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Related Manuals for EWM Phoenix 351 Expert 2.0 puls MM FDW
Summary of Contents for EWM Phoenix 351 Expert 2.0 puls MM FDW
- Page 1 Operating instructions Welding machine Phoenix 351 Expert 2.0 puls MM FDW Phoenix 401 Expert 2.0 puls MM FDW Phoenix 451 Expert 2.0 puls MM FDW Phoenix 551 Expert 2.0 puls MM FDW 099-005329-EW501 Observe additional system documents! 13.06.2016...
- 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 Contents ..............................3 Safety instructions ..........................6 Notes on the use of these operating instructions ................6 Complete documentation ....................... 7 Explanation of icons ........................8 ... - Page 4 Remote control/connecting and extension cable ................. 50 9.4.1 7-pole connection ......................50 Computer communication ......................50 Appendix A ............................51 10.1 Overview of EWM branches......................51 099-005329-EW501 13.06.2016...
- Page 5 Contents Notes on the use of these operating instructions 099-005329-EW501 13.06.2016...
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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: Complete Documentation
Safety instructions Complete documentation Complete documentation This document is part of the complete documentation and valid only in combination with the "Control" 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. -
Page 8: Explanation Of Icons
Safety instructions 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/do not activate Switch on machine Press and hold switch Wrong Turn Correct Numerical value – adjustable Menu entry Signal light lights up in green Navigating the menu... -
Page 9: General
Safety instructions General General DANGER Electric shock! Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents. • Do not touch any live parts in or on the machine! •... - Page 10 Safety instructions General WARNING Fire hazard! Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts and hot slag produced during the welding process. Stray welding currents can also result in flames forming! • Check for fire hazards in the working area! •...
- Page 11 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes > see 8 chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
- Page 12 Safety instructions General 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.
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Page 13: Transport And Installation
Safety instructions 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 14: Lifting By Crane
Safety instructions Transport and installation 2.5.1 Lifting by crane WARNING Risk of injury during lifting by crane When lifting the machine by crane, persons may be severely injured by falling machines or mount-on components. • Simultaneous lifting of system components such as power source wire feeder or cooling unit without suitable crane components is not allowed. -
Page 15: Ambient Conditions
Safety instructions Transport and installation 2.5.2 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 16: Intended Use
Intended use Use and operation solely with the following machines Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate. -
Page 17: Documents Which Also Apply
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 18: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-005329-EW501 13.06.2016... - Page 19 Machine description – quick overview Front view Item Symbol Description Lifting lug Ready for operation signal light Signal light on when the machine is switched on and ready for operation Main switch, machine on/off Carrying handle Cooling air inlet Wheels, guide castors Coolant tank Coolant tank cap Automatic cut-out of coolant pump key button...
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Page 20: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 099-005329-EW501 13.06.2016... - Page 21 Machine description – quick overview Rear view Item Symbol Description 7-pole connection socket (digital) For connecting digital accessory components 7-pole connection socket (digital) Wire feed unit connection PC interface, serial (D-Sub connection socket, 9-pole) 19-pole mechanised welding interface (analogue) > see 5.14 chapter analog Connection socket, “+”...
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Page 22: 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 23: Installation
Design and function Installation Installation 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 Welding torch cooling system 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 5.5.1 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 Welding torch cooling system 5.5.3 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 •... -
Page 26: 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 27: 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 28 Design and function Notes on the installation of welding current leads 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. Figure 5-5 Stray welding currents can destroy protective earth conductors, damage equipment and electronic devices and cause overheating of components leading to fire.
