EWM Progress puls TDM Phoenix 355, Phoenix 405, Phoenix 505 Welding machine Betriebsanleitungen

Operating instructions
Welding machine
Phoenix 355, 405, 505 Progress puls TDM
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099-005220-EW501
General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
NOTE
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our
customer service department on +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. This exclusion of liability shall be deemed accepted by the
user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are
observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this reason,
we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation,
improper operation or incorrect usage and maintenance or any actions connected to this in any way.
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
Subject to technical amendments.
Contents
Notes on the use of these operating instructions
1
Contents
1 Contents .................................................................................................................................................. 3
2 Safety instructions ................................................................................................................................. 5
2.1 Notes on the use of these operating instructions .......................................................................... 5
2.2 Explanation of icons ....................................................................................................................... 6
2.3 General .......................................................................................................................................... 7
2.4 Transport and installation ............................................................................................................ 11
2.4.1
Ambient conditions ....................................................................................................... 12
2.4.1.1 In operation ................................................................................................... 12
2.4.1.2 Transport and storage ................................................................................... 12
3 Intended use ......................................................................................................................................... 13
3.1 Applications.................................................................................................................................. 13
3.1.1
MIG/MAG pulse welding ............................................................................................... 13
3.1.2
MIG/MAG standard welding ......................................................................................... 13
3.1.2.1 forceArc ......................................................................................................... 13
3.1.2.2 rootArc ........................................................................................................... 13
3.1.3
TIG (Liftarc) welding ..................................................................................................... 13
3.1.4
MMA welding ................................................................................................................ 13
3.1.4.1 Air arc gouging .............................................................................................. 13
3.2 Use and operation solely with the following machines ................................................................ 14
3.3 Documents which also apply ....................................................................................................... 15
3.3.1
Warranty ....................................................................................................................... 15
3.3.2
Declaration of Conformity ............................................................................................. 15
3.3.3
Welding in environments with increased electrical hazards ......................................... 15
3.3.4
Service documents (spare parts and circuit diagrams) ................................................ 15
3.3.5
Calibration/Validation ................................................................................................... 15
4 Machine description – quick overview .............................................................................................. 16
4.1 Front view .................................................................................................................................... 16
4.2 Rear view ..................................................................................................................................... 18
5 Design and function............................................................................................................................. 20
5.1 General ........................................................................................................................................ 20
5.2 Installation .................................................................................................................................... 21
5.3 Machine cooling ........................................................................................................................... 22
5.4 Workpiece lead, general .............................................................................................................. 22
5.5 Notes on the installation of welding current leads ....................................................................... 23
5.6 Welding torch cooling system ...................................................................................................... 24
5.6.1
Cooling module connection .......................................................................................... 24
5.7 Mains connection ......................................................................................................................... 25
5.7.1
Mains configuration ...................................................................................................... 25
5.8 Connecting the intermediate hose package to the power source ............................................... 26
5.8.1
Intermediate hose package strain relief ....................................................................... 26
5.8.2
Intermediate hose package connection ....................................................................... 27
5.9 Shielding gas supply (shielding gas cylinder for welding machine)............................................. 28
5.10 MIG/MAG welding ........................................................................................................................ 29
5.10.1 Connection for workpiece lead ..................................................................................... 29
5.11 TIG welding .................................................................................................................................. 30
5.11.1 Welding torch connection ............................................................................................. 30
5.11.2 Connection for workpiece lead ..................................................................................... 30
5.12 MMA welding ............................................................................................................................... 31
5.12.1 Connecting the electrode holder and workpiece lead .................................................. 31
5.13 Welding torch holder .................................................................................................................... 32
5.14 Remote control............................................................................................................................. 33
