EWM PHOENIX 301 CAR EXPERT PULS Operating Instructions Manual

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EWM

HIGHTEC WELDING GmbH

Dr. Günter - Henle - Straße 8 • D-56271 Mündersbach

Phone: +49 2680 181 0 • Fax: +49 2680 181 244

www.ewm.de • info@ewm.de

Operating instructions

Compact welding machine for MIG brazing and MIG/MAG welding

PHOENIX 301 CAR EXPERT PULS

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 (73/23/EEC)

• EC EMC Directive (89/336/EEC)

In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments with an increased electrical hazard.

Item No.: 099-004998-EWM01

Revised: 25.09.06

Originaldokumen

liegt jedem Gerät bei!

Original document

is enclosed with each machine!

Document original

est joint à toute machine!

EG - Konformitätserklärung

EU - conformity declaration

Déclaration de Conformité de U.E.

Name des Herstellers:

Name of manufacturer: Nom du fabricant:

EWM HIGHTEC WELDING GmbH (nachfolgend EWM genannt) (In the following called EWM) (nommé par la suite EWM)

Anschrift des Herstellers:

Address of manufacturer: Adresse du fabricant:

Dr.- Günter - Henle - Straße 8 D - 56271 Mündersbach – Germany info@ewm.de

Hiermit erklären wir, daß das nachstehend bezeichnete Gerät in seiner Konzeption und Bauart sowie in der von uns in Verkehr gebrachten Ausführung den grundlegenden Sicherheits-anforderungen der unten genannten EG- Richtlinien entspricht. Im Falle von unbefugten Veränderungen, unsachgemäßen Reparaturen und / oder unerlaubten Umbauten, die nicht ausdrücklich von EWM autorisiert sind, verliert diese Erklärung ihre Gültigkeit.

We herewith declare that the machine described below meets the standard safety regulations of the EU- guidelines mentionned below in its conception and construction, as well as in the design put into circulation by us. In case of unauthorized changes, improper repairs and / or unauthorized modifications, which have not been expressly allowed by EWM, this declaration will lose its validity.

Par la présente, nous déclarons que la conception et la construction ainsi que le modèle, mis sur le marché par nous, de l´appareil décrit ci - dessous correspondent aux directives fondamentales de sécurité de la U.E. mentionnées ci- dessous. En cas de changements non autorisés, de réparations inadéquates et / ou de modifications prohibeés, qui n´ont pas été autorisés expressément par EWM, cette déclaration devient caduque.

Gerätebezeichnung:

Description of the machine: Déscription de la machine:

Gerätetyp:

Type of machine: Type de machine:

Artikelnummer EWM:

Article number: Numéro d´article

Seriennummer:

Serial number: Numéro de série:

Optionen:

Options: Options:

keine none aucune

Zutreffende EG - Richtlinien:

Applicable EU - guidelines: Directives de la U.E. applicables:

EG - Niederspannungsrichtlinie (73/23/EWG) EU - low voltage guideline Directive de la U.E. pour basses tensions EG- EMV- Richtlinie (89/336/EWG) EU- EMC guideline U.E.- EMC directive

Angewandte harmonisierte Normen:

Used co-ordinated norms: Normes harmonisées appliquées:

EN 60974 / IEC 60974 / VDE 0544 EN 50199 / VDE 0544 Teil 206

Hersteller - Unterschrift:

Signature of manufacturer: Signature du fabricant:

Michael Szczesny , Geschäftsführer managing director gérant

05.2000

Dear customer,

Congratulations! You have chosen a quali ty product fr om 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.

We develop and produce quality! From in divi dua l com pone nts to the final produc t , we retain sole responsibility for our machines.

In all their high-tech components, our welding machines embody future-oriented advanced technology at the utmost level of quality. Each of our products is carefully checked; we guarantee that the material and processing of our products is faultless.

These operating instructions contain everything about commissioning the machine, notes regarding safety, maintenance and care, technical data as well as information regarding the warranty. Please heed all these notes to ensure many years of safe operation of the machine.

Thank you for the trust that you have placed in us. We look forward to a long-term partnership with you in the spirit of “ONCE EWM – ALWAYS EWM”.

Yours sincerely,

EWM HIGHTEC WELDING GmbH

Bernd Szczesny Executive management

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: ART:

SNR: PROJ:

GEPRÜFT/CONTROL:

Name of Customer / company

Adress

Post code / Place

Country

Stamp / Signature of EWM-distibutor

Date of purchase

Name of Customer / company

Adress

Post code / Place

Country

Stamp / Signature of EWM-distibutor

Date of purchase

Contents

For your safety

Item No.: 099-004998-EWM01 5

1 Contents

1 Contents..................................................................................................................................................5

2 Safety instructions.................................................................................................................................7

2.1 For your safety...............................................................................................................................7

2.2 Transport and installation ..............................................................................................................9

2.2.1 Ambient conditions .........................................................................................................9

2.3 Safety rules while lif ting ...............................................................................................................10

2.4 Notes on the use of these operating instructions ........................................................................10

3 Technical data ......................................................................................................................................11

4 Machine description ............................................................................................................................12

4.1 PHOENIX 301 CAR EXPERT PULS ...........................................................................................12

4.1.1 Front view.....................................................................................................................12

4.1.2 Rear view......................................................................................................................13

5 Functional characteristics...................................................................................................................14

5.1 Machine control – Operating elements........................................................................................14

5.1.1 Welding machine control ..............................................................................................14

5.1.2 Wire feed machine control............................................................................................16

5.1.2.1 Internal operating elements ..........................................................................17

5.1.3 Welding torch operati ng ele ments................................................................................18

5.2 Application-dependent operation.................................................................................................19

5.2.1 Definition of MIG/MAG welding tasks...........................................................................19

5.2.2 MIG/MAG welding data display....................................................................................19

5.2.3 Manufacturer-specific welding task selection...............................................................19

5.2.3.1 Selecting manufacturer-specific JOBs..........................................................19

5.2.3.2 Examples ......................................................................................................20

5.3 Conventional operation................................................................................................................21

5.3.1 Definition of MIG/MAG welding tasks...........................................................................21

5.3.2 Selecting MIG/MAG welding tasks...............................................................................21

5.3.3 MIG/MAG operating point.............................................................................................22

5.4 Other parameters.........................................................................................................................22

5.4.1 Setting the gas post-flow time/wire burn-back..............................................................22

5.5 MIG/MAG welding........................................................................................................................23

5.5.1 MIG/MAG functional sequences / operating modes.....................................................23

5.5.1.1 Explanation of signs and functions ...............................................................23

5.5.1.2 Non-latched mode.........................................................................................24

5.5.1.3 Non-latched operation with superpu ls e .........................................................25

5.5.1.4 Special, non-latched......................................................................................26

5.5.1.5 Spots.............................................................................................................27

5.5.1.6 Special, non-latched with superpulse ...........................................................28

5.5.1.7 Latched mode ...............................................................................................29

5.5.1.8 Latched mode with superpulse.....................................................................30

5.5.1.9 Latched special .............................................................................................31

5.5.1.10 Special, latched with superpulse.................................................................32

5.5.2 MIG/MAG automatic cut-out.........................................................................................33

5.6 Key switch....................................................................................................................................33

