EWM Phoenix 335 Progress Puls FA KGE Operating Instructions Manual
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EWM Phoenix 335 Progress Puls FA KGE Operating Instructions Manual

EWM Phoenix 335 Progress Puls FA KGE Operating Instructions Manual

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Operating instructions
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099-005183-EW501
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www.ewm-group.com
Welding machine
Phoenix 335 Progress Puls FA KGE
17.12.2010
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Summary of Contents for EWM Phoenix 335 Progress Puls FA KGE

  • Page 1 Operating instructions Welding machine Phoenix 335 Progress Puls FA KGE 099-005183-EW501 17.12.2010 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...

  • Page 2: General Instructions

    © 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 Contents 1 Contents..............................3 2 Safety instructions..........................7 Notes on the use of these operating instructions ................7 Explanation of icons........................8 General ............................9 Transport and installation ......................12 Ambient conditions........................13 2.5.1 In operation........................13 2.5.2 Transport and storage ....................13 3 Intended use ............................
  • Page 4 Contents 5.7.8 MIG/MAG operating point .....................38 5.7.8.1 Selecting the display unit................38 5.7.8.2 Operating point setting using material thickness, welding current, wire speed......................39 5.7.8.3 Arc length correction setting................39 5.7.8.4 Accessory components for operating point setting ........39 5.7.9 MIG/MAG welding data display ..................40 5.7.10 forceArc.........................41 5.7.11...
  • Page 5 Wire feed rollers for aluminium wire ................104 9.4.3 Wire feed rollers for cored wire .................. 104 9.4.4 Conversion sets......................104 Options............................104 10 Appendix A ............................105 10.1 JOB-List .............................105 11 Appendix B ............................106 11.1 Overview of EWM branches ......................106 099-005183-EW501 17.12.2010...
  • Page 6 Contents 099-005183-EW501 17.12.2010...

  • Page 7: 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 8: 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 9: General

    Safety instructions General General DANGER Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •...
  • Page 10 Safety instructions General WARNING Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
  • Page 11 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.

  • Page 12: 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 Ambient conditions 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 Phoenix 335 Progress puls Machine description – quick overview Phoenix 335 Progress puls 4.1.1 Front view 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).
  • Page 17 Machine description – quick overview Phoenix 335 Progress puls Item Symbol Description Transport bar Carrying handle Cover for wire delivery unit and operating elements Wire spool inspection window Check wire supply Slide latch, lock for the protective cap Machine control See Machine control –...

  • Page 18: Rear View

    Machine description – quick overview Phoenix 335 Progress puls 4.1.2 Rear view Figure 4-2 099-005183-EW501 17.12.2010...
  • Page 19 Machine description – quick overview Phoenix 335 Progress puls Item Symbol Description Main switch, machine on/off Connecting nipple G¼, shielding gas connection 4-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead 7-pole connection socket (digital) For connecting digital accessory components (documentation interface, robot interface digital or remote control, etc.).

  • Page 20: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements M 3.72 Material Wire JOB- LIST Super- puls VOLT PROG HOLD Progress m/min Figure 4-3 099-005183-EW501 17.12.2010...
  • Page 21 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 22: Machine Control - Concealed Operating Elements

    Machine description – quick overview Machine control – Operating elements 4.2.1 Machine control – Concealed operating elements 11 12 M 3.71 Material Wire JOB- LIST Super- puls Figure 4-4 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 23: Operating Elements In The Machine

    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 24: Design And Function

    Design and function General Design and function General DANGER 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 25: Installation

    Design and function Installation CAUTION Damage due to incorrect connection! Accessory components and the power source itself can be damaged by incorrect connection! • Only insert and lock accessory components into the relevant connection socket when the machine is switched off. •...

  • Page 26: Protective Cap

    Design and function Machine cooling 5.2.1 Protective cap 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 27: 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 (any phase sequence for three-phase machines)!