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Contents
Notes on the use of these operating instructions
5.15 Interfaces ..................................................................................................................................... 34
5.15.1 Automation interface ..................................................................................................... 34
5.15.2 RINT X12 robot interface .............................................................................................. 35
5.15.3 BUSINT X11 Industrial bus interface ............................................................................ 35
5.15.4 DVINT X11 Wire feed interface .................................................................................... 35
5.15.5 PC Interfaces ................................................................................................................ 35
6 Maintenance, care and disposal ......................................................................................................... 36
6.1 General......................................................................................................................................... 36
6.2 Maintenance work, intervals ........................................................................................................ 36
6.2.1
Daily maintenance tasks ............................................................................................... 36
6.2.1.1 Visual inspection ........................................................................................... 36
6.2.1.2 Functional test ............................................................................................... 36
6.2.2
Monthly maintenance tasks .......................................................................................... 37
6.2.2.1 Visual inspection ........................................................................................... 37
6.2.2.2 Functional test ............................................................................................... 37
6.2.3
Annual test (inspection and testing during operation) .................................................. 37
6.3 Maintenance work ........................................................................................................................ 37
6.4 Disposing of equipment................................................................................................................ 38
6.4.1
Manufacturer's declaration to the end user .................................................................. 38
6.5 Meeting the requirements of RoHS.............................................................................................. 38
7 Rectifying faults.................................................................................................................................... 39
7.1 Checklist for rectifying faults ........................................................................................................ 39
7.2 Error messages (power source) ................................................................................................... 40
7.3 General operating problems ........................................................................................................ 41
7.3.1
Interface for automated welding ................................................................................... 41
7.4 Vent coolant circuit ....................................................................................................................... 42
8 Technical data....................................................................................................................................... 43
8.1 Phoenix 355 TDM ........................................................................................................................ 43
8.2 Phoenix 405 ................................................................................................................................. 44
8.3 Phoenix 505 ................................................................................................................................. 45
9 Accessories .......................................................................................................................................... 46
9.1 System components..................................................................................................................... 46
9.2 Options ......................................................................................................................................... 46
9.3 Welding torch cooling system ...................................................................................................... 46
9.4 Transport systems........................................................................................................................ 46
9.5 Remote control / connection cable ............................................................................................... 46
9.5.1
7-pole connection ......................................................................................................... 46
9.6 General accessories .................................................................................................................... 47
9.7 Computer communication ............................................................................................................ 47
10 Appendix A............................................................................................................................................ 48
10.1 Overview of EWM branches......................................................................................................... 48
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Safety instructions
Notes on the use of these operating instructions
2
Safety instructions
2.1
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.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
• The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at the edge of the page.
NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.
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Safety instructions
Explanation of icons
2.2
Explanation of icons
Symbol
Description
Press
Do not press
Turn
Switch
Switch off machine
Switch on machine
ENTER
ENTER
NAVIGATION
EXIT
4s
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
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Safety instructions
General
2.3
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.
• Observe the maintenance instructions! (see Maintenance and Testing chapter)
• Unwind welding leads completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if
necessary).
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.
• Appoint only skilled persons for repair work (trained service personnel)!
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!
• Connection cables and leads must be free of faults!
• Switching off alone is not sufficient!
• Place welding torch and stick electrode holder on an insulated surface!
• The unit should only be opened by specialist staff after the mains plug has been
unplugged!
• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!
WARNING
Risk of injury due to radiation or heat!
Arc radiation results in injury to skin and eyes.
Contact with hot workpieces and sparks results in burns.
• Use welding shield or welding helmet with the appropriate safety level (depending on the
application)!
• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
• Protect persons not involved in the work against arc beams and the risk of glare using
safety curtains!
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!