6 Commissioning ....................................................................................................................................34

6.1 General ........................................................................................................................................34

6.2 Area of application – proper usage..............................................................................................34

6.3 Installation....................................................................................................................................34

6.4 Mains connection.........................................................................................................................34

6.5 Machine cooling...........................................................................................................................34

6.6 Workpiece lead, general..............................................................................................................34

Contents

For your safety

6 Item No.: 099-004998-EWM01

6.7

MIG/MAG welding........................................................................................................................35

6.7.1 Welding torch and workpiece line connection ..............................................................35

6.7.1.1 Preparing the welding torch for MIG brazing and MIG welding ....................35

6.7.1.2 Preparing the torch for welding steel.............................................................37

6.7.1.3 PHOENIX 301 CAR EXPERT PULS .............................................................38

6.7.2 Removing the wire feed unit cover ...............................................................................39

6.7.3 Fixing of the pin reel (adjustment of the pre-tensioning)..............................................39

6.7.4 Inserting the wire spool.................................................................................................40

6.7.5 Changing the wire feed rollers......................................................................................40

6.7.6 Inching the wire electrode.............................................................................................41

6.7.7 Spool brake setting.......................................................................................................42

6.8 Shielding gas supply....................................................................................................................43

7 Maintenance and care..........................................................................................................................44

7.1 General.........................................................................................................................................44

7.2 Cleaning.......................................................................................................................................44

7.3 Repetition test ..............................................................................................................................44

7.3.1 Test intervals and scope...............................................................................................45

7.3.2 Documentation of the test.............................................................................................45

7.3.3 Visual inspection...........................................................................................................45

7.3.4 Measurement of protective conductor resis t ance.........................................................45

7.3.5 Measurement of insulation resistance..........................................................................46

7.3.6 Measuring the leakage current (protective conductor and contact current).................46

7.3.7 Measuring the open circ uit v oltag e...............................................................................46

7.3.8 Function test of the welding machine ...........................................................................46

7.4 Repair Work .................................................................................................................................47

7.5 Disposing of equipment................................................................................................................48

7.5.1 Manufacturer's declaration to the end user ..................................................................48

7.6 Meeting the requirements of RoHS..............................................................................................48

8 3-Year Warranty....................................................................................................................................49

8.1 General Validity............................................................................................................................49

8.2 Warranty Declaration ...................................................................................................................50

9 Operating problems, causes and remedies .......................................................................................51

9.1 Error messages (power source)...................................................................................................51

10 Circuit diagrams ...................................................................................................................................52

10.1 PHOEN IX 301 CAR EXP E RT PULS ...........................................................................................52

Safety instructions

For your safety

Item No.: 099-004998-EWM01 7

2 Safety instructions

2.1 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).

Improper usage However, this machine may be a hazard to persons, animals and property if it is

• not used as directed

• used by unskilled persons who have not been trained

• modified or converted improperly

Our operating instructions will provide you with an introduction into the safe use of the machine. Therefore please read them carefully and only start work when you are familiar with them.

Any person involved in the operation, maintenance and repair of this machine must read and follow these operating instructions, especially the safety precautions. Where appropriate, this should be confirmed by signature.

Furthermore, the

• relevant accident prevention regulations,

• generally accepted safety regulations,

• local regulations, etc. must be observed.

Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves.

• Protect eyes and face with protective visor.

Electric shocks can be fatal!

• Do not touch any live parts in or on the machine!

• The machine may only be connected to correctly earthed sockets.

• Only operate with intact connection lead including protective conductor and safety plug.

• An improperly repaired plug or damaged mains cable insulation can cause electric shocks.

• The machine may only be opened by qualified and authorised specialist staff.

• Disconnect from the mains before opening. Sw itc hi ng off is not suffic i ent. Wa it for 2 minutes until the capacitors have discharged.

• Always put down welding torch, stick electrode holder in an insulated condition.

• The machine must not be used to defrost pipes!

Even touching low voltages can cause you to get a shock and lead to accidents, so:

• Protect yourself from falling before working on platforms or scaffolding.

• During welding ensure that you operate earth tongs, torch and workpiece correctly, and not in ways for which they are not intended. Do not touch live parts with bare skin.

• Only replace electrodes when wearing dry gloves.

• Never use torches or earth cables with damaged insulation.

Smoke and gases can lead to breathing difficulties and poisoning.

• Do not breathe in smoke and gases.

• Ensure that there is sufficient fresh air.

• Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can be converted into poisonous phosgene by ultraviolet radiation.

Safety instructions

For your safety

8 Item No.: 099-004998-EWM01

Workpiece, flying sparks and droplet s 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.

• Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of explosions when apparently harmless substances develop high pressures in enclosed containers by heating.

Take care to avoid fire hazards

• Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when parts are glowing or hot slag is present.

• A constant check must be kept on whether fire hazards have arisen in the working area.

• Highly inflammable objects, such as matches and cigarette lighters for example, must not be carried in trouser pockets.

• You must ensure that fire extinguishing equipment - appropriate for the welding process - is available close to the welding work area and that this equipment can be accessed easily.

• Containers in which fuels or lubricants have been present must be thoroughly cleaned before welding begins. It is not sufficient simply for the receptacle to be empty.

• After a workpiece has been welded, it must only be touched or brought into contact with inflammable material when it has cooled down sufficiently.

• Loose welding connections can completely destroy protective conductor systems of interior installations and cause fires. Before beginning welding work, ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source.

Noise exceeding 70 dBA can cause permanent hearing damage!

• Wear suitable earmuffs or plugs.

• Ensure that other people who spend time in the working area are not inconvenienced by the noise.

Interference by electrical and electromagnetic fields is possible e.g. from the welding machine or from the high-voltage pulses of the ignition unit.

• As laid down in Electromagnetic Compati bi lity Sta ndard EN 50199, the machines are intended for use in industrial areas; if they are operated in residential environments, for example, problems may occur in ensuring electromagnetic compatibility.

• The functioning of heart pacemakers can be adversely affected when you are standing near the welding machine.

• It is possible that electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the welding site could malfunction.

• Other mains supply leads, control leads, signal and telecommunications leads above, under and near the welding device may be subject to interference.

Electromagnetic interference must be reduced to a level that no longer constitutes interference. Possible reduction measures:

• Welding machines must be serviced regularly. (see Chap. Maintenance and care)

• Welding leads should be as short as possible and run closely together on or near to the ground.

• Selective shielding of other leads and equipment in the environment can reduce radiation.

Repair and modifications may only carried out by authorised, trained, specialist staff. The warranty becomes null and void in the event of unauthorised interference.

Safety instructions

Transport and installation

Item No.: 099-004998-EWM01 9

2.2 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 the power source is moved and positioned, it is only tilt resistant up to an angle of 10° (as specified in EN 60974-A2). The following points should be noted here in particular:

• Add-on parts are to be distributed evenly according to their weight and suitably secured during transport.

• Obstacles on the ground can cause additional tilting.

• Damaged fixed castors and guide castors should be replaced immediately.

• For machines with a rotating external wire feed unit (e.g. DRIVE 4L), make sure that it is fixed securely and cannot rotate in an uncontrolled manner.

Secure the gas cylinder!

• Place shielding gas cylinders in the holders provided for them and secure with safety chains.

