EWM PHOENIX 333 PROGRESS PULS forceArc Operating Instructions Manual
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EWM PHOENIX 333 PROGRESS PULS forceArc Operating Instructions Manual

EWM PHOENIX 333 PROGRESS PULS forceArc Operating Instructions Manual

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Operating instructions
Compact welding machines for MIG/MAG,
TIG and MMA welding
PHOENIX 333 PROGRESS PULS forceArc
N. B. These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machines may only be operated by personnel who are familiar with the appropriate safety
regulations.
The machines bear the conformity mark and thus comply with the
•
EC Low Voltage Directive (2006/95/ EG)
•
EC EMC Directive (2004/108/ EG)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.
© 2008
Subject to alteration.
Dr. Günter-Henle-Straße 8 • D-56271 Mündersbach
Fon +49 2680 181-0 • Fax +49 2680 181-244
Item No.: 099-005073-EWM01
HIGHTEC WELDING GmbH
www.ewm.de
•
info@ewm.de
Revised: 10.04.2008
EWM

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Summary of Contents for EWM PHOENIX 333 PROGRESS PULS forceArc

  • Page 1 Operating instructions Compact welding machines for MIG/MAG, TIG and MMA welding PHOENIX 333 PROGRESS PULS forceArc N. B. These operating instructions must be read before commissioning. Failure to do so may be dangerous. Machines may only be operated by personnel who are familiar with the appropriate safety regulations.
  • Page 2 Congratulations! You have chosen a quality product from EWM HIGHTEC WELDING GmbH. EWM machines provide results of the highest perfection thanks to their PREMIUM quality. Therefore we are happy to provide you with a full 3-year warranty according to our operating instructions.
  • Page 3 Machine and Company Data Please enter the EWM machine data and your company’s data in the appropriate fields. EWM HIGHTEC WELDING GMBH D-56271 MÜNDERSBACH TYP: SNR: ART: PROJ: GEPRÜFT/CONTROL: Name of Customer / company Name of Customer / company Adress...

  • Page 4: Table Of Contents

    Contents For your safety Contents 1 Contents ..............................4 2 Safety instructions ..........................9 For your safety ..........................9 Transport and installation......................11 2.2.1 Ambient conditions .......................11 Notes on the use of these operating instructions.................12 3 Technical data............................13 PHOENIX 333 PROGRESS KG ....................13 4 Machine description..........................14 PHOENIX 333 PROGRESS KG ....................14 4.1.1 Front view ........................14...
  • Page 5 Contents For your safety 5.2.6.6 Example, visible seams (latched super pulse)..........44 5.2.6.7 Welding process changeover................ 45 5.2.7 Main program A mode ....................46 5.2.7.1 Selecting parameters (program A) using wire feed unit control M3.70..48 5.2.8 MIG/MAG automatic cut-out..................48 5.2.9 Standard MIG/MAG torch.....................
  • Page 6 Contents For your safety 5.6.1 R10 manual remote control ..................65 5.6.2 Manual remote control R20 ..................66 5.6.3 R40 manual remote control ..................66 Resetting JOBs (welding tasks) to the factory settings..............67 5.7.1 Resetting a single JOB ....................67 5.7.2 Resetting all JOBs ......................67 6 Commissioning.............................68 General............................68 Area of application –...
  • Page 7 Contents For your safety 10.3.2 U-Nut wire conveyors ....................91 10.3.3 Wire feed rollers for cored wire ..................91 10.3.4 Conversion sets......................91 10.4 Options............................92 10.5 Computer communication......................92 11 Circuit diagrams........................... 93 11.1 PHOENIX 333 PROGRESS KG ....................93 12 Appendix A ............................
  • Page 8 Contents For your safety Item No.: 099-005073-EWM01...

  • Page 9: Safety Instructions

    Safety instructions For your safety Safety instructions For your safety Observe accident prevention regulations! Ignoring the following safety procedures can be fatal! Proper usage This machine has been manufactured according to the latest developments in technology and current regulations and standards. It is to be operated only for the use for which it was designed (see chapter Commissioning/Area of application).
  • Page 10 Safety instructions For your safety Workpiece, flying sparks and droplets are hot! • Keep children and animals well away from the working area. Their behaviour is unpredictable. • Move containers with inflammable or explosive liquids away from the working area. There is a danger of fire and explosion.