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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!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
• Check for fire hazards in the working area!
• Do not carry any easily flammable objects such as matches or lighters.
• Keep appropriate fire extinguishing equipment to hand in the working area!
• Thoroughly remove any residue of flammable substances from the workpiece before
starting welding.
• Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
• Connect welding leads correctly!
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
Danger when coupling multiple power sources!
Coupling multiple power sources in parallel or in series has to be carried out by
qualified personnel and in accordance with the manufacturer's guidelines. Before
bringing the power sources into service for arc welding operations, a test has to verify
that they cannot exceed the maximum allowed open circuit voltage.
• Connection of the machine may be carried out by qualified personnel only!
• When decommissioning individual power sources, all mains and welding current leads have
to be safely disconnected from the welding system as a whole. (danger due to inverse
voltages)!
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
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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.
• The regulations regarding work safety and accident prevention for the respective country.
• Setting up and operating the machine according to IEC 60974-9.
• Check at regular intervals that users are working in a safety-conscious way.
• Regular checks of the machine according to IEC 60974-4.
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!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Damage to the machine due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage equipment and
electronic devices and cause overheating of components leading to fire.
• Make sure all welding leads are securely connected and check regularly.
• Always ensure a proper and secure electrical connection to the workpiece!
• Set up, attach or suspend all conductive power source components like casing, transport
vehicle and crane frames so they are insulated!
• Do not place any other electronic devices such as drillers or angle grinders, etc., on the
power source, transport vehicle or crane frames unless they are insulated!
• Always put welding torches and electrode holders on an insulated surface when they are
not in use!
Mains connection
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of
the operator, where necessary in consultation with the mains network operator, to ensure that
the machine can be connected.
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Safety instructions
General
CAUTION
EMC Machine Classification
In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic
compatibility classes (see technical data):
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas,
including residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the
surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding equipment
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
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Safety instructions
Transport and installation
2.4
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!
• Place shielding gas cylinders in the holders provided for them and secure with fixing
devices.
• Avoid heating the shielding gas cylinder!
Risk of accident due to improper transport of machines that may not be lifted!
Do not lift or suspend the machine! The machine can fall down and cause injuries! The
handles and brackets are suitable for transport by hand only!
• The machine may not be lifted by crane or suspended!
CAUTION
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10°
(according to IEC 60974-1).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
• Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
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Safety instructions
Transport and installation
2.4.1
Ambient conditions
CAUTION
Installation site!
The machine must not be operated in the open air and must only be set up and
operated on a suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient
lighting for the place of work.
• Safe operation of the machine must be guaranteed at all times.
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!
2.4.1.1
2.4.1.2
12
In operation
Temperature range of the ambient air:
• -20 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -25 °C to +55 °C
Relative air humidity
• Up to 90% at 20 °C
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Intended use
Applications
3
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. 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!
• Do not modify or convert the equipment improperly!
3.1
Applications
3.1.1
MIG/MAG pulse welding
Welding process for optimum welding results when joining stainless steel and aluminium thanks to
controlled drop transfer and targeted, adapted heat input.
3.1.2
3.1.2.1
3.1.2.2
3.1.3
MIG/MAG standard welding
Metal arc welding using a wire electrode whereby gas from an external source surrounds the arc and the
molten pool to protect them from the atmosphere.
forceArc
Welding with a powerful forced arc, deep fusion penetration and virtually spatter-free weld seams of the
highest quality.
rootArc
Stable, soft, short arc even with long welding leads; ideal for simple, reliable root welding without pool
support, easy gap bridging.
TIG (Liftarc) welding
TIG welding process with arc ignition by means of workpiece contact.
3.1.4
3.1.4.1
MMA welding
Manual arc welding or, for short, MMA welding. It is characterised by the fact that the arc burns between
a melting electrode and the molten pool. There is no external protection; any protection against the
atmosphere comes from the electrode.
Air arc gouging
During air arc gouging, bad welding seams are heated with a carbon electrode and then removed with
compressed air. Special electrode holders and carbon electrodes are required for air arc gouging.
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Intended use
Use and operation solely with the following machines
3.2
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!
Wire feed unit
• Phoenix Progress drive 4 WE
• Phoenix Progress drive 4L WE
• Phoenix Progress drive 200C WE
• Phoenix Progress drive 300C WE
Transport vehicle
• Trolly 55.2-2
Cooling unit
• cool50-2 U40
Remote control
• R40 7POL
• R50 7POL
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Intended use
Documents which also apply
3.3
Documents which also apply
3.3.1
Warranty
NOTE
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
3.3.2
Declaration of Conformity
The designated machine conforms to EC Directives and standards in terms of its design
and construction:
• EC Low Voltage Directive (2006/95/EC),
• EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly
conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted
conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
3.3.3
Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
3.3.4
Service documents (spare parts and circuit diagrams)
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.
• Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.3.5
Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months
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Machine description – quick overview
Front view
4
Machine description – quick overview
NOTE
The maximum possible machine configuration is given in the text description.
If necessary, the optional connection may need to be retrofitted (see "Accessories"
chapter).
4.1
Front view
Figure 4-1
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Machine description – quick overview
Front view
Item Symbol
