EWM Phoenix 355 Progress puls LP MM TKM Operating Instructions Manual
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EWM Phoenix 355 Progress puls LP MM TKM Operating Instructions Manual

EWM Phoenix 355 Progress puls LP MM TKM Operating Instructions Manual

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Operating instructions
Welding machine
Phoenix 355 Progress puls LP MM TKM
EN
099-005502-EW501
Observe additional system documents!
2.12.2022

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Summary of Contents for EWM Phoenix 355 Progress puls LP MM TKM

  • Page 1 Operating instructions Welding machine Phoenix 355 Progress puls LP MM TKM 099-005502-EW501 Observe additional system documents! 2.12.2022...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.

  • Page 3: Table Of Contents

    Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................7 Notes on using these operating instructions ................7 Explanation of icons ....................... 8 Safety instructions ........................9 Transport and installation ....................12 3 Intended use ..........................
  • Page 4 Contents Notes on using these operating instructions 5.3.7.3 Arc dynamics (choke effect) ..............42 5.3.7.4 superPuls ....................42 5.3.7.5 Burn-back ....................43 5.3.8 Conventional MIG/MAG Welding (GMAW non synergic) ........44 5.3.8.1 Setting the operating point (welding output).......... 44 5.3.9 Welding power (operating point) ................
  • Page 5 Contents Notes on using these operating instructions 5.11.3.4 Program limit (P4) ................. 72 5.11.3.5 Special cycle in the operating modes special latched and non-latched (P5) ....................... 72 5.11.3.6 Correction operation, threshold value setting (P7) ....... 73 5.11.3.7 Switching programs with the standard torch trigger (P8) ...... 74 5.11.3.8 Latched/special-latched tap start (P9) ..........
  • Page 6 Contents Notes on using these operating instructions 10.1.4 Wire guide ......................96 11 Appendix ............................97 11.1 JOB-List..........................97 11.2 Parameter overview – setting ranges .................. 98 11.2.1 MIG/MAG welding ....................98 11.2.2 MMA welding ......................98 11.3 Searching for a dealer ......................99 099-005502-EW501 2.12.2022...

  • Page 7: For Your Safety

    For your safety Notes on using these operating instructions For your safety Notes on using these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •...

  • Page 8: Explanation Of Icons

    For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn...

  • Page 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 Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
  • Page 11 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...

  • Page 12: Transport And Installation

    For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.
  • Page 13 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.

  • Page 14: Intended Use

    3.2.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.2.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration.

  • Page 15: Part Of The Complete Documentation

    Intended use Documents which also apply 3.2.6 Part of the complete documentation This document is part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system.

  • Page 16: Machine Description - Quick Overview

    Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-005502-EW501 2.12.2022...
  • Page 17 Machine description – quick overview Front view / rear view Item Symbol Description Carrying handle Machine control > see 4.3 chapter 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Park socket, polarity selection plug Retainer for the polarity selection plug in MMA mode or for transport.

  • Page 18: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-2 Item Symbol Description Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, there are added information stickers on the inside of the flap for the operation and maintenance of the machine.

  • Page 19: Operating Elements In The Machine

    Machine description – quick overview Inside view 4.2.1 Operating elements in the machine Figure 4-3 Item Symbol Description Key button, automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse Welding torch function changeover switch (special welding torch required) ---- Changing over programs or JOBs ---- Infinite adjustment of welding performance.

  • Page 20: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 Item Symbol Description Push-button, welding task selection (JOB) SP1/2/3 - Special JOBs (Phoenix Expert only). Pressing the push-button longer: special JOB selection. Pressing the push-button briefly: switching between special JOBs.

  • Page 21: Welding Data Display

    Machine description – quick overview Machine control – Operating elements Item Symbol Description Rotary knob, welding parameter setting • ----------- Setting the welding task (JOB). With machines of the Phoenix Expert series, welding tasks are selected at the power source control. •...
  • Page 22 Machine description – quick overview Machine control – Operating elements Parameter Nominal values Actual values Hold values Welding current    Material thickness    Wire feed speed    Welding voltage    Welding performance ...

  • Page 23: Design And Function

    Design and function General Design and function General WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •...