  • Page 11: Transport And Installation

    Safety instructions Transport and installation Transport and installation The machines may only be transported and operated in an upright position. Before carrying away or moving, pull out mains plug and place on the machine. When setting up the machine, resistance to tilting is only guaranteed up to an angle of 10° (as specified in EN 60974-1).

  • Page 12: Notes On The Use Of These Operating Instructions

    Safety instructions Notes on the use of these operating instructions Notes on the use of these operating instructions These operating instructions are arranged into chapters. To help you find your way around more quickly, in the margins you will occasionally see symbols along with the sub-headings.

  • Page 13: Technical Data

    Technical data PHOENIX 333 PROGRESS KG Technical data PHOENIX 333 PROGRESS KG PHOENIX 333 Setting range: Welding current/voltage 5A/20.2V–330A/33.2V 5A/10.2V–330A/23.2V 5A/14.2V–330A/30.5V MIG/MAG Duty cycle at 40°C ambient temperature 330A 25%DC 250A 60%DC 210A 100%DC Duty cycle at 20C ambient temperature 330A 30%DC 260A...

  • Page 14: Machine Description

    Machine description PHOENIX 333 PROGRESS KG Machine description PHOENIX 333 PROGRESS KG 4.1.1 Front view Figure 4-1 Item No.: 099-005073-EWM01...
  • Page 15 Machine description PHOENIX 333 PROGRESS KG Item Symbol Description Transport bar Carrying handle Main switch, machine on/off Cooling air inlet Connection socket, “-” welding current • MIG/MAG welding: Workpiece connection • MMA welding: Workpiece or electrode holder connection • TIG welding: Welding current connection for welding torch Connection socket, “+”...

  • Page 16: Rear View

    Machine description PHOENIX 333 PROGRESS KG 4.1.2 Rear view Figure 4-2 Item No.: 099-005073-EWM01...
  • Page 17 Machine description PHOENIX 333 PROGRESS KG Item Symbol Description Slide latch, lock for the protective cap Wire spool inspection window Check wire supply Cover for wire delivery unit and operating elements 7-pole connection socket (digital) For connecting digital accessory components (documentation interface, robot interface digital or remote control, etc.).

  • Page 18: Inside View

    Machine description PHOENIX 333 PROGRESS KG 4.1.3 Inside view Figure 4-3 Item No.: 099-005073-EWM01...
  • Page 19 Machine description PHOENIX 333 PROGRESS KG Item Symbol Description "Program or up/down function" changeover switch This changeover switch is only effective on the POWERCONTROL/POWERCONTROL 2 welding torch Change over welding programs using POWERCONTROL 2 program Programm Programm torch. Set infinite welding performance with the POWERCONTROL 2 Up / Down program torch, up/down function.

  • Page 20: Functional Characteristics

    Functional characteristics Machine control – Operating elements Functional characteristics Machine control – Operating elements 5.1.1 Welding machine control EXPERT M 3.70 Super- puls VOLT PROG HOLD m/min Figure 5-1 Item Symbol Description “Parameter selection ” (left) Welding current (nominal, actual and hold values) HOLD Material thickness (nominal value) Wire speed (actual, nominal and hold values)
  • Page 21 Functional characteristics Machine control – Operating elements Item Symbol Description "Select welding type" button MIG/MAG standard welding MIG/MAG pulse arc welding (PULS series only) "Arc length correction / program number" rotary dial • Arc length correction from -9.9 V to +9.9 V •...

  • Page 22: Covered Operating Elements

    Functional characteristics Machine control – Operating elements 5.1.1.1 Covered operating elements Figure 5-2 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. LED "Gas pre-flow time" Setting range 0.0 sec to 20.0 sec LED "start program (P )"...
  • Page 23 Functional characteristics Machine control – Operating elements Item Symbol Description "Superpulse" LED Super- On when the function is activated puls LED “Joblist” Illuminates upon display or selection of the job number “JOBLIST” key button Selection of the welding task (JOB) from the JOB list “Wire inching”...

  • Page 24: Mig/Mag Welding

    Functional characteristics MIG/MAG welding MIG/MAG welding 5.2.1 Definition of MIG/MAG welding tasks The PHOENIX product range has been designed to be very simple and quick to operate, but still provide all the functions one could ever need. For the most common applications, 128 JOBs (welding tasks) have been pre-programmed. The JOB (welding task) is defined using the four basic welding parameters of welding process, material type, wire diameter and gas type.