1
3
Ready for operation signal light
Signal light on when the machine is switched on and ready for operation
Main switch, machine on/off
4
Cooling air inlet
5
Machine feet
6
Connection socket, "+" welding current
• MIG/MAG cored wire welding:
Workpiece connection
• TIG welding:
Workpiece connection
• MMA welding:
Workpiece connection
"-" welding current connection socket
• MIG/MAG welding:
Workpiece connection
• MMA welding:
electrode holder connection
Torch holder
2
7
8
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Description 0
Carrying handle
17
Machine description – quick overview
Rear view
4.2
Rear view
Figure 4-2
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Machine description – quick overview
Rear view
Item Symbol
Description 0
1
Key button, Automatic cutout
Wire feed motor supply voltage fuse
(press to reset a triggered fuse)
2
Connection socket, 7-pole
Connection for peripheral devices with digital interface
7-pole connection socket (digital)
Wire feed unit connection
Connection socket, “+” welding current
• Standard MIG/MAG welding (intermediate hose package)
Connection socket, “-” welding current
Connection for welding current plug from intermediate hose package
• MIG/MAG flux cored wire welding
• TIG welding
Stirrup
Intermediate hose package strain relief
3
4
5
6
7
Cooling air outlet
8
8-pole connection socket
Cooling unit control lead
9
4-pole connection socket
Cooling unit voltage supply
10
Mains connection cable
11
PC interface, serial (D-Sub connection socket, 9-pole)
12
19-pole mechanised welding interface (analogue)
(See chapter entitled "Design and function > interfaces".)
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Design and function
General
5
Design and function
5.1
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!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
CAUTION
Insulate the arc welder from welding voltage!
Not all active parts of the welding current circuit can be shielded from direct contact. To
avoid any associated risks it is vital for the welder to adhere to the relevant safety
regulations. Even low voltages can cause a shock and lead to accidents.
• Wear dry and undamaged protective clothing (shoes with rubber soles/welder's gloves
made from leather without any studs or braces)!
• Avoid direct contact with non-insulated connection sockets or connectors!
• Always place torches and electrode holders on an insulated surface!
Risk of burns on the welding current connection!
If the welding current connections are not locked, connections and leads heat up and
can cause burns, if touched!
• Check the welding current connections every day and lock by turning in clockwise direction,
if necessary.
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.
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.
• Comprehensive descriptions can be found in the operating instructions for the relevant
accessory components.
• Accessory components are detected automatically after the power source is switched on.
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Design and function
Installation
CAUTION
Using protective dust caps!
Protective dust caps protect the connection sockets and therefore the machine against
dirt and damage.
• The protective dust cap must be fitted if there is no accessory component being operated
on that connection.
• The cap must be replaced if faulty or if lost!
NOTE
Observe documentation of other system components when connecting!
5.2
Installation
WARNING
Risk of accident due to improper transport of machines that may not be lifted!
Do not lift or suspend the machine! The machine can fall down and cause injuries! The
handles and brackets are suitable for transport by hand only!
• The machine may not be lifted by crane or suspended!
•
Depending on machine type, equipment for lifting by crane or use while suspended is
available as a retrofitting option (see chapter "Accessories").
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.
• Safe operation of the machine must be guaranteed at all times.
CAUTION
Damage to the machine due to improper transport!
The machine can be damaged by tensile or lateral forces if it is set
down or picked up in a non-vertical position!
• Do not drag the machine horizontally on the machine feet!
• Always pick up the machine vertically and set it down carefully.
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Design and function
Machine cooling
5.3
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.
• Do not obstruct the air inlets and outlets of the machine.
• Do not allow metal parts, dust or other objects to get into the machine.
5.4
Workpiece lead, general
CAUTION
Risk of burns due to incorrect connection of the workpiece lead!
Paint, rust and dirt on the connection restrict the power flow and may lead to stray
welding currents.
Stray welding currents may cause fires and injuries!
• Clean the connections!
• Fix the workpiece lead securely!
• Do not use structural parts of the workpiece as a return lead for the welding current!
• Take care to ensure faultless power connections!
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Design and function
Notes on the installation of welding current leads
5.5
Notes on the installation of welding current leads
NOTE
Incorrectly installed welding current leads can cause faults in the arc (flickering).
A
Install welding lead and hose package in parallel and as close together as possible.
B
Keep the welding lead and hose packages of each welding machine separate, with an
installation distance of at least 15 cm!
C
Fully unroll welding current leads, torch hose packages and intermediate hose
packages. Avoid loops!
D
Use an individual welding lead to the workpiece for each welding machine!
Connect the work clamp close to the welding point.
E
Always keep leads as short as possible!
Figure 5-1
Item Symbol
1
Description 0
Welding machine
2
Wire feed unit
3
Workpiece
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Design and function
Welding torch cooling system
5.6
Welding torch cooling system
5.6.1
Cooling module connection
NOTE
Observe the fitting and connection instructions given in the relevant operating
instructions for the cooling unit.
Figure 5-2
Item Symbol
Description 0
1
4-pole connection socket
Cooling unit voltage supply
2
8-pole connection socket
Cooling unit control lead
3
Cooling module
•
•
24
Insert and lock the 8-pole control lead plug on the cooling unit into the 8-pole connection socket on the
welding machine.
Insert and lock the 4-pole supply plug on the cooling unit into the 4-pole connection socket on the
welding machine.
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Design and function
Mains connection
5.7
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!
• Mains plug, socket and lead must be checked regularly by an electrician!
• When operating the generator always ensure it is earthed as stated in the operating
instructions. The resulting network has to be suitable for operating devices according to
protection class 1.
5.7.1
Mains configuration
NOTE
The machine may be connected to:
• a three-phase system with four conductors and an earthed neutral conductor
• a three-phase system with three conductors of which any one can be earthed,
e.g. the outer conductor
Figure 5-3
Legend
Item
L1
L2
L3
N
PE
Designation
Outer conductor 1
Outer conductor 2
Outer conductor 3
Neutral conductor
Protective conductor
Colour code
brown
black
grey
blue
green-yellow
CAUTION
Operating voltage - mains voltage!
The operating voltage shown on the rating plate must be consistent with the mains
voltage, in order to avoid damage to the machine!
• For mains fuse protection, please refer to the “Technical data” chapter!
•
Insert mains plug of the switched-off machine into the appropriate socket.