  • Page 24: Transport And Installation

    Design and function Transport and installation Transport and installation WARNING Risk of accident due to improper transport of machines that must not be lifted! Do not lift or suspend the machine! The machine can drop and cause injuries! The handles, straps or brackets are suitable for transport by hand only! •...

  • Page 25: Notes On The Installation Of Welding Current Leads

    Design and function Transport and installation 5.2.4 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 26: Stray Welding Currents

    Design and function Transport and installation 5.2.5 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 27: Mains Connection

    Design and function Transport and installation 5.2.6 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • The connection (mains plug or cable), the repair or voltage adjustment of the device must be carried out by a qualified electrician in accordance with the respective local laws or nati- onal regulations! •...

  • Page 28: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Transport and installation 5.2.7 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 29: Shielding Gas Hose Connection

    Design and function Transport and installation 5.2.8.1 Shielding gas hose connection Figure 5-7 Item Symbol Description Connection thread - G¼" Shielding gas connection (inlet) • Screw the gas hose connection to the shielding gas connection (inlet) on the machine gas-tight. 5.2.9 Shielding gas volume settings If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause...

  • Page 30: Gas Test

    Design and function Transport and installation 5.2.9.1 Gas test Figure 5-8 5.2.9.2 Purge hose package 300s Figure 5-9 5.2.10 Welding torch cooling system 5.2.11 Cooling unit connection Figure 5-10 Item Symbol Description Cooling module 4-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead 099-005502-EW501...

  • Page 31: Welding Torch Holder

    Design and function Transport and installation • Insert and lock the 4-pole supply plug on the cooling unit into the 4-pole connection socket on the welding machine. • Insert and lock the 8-pole control lead plug on the cooling unit into the 8-pole connection socket on the welding machine.

  • Page 32: Protective Flap, Welding Machine Control

    Design and function Transport and installation 5.2.13 Protective flap, welding machine control Figure 5-12 Item Symbol Description Protective cap Bracket, protective cap • Push the right-hand bracket of the protective cap to the right and remove the protective cap. 5.2.14 Dirt filter These accessory components can be retrofitted as an option >...

  • Page 33: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.3.1 Assemble the wire guide The Euro torch connector is factory-fitted with a guide tube for welding torches with steel liner. Conver- sion is necessary if a welding torch with a steel liner is used! •...

  • Page 34: Welding Torch And Workpiece Line Connection

    Design and function MIG/MAG welding 5.3.2 Welding torch and workpiece line connection Figure 5-15 Item Symbol Description Welding torch Polarity selector plug, welding current cable Internal welding current cable for central connection/welding torch. • ---------- Connection socket for “+” welding current Workpiece •...

  • Page 35: Inserting The Wire Spool

    Design and function MIG/MAG welding 5.3.3.1 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 5.3.3.2 Changing the wire feed rollers Figure 5-18 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 5.3.3.3 Inching the wire electrode CAUTION Risk of injury due to welding wire escaping from the welding torch! The welding wire can escape from the welding torch at high speed and cause bodily in- jury including injuries to the face and eyes! •...

  • Page 39: Spool Brake Setting

    Design and function MIG/MAG welding • The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll ten- sioner setting nuts depending on the welding consumable used. A table with the setting values can be found on a sticker near the wire drive.

  • Page 40: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.3.4 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 shiel- ding gas type have been predefined > see 11.1 chapter. •...

  • Page 41: Operating Mode

    Design and function MIG/MAG welding 5.3.5.2 Operating mode The operating mode determines the process sequence controlled by the welding torch. Detailed descripti- ons of the operating modes > see 5.3.12 chapter. Figure 5-23 5.3.6 Welding type Different forms of MIG/MAG processes are collectively referred to as welding type. Standard (welding with standard arc) Depending on the set combination of wire feed speed and arc voltage, the arc types short arc, transitional arc or spray arc can be used for welding.

  • Page 42: Accessory Components For Operating Point Setting

    Design and function MIG/MAG welding 5.3.7.1 Accessory components for operating point setting The operating point can be set at various accessory components as well, such as remote control, special welding torches or robot and industrial bus interfaces (optional interface for automated welding required, not available for all machines of this series).

  • Page 43: Burn-Back

    Design and function MIG/MAG welding Display Setting/selection Switch on Switching on machine function Switch off Switching off machine function 5.3.7.5 Burn-back The wire burn-back parameter prevents the sticking of the wire electrode in the weld pool or at the contact tip at the end of the welding process.