• Take care when handling cylinders; do not throw or heat, guard against them toppling over.

• When moving by crane, take off the gas cylinder from the welding machine.

2.2.1 Ambient conditions

This machine must not be operated in any area where any risk of explosion exists. The following conditions must be observed during operation:

Temperature range of the ambient air

• During welding: -10°C to +40°C *),

• For transport and storage: -25°C to +55°C *)

*) Using the appropriate coolant.

Relative air humidity

• up to 50% at 40°C

• up to 90% at 20°C

The ambient air must be free of unusual amounts of dust, acids, corrosive gases or substances, etc., assuming these are not produced by the welding proc e ss . Examples of unusual operating conditions:

• unusual corrosive smoke,

• vapour,

• excessive oil vapour,

• unusual vibrations or jolts,

• excessive quantities of dust such as grinding dust etc.,

• severe weather conditions,

• unusual conditions near the coast or on board ship.

When setting up the machine, ensure a free inlet and outlet of air. The machine is tested to protection class IP23, i.e.:

• Protection against penetration of solid foreign bodies ∅ > 12mm,

• Protection against water spray up to an angle of 60° to the vertical.

Safety instructions

Safety rules while lifting

10 Item No.: 099-004998-EWM01

2.3 Safety rules while lifting

Carefully observe the accident prevention regulations VBG 9, VBG 9a and VGB 15.

Crane principle

mind. 60°

mind. 1m

Angle of the

suspension ropes

Machines must be connected on the lifting lugs when being lifted by crane (not on the transport bar)!

• Lift on all 4 ring screws simultaneously (as shown in Fig. 1).

• Ensure an even distribution of the load to all four ropes and maintain an angle of at least 60° on the suspension ropes (see Fig. 2). Only use ring chains or suspension ropes of equal length (at least 1 m).

• Use load hooks with circlips and shackles of the relevant size specified in DIN 82 101, Form A, minimum size 0.4.

• Before lifting, always remove the shielding gas cylinder from the welding machine.

• Never lift other loads along with the welding machine, e.g. persons, toolboxes, wire spools etc.

• Avoid jerky movements when raising or lowering the welding machine.

• Wire spools are to be removed from the welding and wire feed units before they are lifted.

• No equipment may be operated during lifting.

2.4 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. These symbols refer to particularly important passages of text which are graded as follows depending on their importance:

Please note: Technical features which users must observe. Warning: Working and operating procedures which must be followed precisely to avoid damaging or

destroying the machine. Caution: Working and operating procedures which must be followed precisely to avoid risk to persons and

includes the "Warning" symbol.

Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet points, e.g.:

• Insert the welding current lead socket into the relevant socket and lock.

Symbol Description

Press

Do not press

Turn

Switch

Technical data

Notes on the use of these operating instructions

Item No.: 099-004998-EWM01 11

3 Technical data

301 CAR EXPERT PULSE Welding current/voltage set ti ng range:

5A/14.3V–300A/29.0V

Duty cycle at 20°C 80% DC

300A

100% DC

270A

Duty cycle at 40°C 60% DC

300A

100% DC

250A

Load alternation

10 min (60% DC

∧

6 min. welding, 4 min. break)

Open circuit voltage

98V

Mains voltage (tolerances)

3 x 400V (-25% to +20%)

Frequency

50/60Hz

Mains fuse (slow-blow safety fuse)

3 x 16A

Mains connection lead

H07RN-F4G2.5

Max. connected power

14.3kVA

Recommended generator rating

19.3kVA

Cosϕ/efficiency

0.99/89%

Insulation class/protection classification

H/IP 23

Ambient temperature

-10°C to +40°C

Machine/torch cooling

Fan/gas

Workpiece lead

50mm²

Dimensions L/W/H [mm]

930 x 455 x 730

Weight

69.5kg

Wire-feed speed

0.5m/min to 24m/min

Standard WF roller fitting

0.8mm + 1.0mm

WF drive unit

4-roller (37mm)

Torch connection

Euro Central

Protection classification

IP 23

Constructed to standards

IEC 60974/EN 60974/VDE 0544

EN 50199/VDE 0544 Part 206/

Machine description

PHOENIX 301 CAR EXPERT PULS

12 Item No.: 099-004998-EWM01

4 Machine description

4.1 PHOENIX 301 CAR EXPERT PULS

4.1.1 Front view

Figure 4-1

Item Symbol Description 0 1

Lifting lug

Main switch, machine on/off

3 Control / Operating elements (see chapter Function specification) 4 Cooling air inlet 5

19-pole connection socket (analogue)

For connecting analogue remote controls

Euro-central connector (welding torch connection)

Welding current, shielding gas and torch trigger included

7 Carrying handle 8

Connection socket, “-” welding current

Workpiece connection

9 Conveyor rolls, guide castors 10 Conveyor rolls, fixed castors

Machine description

PHOENIX 301 CAR EXPERT PULS

Item No.: 099-004998-EWM01 13

4.1.2 Rear view

Figure 4-2

Item Symbol Description 0 1 Shielding gas cylinder circlip 2

Connecting nipple G¼, shielding gas connection

42V/4A

"Automatic cutout" key button

Wire feed motor supply voltage fuse (press to reset a triggered fuse)

7-pole connection socket (digital)

For connecting digital accessory components (remote control, welding torch control lead, etc.)

5 Strain relief with mains connection cable 6 "Wire feed unit cover" lock 7 Wire spool inspection window

Check wire suppl y

8 Cooling air outlet 9 Cylinder bracket

Functional characteristics

Machine control – Operating elements

14 Item No.: 099-004998-EWM01

5 Functional characteristics

5.1 Machine control – Operating elements

5.1.1 Welding machine control

Figure 5-1

Item Symbol Description 0

“Up” and “Down” buttons, left

Switching of the digital display between the following welding parameters:

Welding current (nominal, actual and hold values) Panel thickness (nominal value) Wire speed

Motor current

Select other welding parameters on deeper programming levels.

Button for welding programs for vehicles from specific manufacturers

Key switch signal light “Select material type/gas type” key button

Steel/CO2

MIX

Steel/mixed gas

CuAl

Copper/aluminium/pure arg on

CuS i

Copper/silicon/pure argon

ALU AlMg

Aluminium/magnesium/pure argon

ALU AlSi

Aluminium/silicon/pure argon

Spezial

MIX

ALU AlMg ALU AlSi

CuAl

CuSi

Spezial

Customer-specific

Functional characteristics

Machine control – Operating elements

Item No.: 099-004998-EWM01 15

Item Symbol Description 0

“Select wire diameter” key button

0,8 mm

0.8mm wire diameter

1,0 m m

1.0mm wire diameter

0,8 mm 1,0 mm 1,2 mm

1,2 m m

1.2mm wire diameter

Panel thickness button

0,8 mm

1,0 mm 1,2 mm 1,5 mm

0,8 mm

1,0 mm

1,2 mm

1,5 mm

2,0 mm

2,0 m m

The signal light shows the selected panel thickness in mm.

Seam type/program button

To switch the program or the seam type between:

Lap weld

Butt weld

Fillet weld

Raised-edge weld

Tack weld

Plug weld

Slot weld

Prog

1 2 3 4 5 6 7 8

Fillet weld for tie rod

Key switch for protection against unauthorised use

Position “1” > changes possible, Position “0” > changes not possible.