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Design and function
Connecting the intermediate hose package to the power source
5.8
Connecting the intermediate hose package to the power source
5.8.1
Intermediate hose package strain relief
CAUTION
Missing or incorrectly fitted strain relief!
Connection sockets or connection plugs on the machine, or the intermediate tube
package, may be damaged if the strain relief is missing or incorrectly fitted. The strain
relief takes the strain from cables, plugs and sockets.
• Check the strain relief function by pulling in all directions. Cables and hoses must have
sufficient play when the relief cord is fully stretched!
Figure 5-4
Item Symbol
2
Description 0
Stirrup
Intermediate hose package strain relief
Snap hooks
3
Intermediate hose package strain relief
1
•
26
Insert the end of the hose package through the strain relief of the hose package and lock by turning to
the right.
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Connecting the intermediate hose package to the power source
5.8.2
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 "+" welding current socket.
• Observe the information from the electrode manufacturer!
Figure 5-5
Item Symbol
1
Description 0
Wire feed unit
2
Intermediate hose package
3
7-pole connection socket (digital)
Wire feed unit connection
Connection socket, “+” welding current
• Standard MIG/MAG welding (intermediate hose package)
Connection socket, “-” welding current
Connection for welding current plug from intermediate hose package
• MIG/MAG flux cored wire welding
• TIG welding
4
5
•
•
•
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 of the welding current lead into the welding current connection socket and lock in place
by turning to the right.
Insert cable plug on the control lead into the 7-pole connection socket and secure with crown nut (the
plug can only be inserted into the connection socket in one position).
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Design and function
Shielding gas supply (shielding gas cylinder for welding machine)
5.9
Shielding gas supply (shielding gas cylinder for welding machine)
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders
can cause serious injuries!
• The fastening elements must tightly enclose the shielding gas cylinder!
• Attach the fastening elements within the upper half of the shielding gas
cylinder!
• Do not attach any element to the shielding gas cylinder valve!
• Observe the instructions from the gas manufacturer and any relevant
regulations concerning the use of compressed air!
• Avoid heating the shielding gas cylinder!
CAUTION
Faults in the shielding gas supply.
An unhindered shielding gas supply from the shielding gas cylinder to the welding
torch is a fundamental requirement for optimum welding results. In addition, a blocked
shielding gas supply may result in the welding torch being destroyed.
• Always re-fit the yellow protective cap when not using the shielding gas connection.
• All shielding gas connections must be gas tight.
NOTE
Before connecting the pressure regulator to the gas cylinder, open the cylinder valve
briefly to expel any dirt.
Figure 5-6
Item Symbol
1
Description 0
Pressure regulator
2
Shielding gas cylinder
3
Output side of the pressure regulator
4
Cylinder valve
•
•
•
•
28
Place the shielding gas cylinder into the relevant cylinder bracket.
Secure the shielding gas cylinder using a securing chain.
Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.
Screw the gas hose (intermediate hose package) to the pressure regulator ensuring that it is gas tight.
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Design and function
MIG/MAG welding
5.10
MIG/MAG welding
5.10.1 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 "+" welding current socket.
• Observe the information from the electrode manufacturer!
Figure 5-7
Item Symbol
1
"-" welding current connection socket
• MIG/MAG welding:
Workpiece connection
Connection socket, "+" welding current
• MIG/MAG cored wire welding:
Workpiece connection
2
3
•
Insert the plug on the workpiece lead into the "-" welding current connection socket and lock.
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Description 0
Workpiece
29
Design and function
TIG welding
5.11
TIG welding
5.11.1 Welding torch connection
NOTE
The welding torch is connected to the wire feeder.
Observe the operating instructions for the wire feeder (system component)!
5.11.2 Connection for workpiece lead
Figure 5-8
Item Symbol
1
2
•
30
Description 0
Workpiece
Connection socket, "+" welding current
• TIG welding:
Workpiece connection
Insert the plug on the welding current lead into the welding current connection socket "+" and lock.
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Design and function
MMA welding
5.12
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
• Always put the electrode holder down on an insulated surface.
5.12.1 Connecting the electrode holder and workpiece lead
Figure 5-9
Item Symbol
1
Description 0
Workpiece
2
Electrode holder
3
Connection socket, “-” welding current
4
Connection socket, “+” welding current
•
•
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.
NOTE
Polarity depends on the instructions from the electrode manufacturer given on the
electrode packaging.
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Design and function
Welding torch holder
5.13
Welding torch holder
NOTE
The item described in the following is part of the machine´s scope of delivery.
Figure 5-10
Item Symbol
1
Description 0
Crossmember of the transport handle
2
Torch holder
3
Fan-type lock washers
4
Fixing screws (x 4)
•
•
32
Use the mounting screws to screw the torch holder onto the crossmember of the transport handle.
Insert the welding torch into the welding torch holder as shown.
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Design and function
Remote control
5.14
Remote control
CAUTION
Damage to the machine due to improper connection!
The remote controls have been developed to be connected to welding machines or wire
feed units only. Connecting them to other machines may cause damage to the
machines!
• Observe the operating instructions for the welding machine or wire feed unit!
• Switch off the welding machine before connecting!
NOTE
Please note the relevant documentation of the accessory components.
The operation of the remote control and its settings are directly dependent on the configuration of the
respective welding machine or wire feed unit. The settings are defined by changeover switches or by
setting special parameters (dependent on the control).
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Design and function
Interfaces
5.15
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!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
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.
• Comprehensive descriptions can be found in the operating instructions for the relevant
accessory components.
• Accessory components are detected automatically after the power source is switched on.
5.15.1 Automation interface
NOTE
These accessory components can be retrofitted as an option, see Accessories chapter.
Pin
A
D
E
+
R
Input /
output
Output
Output
(open
collector)
Input
F
G/P
Output
Output
H
Output
L
M
N
S
T
Input
Output
Output
Output
Output
Description
Diagram
PE
IGRO
Connection for cable shielding
Current flows signal I>0 (maximum load 20
mA / 15 V)
0 V = welding current flows
Not/Aus Emergency stop for higher level shut-down
of the power source.
To use this function, jumper 1 must be
unplugged on PCB M320/1 in the welding
machine. Contact open = welding current
off
0V
Reference potential
I>0
Power relay contact, galvanically isolated
(max. +/-15 V / 100 mA)
Uist
Welding voltage, measured against pin F,
0-10 V (0 V = 0 V; 10 V = 100 V)