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Page 29: Intermediate Hose Package Connection
Design and function Intermediate hose package connection 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 30: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Shielding gas supply (shielding gas cylinder for welding machine) • Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right. • Insert the plug on the welding current lead into the welding current connection socket "+" and lock. •... -
Page 31: Connection
Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.9.1 Connection Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to expel any dirt. Figure 5-8 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve •... -
Page 32: Setting The Shielding Gas Volume (Gas Test)/Rinse Hose Package
Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.9.2 Setting the shielding gas volume (gas test)/rinse hose package • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. •... -
Page 33: Mig/Mag Welding
Design and function MIG/MAG welding 5.10 MIG/MAG welding 5.10.1 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 34: Tig Welding
Design and function TIG welding 5.11 TIG welding 5.11.1 Welding torch connection TIG welding torches to be connected to a Euro torch connector are available in two versions: • TIG combi welding torches are connected to the Euro torch connector of the wire feeder and to the (-) welding current plug of the power source. -
Page 35: Connection For Workpiece Lead
Design and function TIG welding • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the welding current plug of the combi welding torch into the (-) welding current connection socket and lock into place by turning to the right (only in case of a separate welding current connection). -
Page 36: Mma Welding
Design and function MMA welding 5.12 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: Welding Task Selection
Design and function Remote control 5.12.2 Welding task selection For selection of the welding task and for general operation see the relevant Control operating instructions. 5.13 Remote control 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: Interfaces For Automation
Design and function Interfaces for automation 5.14 Interfaces for automation DANGER Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. •... -
Page 39: Rint X12 Robot Interface
Design and function PC Interfaces 5.14.2 RINT X12 robot interface The standard digital interface for mechanised applications Functions and signals: • Digital inputs: start/stop, operating modes, JOB and program selection, inching, gas test • Analogue inputs: control voltages, e.g. for welding performance, welding current, etc. •... -
Page 40: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal 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 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 Error messages 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 Rectifying faults Error messages Error Category Possible cause Remedy Error 17 Wire feed mechanism Check the wire feeding (WF. Ov.) overcurrent detection Error 18 No speedometer signal from Check the connection and particularly the (WF. Sl.) second wire feeder (slave speedometer of the second wire feeder drive) (slave drive).
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Page 44: 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 Coolant error/no coolant flowing ... -
Page 45: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! blau / blue ca. 5s KLICK CLICK KLICK CLICK... -
Page 46: Technical Data
Technical data Phoenix 351 FDW Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 351 FDW MIG/MAG 5 A–350 A Setting range for welding current 10.2 V–24.0 V 20.2 V–34.0 V 14.3 V–31.5 V Setting range for welding voltage 350 A Duty cycle at 40 °C (100% DC) -
Page 47: Phoenix 401 Fdw
Technical data Phoenix 401 FDW Phoenix 401 FDW MIG/MAG 5 A–400 A Setting range for welding current 10.2 V–26.0 V 20.2 V–36.0 V 14.3 V–34.0 V Setting range for welding voltage 400 A Duty cycle at 40 °C (100% DC) 10 min. -
Page 48: Phoenix 451, 551 Fdw
Technical data Phoenix 451, 551 FDW Phoenix 451, 551 FDW Setting range of welding current/voltage: 5 A/10.2 V to 5 A/10.2 V to 450 A/28.0 V 550 A/32.0 V 5 A/20.2 V to 5 A/20.2 V to 450 A/38.0 V 550 A/42.0 V 5 A/14.3 V to 5 A/14.3 V to... -
Page 49: Accessories
Accessories System components Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. System components Type Designation Item no. drive 4X HP Wire feeder, water-cooled, Euro torch connector 090-005392-00502 drive 4X LP Wire feeder, water-cooled, Euro torch connector 090-005412-00502 drive 4X HP MMA... -
Page 50: Remote Control/Connecting And Extension Cable
Accessories Remote control/connecting and extension cable Remote control/connecting and extension cable 9.4.1 7-pole connection Type Designation Item no. R40 7POL Remote control, 10 programs 090-008088-00000 R50 7POL Remote control, all welding machine functions can 090-008776-00000 be set directly at the workplace FRV 7POL 0.5 m Extension/connecting cable 092-000201-00004... -
Page 51: Overview Of Ewm Branches
Tel: +44 1670 505875 · Fax: -514305 www.ewm.cn · info@ewm.cn · info@ewm-group.cn www.ewm-morpeth.co.uk · info@ewm-morpeth.co.uk EWM HIGHTEC WELDING GmbH EWM HIGHTEC WELDING Sales s.r.o. / Prodejní a poradenské centrum Wiesenstraße 27b Tyršova 2106 4812 Pinsdorf · Austria · Tel: +43 7612 778 02-0 · Fax: -20 256 01 Benešov u Prahy ·...
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