Please take note of chapter “Key switch”

Gas post-flow/wire burn-back key button

For setting the gas post-flow time or wire burn-back

“Up” and “Down” buttons, right

Switching of the digital display between the following welding parameters:

Welding voltage Manufacturer-specific program description

Select other parameters on deeper programming levels.

500A 49,9V

LCD display, 16-digit

Display of all welding parameters and their values

“Conventional operation” signal light

Functional characteristics

Machine control – Operating elements

16 Item No.: 099-004998-EWM01

5.1.2 Wire feed machine control

Figure 5-2

Item Symbol Description 0 1

“Wire speed” rotary dial

In conventional operation, infinite setting of the wire speed from 0.5 to 20m/min. (welding performance one-dia l oper at ion).

No function in application-specific operation (factory setting)

“Select operating mode” button

Non-latched Latched Special, non-latched

Special, latched

Earth fault signal light

Safety shut-down, see “Troubleshooting, causes and remedies” chapter

“Welding process” button

MIG/MAG standard welding

MIG/MAG pulse arc welding (EXPERT PULS only)

Arc length correction rotary dial

“Dynamic correction/choke effect” rotary switch

In conventional operation, dynamics correction or choke effect in nine stages from hard and narrow arc to soft, wide arc.

No function in application-specific operation (factory setting).

Functional characteristics

Machine control – Operating elements

Item No.: 099-004998-EWM01 17

5.1.2.1 Internal operating elements

Figure 5-3

Item Symbol Description 0

“Program or up/down function” changeover switch

This changeover switch only affects the CAR CONTROL program torch.

Programm

Switch over the welding programs using the rocker on the CAR CONTROL program torch. (Factory setting)

Up / Down

Set welding performance using the rocker on the CAR CONTROL program torch via infinite setting. (Conventional operation)

"Wire inching" button

For inching the wire electrode when changing the wire spool (speed = 50% of set wire speed)

The welding wire is inched into the tube package with the current off and without the gas being expelled.

“Gas test” key button Currentless gas test

Functional characteristics

Machine control – Operating elements

18 Item No.: 099-004998-EWM01

5.1.3 Welding torch operating elements

Figure 5-4

Item Symbol Description 0 1

“Seam type/program number” display

Displays the selected seam type, or the selected welding program.

Torch trigger – rocker

Application-specific operation: Select seam types or welding programs

Conventional operation: Control the WF speed in nine stages

“Seam type” legend

Allocation of the seam types to the numerical indicator on the torch display.

Functional characteristics

Application-depend ent operation

Item No.: 099-004998-EWM01 19

5.2 Application-dependent operation

5.2.1 Definition of MIG/MAG welding tasks

This machine range has been designed to be very easy and quick to operate, whilst still providing all the functions one could ever need.

The application-specific operation of this machine range combined with machine control M3.15 offers an intuitive operating interface covering typical welding tasks for every kind of bodywork repair.

All parameters for different seam types, panel thicknesses, welding current and welding voltage are automatically set by the machine control.

The seam types can also be called up on the welding torch using the integrated remote control and display, without interrupting work.

The arc length can also be modified where necessary on the “Arc length correction” rotary dial. There are presets for other welding parameters such as gas pre-flow, free-burning, etc., for numerous

applications however, these can be changed as necessary. The welding task is normally selected via two basic welding parameters (material/gas type, wire electrode

diameter) and two bodywork-specific welding parameters (panel thickness, seam shape).

5.2.2 MIG/MAG welding data display

To the left and right of the LCD display on the control there are 2 “arrow keys” on each side for selecting the welding parameter to be displayed. The

button is used to scroll through the parameters from the

bottom upwards and the

button is used to scroll downwards from the top.

As soon as changes have been made to the settings after welding (display on hold values), the display switches back to the nominal values.

Figure 5-5

5.2.3 Manufacturer-specific welding task selection

This machine offers 10 additional JOBs where welding tasks (e.g. f or different vehicle types from a vehicle manufacturer) can be stored.

In each of these 10 JOBs, 8 specific programs can be called up for the relevant tasks/seams on the bodywork via the machine control or the weldi ng tor ch.

5.2.3.1 Selecting manufacturer-specific JOBs Operating

element

Action Result Display

1 x

Select manufacturer-specific JOBs

LOAD JOB CAR 1

X x

Select manufacturer-specific JOBs

The signal light displays the selection. (Also using rocker on the Power Control torch.)

LOAD JOB CAR 1

1 x

Transfer selected JOB

The JOB is automatically transferred after 5 seconds if applicable.

Display of the parameters

If one of the buttons , or is pressed, manufacturer-specific JOBs are ended.

Functional characteristics

Application-depend ent operation

20 Item No.: 099-004998-EWM01

5.2.3.2 Examples

Figure 5-6

Pos. Seam shape Program Panel thicknesses 1

Butt 1 0.8/0.8

Lap 2 1.2/1.2

Slot 2 1.2/1.2

Butt 1 0.8/0.8

For brazing work on a vehicle, there are optimised brazing programs specific to the manufacturer in JOB 4 (up to 8 possible). The relevant program number for each brazing position can be found in the welding instructions for the specific vehicle. Selecting this program means that all the optimum brazing or welding parameters are preset.

Figure 5-7

Item Symbol Description 0 1 Display, or changeover of program on the torch or machine control.

You can switch between the programs on the welding torch or on the machine control. The program numbers for the various positions and seam types can be found in the welding instructions

for the specific vehicle from the vehicle manufacturer.

Functional characteristics

Conventional operation

Item No.: 099-004998-EWM01 21

5.3 Conventional operation

5.3.1 Definition of MIG/MAG welding tasks

In addition to the application-specific operation of the CAR EXPERT range, it is possible to specify the operating point conventionally via one-dial operation.

The welding task is selected via two basic welding parameters (material/gas type and wire electrode diameter).

There are presets for other welding parameters such as gas pre-flow, free-burning, etc., for numerous applications however, these can be changed as necessary.

5.3.2 Selecting MIG/MAG welding tasks

The welding task is selected on the welding machine control. LEDs display the welding parameter selection.

It is possible to change the basic welding parameters only if:

• No welding current is flowing and

• The key switch is set to position “1”.

Operating element

Action Result Display

X x

Select welding process

The LED displa ys the selection.

No change

X x

Select wire diameter

The LED displa ys the selection.

No change

X x

Select operating mode

The LED displa ys the selection.

Non-latched, latched, special non-latched, special latched

No change

X x

Select welding type

The LED displa ys the selection. MIG standard/MIG pulse arc.

No change

Select dynamic correction/choke effect

Harder to softer arc in 9 stages

No change

Functional characteristics

Other parameters

22 Item No.: 099-004998-EWM01

5.3.3 MIG/MAG operating point

The operating point (welding performance) 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).

The operating point can also be specified using the welding torch rocker switch. In the following versions, only the wire speed is given to represent the operating point setting.

Operating element

Action Result Display

Operating point is set using the wire speed previously set.

Selected parameter

Application example

The material AlSi must be welded using 100% argon. Wire diameter = 1.2mm, material thickness = 5mm. Let's say you don’t have any existing values and do not know the required settings for the wire speed, for example.

