EWM Phoenix 355 Concept puls TKM Operating Instructions Manual
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EWM Phoenix 355 Concept puls TKM Operating Instructions Manual

EWM Phoenix 355 Concept puls TKM Operating Instructions Manual

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Operating instructions
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099-005236-EW501
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Welding machine
Phoenix 355 Concept puls TKM
30.10.2012
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  • Page 1 Operating instructions Welding machine Phoenix 355 Concept puls TKM 099-005236-EW501 30.10.2012 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
  • Page 2 © EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents..............................3 2 Safety instructions..........................6 Notes on the use of these operating instructions ................6 Explanation of icons........................7 General ............................8 Transport and installation ......................12 2.4.1 Ambient conditions .......................
  • Page 4 Contents Notes on the use of these operating instructions 5.9.4 Definition of MIG/MAG welding tasks ................43 5.9.5 Welding task selection ....................43 5.9.5.1 Basic welding parameters ................43 5.9.5.2 Operating mode.....................43 5.9.5.3 Welding type (MIG/MAG standard/pulse arc welding) ........43 5.9.5.4 Choke effect / dynamics ................44 5.9.5.5 Superpulses ....................44 5.9.5.6...
  • Page 5 Wire feed rollers for aluminium wire ................102 10.1.3 Wire feed rollers for cored wire .................. 102 10.1.4 Conversion sets......................103 11 Appendix A ............................104 11.1 JOB-List .............................104 12 Appendix B ............................105 12.1 Overview of EWM branches ......................105 099-005236-EW501 30.10.2012...

  • 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: Explanation Of Icons

    Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine Switch on machine ENTER (enter the menu) NAVIGATION (Navigating in the menu) EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use...

  • Page 8: 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 9 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 10 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 11 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.

  • Page 12: 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 13: 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 14: Intended Use

    Intended use Applications Intended use This machine has been manufactured according to the latest developments in technology and current regulations and standards. It must only be operated in line with the instructions on correct usage. WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly.

  • Page 15: Documents Which Also Apply

    Intended use Documents which also apply Documents which also apply 3.2.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.2.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •...

  • Page 16: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview NOTE The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted (see "Accessories" chapter). Front view Figure 4-1 099-005236-EW501 30.10.2012...
  • Page 17 Machine description – quick overview Front view Item Symbol Description Transport bar Carrying handle 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. Wire spool inspection window Check wire supply Slide latch, lock for the protective cap...

  • Page 18: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-005236-EW501 30.10.2012...
  • Page 19 Machine description – quick overview Rear view Item Symbol Description Main switch, machine on/off Connecting nipple G¼, shielding gas connection Mains connection cable Cooling air inlet Cooling air outlet External wire feed inlet Pre-cut casing inlet for external wire feed. 8-pole connection socket Cooling unit control lead 4-pole connection socket...

  • Page 20: Operating Elements In The Machine

    Machine description – quick overview Operating elements in the machine Operating elements in the machine Figure 4-3 099-005236-EW501 30.10.2012...
  • Page 21 Machine description – quick overview Operating elements in the machine Item Symbol Description Wire spool holder Wire feed unit Welding torch function changeover switch (special welding torch required) Programm Changing over programs or JOBs Infinite adjustment of welding performance. Up / Down Key button, automatic cutout Wire feed motor supply voltage fuse press to reset a triggered fuse...

  • Page 22: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements M 3.73 Material Wire JOB- LIST Super- puls VOLT PROG HOLD Concept m/min Figure 4-4 099-005236-EW501 30.10.2012...
  • Page 23 Machine description – quick overview Machine control – Operating elements Item Symbol Description Lid (see chap. "Machine control – concealed operating elements") Button, Parameter selection left Welding current Material thickness Wire speed After each completed welding process, the last parameter values used for the HOLD welding process are shown on the display in the main program;...

  • Page 24: Covered Operating Elements

    Machine description – quick overview Machine control – Operating elements 4.4.1 Covered operating elements 11 12 M 3.73 Material Wire JOB- LIST Super- puls Figure 4-5 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used.
  • Page 25 Machine description – quick overview Machine control – Operating elements Item Symbol Description Super- Signal lamp, super pulse function puls Lights up when the super pulse function is active. Signal light, JOB-List Material Illuminates upon display or selection of the JOB number Wire Key button, JOB-List JOB-...