  • Page 28: 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 29: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.7.1 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 30: Mig/Mag Standard Welding

    Design and function MIG/MAG welding 5.7.1.1 MIG/MAG standard welding Figure 5-4 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 31: Mig/Mag Cored Wire Welding With A Negative Wire Electrode

    Design and function MIG/MAG welding 5.7.1.2 MIG/MAG cored wire welding with a negative wire electrode Figure 5-5 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 32: Mig/Mag Cored Wire Welding With A Positive Wire Electrode

    Design and function MIG/MAG welding 5.7.1.3 MIG/MAG cored wire welding with a positive wire electrode NOTE To connect the positive wire electrode, follow the procedure in the "MIG/MAG standard welding" chapter! 5.7.2 Inserting the wire spool NOTE Standard D300 pin reels can be used. Adapters (see accessories) are required when using standardised basket coils (DIN 8559).

  • Page 33: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.7.3 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 34: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.7.4 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 injury including injuries to the face and eyes! •...

  • Page 35: Spool Brake Setting

    Design and function MIG/MAG welding • Extend and lay out the torch tube package. • Unfasten pressure units and fold out (clamping units and counter-pressure rollers will automatically flip upwards). • Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe.

  • Page 36: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.7.6 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 37: Choke Effect / Dynamics

    Design and function MIG/MAG welding 5.7.7.4 Choke effect / dynamics DY N m /m in Figure 5-10 Display Setting/selection Dynamics setting 40: Arc harder and narrower -40: Arc softer and wider 5.7.7.5 Superpulses m /m in Figure 5-11 Display Setting/selection Selects super pulses Switches function on or off.

  • Page 38: Wire Burn-Back

    Design and function MIG/MAG welding 5.7.7.6 Wire burn-back m /m in Figure 5-12 Display Setting/selection menu wire burn-back Set wire burn-back Parameter setting (setting range 0 to 499) Wire 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 39: Operating Point Setting Using Material Thickness, Welding Current, Wire Speed

    Design and function MIG/MAG welding The correct wire speed is not known and is to be determined. • Select the appropriate JOB (see "JOB list" sticker) • Switch to the material thickness display • Set the material thickness as appropriate (e.g. 5 mm) •...

  • Page 40: Mig/Mag Welding Data Display

    Design and function MIG/MAG welding 5.7.9 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 41: Forcearc

    Design and function MIG/MAG welding 5.7.10 forceArc The forceArc process is welding in the spray arc range with a considerably shortened arc. Disadvantages of short-circuit phases are compensated by the fast control inverter technology. Benefits of forceArc welding: • Good fusion penetration •...

  • Page 42: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.7.12 MIG/MAG functional sequences / operating modes NOTE There are optimum pre-sets for welding parameters such as gas pre-flow and free-burn, etc. for numerous applications (although these can also be changed if required). 5.7.12.1 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 43 Design and function MIG/MAG welding Non-latched mode Figure 5-15 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 44 Design and function MIG/MAG welding Non-latched operation with superpulse Figure 5-16 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 45 Design and function MIG/MAG welding Special, non-latched START Figure 5-17 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 46 Design and function MIG/MAG welding Spots START Figure 5-18 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 47 Design and function MIG/MAG welding Special, non-latched with superpulse START 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 is flowing (start program P for the time t START...
  • Page 48 Design and function MIG/MAG welding Latched mode 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 49 Design and function MIG/MAG welding Latched mode with superpulse 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 flows. •...
  • Page 50 Design and function MIG/MAG welding Latched mode with alternating welding process Figure 5-22 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 51 Design and function MIG/MAG welding Latched special 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 START Step 2...
  • Page 52 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 5-24 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
  • Page 53 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 5-25 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) •...
  • Page 54 Design and function MIG/MAG welding Special, latched with superpulse START Figure 5-26 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: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Design and function MIG/MAG welding 5.7.13 Conventional MIG/MAG Welding (GMAW non synergic) • With wire-feed speeds less than 8 m/min select JOB 188. • With wire-feed speeds over 8 m/min select JOB 187. You can only change the JOB number when no welding current is flowing. Operating Action Result...

  • Page 56: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.7.14 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 57: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.7.14.2 MIG/MAG overview of parameters Super- puls Figure 5-28 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 58: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.7.14.3 Example, tack welding (non-latched) Figure 5-29 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 59: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.7.14.5 Example, aluminium welding (latched special) START Figure 5-31 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 60: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.7.14.6 Example, visible seams (latched super pulse) START Figure 5-32 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 61: Welding Process Changeover

    Design and function MIG/MAG welding 5.7.14.7 Welding process changeover START Figure 5-33 Program Setting option Relates to Setting Pulse arc welding process on/off All special, non-latched 1 (= on) START Changes using PC300.Net software All special, latched 0 (= off) Welding process changeover Non-latched/latched mode 1 (= active)

  • Page 62: Main Program A Mode

    Design and function MIG/MAG welding 5.7.15 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 63 Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-34 Example 2: Welding different positions on a workpiece (latched) Figure 5-35 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-36 NOTE...

