Related Manuals for EWM Phoenix 351-551
Summary of Contents for EWM Phoenix 351-551
- Page 1 Operating instructions Welding machine Phoenix 351-551 Progress puls MM FDW 099-005325-EW501 Observe additional system documents! 05.12.2014 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
-
Page 2: General Instructions
+49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted. -
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 Lifting by crane ...................... - Page 4 System components ........................55 General accessories ........................55 Options ............................55 Remote control/connecting and extension cable ................. 56 9.4.1 7-pole connection ......................56 Computer communication ......................56 10 Appendix A ............................57 10.1 Overview of EWM branches......................57 099-005325-EW501 05.12.2014...
- Page 5 Contents Notes on the use of these operating instructions 099-005325-EW501 05.12.2014...
-
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 Correct Wrong Press Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu) EXIT 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... -
Page 8: General
Safety instructions General General DANGER Electric shock! Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents. • Do not touch any live parts in or on the machine! •... - Page 9 Safety instructions General WARNING Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure when heated. • Move containers with inflammable or explosive liquids away from the working area! • Never heat explosive liquids, dusts or gases by welding or cutting! Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning.
- 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 8 Technical data chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
-
Page 12: 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: Lifting By Crane
Safety instructions Transport and installation 2.4.1 Lifting by crane WARNING Risk of injury during lifting by crane When lifting the machine by crane, persons may be severely injured by falling machines or mount-on components. • Simultaneous lifting of system components such as power source wire feeder or cooling unit without suitable crane components is not allowed. -
Page 14: Ambient Conditions
Safety instructions Transport and installation 2.4.2 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 15: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with proper usage and by trained or expert staff! •... -
Page 16: Use And Operation Solely With The Following Machines
Intended use Use and operation solely with the following machines Use and operation solely with the following machines NOTE A suitable wire feed unit (system component) is required in order to operate the welding machine! Phoenix Progress 351-451 351-551 D 351-551 2DV miniDrive ... -
Page 17: Documents Which Also Apply
Warranty NOTE 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 The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 18: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-005325-EW501 05.12.2014... - Page 19 Machine description – quick overview Front view Item Symbol Description Lifting lug Voltage reduction device (VRD) The VRD signal light is illuminated, when the voltage reduction device is operating without fault and the output voltage is reduced to a value specified in the relevant standard- See 8 Technical data chapter.
-
Page 20: Rear View
Machine description – quick overview Rear view Rear view NOTE The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted- See 9 Accessories chapter. Rear view Figure 4-2 099-005325-EW501 05.12.2014... - Page 21 Machine description – quick overview Rear view Item Symbol Description 7-pole connection socket (digital) For connecting digital accessory components 7-pole connection socket (digital) Wire feed unit connection PC interface, serial (D-Sub connection socket, 9-pole) 19-pole mechanised welding interface (analogue) - See 7.4.1 Interface for automated welding chapter Connection socket, “+”...
-
Page 22: Design And Function
Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 23: Installation
Design and function Installation 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 24: Notes On The Installation Of Welding Current Leads
Design and function Notes on the installation of welding current leads Notes on the installation of welding current leads NOTE 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 Notes on the installation of welding current leads NOTE Use an individual welding lead to the workpiece for each welding machine! Figure 5-2 NOTE Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders.
-
Page 26: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! • Only use the coolant described in this manual (overview of coolants). •... -
Page 27: Adding Coolant
Design and function Welding torch cooling system 5.6.3 Adding coolant The unit is supplied ex works with a minimum level of coolant. Figure 5-4 Item Symbol Description Coolant tank cap Coolant filter sieve Coolant tank "Min" mark Minimum coolant level •... -
Page 28: 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 29: Intermediate Hose Package Connection
Design and function Intermediate hose package connection Intermediate hose package connection NOTE Note the polarity of the welding current! Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity. In this case, the welding current lead should be connected to the "-" welding current socket, and the workpiece lead should be connected to the "+"... -
Page 30: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Shielding gas supply (shielding gas cylinder for welding machine) • Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right. • Insert the plug on the welding current lead into the welding current connection socket "+" and lock. •... - Page 31 Design and function Shielding gas supply (shielding gas cylinder for welding machine) Figure 5-7 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 32: Adjusting The Cable Resistance
Design and function Adjusting the cable resistance 5.10 Adjusting the cable resistance The resistance value of cables can either be set directly or it can be matched using the power source. The factory setting of the power sources is 8 m-ohm. This value correponds to a 5 m earth cable, a 1.5 m intermediate hose package and a 3 m water-cooled welding torch. - Page 33 Design and function Adjusting the cable resistance 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Trim the welding wire, so that it is flush with the contact tip. • Retract the welding wire a little (approx. 50 mm) on the wire feeder. There should now be no more welding wire in the contact tip.