  • Page 26: 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 27: Installation

    Design and function Installation 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 28: Protective Flap, Welding Machine Control

    Design and function Machine cooling 5.2.1 Protective flap, welding machine control Figure 5-1 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. Machine cooling To obtain an optimal duty cycle from the power components, the following precautions should be observed: Ensure that the working area is adequately ventilated.

  • Page 29: 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 30: Cooling Module Connection

    Design and function Cooling module connection Cooling module connection NOTE Observe the fitting and connection instructions given in the relevant operating instructions for the cooling unit. Figure 5-3 Item Symbol Description 4-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead Cooling module •...

  • Page 31: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) Shielding gas supply (shielding gas cylinder for welding machine) 5.7.1 Connecting the shielding gas supply WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. •...

  • Page 32: Gas Test

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) Figure 5-4 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve • Place the shielding gas cylinder into the relevant cylinder bracket. •...

  • Page 33: Setting The Shielding Gas Quantity

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.7.4 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11.5 = l/min MIG brazing Wire diameter x 11.5 = l/min MIG welding (aluminium) Wire diameter x 13.5 = l/min (100 % argon) Gas nozzle diameter in mm corresponds to l/min gas throughput...

  • Page 34: Welding Torch Holder

    Design and function Welding torch holder Welding torch holder NOTE The item described in the following is part of the machine´s scope of delivery. Figure 5-5 Item Symbol Description Crossmember of the transport handle Torch holder Fan-type lock washers Fixing screws (x 4) •...

  • Page 35: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.9.1 Welding torch and workpiece line connection NOTE Fault with the wire guide! On delivery, the central connector (Euro) is fitted with a capillary tube for welding torches with spiral guides. Conversion is necessary if a welding torch with a plastic core is used! Welding torch with plastic core: •...

  • Page 36: Mig/Mag Standard Welding

    Design and function MIG/MAG welding 5.9.2 MIG/MAG standard welding Figure 5-6 Item Symbol Description Welding torch Welding torch hose package Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger 19-pole connection socket (analogue) Connection for welding torch control lead Welding current cable, polarity selection Welding current to central connection/torch.

  • Page 37: Mig/Mag Cored Wire Welding With A Negative Wire Electrode

    Design and function MIG/MAG welding 5.9.2.1 MIG/MAG cored wire welding with a negative wire electrode Figure 5-7 Item Symbol Description Welding torch Welding torch hose package Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger 19-pole connection socket (analogue) Connection for welding torch control lead Connection socket, “+”...

  • Page 38: Wire Feed

    Design and function MIG/MAG welding 5.9.3 Wire feed 5.9.3.1 Open the protective flap of the wire feeder CAUTION To perform the following steps, the protective flap of the wire feeder needs to be opened. Make sure to close the protective flap again before starting to work. •...

  • Page 39: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.9.3.3 Changing the wire feed rollers NOTE Unsatisfactory welding results due to faulty wire feeding! Wire feed rollers must be suitable for the diameter of the wire and the material. • Check the roller label to verify that the rollers are suitable for the wire diameter. Turn or change if necessary! •...

  • Page 40: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.9.3.4 Inching the wire electrode CAUTION Risk of injury due to moving parts! The wire feed units are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons! • Do not reach into rotating or moving parts or drive components! •...
  • Page 41 Design and function MIG/MAG welding Figure 5-10 Item Symbol Description Pressure unit Clamping unit Knurled nut Pressure roller Wire feed nipple Guide tube Drive rollers "Undetachable" knurled screws Wire feed nipple with wire stabiliser • Extend and lay out the torch hose package. •...

  • Page 42: Spool Brake Setting

    Design and function MIG/MAG welding 5.9.3.5 Spool brake setting Figure 5-11 Item Symbol Description Allen screw Securing the wire spool retainer and adjustment of the spool brake • Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect. NOTE Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation!

