EWM Sirion 405 puls Operating Instructions Manual

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Operating instructions

Power source

Sirion 405 puls

Sirion 505 puls

099-005720-EW501

Observe additional system documents!

09.04.2024

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Summary of Contents for EWM Sirion 405 puls

Page 1 Operating instructions Power source Sirion 405 puls Sirion 505 puls 099-005720-EW501 Observe additional system documents! 09.04.2024...
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 Contents Notes on using these operating instructions Contents 1 Contents........................3 2 For your safety......................6 Notes on using these operating instructions ............... 6 Explanation of icons ....................7 Safety instructions ....................8 Transport and installation ..................11 3 Intended use ........................13 Applications......................13 Use and operation solely with the following machines ..........13 Documents which also apply ...................13...
Page 4 Notes on using these operating instructions Checklist for rectifying faults ...................41 Vent coolant circuit ....................42 8 Technical data ......................43 Dimensions and weighte ..................43 Performance data....................44 8.2.1 Sirion 405 puls ..................44 8.2.2 Sirion 505 puls ..................45 9 Accessories.........................46 System components ....................46 9.1.1 Wire feed unit..................46 9.1.2...
Page 5 Contents Notes on using these operating instructions 099-005720-EW501 09.04.2024...
Page 6 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 7 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 8 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 9 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 10 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases may lead to shortness of breath and poisoning! The ultraviolet radia- tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso- nous phosgene. • Ensure sufficient fresh air! •...
Page 11 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 12 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 13 3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration.
Page 14 Intended use Documents which also apply 3.3.4 Service documents (spare parts and circuit diagrams) WARNING No improper repairs and modifications! To prevent injuries and damage to the machine, only competent personnel (authorised service personnel) are allowed to repair or modify the machine. Unauthorised manipulations will invalidate the warranty! •...
Page 15 Machine description – quick overview Front view / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-005720-EW501 09.04.2024...
Page 16 Machine description – quick overview Front view / rear view Item Symbol Description Carrying handle Ready for operation signal light Signal light on when the machine is switched on and ready for operation Main Switch Switching the machine on or off. Cooling air inlet Dirt filter optional >...
Page 17 Machine description – quick overview Front view / rear view 4.1.1 Connection panel Figure 4-2 Item Symbol Description Key button, Automatic cutout Wire feed motor supply voltage fuse (press to reset a triggered fuse) 7-pole connection socket (digital) Wire feed unit connection 8-pole connection socket Cooling unit control lead 4-pole connection socket...
Page 18 Design and function Transport and installation Design and function 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 19 Design and function Transport and installation Transport and storage Storage in a closed room, temperature range of the ambient air: • -30 °C to +70 °C (-22 °F to 158 °F) Relative humidity • up to 90 % at 20 °C (68 °F) Ambient temperature dependent on coolant! Observe the coolant temperature range of the torch coo- ling 5.1.2...
Page 20 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 21 Design and function Transport and installation 5.1.6 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 22 Design and function Transport and installation 5.1.6.2 Adjusting the power source to the mains voltage The mains voltage is adapted by replugging the operating voltage plug on the printed circuit board VB xx0 into the power source. The machine can be reconnected between two voltage ranges: 1.
Page 23 Design and function Transport and installation 5.1.6.4 Mains configuration The machine may be connected to: • a three-phase system with four conductors and an earthed neutral conductor • a three-phase system with three conductors of which any one can be earthed, e.g.
Page 24 Design and function Transport and installation 5.1.8 Notes on the installation of welding current leads • Incorrectly installed welding current leads can cause faults in the arc (flickering). • Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel.