Str/Stp Start = 15 V / Stop = 0 V 1)
+15 V
Voltage supply (max. 75 mA)
-15 V
Voltage supply (max. 25 mA)
0V
Reference potential
Iist
Welding current, measured on pin F;
0-10 V (0 V = 0 A, 10 V = 1000 A)
1
) The operating mode is given by the wire feed unit (the start / stop function equates to pressing
the torch trigger and is used in mechanised applications, for example).
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Design and function
Interfaces
5.15.2 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
• Analogue inputs: control voltages, e.g. for welding performance, welding current, etc.
• Relay outputs: process signal, ready for welding, system composite fault, etc.
5.15.3 BUSINT X11 Industrial bus interface
The solution for easy integration into automated production lines, with for example
• Profi bus
• CAN bus and
• Interbus systems
(optional, external installation by customer)
5.15.4 DVINT X11 Wire feed interface
For the flexible connection of special wire feed units (optional, retrofitting on the machine or externally by
the customer).
As examples: Binzel (APD system), Dinse wire feed systems.
5.15.5 PC 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!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Equipment damage or faults may occur if the PC is connected incorrectly!
Not using the SECINT X10USB interface results in equipment damage or faults in signal
transmission. The PC may be destroyed due to high frequency ignition pulses.
• Interface SECINT X10USB must be connected between the PC and the welding machine!
• The connection must only be made using the cables supplied (do not use any additional
extension cables)!
NOTE
Please note the relevant documentation of the accessory components.
PC 300 welding parameter software
Create all welding parameters quickly on the PC and easily transfer them to one or more welding
machines (accessories: set consisting of software, interface, connection leads).
Q-DOC 9000 welding data documentation software
(Accessories: set consisting of software, interface, connection leads)
The ideal tool for welding data documentation of, for example:
welding voltage and current, wire speed and motor current.
WELDQAS welding data monitoring and documentation system
Network-compatible welding data monitoring and documentation system for digital machines
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Maintenance, care and disposal
General
6
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!
• Wait for 4 minutes until the capacitors have discharged!
6.1
General
When used in the specified environmental conditions and under normal operating conditions, this
machine is largely maintenance-free and requires a minimum of care.
There are some points, which should be observed, to guarantee fault-free operation of your welding
machine. Among these are regular cleaning and checking as described below, depending on the pollution
level of the environment and the length of time the unit is in use.
6.2
Maintenance work, intervals
CAUTION
Electric current!
Repairs may only be carried out by authorised specialist staff!
• Do not remove the torch from the hose package!
• Never clamp the torch body in a vice or similar, as this can cause the torch to be irreparably
destroyed!
• If damage occurs to the torch or to the hose package which cannot be corrected as part of
the maintenance work, the entire torch must be returned to the manufacturer
6.2.1
6.2.1.1
6.2.1.2
36
Daily maintenance tasks
•
•
Check that all connections and wearing parts are hand-tight and tighten if necessary.
Check that all screw and plug connections and replaceable parts are secured correctly, tighten if
necessary.
• Remove any spatter.
• Clean the wire feed rollers on a regular basis (depending on the degree of soiling).
Visual inspection
• Check hose package and power connections for exterior damage and replace or have repaired by
specialist staff as necessary!
• Mains supply lead and its strain relief
• Gas tubes and their switching equipment (solenoid valve)
• Other, general condition
Functional test
• Check correct mounting of the wire spool.
• Welding current cables (check that they are fitted correctly and secured)
• Gas cylinder securing elements
• Operating, message, safety and adjustment devices (Functional test)
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Maintenance work
6.2.2
Monthly maintenance tasks
6.2.2.1
Visual inspection
• Casing damage (front, rear and side walls)
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
• Check coolant tubes and their connections for impurities
Functional test
• Selector switches, command devices, emergency stop devices, voltage reducing devices, message
and control lamps
• Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
6.2.2.2
6.2.3
Annual test (inspection and testing during operation)
NOTE
The welding machine may only be tested by competent, capable personsl.
A capable person is one who, because of his training, knowledge and experience, is
able to recognise the dangers that can occur while testing welding power sources as
well as possible subsequent damage and who is able to implement the required safety
procedures.
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
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.
6.3
Maintenance work
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.
• Appoint only skilled persons for repair work (trained service personnel)!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service matters, always consult the dealer who supplied the
machine. Return deliveries of defective equipment subject to warranty may only be made through your
dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the
machine type, serial number and item number of the machine, as well as the type designation and item
number of the spare part.
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Maintenance, care and disposal
Disposing of equipment
6.4
Disposing of equipment
NOTE
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and
electronic components, which must be disposed of.
• Do not dispose of in household waste!
• Observe the local regulations regarding disposal!
6.4.1
Manufacturer's declaration to the end user
•
•
•
•
•
6.5
According to European provisions (guideline 2002/96/EG of the European Parliament and the Council
of January, 27th 2003), used electric and electronic equipment may no longer be placed in unsorted
municipal waste. It must be collected separately. The symbol depicting a waste container on wheels
indicates that the equipment must be collected separately.
This machine is to be placed for disposal or recycling in the waste separation systems provided for
this purpose.
According to German law (law governing the distribution, taking back and environmentally correct
disposal of electric and electronic equipment (ElektroG) from 16.03.2005), used machines are to be
placed in a collection system separate from unsorted municipal waste. The public waste management
utilities (communities) have created collection points at which used equipment from private
households can be disposed of free of charge.
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.
In addition to this, returns are also possible throughout Europe via EWM sales partners.
Meeting the requirements of RoHS
We, EWM HIGHTEC Welding GmbH Mündersbach, hereby confirm that all products supplied by us which
are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).
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Rectifying faults
Checklist for rectifying faults
7
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.
7.1
Checklist for rectifying faults
NOTE
The correct machine equipment for the material and process gas in use is a
fundamental requirement for perfect operation!
Legend
Symbol