  • Page 43: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.9.4 Definition of MIG/MAG welding tasks This range of machines feature simple operation with a very wide range of functions. • Various JOBs (i.e. welding tasks consisting of welding process, material type, wire diameter and shielding gas type) have been pre-defined (see appendix for a list of JOBs).

  • Page 44: Choke Effect / Dynamics

    Design and function MIG/MAG welding 5.9.5.4 Choke effect / dynamics DY N m /m in Figure 5-12 Display Setting/selection Dynamics setting 40: Arc harder and narrower -40: Arc softer and wider 5.9.5.5 Superpulses m /m in Figure 5-13 Display Setting/selection Selects super pulses Switches function on or off.

  • Page 45: Burn-Back

    Design and function MIG/MAG welding 5.9.5.6 Burn-back m /m in Figure 5-14 Display Setting/selection menu burn back Set burn back Parameter setting (setting range 0 to 499) Back-burn set too high: large drops developing on the wire electrode result in poor ignition properties or the wire electrode sticking to the welding nozzle.

  • Page 46: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.9.6 MIG/MAG operating point The operating point (welding output) is specified using the principle of MIG/MAG one-dial operation, i.e. the user need only specify the operating point by setting the required wire speed, for example, and the digital system will calculate the optimum values for welding current and voltage (operating point).

  • Page 47: Operating Point Setting Using Material Thickness

    Design and function MIG/MAG welding Application example Aluminium is to be welded. • Material = AlMg, • Gas = Ar 100%, • Wire diameter = 1.2 mm The correct wire speed is not known and is to be determined. • Select the appropriate JOB (see "JOB list"...

  • Page 48: Mig/Mag Welding Data Display

    Design and function MIG/MAG welding 5.9.7 MIG/MAG welding data display To the left and right of the control displays are the "Parameter selection" buttons ( ). They are used to select welding parameters to be displayed. Each press of the button advances the display to the next parameter (LEDs next to the button indicate the selection).

  • Page 49: Forcearc

    Design and function MIG/MAG welding 5.9.8 forceArc Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range. Figure 5-17 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 50: Rootarc

    Design and function MIG/MAG welding 5.9.9 rootArc Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding. Figure 5-18 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion • Un-alloyed and low-alloy steels •...

  • Page 51: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.9.10 MIG/MAG functional sequences / operating modes NOTE There are optimum pre-sets for welding parameters such as gas pre-flow and burn back, etc. for numerous applications (although these can also be changed if required). 5.9.10.1 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 52 Design and function MIG/MAG welding Non-latched mode Figure 5-19 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 Non-latched operation with superpulse Figure 5-20 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 54 Design and function MIG/MAG welding Special, non-latched START Figure 5-21 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P for the time t START...
  • Page 55 Design and function MIG/MAG welding Spot welding START Figure 5-22 NOTE The ignition time t must be added to the spot time t start 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed"...
  • Page 56 Design and function MIG/MAG welding Special, non-latched with superpulse START Figure 5-23 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 57 Design and function MIG/MAG welding Latched mode Figure 5-24 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 58 Design and function MIG/MAG welding Latched mode with superpulse Figure 5-25 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 59 Design and function MIG/MAG welding Latched mode with alternating welding process Figure 5-26 1st cycle: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows •...
  • Page 60 Design and function MIG/MAG welding Latched special START Figure 5-27 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P START Step 2...
  • Page 61 Design and function MIG/MAG welding Latched special with welding process alternation NOTE This function can be activated using the PC300.NET software. • Refer to the software operating instructions. START Figure 5-28 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
  • Page 62 Design and function MIG/MAG welding Latched special with alternating welding process NOTE This function can be activated using the PC300.NET software. • Refer to the software operating instructions. START Figure 5-29 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) •...
  • Page 63 Design and function MIG/MAG welding Special, latched with superpulse START 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 64: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.9.12 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 65: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.9.12.2 MIG/MAG overview of parameters Super- puls Figure 5-32 Basic Parameters Item Meaning / Explanation Setting Range Gas pre-flow time 0.0s to 20.0s 1% to 200% START Wire speed, relative -9.9V to +9.9V Arc length correction Duration 0.0s to 20.0s Slope duration from P...