Page 25 Design and function Transport and installation 5.1.9 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 26 Design and function MIG/MAG welding MIG/MAG welding 5.2.1 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 27 Design and function MMA welding or gouging MMA welding or gouging 5.3.1 Connection of electrode holder or gouging torch 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 28 Design and function TIG welding TIG welding 5.4.1 Connection Figure 5-12 Item Symbol Description Wire feeder Note the additional system documents! Welding torch Observe additional system documents! Connection socket, welding current “–” Workpiece Connection socket, “+” welding current • Insert the cable plug of the welding current lead (intermediate hose package) into the connection so- cket, welding current "-"...
Page 29 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 30 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! 099-005720-EW501 09.04.2024...
Page 31 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 32 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 33 Rectifying faults Error messages (power source) Error 7: Low coolant level Category B  Low flow rate. Fill with coolant.  Check coolant flow - remove kinks in the hose package.  Adjust the flow threshold  Clean the cooler. ...
Page 34 Rectifying faults Error messages (power source) Error 16: Pilot arc power source - collective error Category A  The external emergency stop circuit has been interrupted. Check the emergency stop circuit and eliminate the cause of the error.   The emergency stop circuit of the power source has been activated (internally configurable). Deactivate the emergency stop circuit.
Page 35 Rectifying faults Error messages (power source) Error 20: Low coolant level Category B  Low flow rate. Fill with coolant.  Check coolant flow - remove kinks in the hose package.  Adjust the flow threshold  Clean the cooler. ...
Page 36 Rectifying faults Error messages (power source) Error 26: Excess pilot arc module temperature Category A  The power source is overheating. Allow the switched-on machine to cool.   Fan is blocked, dirty or faulty. Check the fan and clean or replace it. ...
Page 37 Rectifying faults Error messages (power source) Error 40: Electronics error  Error I>0 Request service.  Error 47: Radio link (BT) Category B  Connection error between the welding machine and peripheral unit. Note the documentation for the data interface with radio transmission. ...
Page 38 Rectifying faults Error messages (power source) Error 56: Mains phase failure  One phase of the mains voltage has failed. Check the mains connection, mains plug and mains fuses.  Error 57: Slave tacho error Category B  Fault in the wire feeder (slave drive). Check the connections (connectors, lines).
Page 39 Rectifying faults Warnings Warnings Depending on the display options of the machine display, a warning message is displayed as follows: Display type - machine control Display Graphic display two 7-segment displays one 7-segment display The cause of the warning is indicated by a corresponding warning number (see table). •...
Page 40 Rectifying faults Warnings Warning Potential cause / remedy 24 Coolant flow warning Check the coolant supply. Check the coolant level and top up if necessary. Check flow and switching thresholds. 25 Flow 2 reserved 26 Flow 3 reserved 27 Flow 4 reserved 28 Wire stock warning Check the wire feeding.
Page 41 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 42 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 43 Technical data Dimensions and weighte Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Dimensions and weighte Sirion 405 Sirion 505 Dimensions (l x b x h) 625 x 298 x 531 mm 24.6 x 11.7 x 20.9 inch Weight 39,4 kg 42,7 kg...
Page 44 Technical data Performance data Performance data 8.2.1 Sirion 405 puls MIG/MAG Welding current (I 5 A to 400 A Welding voltage according to standard (U 14,3 V to 34 V 20,2 V to 36,0 V 10,2 V to 26,0 V Duty cycle DC at 40°...
Page 45 Technical data Performance data 8.2.2 Sirion 505 puls MIG/MAG Welding current (I 5 A to 500 A Welding voltage according to standard (U 14,3 V to 39 V 20,2 V to 40 V 10,2 V to 30 V Duty cycle DC at 40° C 500 A (40%) 430 A (60%) 370 A (100%)
Page 46 Accessories System components Accessories Performance-dependent accessories like torches, workpiece leads, e lectrode holders or intermediate hose packages are available from your authorised dealer. System components 9.1.1 Wire feed unit Type Designation Item no. Drive 4X S Wire feeder drive 090-005719-00502 9.1.2 Welding torch cooling system Type...
Page 47 Appendix Average wire electrode usage Appendix 10.1 Average wire electrode usage 5 m/min – 197 ipm inch .040 .045 .060 Steel kg/h 10.3 lb/h Stainless steel 10.5 Aluminium 10 m/min – 394 ipm Steel kg/h 11.6 20.9 lb/h Stainless steel 11.9 21.1 Aluminium...
Page 48 Appendix Searching for a dealer 10.3 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005720-EW501 09.04.2024...

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