Switch to the material thickness display, set to 5mm. This corresponds to a wire speed of 8.4m/min. This sets the operating point and the welding process can be started.

5.4 Other parameters

5.4.1 Setting the gas post-flow time/wire burn-back

Operating element

Action Result Display

1 x

Set gas post-flow time/wire burn-back

The signal light indicates the parameter set.

GASend: x.x

X x

Set gas post-flow time/wire burn-back

The signal light displays the selection.

GASend: x.x or BACK xx

X x

Modify the parameter previously selected

GASend: x.x or BACK: xx

Functional characteristics

MIG/MAG welding

Item No.: 099-004998-EWM01 23

5.5 MIG/MAG welding

5.5.1 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.

There are optimum pre-sets for welding parameters such as gas pre-flow and free-burn, etc. for numerous applications (although these can also be changed if required).

5.5.1.1 Explanation of signs and functions Symbol Meaning

Press torch trigger Release torch trigger Tap torch trigger (press briefly and release) Shielding gas flowing

Welding output Wire electrode is being conv eyed

Wire creep Wire burn-back

Gas pre-flows

Gas post-flows

Non-latched Special, non-latched Latched Special, latched

Time

PSTART

Ignition program

Main program

Reduced main program

PEND

End program

Spot time

Functional characteristics

MIG/MAG welding

24 Item No.: 099-004998-EWM01

5.5.1.2 Non-latched mode

Figure 5-8

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.

• Change over to pre-selected wire speed (main program P

Step 2

• Release torch trigger.

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

Functional characteristics

MIG/MAG welding

Item No.: 099-004998-EWM01 25

5.5.1.3 Non-latched operation with superpulse

1. 2.

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 flows.

• Start the super pulse function beginning with main program P

The welding parameters change at the specified times between main program P

and the reduced

main program P

Step 2

• Release torch trigger.

• Super pulse function is ended.

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

Functional characteristics

MIG/MAG welding

26 Item No.: 099-004998-EWM01

5.5.1.4 Special, non-latched

1. 2.

END

START

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 is flowing (start program P

START

for the time t

start

)

• Slope to main program P

Step 2

• Release torch trigger

• Slope to end program P

END

for the time t

end

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

Functional characteristics

MIG/MAG welding

Item No.: 099-004998-EWM01 27

5.5.1.5 Spots Selecting Spot operating mode

Operating element

Action Result Displays

x x

Press until signal light

comes on.

No change

1 x

• Press and hold for approx. 2 sec. until signal light

flashes. The machine is switched

over to Spot operating mode

• On the version with a two-colour LED, the "red" signal light will be on.

No change

1. 2.

END

START

Figure 5-11

The start time t

start

must also be calculated at spot time t2. The start and spot times are set in

the "Program steps mode" menu. 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

, spot time starts).

• Slope on main program P

• After the set spot time elapses, slope goes to end program P

END

• WF motor stops.

• Arc is extinguished after the pre-selected wire burn-back time elapses.

• Gas post-flow time elapses.

Step 2

• Release torch trigger

Releasing the torch trigger (step 2) interrupts the welding process even if the spot time has not yet elapsed (slope to end program P

END

Functional characteristics

MIG/MAG welding

28 Item No.: 099-004998-EWM01

5.5.1.6 Special, non-latched with superpulse

1. 2.

END

START

Figure 5-12

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

for the time t

start

• Slope on main program P

• Start the super pulse function beginning with main program P

The welding parameters change at the specified times between main program P

and the reduced

main program P

Step 2

• Release torch trigger

• Super pulse function is ended.

• Slope to end program P

END

for the time t

end

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

Functional characteristics

MIG/MAG welding

Item No.: 099-004998-EWM01 29

5.5.1.7 Latched mode

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 flows.

• Change over to pre-selected WF speed (main program P

Step 2

• Release torch trigger (no effect)

Step 3

• Press torch trigger (no effect)

Step 4

• Release torch trigger

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

Functional characteristics

MIG/MAG welding

30 Item No.: 099-004998-EWM01

5.5.1.8 Latched mode with superpulse

1. 2. 3. 4.

Figure 5-14

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.

• Start the super pulse function beginning with main program P

The welding parameters change at the specified times between main program P

and the reduced

main program P

Step 2:

• Release torch trigger (no effect)

Step 3:

• Press torch trigger (no effect)

Step 4:

• Release torch trigger

• Super pulse function is ended.

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

Functional characteristics

MIG/MAG welding

Item No.: 099-004998-EWM01 31

5.5.1.9 Latched special

1. 2. 3. 4.

END

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

START

)

Step 2

• Release torch trigger

• Slope to main program P

The slope on main program P

is given at the earliest after the set time t

START

elapses and at the latest when the torch trigger is released. Tapping

can be used to change over to the reduced main program PB.

Repeated tapping will switch back to the main program P

Step 3

• Press and hold torch trigger

• Slope to end program P

END

Step 4

• Release torch trigger

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

Prevent tapping (brief press and release within 0.3 seconds)

If the welding current is to be prevented from switching over to the reduced main program P

by tapping, the parameter value for WF3 needs to be set to 100% (PA = PB) in the program

sequence.

Functional characteristics

MIG/MAG welding

32 Item No.: 099-004998-EWM01

5.5.1.10 Special, latched with superpulse

1. 2.

END

START

Figure 5-16

Step 1

• Press and hold torch trigger

• Shielding gas is expelled (gas pre-flows)

• Wire feed motor runs at “creep speed”.

• Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P

START

for the time t

start

Step 2

• Release torch trigger

• Slope on main program P

• Start the super pulse function beginning with main program P

The welding parameters change at the specified times between main program P

and the reduced

main program P

Step 3

• Press the torch trigger.

• Super pulse function is ended.

• Slope in the end program P

END

for the time t

end

Step 4

• Release torch trigger

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

Functional characteristics

Key switch

Item No.: 099-004998-EWM01 33

5.5.2 MIG/MAG automatic cut-out

If pressing the torch trigger does not ignite the arc or if the arc is interrupted by the torch being removed during the welding process, automatic cut-out occurs within 5 seconds. The welding machine ends the welding process immediately (open circuit voltage or welding current, wire feed and shielding gas are shut off).

5.6 Key switch

To protect against unauthorised or unintentional adjustment of the welding parameters on the machine, the control input can be locked with the aid of a key switch.

In key switch position 1 all functions and parameters can be set without restriction. In key switch position 0 the following functions and parameters cannot be changed:

• Job switching function, welding task selection (block job mode possible with Power-control torch)

• Job Manager mode

• Program Steps mode

• Program A mode

• Job Info mode

• Super pulse function

When using a wire feed unit with control M3.70, the welding type and operating mode functions cannot be changed if the key switch is in position "0". The parameters can be displayed in the function sequence on the control, but not changed.

Commissioning

General

34 Item No.: 099-004998-EWM01

6 Commissioning

6.1 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.

6.2 Area of application – proper usage

These welding machines are only suitable for GMAW welding and GMAW brazing. Any other use is regarded as "improper" and no liability is assumed for any damage arising therefrom.

We can only guarantee smooth and trouble-free operation of the machines when used in conjunction with the welding torches and accessories from our range.