  • Page 25: Choke Effect / Dynamics

    Functional characteristics MIG/MAG welding 5.2.2.4 Choke effect / dynamics Operating Action Result Display element Select Dynamics welding parameter -40 to +40 Dynamics comes on Dynamics setting -40 to +40 Arc harder and narrower m/min Arc softer and wider 5.2.2.5 Superpulses Operating Action Result...

  • Page 26: Mig/Mag Operating Point

    Functional characteristics MIG/MAG welding 5.2.3 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 27: Wire Burn-Back

    Functional characteristics MIG/MAG welding 5.2.3.4 Wire burn-back Operating Action Result Display element Selects wire burn-back 3 sec. Parameter setting (setting range 0 to 499) m/min 5.2.3.5 Accessory components for operating point setting Accessory component Description PHOENIX R10 remote control See "Remote controls" chapter PHOENIX R20 remote control See "Remote controls"...

  • Page 28: Mig/Mag Functional Sequences / Operating Modes

    Functional characteristics MIG/MAG welding 5.2.5 MIG/MAG functional sequences / operating modes The following applies during the wire creep phase: If there is no welding current flowing after 5 seconds (factory setting), the ignition process is cancelled (ignition error). The following applies during the welding phase: If the arc is broken during the welding process and is not re-ignited within 5 seconds (factory setting), there is an automatic cut-out.

  • Page 29: Non-Latched Mode

    Functional characteristics MIG/MAG welding 5.2.5.2 Non-latched mode Figure 5-5 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 30: Special, Non-Latched

    Functional characteristics MIG/MAG welding 5.2.5.4 Special, non-latched START Figure 5-7 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 31: Spots

    Functional characteristics MIG/MAG welding 5.2.5.5 Spots START Figure 5-8 The start time t must also be calculated at spot time t . The start and spot times are set in start the "Program steps mode" menu. Step 1 • Press and hold torch trigger. •...

  • Page 32: Special, Non-Latched With Superpulse

    Functional characteristics MIG/MAG welding 5.2.5.6 Special, non-latched with superpulse START Figure 5-9 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 33: Latched Mode

    Functional characteristics MIG/MAG welding 5.2.5.7 Latched mode Figure 5-10 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 34: Latched Mode With Superpulse

    Functional characteristics MIG/MAG welding 5.2.5.8 Latched mode with superpulse Figure 5-11 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 35: Latched Mode With Alternating Welding Process

    Functional characteristics MIG/MAG welding 5.2.5.9 Latched mode with alternating welding process Pulse arc welding machines only. Figure 5-12 1st cycle: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" •...

  • Page 36: Latched Special

    Functional characteristics MIG/MAG welding 5.2.5.10 Latched special START Figure 5-13 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 37: Latched Special With Welding Process Alternation

    Functional characteristics MIG/MAG welding 5.2.5.11 Latched special with welding process alternation Pulse arc welding machines only. START Figure 5-14 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" •...

  • Page 38: Special, Latched With Superpulse

    Functional characteristics MIG/MAG welding 5.2.5.12 Special, latched with superpulse START 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 is flowing (start program P for the time t START...

  • Page 39: Latched Special With Alternating Welding Process

    Functional characteristics MIG/MAG welding 5.2.5.13 Latched special with alternating welding process Pulse arc welding machines only. START Figure 5-16 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" •...

  • Page 40: Mig/Mag Program Sequence ("Program Steps" Mode)

    Functional characteristics MIG/MAG welding 5.2.6 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 41: Mig/Mag Overview Of Parameters, M3.70

    Functional characteristics MIG/MAG welding 5.2.6.2 MIG/MAG overview of parameters, M3.70 Super- puls Figure 5-18 Basic Parameters Item Meaning / Explanation Setting Range Gas pre-flow time 0.0s to 20.0s Wire speed, relative 1% to 200% Wire speed, absolute 0.1 m/min to 40 m/min Arc length correction -9.9V to +9.9V Duration...