  • Page 44: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Design and function MIG/MAG welding 5.3.8 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 45: Welding Power (Operating Point)

    Design and function MIG/MAG welding 5.3.9 Welding power (operating point) The welding power is adjusted according to the principle of one-knob operation. The user can set their operating point optionally as wire feed speed, welding current or material thickness. The optimum welding voltage for the operating point is calculated and set by the welding machine.

  • Page 46: Forcearc / Forcearc Puls

    Design and function MIG/MAG welding 5.3.10 forceArc / forceArc puls Heat-reduced, directionally-stable and powerful arc with deep fusion penetration for the upper power range. Figure 5-34 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 47: Operating Modes (Functional Sequences)

    Design and function MIG/MAG welding 5.3.12 Operating modes (functional sequences) 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). 5.3.12.1 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 48 Design and function MIG/MAG welding Non-latched mode Figure 5-36 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 49 Design and function MIG/MAG welding Special, non-latched 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 50 Design and function MIG/MAG welding Spot welding Figure 5-38 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 51 Design and function MIG/MAG welding Latched mode Figure 5-39 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 special Figure 5-40 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 53: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.3.13 MIG/MAG program sequence ("Program steps" mode) Certain materials, aluminium for example, require special functions for reliable and high-quality welding. In this case, the special latched mode is used with the following programs: • Start program P (avoidance of cold welds at start of seam) START •...

  • Page 54: Main Program A Mode

    Design and function MIG/MAG welding 5.3.14 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 55: Selecting Parameters (Program A)

    Design and function MIG/MAG welding Example 2: Welding different positions on a workpiece (latched) Figure 5-46 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-47 Up to 16 programs (P to P ) can be defined. An operating point (wire speed, arc length correction, dynamics/choke effect) can be defined permanently in each program.

  • Page 56: Mig/Mag Special-Torches

    Design and function MIG/MAG welding 5.3.16 MIG/MAG special-torches Function specifications and more indepth information can be found in the operating manual for the relevant welding torch! 5.3.16.1 Program and up/down operation Figure 5-49 Item Symbol Description Welding torch function changeover switch (special welding torch required) --- Changing over programs or JOBs --- Infinite adjustment of welding performance.

  • Page 57: Mma Welding

    Design and function MMA welding MMA welding 5.4.1 Connecting the electrode holder and workpiece lead CAUTION Risk of crushing and burns! When changing stick electrodes there is a risk of crushing and burns! • Wear appropriate and dry protective gloves. •...

  • Page 58: Welding Task Selection

    Design and function MMA welding 5.4.2 Welding task selection EXIT Figure 5-51 5.4.3 Welding current setting Figure 5-52 5.4.4 Arcforce Figure 5-53 Setting: • Negative values: rutile electrode types • Values at zero: basic electrode types • Positive values: cellulose electrode types 5.4.5 Hotstart The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent...

  • Page 59: Antistick

    Design and function TIG welding 5.4.6 Antistick The Antistick feature prevents the electrode from annealing. Should the electrode stick despite the Arcforce feature, the machine au- tomatically switches to the minimum current within approx. one second. This prevents the electrode from annealing. Check the welding current setting and correct for the welding task in hand.

  • Page 60: Welding Task Selection

    Design and function TIG welding 5.5.3 Welding task selection You can only change the JOB number when no welding current is flowing. EXIT Figure 5-57 5.5.4 Welding current setting Figure 5-58 5.5.5 Arc ignition 5.5.5.1 Liftarc Figure 5-59 The arc ignites through contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip against the workpiece (lift arc current flows independent of the set main current) b) Angle the torch above the torch gas nozzle until the distance between electrode tip and workpiece is...

  • Page 61: Operating Modes (Functional Sequences)

    Design and function TIG welding 5.5.6 Operating modes (functional sequences) 5.5.6.1 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...
  • Page 62 Design and function TIG welding Non-latched mode Figure 5-60 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 63 Design and function TIG welding Latched mode Figure 5-62 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 64: Remote Control

    Design and function Remote control Latched special Figure 5-63 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 65: Access Control

    Design and function Access control Access control The key switch is only available for machines which are fitted with the "OW KL XX5" option ex works. 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.