6.3 Installation

Ensure that the machine is set up in a stable position and is appropriately secured. With modular systems (power source, transport vehicle, cooling module), observe the operating

instructions for the relevant machine. Set up the machine so that there is sufficient room to adjust the operating elements.

When lifting the wire feed unit, the wire spool should be removed (please see the operating

instructions for the transport vehicle for more information on crane work).

6.4 Mains connection

The operating voltage shown on the rating plate must match the mains voltage. For mains fuse protection, please refer to the “Technical Data” chapter.

The correct mains plug must be attached to the mains supply lead on the machine. The connection must be made by a qualified electrician in compliance with the relevant local laws

and regulations. The phase sequence for three-phase machines is optional and has no effect on the fans direction

of rotation.

• Insert mains plug of the switched-off machine into the appropriate socket.

6.5 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.

6.6 Workpiece lead, general

Remove paint, rust and dirt from clamping and welding areas with a wire brush. The workpiece clamp must be mounted near the welding point and must be fixed in such a way that it cannot come loose of its own accord.

Structural parts, pipes, rails etc. may not be used as return leads for the welding current unless they are part of the actual workpiece. Correct current connection must be ensured when using welding benches and appliances.

Commissioning

MIG/MAG welding

Item No.: 099-004998-EWM01 35

6.7 MIG/MAG welding

6.7.1 Welding torch and workpiece line connection

The welding torch must be set up with equipment appropriate to the welding task. The relevant measures to equip the torch for MIG brazing and MIG welding (CuSi & CuAl, or AlSi &

AlMg) and for MAG welding (SG 2/3) are described below.

6.7.1.1 Preparing the welding torch for MIG brazing and MIG welding

Figure 6-1

Item Symbol Description 0 1

Gas nozzle

Flow contact nozzle

Gas distributor

Nozzle holder

5 Nozzle holder mount 6

Clamping nut

7 Spring 8 Teflon core 9

Collet

O-ring

11 Wire guide tube

Commissioning

MIG/MAG welding

36 Item No.: 099-004998-EWM01

The flow nozzle must match the application and for that reason may need to be changed.

This depends on the welding wire and wire diameter being used. For example, aluminium and aluminium alloys with 0.8mm welding wire: Gas nozzle “0.8A”

• Remove the gas nozzle

• Unscrew the flow nozzle

• Screw on the flow nozzle for that specific application

• Fit the gas nozzle

The torch is equipped with a Teflon or plastic core for MIG brazing or MIG welding.

• Extend and lay out the tube package

• Remove the existing wire or Teflon core, if necessary

• Insert the Teflon core with spring forwards onto the central connector on the torch as far as it will go

• Push on the collet

• Push on the O-ring

• Push on the clamping nut

• Push on the guide tube up to the clamping nut

• Cut off the Teflon core using a sharp knife 5mm after the end of the guide tube

The distance between the Teflon core and drive rollers should be as short as possible. Use only sharp, stable knives or special tongs for cutting to ensure that the Teflon core does not

become misshapen!

Commissioning

MIG/MAG welding

Item No.: 099-004998-EWM01 37

6.7.1.2 Preparing the torch for welding steel

Figure 6-2

Item Symbol Description 0 1

Gas nozzle

Flow contact nozzle

Gas distributor

Nozzle holder

5 Nozzle holder mount 6

Clamping nut

7 Conically ground end of the guide spiral 8 Guide spiral 9 Holding nipple

• Remove the gas nozzle

• Unscrew the flow nozzle

• Remove the gas distributor

• Unscrew the clamping nut

• Extend and lay out the tube package

• Remove the existing wire or Teflon core, if necessary

• Insert the holding nipple far enough in so that it is flush with the clamping nut thread on the central connection.

• Screw the guide spiral and holding nipple handtight using a clamping nut.

• Press the guide spiral from the torch head into the torch tube package, using as little force as possible.

• Use a side cutter to cut the guide spiral flush to the nozzle holder mount.

• Unscrew the clamping nut on the central connector and take off the guide spiral.

• Grind spiral guides on one side conically using a grinding stone.

The ground end should be fitted against the nozzle holder to ensure a precise fit.

• Insert the guide spiral onto the central connector.

The guide spiral must be aligned centrally in the nozzle holder mount.

• Re-assemble the torch head in the reverse order in which it was disassembled.

Commissioning

MIG/MAG welding

38 Item No.: 099-004998-EWM01

6.7.1.3 PHOENIX 301 CAR EXPERT PULS We can only guarantee correct functioning of our machines when used with our range of welding

torches. The correct spirals or cores must be used for the relevant wire diameter and wire type. Welding torch with insulatated liner: A capillary tube must be installed in the central connection. Welding torch with Teflon or plastic core: The capillary tube must be removed from the central connection.

Preparing the welding torch for the welding task:

• Shorten the Teflon core and surrounding guide pipe so that the distance to the drive roller is as short

as possible.

• The Teflon core and the guide pipe must not be deformed.

• Deburr the Teflon core and the guide pipe.

Figure 6-3

Item Symbol Description 0 1

Euro-central connector (welding torch connection)

Welding current, shielding gas and torch trigger included

Connection socket, “-” welding current

Workpiece connection

19-pole connection socket (analogue)

For connecting analogue remote controls

• Insert the central plug for the welding torch into the central connector and screw together with crown

nut.

• Insert the plug on the workpiece lead into the "-" welding current connection socket and lock.

Only MIG/MAG torches with special functions (additional control lead):

• Insert the torch control lead plug into either the 7-pole connection socket (digital) or the 19-pole

connection socket (depending on the version) and lock.

Commissioning

MIG/MAG welding

Item No.: 099-004998-EWM01 39

6.7.2 Removing the wire feed unit cover

For the following processes the cover must be removed; to protect the machine it is essential that the cover is fitted back into position afterwards.

• Unlock the right-hand cover on the machine.

• Tilt the cover forwards, then remove upwards.

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.

Figure 6-4

Item Symbol Description 0 1 Securing and braking unit 2 Allen screw

Securing the wire spool retainer and adjustment of the spool brake

3 Spool holder retainer

• Loosen the Allen screw of the securing and braking unit till the screw comes out of the thread in the spool holder retainer (but do not screw it out completely to prevent losing it).

• Pre-tension the securing and braking unit in the spool holder retainer by making at least 4 complete turns of the Allen screw (4 x 360°) in the clockwise direction.

Commissioning

MIG/MAG welding

40 Item No.: 099-004998-EWM01

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. Adapters (see accessories) are required when using standardised basket coils (DIN 8559).

Figure 6-5

Item Symbol Description 0 1 Carrier pin

For fixing the wire spool

2 Knurled nut

For fixing the wire spool

• Loosen knurled nut from spool holder.

• Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore.

• Fasten wire spool using knurled nut.

6.7.5 Changing the wire feed rollers

To ensure optimum wire feed, it is essential that the wire feed rollers match the wire electrode diameter used (change if necessary).

The wire feed rollers are only suitable for two wire diameters (factory setting 1.0 mm or 1.2 mm). Turning the WF rollers changes between the two wire diameters.

• Slide new drive rollers into place so that the diameter of the wire electrode printed on the wire feed roller is visible. Screw the drive rollers in place with knurled screws.