Description
Fault/Cause
Remedy
Coolant error/no coolant flowing
 Insufficient coolant flow

Check coolant level and refill if necessary
 Air in the coolant circuit

see chapter "Vent coolant circuit"
Wire feed problems
 Contact tip blocked

Clean, spray with anti-spatter spray and replace if necessary
 Setting the spool brake (see "Setting the spool brake" chapter)

Check settings and correct if necessary
 Setting pressure units (see "Inching wire electrodes" chapter)

Check settings and correct if necessary
 Worn wire rolls

Check and replace if necessary
 Wire feed motor without supply voltage (automatic cutout triggered by overloading)

Reset triggered fuse (rear of the power source) by pressing the key button
 Kinked hose packages

Extend and lay out the torch hose package
 Wire guide core or spiral is dirty or worn

Clean core or spiral; replace kinked or worn cores
Functional errors
 Machine control without displaying the signal lights after switching on

Phase failure > check mains connection (fuses)
 No welding performance

Phase failure > check mains connection (fuses)
 Various parameters cannot be set

Entry level is blocked, disable access lock (see chapter entitled "Lock welding parameters
against unauthorised access")
 Connection problems

Make control lead connections and check that they are fitted correctly.
 Loose welding current connections

Tighten power connections on the torch and/or on the workpiece

Tighten contact tip correctly
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Rectifying faults
Error messages (power source)
7.2
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).
• Document machine errors and inform service staff as necessary.
• If multiple errors occur, these are displayed in succession.
Error
Category
Possible cause
Remedy
a) b) c)
Error 1
x
Mains overvoltage
Check the mains voltages and compare with
(Ov.Vol)
the connection voltages of the welding
machine
Error 2
x
Mains undervoltage
(Un.Vol)
Error 3
x
Welding machine excess
Allow the machine to cool down (mains
(Temp)
temperature
switch to "1")
Error 4
xx x
Low coolant level
Top off the coolant
(Water)
Leak in the coolant circuit >
rectify the leak and top off the coolant
Coolant pump is not working > check excess
current trigger on air cooling unit
Error 5
x
Wire feeder, speedometer
Check the wire feeder
(Wi.Spe)
error
speedometer is not issuing a signal,
M3.00 defective > inform Service
Error 6
x
Shielding gas error
Check shielding gas supply (for machines
(gas)
with shielding gas monitoring)
Error 7
x
Secondary excess voltage
Inverter error > inform Service
(Se.Vol)
Error 8
x
Earth fault between welding
Separate the connection between the
(no PE)
welding wire and casing or an earthed object
wire and earth line
(Phoenix 330 only)
Error 9
x
Fast cut-out
Rectify error on robot
(fast stop)
triggered by BUSINT X11 or
RINT X12
Error 10
x
Arc break
Check wire feeding
(no arc)
triggered by BUSINT X11 or
RINT X12
Error 11
x
Ignition fault after 5 s
Check wire feeding
(no ign)
triggered by BUSINT X11 or
RINT X12
Error 14
x
Wire feeder not detected.
Check cable connections
Control cable not connected.
(no DV)
Incorrect ID numbers
Check assignment of ID numbers (see the
assigned during operation
"Changing ID number of wire feeder"
with multiple wire feeders.
chapter)
Error 15
x
Wire feeder 2 not detected.
Check cable connections
(DV2?)
Control cable not connected.
Error 16
x
VRD (open circuit voltage
Inform Service
(VRD)
reduction error)
Error 17
x
x
Wire feed mechanism
Check the wire feeding
(WF. Ov.)
overcurrent detection
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Rectifying faults
General operating problems
Legend for categories (error reset)
a) The error message will disappear once the error has been rectified.
b) The error message can be reset by pressing a key button:
Welding machine control
Key button
RC1 / RC2
Expert
CarExpert / Progress (M3.11)
alpha Q / Concept / Basic / Basic S / Synergic /
not possible
Synergic S / Progress (M3.71) Picomig 305
c) The error message can only be reset by switching the machine off and on again.
The shielding gas error (Err 6) can be reset by pressing the "Welding parameters" key button.
7.3
General operating problems
7.3.1
Interface for automated welding
WARNING
No function of the external interrupt equipment (emergency stop switch)!
If the emergency stop circuit has been realised using an external interrupt equipment
via the interface for automated welding, the machine must be configured for this setup.
If this is not observed, the power source will ignore the external interrupt equipment
and will not shut down!
• Disconnect jumper 1 on PCB T320/1 (Tetrix) or M320/1 (Phoenix / alpha Q)!
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Rectifying faults
Vent coolant circuit
7.4
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 7-1
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Technical data
Phoenix 355 TDM
8
Technical data
NOTE
Performance specifications and guarantee only in connection with original spare and
replacement parts!
8.1
Phoenix 355 TDM
TIG
MIG/MAG
Setting range for welding current
Setting range for welding voltage
5 A–350 A
10,2 V - 24,0 V
40 °C
60%
350 A
100%
300 A
79 V
Mains voltage (tolerances)