  • Page 64: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.7.15.1 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 65: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.7.17 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 66: Remote Control

    Design and function MIG/MAG welding 5.7.19 Remote control Remote controls are operated on the 19-pole remote control connection socket (analogue). If required, extension cables are available in different lengths (see chapter "Accessories"). • The remote control is detected automatically when the welding machine is switched on. 5.7.20 R10, R20, R40 Type Port...

  • Page 67: Advanced Settings

    Design and function MIG/MAG welding 5.7.21 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: 5.7.21.1 Selecting, changing and saving parameters VOLT A M P PROG HOLD m /m in...
  • Page 68 Design and function MIG/MAG welding 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 POWERCONTROL torch display mode 0 = normal display (factory setting) program number/JOB or...

  • Page 69: Reset To Factory Settings

    Design and function MIG/MAG welding Display Setting/selection Block JOB mode 0 = Block JOB mode not enabled (Ex works) 1 = Block JOB mode enabled Program selection with standard torch trigger 0 = no program selection (Ex works) 1 = program selection possible 5.7.21.2 Reset to factory settings NOTE All special parameters saved by the user will be overwritten by the factory settings!

  • Page 70: The Special Parameters In Detail

    Design and function MIG/MAG welding 5.7.21.3 The special parameters in detail 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 parameter setting rotary dial.
  • Page 71 Design and function MIG/MAG welding 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 correction 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 72 Design and function MIG/MAG welding Operating Action Result Display (examples) element Left Right VOLT Press button until "PROG" LED comes PROG Left: Wire feed speed Right: Program number VOLT Press button and hold down for approx. PROG Left: Current limit value of the wire feed speed correction Right: Current limit value of the...
  • Page 73 Design and function MIG/MAG welding 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". • Cycle 3: absolute program 3 is run until the "t3"...
  • Page 74 Design and function MIG/MAG welding 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 75 Design and function MIG/MAG welding "Single or dual operation" (P10) setting NOTE If the system is fitted with two wire feeds, no further accessory components may be operated on the 7-pole connection socket (digital)! This relates to digital remote controls, robot interfaces, documentation interfaces, welding torches with digital control lead connection, etc.
  • Page 76 Design and function MIG/MAG welding Creating user-defined JOB lists A consecutive memory range where accessories such as the POWERCONTROL 2 torch can be used to switch between JOBs will be created. • Set special parameter P12 to "2". • Set "Program or Up/Down function" changeover switch to "Up/Down" position. •...
  • Page 77 Design and function MIG/MAG welding Block JOB mode (P16) The following accessory components support block JOB mode: • R20 remote control and POWERCONTROL welding torch Program 0 is always active in JOB 0 and program 1 in all other JOBs In this operating mode, a total of 27 JOBs (welding tasks) divided into three blocks can be called up using accessory components.

  • Page 78: Switching Between Push/Pull And Intermediate Drive

    Design and function MIG/MAG welding 5.7.21.4 Switching between Push/Pull and intermediate drive 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 79: Tig Welding

    Design and function TIG welding TIG welding 5.8.1 Welding torch and workpiece line connection Figure 5-43 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) For connecting analogue remote controls Welding current cable, polarity selection Welding current to the central connector/torch, enables polarity selection.
  • Page 80 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 81: Welding Task Selection

    Design and function TIG welding 5.8.2 Welding task selection • Select JOB 127 (TIG welding task). It is only possible to change the JOB number when no welding current is flowing. On decompact welding systems, the "JOB list" sticker is located on the inside on the wire feed unit cover; with compact machines it is on the right-hand power source cover.