  • Page 66: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation Input / Name Figure Output Output PE -------- Connection for cable screen Output IGRO ---- Current flows signal I>0 (maximum load 20 mA / (open collec- 15 V) 0 V = welding current flows tor) Input Not-Aus - Emergency stop for higher level shut-down of the...

  • Page 67: Rint X12 Robot Interface

    Design and function PC interface Signal form Short description Output Connection for PE cable screen Output Reference voltage for potentiometer 10 V (max. 10 mA) Input Control voltage specification (0 V–10 V) – wire feed speed Output Reference potential (0 V) Input Welding power start/stop (S1) Input...

  • Page 68: Connection

    Design and function PC interface 5.10.1.1 Connection Equipment damage or faults may occur if the PC is connected incorrectly! Not using the SECINT X10USB interface results in equipment damage or faults in signal trans- mission. The PC may be destroyed due to high frequency ignition pulses. •...

  • Page 69: Special Parameters (Advanced Settings)

    Design and function Special parameters (advanced settings) 5.11 Special parameters (advanced settings) Special parameters (P1 to Pn) are applied for customer-specific configuration of machine functions. This allows the user maximum flexibility in optimising their requirements. These settings are not configured directly on the machine control since a regular setting of the parame- ters is generally not required.
  • Page 70 Design and function Special parameters (advanced settings) Display Setting/selection Correction operation, threshold value setting 0 = ------- correction operation switched off (Ex works) 1 = ------- correction operation on "Main program (PA)" flashing Program switching with standard welding torch No program switching (factory setting) 1 = ------- Special latched 2 = ------- Special latched (n-cycle active) 3 = ------- Special latched (n-cycle sequence from any program)

  • Page 71: Reset To Factory Settings

    Design and function Special parameters (advanced settings) Display Setting/selection Electronic gas flow control, type 1 = ------- type A (ex works) 0 = ------- type B Program settings for relative programs 0 = ------- Combined setting of relative programs possible (ex works). 1 = ------- Individual setting of relative programs possible (ex works).

  • Page 72: Special Parameters In Detail

    Design and function Special parameters (advanced settings) 5.11.3 Special parameters in detail 5.11.3.1 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 power rotary knob.

  • Page 73: Correction Operation, Threshold Value Setting (P7)

    Design and function Special parameters (advanced settings) 5.11.3.6 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 cor- rection 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 74: Switching Programs With The Standard Torch Trigger (P8)

    Design and function Special parameters (advanced settings) 5.11.3.7 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 75: Latched/Special-Latched Tap Start (P9)

    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 76: Latched Special Tapping Time Setting (P11)

    Design and function Special parameters (advanced settings) 5.11.3.10 Latched special tapping time setting (P11) The tapping time for changing over between the main program and reduced main program can be set in three levels. 0 = no tapping 1 = 320ms (factory setting) 2 = 640ms 5.11.3.11 JOB list switching (P12) Name...

  • Page 77: Lower And Upper Limits Of The Remote Job Changeover Process (P13, P14)

    Design and function Special parameters (advanced settings) Copying JOBs, "Copy to" function The possible target range is between 129 - 169. • First configure special parameter P12 to P12 = 2 or P12 = 1! Figure 5-72 5.11.3.12 Lower and upper limits of the remote JOB changeover process (P13, P14) The highest and lowest JOB numbers which can be selected using accessory components, such as the PowerControl 2 torch.

  • Page 78: Block Job Mode (P16)

    Design and function Special parameters (advanced settings) 5.11.3.14 Block JOB mode (P16) The following accessory components support block JOB mode: • Up/Down welding torch with one-digit 7-segment display (two keys) Program 0 is always active in JOB 0 and program 1 in all other JOBs In this operating mode, up to 30 JOBs (welding tasks) divided into three blocks can be called up with ac- cessory components.

  • Page 79: Average Value Display For Superpuls (P19)

    Design and function Special parameters (advanced settings) 5.11.3.16 Average value display for superPuls (P19) Function active (P19 = 1) • For superPuls, the performance average value from program A (P ) and program B (P ) is shown on the display (ex factory). Function inactive (P19 = 0) •...

  • Page 80: Machine Configuration Menu

    Design and function Machine configuration menu 5.12 Machine configuration menu Figure 5-73 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 81: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.12.1 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 inter- mediate hose package and a 3 m water-cooled welding torch.