  • Page 66: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.9.12.3 Example, tack welding (non-latched) Figure 5-33 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 67: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.9.12.5 Example, aluminium welding (latched special) START Figure 5-35 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 68: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.9.12.6 Example, visible seams (latched super pulse) START Figure 5-36 Basic parameters Welding parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20.0s RUECK Wire burn-back length 2 to 500 PROC.SP.

  • Page 69: Main Program A Mode

    Design and function MIG/MAG welding 5.9.13 Main program A mode Different welding tasks or positions on a workpiece demand various welding performances (operating points) or welding programs. The following parameters are stored in each of the up to 16 programs: •...

  • Page 70: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.9.13.1 Selecting parameters (program A) Operating Action Result Display element Change welding data display over to program display. (LED PROG is on) Select program number. Display example: Program "1". Select program sequence parameter "Main program (P )".

  • Page 71: Standard Mig/Mag Torch

    Design and function Remote control 5.9.14 Standard MIG/MAG torch The MIG welding torch trigger is essentially used to start and stop the welding process. Operating elements Functions Torch trigger • Start/stop welding Other functions are also possible by tapping the torch trigger, depending on the machine type and control configuration: •...

  • Page 72: Advanced Settings

    Design and function Advanced settings 5.11 Advanced settings The special parameters cannot be viewed directly since they are normally only set and stored once. The machine control offers the following special functions: 5.11.1 Selecting, changing and saving parameters VOLT A M P PROG HOLD m /m in...
  • Page 73 Design and function Advanced settings Display Setting/selection Ramp time for wire inching 0 = normal inching (10s ramp time) 1 = fast inching (3s ramp time) (Ex works) Block program "0" 0 = P0 enabled (Ex works) 1 = P0 blocked Program limitation Programs 1 to max.

  • Page 74: Reset To Factory Settings

    Design and function Advanced settings 5.11.2 Reset to factory settings NOTE All customised welding parameters that are stored will be replaced by the factory settings. Operating Action Result Displays element Left Right Switch off welding machine VOLT Keep the button pressed PROG Switch on welding machine VOLT...
  • Page 75 Design and function Advanced settings Enabling special JOBs SP1 to SP3 (P6) The JOB changeover is blocked if the key switch is in the “0” position. This block can be cancelled for the special JOBs (SP1 - SP3). Correction operation, threshold value setting (P7) The correction operation is switched on and off for all JOBs and their programs at the same time.
  • Page 76 Design and function Advanced settings Setting the correction range: • Switch on the "Correction operation" special parameter (P7=1) and save the setting. (See chapter entitled "Selecting, changing and saving parameters".) • Key switch to position "1". • Set correction range according to the following table: Operating Action Result...
  • Page 77 Design and function Advanced settings Specific latched special (n cycle) In the n cycle program sequence, the unit starts in the 1st cycle with start program P from P start In the second cycle, the machine switches to absolute program 2, once the start time "tstart" has elapsed. Tapping switches to other programs (P to max.
  • Page 78 Design and function Advanced settings N cycle setting NOTE The n cycle function should always be activated before the n cycle setting (see "Program changeover with standard torch (P8)". m /m in Figure 5-44 Latched/special-latched tap start (P9) In latched – tap start – operating mode it is possible to switch straight to the second step by tapping the torch trigger;...
  • Page 79 Design and function 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 80: Tig Welding

    Design and function TIG welding 5.12 TIG welding 5.12.1 Welding torch and workpiece line connection Figure 5-45 Item Symbol Description Welding torch Welding torch hose package Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger 19-pole connection socket (analogue) Connection for welding torch control lead Welding current cable, polarity selection...

  • Page 81: Welding Task Selection

    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 cable plug on the work piece lead into the "+" welding current connection socket and lock by turning to the right.

  • Page 82: Pulses, Function Sequences

    Design and function TIG welding 5.12.4 Pulses, function sequences 5.12.5 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 83 Design and function TIG welding Non-latched mode Figure 5-47 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 84 Design and function TIG welding Latched mode Figure 5-49 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 85: Tig Automatic Cut-Out

    Design and function TIG welding Latched special START Figure 5-50 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 86: Tig Program Sequence ("Program Steps" Mode)

    Design and function TIG welding 5.12.7 TIG program sequence ("Program steps" mode) 5.12.7.1 TIG parameter overview Super- puls Figure 5-51 Basic parameters Item Meaning/explanation Setting range Gas pre-flow time 0 s to 0.9 s START 0% to 200% Ignition current Duration (start program) 0 s to 20 s Slope duration from P...