  • Page 82: Pulses, Function Sequences

    Design and function TIG welding 5.8.5 Pulses, function sequences 5.8.5.1 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 Special, latched...
  • Page 83 Design and function TIG welding Non-latched mode Figure 5-45 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 5-47 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 5-48 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 MMA welding 5.8.7 TIG program sequence ("Program steps" mode) 5.8.7.1 TIG parameter overview Super- puls Figure 5-49 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: Connecting The Electrode Holder And Workpiece Lead

    Design and function MMA welding 5.9.1 Connecting the electrode holder and workpiece lead Figure 5-50 Item Symbol Description Workpiece Connection socket, "+" welding current • MMA welding: Workpiece connection "-" welding current connection socket • MMA welding: electrode holder connection Park socket, polarity selection plug Retainer for the polarity selection plug in MMA mode or for transport.

  • Page 88: Welding Task Selection

    Design and function MMA welding 5.9.2 Welding task selection • Select JOB 128 (MMA welding task). It is only possible to change the JOB number when no welding current is flowing. On decompact welding systems, the "JOB list" sticker is located on the inside on the wire feed unit cover; with compact machines it is on the right-hand power source cover.

  • Page 89: Hotstart

    Design and function MMA welding 5.9.5 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 Figure 5-51 For hotstart parameter settings, see "parameter overview" chapter 5.9.6 Antistick Anti-stick prevents the electrode from annealing.

  • Page 90: Shielding Gas Supply

    Design and function Shielding gas supply 5.10 Shielding gas supply 5.10.1 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. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •...

  • Page 91: Gas Test

    Design and function Shielding gas supply Figure 5-54 Item Symbol Description Pressure reducer Shielding gas cylinder Output side of the pressure reducer Cylinder valve • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. •...

  • Page 92: Setting The Shielding Gas Quantity

    Design and function Shielding gas supply 5.10.4 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 Helium-rich gas mixtures require a higher gas volume! The table below can be used to correct the gas volume calculated where necessary:...

  • Page 93: Interfaces

    Design and function Interfaces 5.11 Interfaces 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 94: Rint X11 Robot Interface

    Design and function Interfaces 5.11.2 RINT X11 robot interface The standard digital interface for mechanised applications• (optional, retrofitting on the machine or external fitting by the customer) Functions and signals: • Digital inputs: start/stop, operating modes, JOB and program selection, inching, gas test •...

  • Page 95: Protecting Welding Parameters From Unauthorised Access

    Design and function Protecting welding parameters from unauthorised access 5.12 Protecting welding parameters from unauthorised access 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. In key switch position 1 all functions and parameters can be set without restriction.

  • Page 96: 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 97: Repair Work

    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 98: Rectifying Faults

    Rectifying faults Meeting the requirements of RoHS 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 99: 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. •...

  • Page 100: 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. 7.2.1 Resetting a single JOB JOB- JOB- LIST LIST m /m in...

  • Page 101: Resetting All Jobs

    Rectifying faults General operating problems 7.2.2 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. General operating problems 7.3.1 Interface for mechanised welding...

  • Page 102: Technical Data

    Technical data Phoenix 335 Progress puls Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 335 Progress puls Setting range: Welding current/voltage 5 A-330 A 5 A-330 A MIG/MAG 5 A-330 A Duty cycle at 40 °C ambient temperature 35% DC 330 A...

  • Page 103: Accessories, Options

    Accessories, options General accessories Accessories, options 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 cool 50 Cooling module 090-008598-00502 TYP 1 Frost protection tester...

  • Page 104: Wire Feed Rollers

    Accessories, options Wire feed rollers Wire feed rollers 9.4.1 Wire feed rollers for steel wire Type Designation Item no. FE 2DR4R 0,6+0,8 Drive rollers, 37 mm, steel 092-000839-00000 FE 2DR4R 0,8+1,0 Drive rollers, 37 mm, steel 092-000840-00000 FE 2DR4R 0,9+1,2 Drive rollers, 37 mm, steel 092-000841-00000 FE 2DR4R 1,0+1,2...

  • Page 105: Job-List

    Appendix A JOB-List Appendix A 10.1 JOB-List 094-015723-00500 Wire Material Job-Nr. CO 100 / C1 SG2/3 G3/4 Si1 Ar80-90 / M2 Figure 10-1 099-005183-EW501 17.12.2010...

  • Page 106: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 11.1 Overview of EWM branches 099-005183-EW501 17.12.2010...

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