  • Page 82: 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 83: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed.

  • Page 84: Maintenance Work, Intervals

    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. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-005502-EW501 2.12.2022...

  • Page 85: Disposing Of Equipment

    Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html.

  • Page 86: Rectifying Faults

    Rectifying faults Error messages (power source) Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dea- ler.
  • Page 87 Rectifying faults Error messages (power source) Category Possible cause Remedy ID number allocation error Correct ID numbers (2DV) Detection of wire feeder 2 Check cable connections Error in open circuit voltage Inform Service. reduction (VRD) Overcurrent detection on wire Check ease of wire feeding feeder Error in tachometer generator Check the connection and particularly the ta-...

  • Page 88: Checklist For Rectifying Faults

    Rectifying faults Checklist for rectifying faults Checklist for rectifying faults The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation! Legend Symbol Description Fault/Cause  Remedy  Functional errors  Mains fuse triggers - unsuitable mains fuse Set up recommended mains fuse >...

  • Page 89: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit Figure 7-1 • Switch off the machine and fill the coolant tank to the maximum level. • Unlock the quick-connect coupling with a suitable tool (connection open). To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-2 •...

  • Page 90: 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 All customised welding parameters that are stored will be replaced by the factory settings. 7.4.1 Resetting a single JOB ENTER RESET EXIT Figure 7-3 7.4.2 Resetting all JOBs...

  • Page 91: Technical Data

    Technical data Phoenix 355 Progress puls MM TKM Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 355 Progress puls MM TKM MIG/MAG Welding current (I 5 A to 350 A Welding voltage according to stan- 14,3 V to 31,5 V 10,2 V to 24,0 V 20,2 V to 34,0 V...

  • Page 92: Accessories

    Accessories Welding torch cooling system Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Welding torch cooling system Type Designation Item no. cool50 U40 Cooling module 090-008598-00502 cool50-2 U42 Cooling unit with reinforced pump 090-008797-00502 HOSE BRIDGE UNI Tube bridge...

  • Page 93: General Accessories

    Accessories General accessories General accessories Type Designation Item no. AK300 Wire spool adapter K300 094-001803-00001 CA D200 Centering adapter for 5-kg spools 094-011803-00000 16A 5POLE/CEE Mains plug 094-000712-00000 DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 G1 G1/4 R 3M Gas hose 094-000010-00003 Sharpener for liner...

  • Page 94: Networking / Xnet

    Accessories Networking / Xnet Networking / Xnet Type Designation Item no. Xnet LAN Gateway LAN gateway in external casing 090-008833-00502 Xnet WiFi Gateway WiFi gateway in external casing 090-008834-00502 Xnet Extended-Set LAN Xnet retrofit set LAN: One machine licence, a LAN 091-008833-00001 gateway and a network cable (10 m) Xnet Extended-Set WiFi...

  • Page 95: Replaceable Parts

    Replaceable parts Wire feed rollers Replaceable parts Performance specifications and guarantee only in connection with original spare and replacement parts! 10.1 Wire feed rollers 10.1.1 Wire feed rollers for steel wire Type Designation Item no. FE 4R 0.6 MM/0.023 INCH Drive roll set, 37 mm, 4 rolls, V-groove for steel, 092-002770-00006 LIGHT PINK...

  • Page 96: Wire Feed Rollers For Cored Wire

    Replaceable parts Wire feed rollers 10.1.3 Wire feed rollers for cored wire Type Designation Item no. FUEL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00008 WHITE/ORANGE flux cored wire 092-002848-00010 FUEL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for BLUE/ORANGE flux cored wire...

  • Page 97: Appendix

    Appendix JOB-List Appendix 11.1 JOB-List Figure 11-1 099-005502-EW501 2.12.2022...

  • Page 98: Parameter Overview - Setting Ranges

    Appendix Parameter overview – setting ranges 11.2 Parameter overview – setting ranges 11.2.1 MIG/MAG welding Name Display Setting range Start current Correction of arc length in start program P -9,9 START Slope time of start program P to main program P START Slope time of main program P to end program P...

  • Page 99: Searching For A Dealer

    Appendix Searching for a dealer 11.3 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005502-EW501 2.12.2022...

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