  • Page 87: 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 88: Welding Task Selection

    Design and function MMA welding • Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right. • Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and lock by turning to the right.

  • Page 89: Hotstart

    Design and function MMA welding 5.13.5 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current Welding current Time 5.13.6 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...

  • Page 90: Pc Interfaces

    Design and function PC Interfaces 5.14 PC Interfaces CAUTION 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 transmission. The PC may be destroyed due to high frequency ignition pulses. •...

  • Page 91: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! •...

  • Page 92: Monthly Maintenance Tasks

    Maintenance, care and disposal Maintenance work 6.2.2 Monthly maintenance tasks 6.2.2.1 Visual inspection • Casing damage (front, rear and side walls) • Wheels and their securing elements • Transport elements (strap, lifting lugs, handle) • Check coolant tubes and their connections for impurities 6.2.2.2 Functional test •...

  • Page 93: Disposing Of Equipment

    Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922. •...

  • Page 94: 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 95: Error Messages (Power Source)

    Rectifying faults Error messages (power source) Error messages (power source) NOTE A welding machine error is indicated by an error code being displayed (see table) on the display on the machine control. In the event of a machine error, the power unit is shut down. The display of possible error numbers depends on the machine version (interfaces/functions).
  • Page 96 Rectifying faults Error messages (power source) b) The error message can be reset by pressing a key button: Welding machine control Key button RC1 / RC2 Expert CarExpert / Progress (M3.11) alpha Q / Concept / Basic / Basic S / Synergic / not possible Synergic S / Progress (M3.71) Picomig 305 c) The error message can only be reset by switching the machine off and on again.

  • Page 97: 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 NOTE All customised welding parameters that are stored will be replaced by the factory settings. 7.3.1 Resetting a single JOB JOB- JOB- LIST LIST m /m in...

  • Page 98: Resetting All Jobs

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings 7.3.2 Resetting all JOBs JOB- JOB- LIST LIST m /m in Figure 7-2 Display Setting/selection Reset to factory settings The RESET will be done after pressing the button. The menu will be ended when no changes are done after 3 sec. 099-005236-EW501 30.10.2012...

  • Page 99: Vent Coolant Circuit

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

  • Page 100: Technical Data

    Technical data Phoenix 355 Concept puls Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 355 Concept puls MIG/MAG Setting range Welding current 5 A-350 A Setting range Welding voltage 14,3 V - 31,5 V 20,2 V - 34,0 V 10,2 V - 24,0 V Duty cycle at 40 °C ambient temperature...

  • Page 101: Accessories

    Accessories General accessories Accessories NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. Trolly 55-2 Transport vehicle 090-008628-00000 cool50 Cooling module 090-008598-00502 TYP 1 Frost protection tester 094-014499-00000 KF 23E-10...

  • Page 102: Replaceable Parts

    Replaceable parts Wire feed rollers Replaceable parts CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...

  • Page 103: Conversion Sets

    Replaceable parts Wire feed rollers 10.1.4 Conversion sets Type Designation Item no. URUE VERZ>UNVERZ FE/AL Conversion kit, 37mm, 4-roller drive on non-toothed 092-000845-00000 rollers (steel/aluminium) URUE AL 4ZR4R 0,8+1,0 Conversion kit, 37mm, 4-roller drive for aluminium 092-000867-00000 URUE AL 4ZR4R 1,0+1,2 Conversion kit, 37mm, 4-roller drive for aluminium 092-000846-00000 URUE AL 4ZR4R 1,2+1,6...

  • Page 104: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List 094-015723-00500 Wire Material Job-Nr. CO 100 / C1 SG2/3 G3/4 Si1 Ar80-90 / M2 Figure 11-1 099-005236-EW501 30.10.2012...

  • Page 105: Overview Of Ewm Branches

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

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