and ready for operation Main switch, machine on/off Cooling air inlet Machine feet Connection socket, "+" welding current •...
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Page 18: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 099-005352-EW501 13.01.2016... - Page 19 Machine description – quick overview Rear view Item Symbol Description Key button, Automatic cutout Wire feed motor supply voltage fuse (press to reset a triggered fuse) Connection socket, 7-pole Connection for peripheral devices with digital interface 7-pole connection socket (digital) Wire feed unit connection Connection socket, “+”...
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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 Design and function General 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. •...
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Page 22: Transport And Installation
Design and function Transport and installation Transport and installation WARNING Risk of accident due to improper transport of machines that may not be lifted! Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only! •... -
Page 23: 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 24: 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 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 25 Design and function Notes on the installation of welding current leads Use an individual welding lead to the workpiece for each welding machine! Figure 5-3 Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders.
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Page 26: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system 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 27: Cooling Module Connection
Design and function Welding torch cooling system 5.7.3 Cooling module connection Please note the relevant documentation of the accessory components. Figure 5-5 Item Symbol Description 4-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead Cooling module •... -
Page 28: Aligning The Cable Resistance
Design and function Aligning the cable resistance Aligning the cable resistance Menu navigation: Resistance value of the welding leads to optimise the welding properties. 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. - Page 29 Design and function Aligning the cable resistance 50mm DE - Abgleich Leitungswiderstand EN - Cable resistance alignment FR - Alignement résistance ligne IT - Compensazione resistenza circuito ES - Compensación de la resistencia del cable NL - Compensatie leidingsweerstand SE - Kalibrering av ledningsmotståndet PL - Porównanie rezystancji przewodu RU - Компенсация...
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Page 30: Connecting The Intermediate Hose Package To The Power Source
Design and function Connecting the intermediate hose package to the power source Connecting the intermediate hose package to the power source 5.9.1 Intermediate hose package strain relief CAUTION Missing or incorrectly fitted strain relief! Connection sockets or connection plugs on the machine, or the intermediate tube package, may be damaged if the strain relief is missing or incorrectly fitted. -
Page 31: Intermediate Hose Package Connection
Design and function Connecting the intermediate hose package to the power source 5.9.2 Intermediate hose package connection 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 "+"... -
Page 32: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Connecting the intermediate hose package to the power source 5.9.3 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 33: Welding Torch Holder
Design and function Welding torch holder 5.10 Welding torch holder The item described in the following is part of the machine´s scope of delivery. Figure 5-10 Item Symbol Description Crossmember of the transport handle Torch holder Fan-type lock washers Fixing screws (x 4) •... -
Page 34: Mig/Mag Welding
Design and function MIG/MAG welding 5.11 MIG/MAG welding 5.11.1 Connection for workpiece lead 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 "+"... -
Page 35: Tig Welding
Design and function TIG welding 5.12 TIG welding 5.12.1 Welding torch connection The welding torch is connected to the wire feeder. Observe the operating instructions for the wire feeder (system component)! 5.12.2 Connection for workpiece lead Figure 5-12 Item Symbol Description Workpiece Connection socket, "+"... -
Page 36: Mma Welding
Design and function MMA welding 5.13 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 37: Remote Control
Design and function Remote control 5.14 Remote control 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 38: 5.15.1 Automation Interface
Design and function Interfaces 5.15.1 Automation interface These accessory components can be retrofitted as an option - See 9 Accessories chapter. Input / Description Diagram output Output Connection for cable shielding Output IGRO Current flows signal I>0 (maximum load 20 (open mA / 15 V) collector) -
Page 39: 5.15.2 Rint X12 Robot Interface
Design and function PC Interfaces 5.15.2 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 40: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Improper maintenance and testing The equipment may only be cleaned, repaired or tested by specialist, skilled persons! A skilled person is one who, due to training, knowledge and experience, is able to recognise the dangers that can occur during testing of this equipment as well as possible subsequent damage and who is able to implement the required safety procedures. -
Page 41: Monthly Maintenance Tasks
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU). -
Page 42: 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 43: General Operating Problems
Rectifying faults General operating problems General operating problems 7.2.1 Interface for automated welding WARNING No function of the external interrupt equipment (emergency stop switch)! If the emergency stop circuit has been set up using an external interrupt equipment connected to the interface for automated welding, the machine must be configured for this setup. -
Page 44: Technical Data
Technical data Phoenix 355 TDM Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 355 TDM MIG/MAG Setting range for welding current 5 A–350 A Setting range for welding voltage 10.2 V–24.0 V 14.3 V–31.5 V 20.2 V–34.0 V Duty cycle... -
Page 45: Phoenix 405
Technical data Phoenix 405 Phoenix 405 MIG/MAG Setting range for welding current 5 A–400 A Setting range for welding voltage 10.2 V–26.0 V 14.3 V–34.0 V 20.2 V–36.0 V Duty cycle 40 °C 100% 400 A Load cycle 10 min. (60% DC 6 min. -
Page 46: Phoenix 505
Technical data Phoenix 505 Phoenix 505 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 500 A 500 A... -
Page 47: Accessories
Accessories Wire feed units Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Wire feed units Type Designation Item no. drive 4X HP Wire feeder, water-cooled, Euro torch connector 090-005392-00502 drive 4X HP MMA Wire feeder, water-cooled, Euro torch connector 090-005392-51502... -
Page 48: Overview Of Ewm Branches
Appendix A Overview of EWM branches Appendix A 10.1 Overview of EWM branches 099-005352-EW501 13.01.2016...
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