3 x 400 V (-25% to +20%)
Frequency
50/60 Hz
Mains fuse
(safety fuse, slow-blow)
Mains connection lead
3 x 25 A
Max. connected load
Recommended generator rating
cosϕ
Insulation class/protection
classification
Ambient temperature
H07RN-F4G4
10,6 kVA
13,9 kVA
0.99
H/IP 23
-20 °C to +40 °C
Fan/gas
Workpiece lead
70 mm2
Weight
EMC class
Constructed to standards
099-005220-EW501
15,0 kVA
20,2 kVA
Machine/torch cooling
Dimensions (L x W x H)
20,2 V - 34,0 V
10 min. (60% DC ∧ 6 min. welding, 4 min. pause)
Open circuit voltage
13.05.2013
14,3 V - 31,5 V
Duty cycle
Load alternation
MMA
625 mm x 300 mm x 535 mm
41 kg
A
IEC 60974 -1, -10
/
43
Technical data
Phoenix 405
8.2
Phoenix 405
TIG
MIG/MAG
Setting range for welding current
Setting range for welding voltage
5 A–400 A
10.2 V–26.0 V
40 °C
100%
400 A
79 V
Mains voltage (tolerances)
3 x 400 V (-25% to +20%)
Frequency
50/60 Hz
Mains fuse
(safety fuse, slow-blow)
Mains connection lead
3 x 35 A
Max. connected load
Recommended generator rating
cosϕ
Insulation class/protection
classification
Ambient temperature
H07RN-F4G4
13.1 kVA
17.2 kVA
0.99
H/IP 23
-20 °C to +40 °C
Fan/gas
Workpiece lead
70 mm2
Weight
EMC class
Constructed to standards
18.2 kVA
25.0 kVA
Machine/torch cooling
Dimensions (L x W x H)
20.2 V–36.0 V
10 min. (60% DC ∧ 6 min. welding, 4 min. pause)
Open circuit voltage
44
14.3 V–34.0 V
Duty cycle
Load alternation
MMA
625 mm x 300 mm x 535 mm
41 kg
A
IEC 60974 -1, -10
/
099-005220-EW501
13.05.2013
Technical data
Phoenix 505
8.3
Phoenix 505
TIG
MIG/MAG
Setting range for welding current
Setting range for welding voltage
5 A–500 A
10.2 V–32.0 V
14.3 V–39.0 V
20.2 V–40.0 V
Duty cycle
40 °C
25 °C
40 °C
25 °C
40 °C
25 °C
60 %
500 A
-
500 A
-
500 A
-
65 %
-
500 A
-
500 A
-
500 A
100 %
430 A
460 A
430 A
460 A
430 A
460 A
Load alternation
10 min. (60% DC ∧ 6 min. welding, 4 min. pause)
Open circuit voltage
79 V
Mains voltage (tolerances)
3 x 400 V (-25% to +20%)
Frequency
50/60 Hz
Mains fuse
(safety fuse, slow-blow)
Mains connection lead
3 x 35 A
Max. connected load
Recommended generator rating
cosϕ
Insulation class/protection
classification
Ambient temperature
H07RN-F4G4
18.9 kVA
24.6 kVA
0.99
H/IP 23
-20 °C to +40 °C
Fan/gas
Workpiece lead
95 mm2
Weight
EMC class
Constructed to standards
099-005220-EW501
25.3 kVA
35.0 kVA
Machine/torch cooling
Dimensions (L x W x H)
13.05.2013
MMA
625 mm x 300 mm x 535 mm
45 kg
A
IEC 60974 -1, -10
/
45
Accessories
System components
9
Accessories
NOTE
Performance-dependent accessories like torches, workpiece leads, electrode holders or
intermediate hose packages are available from your authorised dealer.
9.1
System components
Type
Phoenix Progress drive 4L
WE
Phoenix Progress drive 4 WE
Phoenix Progress drive 300C
WE
Phoenix Progress drive 200C
WE
9.2
Wire feed unit, water, Euro central connector
Wire feed unit, water, Euro central connector
090-004843-00502
090-005103-00502
Wire feed unit, water, Euro central connector
090-005102-00502
Designation
Contamination filter for air inlet
Automation interface
Pedestal for transport with floor conveyors
Wheel assembly kit for CS 505
Item no.
092-002698-00000
092-007891-00000
092-007896-00000
092-007897-00000
Welding torch cooling system
Type
cool50-2 U40
9.4
Item no.
090-004844-00502
Options
Type
ON Filter 355/405/505/50
ON AIF MOD 505
ON FC CS 405/505
ON WAK CS 405/505
9.3
Designation
Wire feed unit, water, Euro central connector
Designation
Cooling module
Item no.
090-008603-00502
Designation
Transport vehicle
Cross arm and holder for wire feeder
Pivot support for drive 4L on Trolly 55.2-2
Pivot support
Item no.
090-008630-00000
092-002700-00000
092-002701-00000
092-002634-00000
Crane console, transport/ram protection
Phoenix/Taurus 505
092-007895-00000
Transport systems
Type
Trolly 55.2-2
ON TR Trolly 55.2-2
ON PS Trolly 55.2-2 drive 4L
ON PS Trolly 55.2-2
drive 200/300c
ON CS 505
9.5
Remote control / connection cable
9.5.1
7-pole connection
Type
R40 7POL
R50 7POL
FRV 7POL 0.5 m
FRV 7POL 5 m
FRV 7POL 10 m
FRV 7POL 20 m
FRV 7POL 25M
46
Designation
Remote control, 10 programs
Remote control, all welding machine functions can
be set directly at the workplace
Extension/connecting cable
Extension/connecting cable
Extension/connecting cable
Extension/connecting cable
Extension/connecting cable
Item no.
090-008088-00000
090-008776-00000
092-000201-00004
092-000201-00003
092-000201-00000
092-000201-00001
092-000201-00007
099-005220-EW501
13.05.2013
Accessories
General accessories
9.6
General accessories
Type
5POLE/CEE/32A/M
DM1 35L/MIN
9.7
Item no.
094-000207-00000
094-000009-00000
Computer communication
Type
PC300.Net
CD PC300.Net update
FRV 7POL 5 m
FRV 7POL 10 m
FRV 7POL 20 m
QDOC9000 V2.0
099-005220-EW501
13.05.2013
Designation
Machine plug
Manometer pressure regulator
Designation
PC300.Net welding parameter software kit incl.
cable and SECINT X10 USB interface
PC300.Net Update on CD-ROM
Extension/connecting cable
Extension/connecting cable
Extension/connecting cable
Set consisting of interface, documentation software,
connection lead
Item no.
090-008777-00000
092-008172-00001
092-000201-00003
092-000201-00000
092-000201-00001
090-008713-00000
47
Appendix A
Overview of EWM branches
10
Appendix A
10.1
Overview of EWM branches
48
099-005220-EW501
13.05.2013