  • Page 42: Example, Tack Welding (Non-Latched)

    Functional characteristics MIG/MAG welding 5.2.6.3 Example, tack welding (non-latched) Figure 5-19 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 43: Example, Aluminium Welding (Latched Special)

    Functional characteristics MIG/MAG welding 5.2.6.5 Example, aluminium welding (latched special) START Figure 5-21 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 44: Example, Visible Seams (Latched Super Pulse)

    Functional characteristics MIG/MAG welding 5.2.6.6 Example, visible seams (latched super pulse) START 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 45: Welding Process Changeover

    Functional characteristics MIG/MAG welding 5.2.6.7 Welding process changeover Pulse arc welding machines only. START Figure 5-22 Program Setting option Relates to Setting All special, non-latched 1 (= on) Pulse arc welding process on/off START Changes using PC300.Net software All special, latched 0 (= off) Non-latched/latched mode 1 (= active)

  • Page 46: Main Program A Mode

    Functional characteristics MIG/MAG welding 5.2.7 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: • Operating mode •...
  • Page 47 Functional characteristics MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-23 Example 2: Welding different positions on a workpiece (latched) Figure 5-24 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-25 This mode can be used to define 16 different programs (P to P...

  • Page 48: Selecting Parameters (Program A) Using Wire Feed Unit Control M3.70

    Functional characteristics MIG/MAG welding 5.2.7.1 Selecting parameters (program A) using wire feed unit control M3.70 Operating Action Result Display Element VOLT Press (program number) PROG PROG Select program number Select parameter LED “Main program (P )” Set wire speed m/min Set voltage correction Select Dynamics parameter...

  • Page 49: Special Parameter, "M3.70/M3.71

    Functional characteristics MIG/MAG welding 5.2.11 Special parameter, “M3.70/M3.71” The special parameters cannot be viewed directly since they are normally only set and stored once. The machine control offers the following special functions: 5.2.11.1 Special parameters list Function Setting options works Ramp time for wire inching 0 = normal inching (10s ramp time) 1 = fast inching (3s ramp time)

  • Page 50: Selecting, Changing And Saving Parameters

    Functional characteristics MIG/MAG welding 5.2.11.2 Selecting, changing and saving parameters Operating Action Result Display element Left Right Switch off the welding machine Keep the key button pressed HOLD Switch on welding machine Release the key button Value HOLD Parameter selection P 1-x, Value (see list of special parameters)

  • Page 51: Program Limit (P4)

    Functional characteristics MIG/MAG welding 5.2.11.7 Program limit (P4) The number of the absolute programs can be limited to above limit. 5.2.11.8 Special cycle in the operating modes special latched and non-latched (P5) In the “normal” cycle of latched/non-latched the system starts with the start program Dvstart and subsequently enters into the main program DV2.

  • Page 52: Program Changeover With Standard Torch (P8)

    Functional characteristics MIG/MAG welding Operating Action Result Display (example) Element Left Right Press key button until only LED 7,5 (DV) 4 (prog.-no.) „PROG“ is shining Keep the key button pressed 0 (DVGrenz) 2.0 (UKorr) 4 sec. Release the key button 0 (DVGrenz) 2.0 (UKorr) Set tolerance value for wire speed...
  • Page 53 Functional characteristics MIG/MAG welding 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 54: N Cycle Setting

    Functional characteristics MIG/MAG welding 5.2.11.12 N cycle setting The n cycle function should always be activated before the n cycle setting (see "Program changeover with standard torch (P8)". Operating Action Result Display element Select wire burn-back 3 sec Select N cycle setting Parameter setting (setting range 1 to 9) m/min 5.2.11.13 Latched/special-latched tap start (P9)

  • Page 55: Job List Switching (P12)

    Functional characteristics MIG/MAG welding 5.2.11.16 JOB list switching (P12) Factory setting for parameter P12 • PHOENIX 301,351,421 PROGRESS KG • PHOENIX 333 PROGRESS KG • PHOENIX 303 PROGRESS coldArc KG • PHOENIX PROGRESS 4.4L • PHOENIX PROGRESS DRIVE 4L coldArc Value Designation Explanation Task-oriented...

  • Page 56: Copying Jobs, "Copy To" Function

    Functional characteristics MIG/MAG welding 5.2.11.18 Copying JOBs, "Copy to" function The possible target range is between 129 - 169. • First configure special parameter P12 to P12 = 2 or P12 = 1! Operating Action Result Display element Select JOB list JOB- LIST Select the source JOB...