-
Page 34: Mig/Mag Welding
Design and function MIG/MAG welding 5.11 MIG/MAG welding 5.11.1 Connection for workpiece lead NOTE Note the polarity of the welding current! 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 35: Tig Welding
Design and function TIG welding 5.12 TIG welding 5.12.1 Welding torch connection NOTE TIG welding torches to be connected to a Euro torch connector are available in two versions: • TIG combi welding torches are connected to the Euro torch connector of the wire feeder and to the (-) welding current plug of the power source. -
Page 36: 5.12.2 Connection For Workpiece Lead
Design and function TIG welding • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the welding current plug of the combi welding torch into the (-) welding current connection socket and lock into place by turning to the right (only in case of a separate welding current connection). -
Page 37: 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 38 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 39: Voltage Reducing Device (Vrd)
Design and function Voltage reducing device (VRD) 5.14 Voltage reducing device (VRD) To increase safety, particularly in hazardous environments (like shipbuilding, pipe construction or mining), the machine is equipped with the VRD (Voltage-reducing device) voltage reduction device. The VRD signal light is illuminated, when the voltage reduction device is operating without fault and the output voltage is reduced to a value specified in the relevant standard (see technical data). -
Page 40: 5.16.1 Automation Interface
Design and function Interfaces for automation 5.16.1 Automation interface NOTE These accessory components can be retrofitted as an option . Input / Description Diagram output Output Connection for cable shielding Output IGRO Current flows signal I>0 (maximum load 20 (open mA / 15 V) collector) 0 V = welding current flows... -
Page 41: 5.16.2 Rint X12 Robot Interface
Design and function PC Interfaces 5.16.2 RINT X12 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 42: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal 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 43: Monthly Maintenance Tasks
For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 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. -
Page 44: Disposing Of Equipment
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU). -
Page 45: 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 46: 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 47 Rectifying faults Error messages (power source) Error Category Possible cause Remedy Error 17 Wire feed mechanism Check the wire feeding (WF. Ov.) overcurrent detection Error 18 No speedometer signal from Check the connection and particularly the (WF. Sl.) second wire feeder (slave speedometer of the second wire feeder drive) (slave drive).
-
Page 48: 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 7.3.1 Resetting a single JOB NOTE All customised welding parameters that are stored will be replaced by the factory settings. RESET ENTER JOB- JOB- LIST... -
Page 49: Resetting All Jobs
Rectifying faults General operating problems 7.3.2 Resetting all JOBs NOTE JOBs 1–128 and 170–256 will be reset. Custom JOBs 129–169 are maintained. RESET ENTER JOB- JOB- LIST LIST EXIT 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. -
Page 50: 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)! Figure 7-3 099-005325-EW501... -
Page 51: Specifications
Technical data Phoenix 351 FDW Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Phoenix 351 FDW MIG/MAG 5 A–350 A Setting range for welding current 10.2 V - 24.0 V 20.2 V - 34.0 V 14.3 V - 31.5 V Setting range for welding voltage 350 A... -
Page 52: Phoenix 401 Fdw
Technical data Phoenix 401 FDW Phoenix 401 FDW MIG/MAG 5 A–400 A Setting range for welding current 10.2 V–26.0 V 20.2 V–36.0 V 14.3 V–34.0 V Setting range for welding voltage 400 A Duty cycle at 40 °C (100% DC) 10 min. -
Page 53: Phoenix 501 Fdw
Technical data Phoenix 501 FDW Phoenix 501 FDW MIG/MAG 5 A–500 A Setting range for welding current 10.2 V–30.0 V 20.2 V–40.0 V 14.3 V–39.0 V Setting range for welding voltage 500 A (60% DC) Duty cycle at 40 °C (100% DC) 430 A (100% DC) 10 min (60% DC ∧... -
Page 54: Phoenix 451, 551 Fdw
Technical data Phoenix 451, 551 FDW Phoenix 451, 551 FDW Setting range of welding current/voltage: 5 A/10.2 V to 5 A/10.2 V to 450 A/28.0 V 550 A/32.0 V 5 A/20.2 V to 5 A/20.2 V to 450 A/38.0 V 550 A/42.0 V 5 A/14.3 V to 5 A/14.3 V to... -
Page 55: Accessories
Accessories System components Accessories NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. System components Type Designation Item no. Phoenix Progress drive 4L Wire feed unit, water, Euro central connector 090-004844-00502 Phoenix Progress drive 4L RE Wire feeder, water-cooled, Euro torch connector, 090-008602-00502... -
Page 56: Remote Control/Connecting And Extension Cable
Accessories Remote control/connecting and extension cable Remote control/connecting and extension cable 9.4.1 7-pole connection Type Designation Item no. R40 7POL Remote control, 10 programs 090-008088-00000 R50 7POL Remote control, all welding machine functions can 090-008776-00000 be set directly at the workplace FRV 7POL 0.5 m Extension/connecting cable 092-000201-00004... -
Page 57: Overview Of Ewm Branches
Appendix A Overview of EWM branches Appendix A 10.1 Overview of EWM branches 099-005325-EW501 05.12.2014...
Need help?
Do you have a question about the Phoenix 351-551 and is the answer not in the manual?
Questions and answers