0,8 mm

1,0 mm

Figure 6-6

Commissioning

MIG/MAG welding

Item No.: 099-004998-EWM01 41

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. Screw the drive rollers in place with knurled screws.

Figure 6-7

Item Symbol Description 0 1 Pressure units 2 Clamping units 3 Wire inlet nipple 4 Guide tube 5 Capillary tube or Teflon core

• Extend and lay out the torch tube package.

• Unfasten pressure units and fold out (clamping units and counter-pressure rollers will automatically flip upwards).

• Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe.

• Press the clamping element with the counter-roller back downwards and fold the wire units back up again (wire electrode should in the groove on the drive roller).

The clamping pressure must be set on the adjusting nuts of the pressure units so that the wire electrode is conveyed but will still slip through if the wire spool jams.

• Press the wire inching button until the wire electrode projects out of the welding torch.

Caution, risk of injury! Never point a welding torch at people or animals!

Commissioning

MIG/MAG welding

42 Item No.: 099-004998-EWM01

6.7.7 Spool brake setting

Figure 6-8

Item Symbol Description 0 1 Allen screw

Securing the wire spool retainer and adjustment of the spool brake

• Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect.

Tighten spool brake only to the point where the wire spool no longer runs on when the trigger "wire inching" is released! The wire spool must not jam!

If the Allen screw is now loosened by as much as it was previously tightened, a renewed tightening of the pin reel will be necessary, see chapter "Fixing of the pin reel (adjustment of the pretensioning)".

Commissioning

Shielding gas supply

Item No.: 099-004998-EWM01 43

6.8 Shielding gas supply

Figure 6-9

Item Symbol Description 0 1 Cylinder bracket 2 Shielding gas cylinder circlip 3 Pressure reducer 4 G ¼" crown nut 5 Cylinder valve 6 Shielding gas cylinder

No dirt must be allowed to enter the shielding gas supply as this would cause blockages. All shielding gas connections must be gastight!

• Place the shielding gas cylinder in the cylinder holder and secure it from tipping over using the safety strap!

• Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to blow out any dirt.

• Mount the pressure regulator on the gas cylinder valve.

• Fit the gas hose and G1/4" crown nut onto the relevant connection on the pressure reducer.

• Fit the gas hose and G1/4" crown nut onto the relevant connection on the welding machine, and fit the wire feed unit (if present on this version).

Maintenance and care

General

44 Item No.: 099-004998-EWM01

7 Maintenance and care

7.1 General

Under the indicated environmental conditions and normal operating conditions, this machine is largely maintenance-free and requires minimum care. However, a number of points 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 level of contamination in the environment and the usage time of the welding machine.

Cleaning, testing and repairing of the welding machines may only be carried out by competent, capable personnel. A capable person is one who, due to training, knowledge and experience, is able to recognise the dangers that can occur during testing of welding power sources as well as possible subsequent damage and who is able to implement the required safety procedures.

In the event of failure to comply with any one of the following tests, the machine must not be operated again until it has been repaired and a new test has been carried out.

7.2 Cleaning

Before cleaning, carefully disconnect the machine from the mains. PULL OUT THE MAINS PLUG. (Switching off or pulling out the fuse does not provide adequate insulation protection) Wait 2 minutes until the capacitors are discharged. Remove the casing cover.

The individual components should be handled as follows: Power source: Depending on the amount of dust, blow out power source using oil- and moisture-free

compressed air. Electronics: Do not blast electronic components or circuit boards with compressed air but instead use

suction from a vacuum cleaner for cleaning purposes.

7.3 Repetition test

The repetition test described below must be conducted correctly and on a regular basis in order to claim under the EWM warranty.

The repetition test must be conducted in accordance with E VDE 0544-207 "Repetition test on arc welding equipment", according to the German Ordinance on Operational Safety. This draft standard covers all the required test points specifically for welding machines, as mentioned in VDE 0702 "Repetition test on electrical equipment", in addition to special instructions for usage and specific limit values.

In addition to the regulations on the repetition test given here, the relevant local laws and regulations must also be observed.

Unfortunately, many test devices are not suitable for VDE 0702 in all respects due to the special conditions in inverter arc welding machines!

EWM as a manufacturer offers all appropriately trained and authorised EWM sales partners the appropriate test equipment and measuring devices conforming to VDE 0404-2, which evaluate the frequency response conforming to 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 E VDE 0544-207 and are tested with the relevant test equipment and measuring devices given above.

The following description of the repetition test is only a brief overview of the points to be tested. For details on the test points or in the event of any queries, please refer to E VDE 0544-207.

Maintenance and care

Repetition test

Item No.: 099-004998-EWM01 45

7.3.1 Test intervals and scope

A quarterly partial test and an annual extensive test are to be carried out. The extensive test must also be carried out each time that repairs are made; in the case of heavy use, the period can be reduced (e.g. to 6 months when used at construction sites). In the extensive test, the machine must be opened and cleaned according to the section entitled “Cleaning”. Only exterior cleaning is required for the partial test.

Partial test Full test

a) Visual check a) Visual check b) Electrical test: measurement of

• Protective conductor resistance

b) Electrical test: measurement of

• Protective conductor resistance

• Insulation resistance

• Leakage currents

• Open circuit voltage

c) Functional test c) Functional test

7.3.2 Documentation of the test

The result of the test must be documented to show the following clearly:

• Identify the tested machines,

• The date of the test

• The time of the next test and

• The results

for later reference. The machine must be marked if the test is successful (e.g. with a test plate). This plate must include the date of the next repetition test.

7.3.3 Visual inspection

Given below are the main points in the full test. The points to be tested with the machine open are not required for the partial test.

1. Torch/stick electrode holder, welding current return lead clamp

2. Leads incl udi ng plu gs and c oupl ings

3. Open plugs and couplings

4. Casing

5. Open casing

6. Special features of the welding power sources for plasma cutting

7. Operating, message, safety and adjustment devices

8. Other, general condition

7.3.4 Measurement of protective conductor resistance

Measure between the plug earthed contact and accessible metal parts, e.g. casing screws. During the measurement, the connection lead must be moved across the entire length, but especially close to the casing and plug inputs. This should uncover any interruptions in the protective conductor. All conductive parts of the casing accessible from outside should also be tested to ensure a correct PE connection for safety class I.

The resistance must not exceed a mains connection lead 0.3 Ω up to 5m in length. For longer leads, the permissible value increases by 0.1 Ω per 7.5m of lead.

Maintenance and care

Repetition test

46 Item No.: 099-004998-EWM01

7.3.5 Measurement of insulation resistance

The mains switch must be on before the insulation in the interior of the machine through to the transformer can be checked. If a mains contactor is fitted, this should be bridged or the measurement must be carried out on both sides.

The insulation resistance must not be less than:

Input power circuit (mains)

against Welding current circuit and

electronics

5 MΩ at test voltage 1000V=

Input power circuit (mains)

against Casing (PE)

2.5 MΩ at test voltage 500V =

Welding current circuit and electronics

against Casing (PE)

2.5 MΩ at test voltage 500V =

7.3.6 Measuring the leakage current (protective conductor and contact current)

These measurements cannot be carried out with a normal multimeter. Even test devices for VDE 0702 (especially older devices) are generally only intended for 50/60Hz. With inverter welding machines, however, significantly higher frequencies occur, which can interfere with some measuring devices, and results in others measuring the frequency incorrectly.