  • Page 57: Tig Welding

    Functional characteristics TIG welding TIG welding 5.3.1 TIG welding task selection • Select JOB 250 (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 58: Tig Function Sequences / Operating Modes

    Functional characteristics TIG welding 5.3.4 TIG function sequences / operating modes The arc ignition takes place with Liftarc (see chapter "TIG Arc ignition"). After unsuccessful ignition or interruption of the welding procedure, the automatic cut-out takes place (see chapter "TIG Automatic cut-out"). The welding parameters are optimally preset for a multiplicity of applications (can be adapted if required (see chapter TIG Program sequence "Program-Steps mode").

  • Page 59: Non-Latched Mode

    Functional characteristics TIG welding 5.3.4.2 Non-latched mode Figure 5-30 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 60: Latched Mode

    Functional characteristics TIG welding 5.3.4.4 Latched mode Figure 5-32 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 61: Latched Special

    Functional characteristics TIG welding 5.3.4.5 Latched special START Figure 5-33 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 62: Mma Welding

    Functional characteristics MMA welding MMA welding 5.4.1 MMA welding task selection • Select JOB 251 (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 63: Interfaces

    Functional characteristics Interfaces Interfaces Only the accessory components described in these operating instructions may be connected. Only plug accessory components into the relevant connection socket on the welding machine and lock it when the machine is switched off. The component is detected automatically when the welding machine is switched on.

  • Page 64: Rint X11 Robot Interface

    Functional characteristics Interfaces 5.5.2 RINT X11 robot interface The standard digital interface for automated applications (optional, retrofitting on the machine or external fitting by the customer) Functions and signals: • Digital inputs: Start/stop, operating mode, job and program selection, inching, gas test •...

  • Page 65: Remote Control

    Functional characteristics Remote control Remote control Only the remote controls described in these operating instructions may be connected. Plug the remote control unit into the remote control connection socket on the welding machine or wire feed unit and lock it only when the machine is switched off. The remote control is detected automatically when the welding machine is switched on.

  • Page 66: Manual Remote Control R20

    Functional characteristics Remote control 5.6.2 Manual remote control R20 Manual remote controls R20 can only be used together with controls M3.70 or M3.71! Figure 5-35 Item Symbol Description 6 7 8 9 10 "Wire speed" rotary dial • Infinitely adjustable setting of the wire speed from min. to max. (welding output, one-dial operation).

  • Page 67: Resetting Jobs (Welding Tasks) To The Factory Settings

    Functional characteristics Resetting JOBs (welding tasks) to the factory settings Resetting JOBs (welding tasks) to the factory settings 5.7.1 Resetting a single JOB Operating Action Result Display element Select JOB Reset 3 sec. Set the JOB number to be reset m/min Confirm JOB reset.

  • Page 68: Commissioning

    Commissioning General Commissioning General Warning – Risk from electrical current! Follow the safety instructions on the opening pages entitled “For your safety”. Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead, interfaces) may only be connected when the machine is switched off. Area of application –...

  • Page 69: Cooling Module Connection

    Commissioning Workpiece lead, general 6.5.1 Cooling module connection Observe the fitting and connection instructions given in the relevant operating instructions for the cooling unit. Figure 6-1 Item Symbol Description 8-pole connection socket Cooling unit control lead 4-pole connection socket Cooling unit voltage supply •...

  • Page 70: Mig/Mag Welding

    Commissioning MIG/MAG welding MIG/MAG welding Warning – Risk from electrical current! If welding is carried out alternately using different methods and if a welding torch and an electrode holder remain connected to the machine, the open-circuit/welding voltage is applied simultaneously on all cables. The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks.
  • Page 71 Commissioning MIG/MAG welding Item Symbol Description Euro-central connector (welding torch connection) Welding current, shielding gas and torch trigger included 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, intermediate drive, etc.) We can only guarantee correct functioning of our machines when used with our range of welding torches.

  • Page 72: Connection For Workpiece Lead

    Commissioning MIG/MAG welding 6.7.2 Connection for workpiece lead Figure 6-3 Item Symbol Description Connection socket, “-” welding current • MIG/MAG welding: Workpiece connection • MMA welding: Workpiece or electrode holder connection • TIG welding: Welding current connection for welding torch Connection socket, “+”...

  • Page 73: Fixing Of The Pin Reel (Adjustment Of The Pre-Tensioning)

    Commissioning MIG/MAG welding 6.7.3 Fixing of the pin reel (adjustment of the pre-tensioning) As the spool brake at the same time also secures the wire spool retainer, the following working steps are to be carried out for every spool change and before every adjustment of the spool brake.

  • Page 74: Inserting The Wire Spool

    Commissioning MIG/MAG welding 6.7.4 Inserting the wire spool The pretensioning of the pin reel shall be checked before each wire spool replacement and before the adjustment of the spool brake, see chapter on fixing of the pin reel (adjustment of the pretensioning)! Standard D300 pin reels can be used.

  • Page 75: Inching The Wire Electrode

    Commissioning MIG/MAG welding 6.7.6 Inching the wire electrode To ensure optimum wire feeding, it is essential that the wire feed rollers match the applied wire electrode diameter and the type of material used (exchange if necessary). Slide new drive rollers into place so that the diameter of the wire electrode printed on the wire feed roller is visible.

  • Page 76: Spool Brake Setting

    Commissioning TIG welding 6.7.7 Spool brake setting The pretensioning of the pin reel shall be checked before each wire spool replacement and before the adjustment of the spool brake, see chapter on fixing of the pin reel (adjustment of the pretensioning)! Figure 6-8 Item...

  • Page 77: Welding Torch Connection

    Commissioning TIG welding 6.8.1 Welding torch connection Figure 6-9 Item Symbol Description Euro-central connector (welding torch connection) Welding current, shielding gas and torch trigger included Connection socket, “-” welding current • MIG/MAG welding: Workpiece connection • MMA welding: Workpiece or electrode holder connection •...

  • Page 78: Mma Welding

    Commissioning MMA welding 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 79 Commissioning MMA welding Item Symbol Description Connection socket, “+” welding current • MMA welding: Workpiece or electrode holder connection • TIG welding: Workpiece connection Connection socket, “-” welding current • MIG/MAG welding: Workpiece connection • MMA welding: Workpiece or electrode holder connection •...

  • Page 80: Shielding Gas Supply

    Commissioning Shielding gas supply 6.10 Shielding gas supply 6.10.1 Connecting the shielding gas supply Figure 6-11 Item Symbol Description G¼” connecting nipple Shielding gas connection on the pressure reducer Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to blow out any dirt.

  • Page 81: Gas Test

    Commissioning Shielding gas supply 6.10.2 Gas test • Slowly open the gas cylinder valve. • Open the pressure reducer. • Switch on the power source at the main switch. • Initiate gas test function on the machine control. • Set the relevant gas quantity for the application on the pressure reducer. 6.10.3 “Rinse tube package”...

  • Page 82: Maintenance And Testing

    DIN EN 61010-1 Appendix A – Measuring Circuit A1. You as the user are tasked with ensuring that your EWM machines conform to the standard IEC/DIN EN 60974-4 and are tested with the relevant test equipment and measuring devices given above.

  • Page 83: Scope Of The Test

    Maintenance and testing Test 7.3.2 Scope of the test a) Visual inspection b) Electrical test: measurement of • open circuit voltage • insulation resistance, or alternatively • leakage currents • protective conductor resistance c) Functional test d) Documentation 7.3.3 Visual inspection The key areas in the test are: 1.

  • Page 84: Measuring The Leakage Current (Protective Conductor And Contact Current)

    Note: Even if the leakage current measurement according to the standard is only an alternative to the insulation resistance measurement, EWM recommends always performing both measurements, especially following repair work. The leakage current is based for the greater part on a physical effect other than the insulation resistance.

  • Page 85: Repair Work

    Returns of defective equipment subject to warranty may only be made through your EWM sales partner. In the event of problems or queries, please contact the EWM Service Department directly (+49 (0) 2680 181 0). Use only genuine spare parts and replacement parts when replacing. When placing an order, please quote the type designation and item number, as well as the type, serial number and item number of the relevant equipment.

  • Page 86: Disposing Of Equipment

    Your administrative office will be pleased to inform you of the options. 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 87: Warranty

    • Wire feeds • Cooling units • Trolleys * If these are operated with genuine EWM accessories (such as intermediate tube package, remote control, remote control extension cable, coolant, etc.). 1-year warranty on: • Used EWM machines • Automation and mechanisation components •...

  • Page 88: Warranty Declaration

    This limitation does not apply to personal injuries or damage to property caused by negligent behaviour on the part of EWM. In no way will EWM be responsible for lost profits, indirect or subsequent damage. EWM is not liable for damages based on the claims of third parties.

  • Page 89: Operating Problems, Causes And Remedies

    Operating problems, causes and remedies Error messages (power source) Operating problems, causes and remedies Error messages (power source) All machines are subject to rigorous production and final checks. If, despite this, anything fails to work at any time, please check machine using the chart below. If none of the fault rectification procedures described leads to the correct functioning of the machine, please inform your authorised dealer.

  • Page 90: Accessories, Options

    Accessories, options General accessories Accessories, options 10.1 General accessories Type Designation Item no. COOL71 U43 Cooling unit with centrif. pump and reinforced 090-008220-00102 cooling TROLLY 75 B1 Transport vehicle, assembled for 090-008176-00001 power source + 1 module + 1 gas bottle AK300 Adapter for K300 basket coil 094-001803-00001...

  • Page 91: Wire Feed Rollers

    Accessories, options Wire feed rollers 10.3 Wire feed rollers 10.3.1 V-Nut wire conveyors Type Designation Item no. FE 2DR4R 0,6+0,8 Drive rollers, 37mm, 4-roller, steel 092-000839-00000 FE 2DR4R 0,8+1,0 Drive rollers, 37mm, 4-roller, steel 092-000840-00000 FE 2DR4R 0,9+1,2 Drive rollers, 37mm, 4-roller, steel 092-000841-00000 FE 2DR4R 1,0+1,2 Drive rollers, 37mm, 4-roller, steel...

  • Page 92: Options

    Accessories, options Options 10.4 Options Type Designation Item no. MIG PP 24D POTI G 8M MIG welding torch, gas, push/pull 094-003419-00000 MIG 36 2U/D G 3M MIG welding torch, gas, Up/Down 094-007791-00000 POWERCONTROL 36 MIG welding torch, gas, Up/Down, with display 094-007790-00000 U/DLED G 3M MIG PP 401D W 8M...

  • Page 93: Circuit Diagrams

    Circuit diagrams PHOENIX 333 PROGRESS KG Circuit diagrams Original format circuit diagrams are located inside the machine. 11.1 PHOENIX 333 PROGRESS KG X1/1 X1/2 X1/3 X1/4 X1/5 X1/6 X1/7 X1/8 X1/9 X1/10 X1/11 X1/12 X1/13 X1/14 X1/15 X1/16 X1/17 X1/18 X2/1 Lüfter X2/2...
  • Page 94 Circuit diagrams PHOENIX 333 PROGRESS KG Stecker X2 D-SUB 15polig X24/1 Motor + X20/1 X24/2 Motor Motor - X20/2 X24/3 Motor X24/4 X10/1 Tacho X23/1 X10/2 Tacho X23/2 X10/3 Tacho X23/3 X10/4 X23/4 X3/1 X3/2 X19/1 X2/1 +10V X19/2 X2/2 LED-A X2/3 LED-B...
  • Page 95 Circuit diagrams PHOENIX 333 PROGRESS KG X8/1 Fühlerspannung X8/2 Fühlerspannung D-Sub. D-Sub. D-Sub. D-Sub. 15polig 15polig 15polig 15polig D-SUB 15polig Stecker X3 Figure 11-3 Item No.: 099-005073-EWM01...

  • Page 96: Declaration Of Conformity

    Umbauten, die nicht ausdrücklich von authorised by EWM. bées n’ayant pas été autorisés expressé- EWM autorisiert sind, verliert diese ment par EWM, cette déclaration devient Erklärung ihre Gültigkeit. caduque. Gerätebezeichnung: Description of the machine: Déscription de la machine: Gerätetyp:...

  • Page 97: Job-List

    Appendix B JOB-List Appendix B 13.1 JOB-List 09/07 JOB-LIST JOB-LIST Wire Wire Material Material Job-Nr. Job-Nr. CO 100 CO 100 SG2/3 SG2/3 G3/4 Si1 G3/4 Si1 Ar82/18 Ar80 - 90 Ar98/2 Ar91 - 99 CrNi CrNi Ar95/5 Ar/He CuSi CuSi 114 115 116 117 Ar100 Ar100...

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