Test devices must meet the requirements of VDE 0404-2. For the frequency response measurement, please refer to DIN EN 61010-1 Appendix A – Measuring Circuit A1.

For these measurements the welding machine must be switched on and supplying open circuit voltage.

1. Protective conductor current: <3.5mA

2. Contact current from welding sockets separately to PE: <10mA

3. Contact current of accessible, conductive parts not connected to PE, to PE: <0.5mA

7.3.7 Measuring the open circuit voltage

6u8F

10nF

0...5k

0k2

1k0

1N 4007

Measuring circuit according to DIN EN

60974-1

Connect the measuring circuit to the welding current sockets. The voltmeter must display mean values and have an internal resistance ≥ 1 MΩ. In the case of step switch controlled devices, set the maximum output voltage (step switch). Adjust the potentiometer from 0 kΩ to 5 kΩ during the measurement. The measured voltage should not deviate from that specified on the rating plate by more than +/- 5% and may be no greater than 113 V (for devices with VRD: 35 V).

7.3.8 Function test of the welding machine

Safety devices, selector switches and command units (if fitted) and the entire machine or the entire system for arc weld ing, must be functioning perfectly.

1. Main switch

2. Emergency stop devices

3. Danger reduction devices

4. Gas solenoid valve

5. Message and control lamps

6. Command devices and selector switches (including remote controls)

7. Locks

Maintenance and care

Repair Work

Item No.: 099-004998-EWM01 47

7.4 Repair Work

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, please contact your EMW sales partner. 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 original spare parts and replacement parts when servicing. 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.

We hereby confirm that the servicing and maintenance instructions given above and the repetition test described above have been completed correctly.

Date / Stamp / Signature of EWM sales partner

Date of next repetition test

Date / Stamp / Signature of EWM sales partner

Date of next repetition test

Date / Stamp / Signature of EWM sales partner

Date of next repetition test

Maintenance and care

Disposing of equipment

48 Item No.: 099-004998-EWM01

7.5 Disposing of equipment

This machine does not belong in household waste, in accordance with the German Law on Electrical Equipment Waste.

In Germany, waste equipment from private households can be disposed of free of charge at local community collection points. 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 Regis t er (EAR) und er number WE EE DE 576 869 22.

In addition, within Europe the machine can also be returned to your EWM sales partner.

7.5.1 Manufacturer's declaration to the end user

• In accordance with European guidelines (Directive 2002/96/EC from the European Parliament and the Council of 27.01.03), it is no longer permissible to dispose of used electrical and electronic equipment in unsorted household waste collections. It must be kept separate from other waste. The symbol on the wheeled bins indicates the requirement to separate this waste. Help to protect the environment and ensure that this equipment, when you no longer want to use it, is disposed of in the relevant system of separated waste disposal.

• In Germany, (German Law on the Distribution, Return and Environmentally-Friendly Disposal of Electrical and Electronic Equipment (ElektroG) of 16.03.05) you are required to take old equipment to a waste collection point separated from household waste. The public waste disposal contractor (local authorities) have set up collection points for this purpose where old equipment from private households in your area can be collected for you free of charge. It is also possible that the legally responsible waste disposal company will collect old equipment from private households.

• Please obtain the relevant information from your local waste calendar or from your town council or local authority on the options available in your area for returning or collecting old equipment.

7.6 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).

3-Year Warranty

General Validity

Item No.: 099-004998-EWM01 49

8 3-Y ear Warranty

8.1 General Validity

3-year warranty on all new EWM machines:

• Power sources

• Wire feeds

• Cooling units

• Trolleys

1-year warranty on:

• Used EWM machines

• Automation and mechanisation components

• Remote controls

• Inverters

• Intermediate tube packages

6-month warranty on:

• spare parts supplied separately (such as circuit boards, ignition units)

Manufacturer/supplier warranty on:

• all additional parts used by EWM, but manufactured by other companies (e.g. motors, pumps, fans, torches, etc.)

Non-reproducible software errors and parts subject to mechanical aging are excluded from the warranty (e.g. WF rollers, wheels, solenoid valves, workpiece leads, electrode holders, connection tubes, replacement torches and spare torch parts, mains and control leads, etc.).

These terms shall apply without affecting the customer’s legal rights to a warranty and subject to our General Terms and Conditions of Business and our terms on the warranty declaration. Agreements to the contrary must be confirmed by EWM in writing.

Our General Terms and Conditions of Business are available for access anytime online at

www.ewm.de

3-Year Warranty

Warranty Declaration

50 Item No.: 099-004998-EWM01

8.2 Warranty Declaration

Your 3-year warranty

Regardless of statutory warranty rights and based on our General Terms and Conditions, EWM HIGHTEC WELDING GmbH provides a 3-year warranty for its welding products starting on the date of purchase. Different warranty periods apply for accessories and spare parts; please see the “General Validity” section for these periods. Wearing parts are of course exempt from the warranty.

EWM guarantees the error-free condition of our products in terms of materials and processing. If the product proves to be defective in terms of materials or processing within the warranty period, you have the right to free repair or to replacement by an appropriate product, at our discretion. In this case, the returned product becomes the property of EWM when it reaches Mündersbach or our premises.

Conditions

The prerequisite for receiving the full 3-year warranty is simply to operate the products in accordance with the EWM operating instructions observing the relevant legal recommendations and guidelines and regularly having the repetition test conducted by an EWM sales partner (see "Maintenance and care" chapter). This is because only machines that are maintained regularly function correctly in the long term.

Making a claim

When making a claim under the warranty, please only contact your authorised EWM sales partner.

Exclusion of warranty

The warranty does not apply to products that are damaged due to accidents, misuse, improper operation, incorrect installation, use of force, disregard of the specifications and operating instructions, inadequate maintenance (see chapter "Maintenance and care"), damage due to exterior influences, acts of God or personal misfortunes. Furthermore, it is not valid in the case of unauthorised changes, repairs or modifications. In addition, a claim for warranty does not exist in the case of partially or completely dismantled products and interventions by persons who are not authorised by EWM, as well as in the case of normal wear.

Limitation

All claims regarding fulfilment or non-fulfilment on the part of EWM from this declaration in connection with this product are limited to the replacement of the ac tual dam ages , as outlined bel ow. EW M’s lia bi lity stemming from this declaration in connection with this product is strictly limited to the amount that the purchaser originally paid for the original purchase. 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 consequential damage. EWM accepts no liability for damages based on the claims of third parties.

Place of jurisdiction

If the person making the claim is a business person, the sole place of jurisdiction for all disputes resulting directly or indirectly from the contractual relationship shall be the headquarters or the branch office of the supplier, at the discretion of the supplier. The purchaser gains ownership of the products supplied as replacements at the time of replacement within the framework of the warranty provided.

Operating problems, causes and remedies

Error messages (power source)

Item No.: 099-004998-EWM01 51

9 Operating problems, causes and remedies

9.1 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.

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.

• If multiple errors occur, these are displayed in succession.

• Document machine errors and inform service staff as necessary.

EWM PHOENIX 301 CAR EXPERT PULS Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual