EWM Phoenix 351-551 Operating Instructions Manual

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Operating instructions

Welding machine

Phoenix 351-551 Progress puls MM FDW

099-005325-EW501 Observe additional system documents! 05.12.2014

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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 com ponents!

•

Observe accident prevention regulations!

•

Observe all local regulations!

• Confirm with a signature where appropri ate.

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 equipm ent is restricted solely to the function of the equi pm ent. No other form of liability, regardless of type, shall be ac cepted. This exclusion of liability shall be deem ed 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, usag e and m aintenance 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 install ation, improper operation or incorrect usage and maintenance or any actions connected to this in any way.

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

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1 Contents

Contents .................................................................................................................................................. 3

2 Safety instructions ................................................................................................................................. 6

2.1 Notes on the use of these operating instructions .......................................................................... 6

2.2 Explanation of icons ....................................................................................................................... 7

2.3 General .......................................................................................................................................... 8

2.4 Transport and installation ............................................................................................................ 12

2.4.1 Lifting by crane ............................................................................................................. 13

2.4.2 Ambient conditions ....................................................................................................... 14

2.4.2.1 In operation ................................................................................................... 14

2.4.2.2 Transport and storage ................................................................................... 14

3 Intended use ......................................................................................................................................... 15

3.1 Applications .................................................................................................................................. 15

3.1.1 MIG/MAG standard welding ......................................................................................... 15

3.1.1.1 forceArc ......................................................................................................... 15

3.1.1.2 rootArc ........................................................................................................... 15

3.1.2 MIG/MAG pulse welding ............................................................................................... 15

3.1.2.1 forceArc puls ................................................................................................. 15

3.1.2.2 rootArc puls ................................................................................................... 15

3.1.3 TIG (Liftarc) welding ..................................................................................................... 15

3.1.4 MMA welding ................................................................................................................ 15

3.1.4.1 Air arc gouging .............................................................................................. 15

3.1.5 Voltage reduction device – VRD machine version ....................................................... 15

3.2 Use and operation solely with the following machi nes ................................................................ 16

3.3 Documents which also apply ....................................................................................................... 17

3.3.1 Warranty ....................................................................................................................... 17

3.3.2 Declaration of Conformity ............................................................................................. 17

3.3.3 Welding in environments with increased electrical hazards ......................................... 17

3.3.4 Service documents (spare parts and circuit diagrams) ................................................ 17

3.3.5 Calibration/Validation ................................................................................................... 17

4 Machine description – quick overview .............................................................................................. 18

4.1 Front view .................................................................................................................................... 18

4.2 Rear view ..................................................................................................................................... 20

4.3 Rear view ..................................................................................................................................... 20

5 Design and function ............................................................................................................................. 22

5.1 General ........................................................................................................................................ 22

5.2 Installation .................................................................................................................................... 23

5.3 Machine cooling ........................................................................................................................... 23

5.4 Workpiece lead, general .............................................................................................................. 23

5.5 Notes on the installation of welding current l eads ....................................................................... 24

5.6 Welding torch cooling system ...................................................................................................... 26

5.6.1 List of coolants .............................................................................................................. 26

5.6.2 Maximal hose package length ...................................................................................... 26

5.6.3 Adding coolant .............................................................................................................. 27

5.7 Mains connection ......................................................................................................................... 28

5.7.1 Mains configuration ...................................................................................................... 28

5.8 Intermediate hose package connection ....................................................................................... 29

5.9 Shielding gas supply (shielding gas cylinder for welding machine) ............................................. 30

5.9.1 Connection ................................................................................................................... 30

5.10 Adjusting the cable resistance ..................................................................................................... 32

5.11 MIG/MAG welding ........................................................................................................................ 34

5.11.1 Connection for workpiece lead ..................................................................................... 34

5.12 TIG welding .................................................................................................................................. 35

5.12.1 Welding torch connection ............................................................................................. 35

5.12.2 Connection for workpiece lead ..................................................................................... 36

5.13 MMA welding ............................................................................................................................... 37

5.13.1 Connecting the electrode holder and workpiece lead .................................................. 37

Contents

Notes on the use of these operating instructions

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5.14 Voltage reducing device (VRD) .................................................................................................... 39

5.15 Remote control ............................................................................................................................. 39

5.16 Interfaces for automation ............................................................................................................. 39

5.16.1 Automation interface ..................................................................................................... 40

5.16.2 RINT X12 robot interface .............................................................................................. 41

5.16.3 BUSINT X11 Industrial bus interface ............................................................................ 41

5.17 PC Interfaces ............................................................................................................................... 41

6 Maintenance, care and disposal ......................................................................................................... 42

6.1 General......................................................................................................................................... 42

6.2 Maintenance work, intervals ........................................................................................................ 42

6.2.1 Daily maintenance tasks ............................................................................................... 42

6.2.1.1 Visual inspection ........................................................................................... 42

6.2.1.2 Functional test ............................................................................................... 42

6.2.2 Monthly maintenance tasks .......................................................................................... 43

6.2.2.1 Visual inspection ........................................................................................... 43

6.2.2.2 Functional test ............................................................................................... 43

6.2.3 Annual test (inspection and testing during operat i on) .................................................. 43

6.3 Disposing of equipment ................................................................................................................ 44

6.3.1 Manufacturer's declaration to the end user .................................................................. 44

6.4 Meeting the requirements of RoHS .............................................................................................. 44

7 Rectifying faults.................................................................................................................................... 45

7.1 Checklist for rectifying faults ........................................................................................................ 45

7.2 Error messages (power source) ................................................................................................... 46

7.3 Resetting JOBs (welding tasks) to the factory settings ................................................................ 48

7.3.1 Resetting a single JOB ................................................................................................. 48

7.3.2 Resetting all JOBs ........................................................................................................ 49

7.4 General operating problems ........................................................................................................ 49

7.4.1 Interface for automated welding ................................................................................... 49

7.5 Vent coolant circuit ....................................................................................................................... 50

8 Technical data....................................................................................................................................... 51

8.1 Phoenix 351 FDW ........................................................................................................................ 51

8.2 Phoenix 401 FDW ........................................................................................................................ 52

8.3 Phoenix 501 FDW ........................................................................................................................ 53

8.4 Phoenix 451, 551 FDW ................................................................................................................ 54

9 Accessories .......................................................................................................................................... 55

9.1 System components ..................................................................................................................... 55

9.2 General accessories .................................................................................................................... 55

9.3 Options ......................................................................................................................................... 55

9.4 Remote control/connecting and extension cable ......................................................................... 56

9.4.1 7-pole connection ......................................................................................................... 56

9.5 Computer communication ............................................................................................................ 56

10 Appendix A ............................................................................................................................................ 57

10.1 Overview of EWM branches......................................................................................................... 57

Contents

Notes on the use of these operating instructions

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Safety instructions

Notes on the use of these operating instructions

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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 immi nent

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 i n the heading with a general warning symbol.

• The hazard is also highlighted using a symbol in t he 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 t he page.

CAUTION

Working and operating procedures which must be followed precisely to avoid dam agi ng

or destroying the product.

• The safety information includes the "CA UTION" 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 obs er ve.

• Notes include the "NOTE" keyword in the heading without a general warning symbol.

Instructions and lists detailing step-by-step act ions for given situations can be recognised via bullet points, e.g.:

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

Safety instructions

Explanation of icons

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2.2 Explanation of icons

Symbol

Description

Correct

Wrong

Press

Do not press

Turn

Switch

Switch off machine

Switch on machine

ENTER

ENTER (enter the menu)

NAVIGATION

NAVIGATION (Navigating in the menu)

EXIT

EXIT (Exit the menu)

4 s

Time display (example: wait 4s/press)

Interruption in the menu display (other setting options possible)

Tool not required/do not use

Tool required/use

Safety instructions

General

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2.3 General

DANGER

Electric shock!

Welding machines use high voltages which can result in potentially fatal electric shocks

and burns on contact. Even low voltages can cause you to get a shock and lead to accidents.

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

• 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 di scharged!

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 devi ces, telecommunication lines, power cables, signal lines and pacemakers.

• Observe the maintenance instructions - See 6 M ai ntenance, care and disposal chapter!

• Unwind welding leads completely!

• Shield devices or equipment sensitive to radi ation 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)!

WARNING

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 regulat i ons in your country.

• Inform persons in the working area that they must observe the regulations!

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 appr opriate 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!

Safe

ty instructions

General

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WARNING

Explosion risk! Apparently harmless substances in closed con tainers may generate excessive pressure

when heated.

• Move containers with inflammable or explosive l i quids away from the working area!

• Never heat explosive liquids, dusts or gases by welding or cutting!

Smoke and gases!

Smoke and gases can lead to breathing difficulties and poisoning. 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 fi eld!

• Wear suitable breathing apparatus if appropriat e!

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 suc h as matches or lighters.

• Keep appropriate fire extinguishing equipment to hand in the working area!

• Thoroughly remove any residue of flammable subst ances from the workpiece before

starting welding.

• Only continue work on welded workpieces once t hey have cooled down. Do not allow to come into contact with flammable material!

• Connect welding leads correctly!

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

• Do not couple welding machines with pole reversing switch (PWS series) or machines for

AC welding, as a minor error in operation can cause the welding voltages to be combined.

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!

Safety instructions

General

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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 accid ent prevention for the respective country.

• Setting up and operating the machine according to IEC 60974-9.

• Check at regular intervals that users are wor king i n a safety-conscious way.

• Regular checks of the machine according t o 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 (p ower sources, welding torches, electrode holders, remote controls, spare parts and repla cement 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 c onnection 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 f ram es unless they are insulated!

• Always put welding torches and electrode hold ers 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, connect ion restrictions or requirements relating to the maximum possible line impedance or the necessa ry minimum supply capacity at the interface with the public network (Point of Common Coupling, P CC) 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 consultati on with the mains network operator, to ensure that

the machine can be connected.

Safety instructions

General

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CAUTION

EMC Machine Classification

In accordance with IEC 60974-

10, welding machines are grouped in two electromagnetic

compatibility classes - See 8 Techni cal data chapter: Class A machines are not intended for use in resident i al areas whe

re 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-volta ge publ ic 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 elec tromagnetic compatibility in the surrounding area, the user must consider the fol l owing: (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 i s 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

Safety instructions

Transport and installation

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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 provi ded for them and secure with fixing devices.

• Avoid heating the shielding gas cylinder!

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 EN 60974-A2).

• Set up and transport the machine on level, solid ground!

• Secure add-on parts using suitable equipment!

• Replace damaged wheels and their fixing elements!

• Fix external wire feed units during transport (avoi d uncontrolled rotation)!

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!

Safety instru

ctions

Transport and installation

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2.4.1 Lifting by crane

WARNING

Risk of injury during lifting by crane

When lifting the machine by crane,

persons may be severely injured by falling machines

or mount-on components.

• Simultaneous lifting of system components such as power source, wire feeder or cooling unit without suitable crane components is not allowed. Each system component has to be lifted separately!

• Remove any supply leads and accessories before l ifting by crane

(e.g.

hose package

, wire spool, shielding gas cylinder, toolbox, wire feeder,

remote control,etc.)!)

• Properly close and lock all casing covers and prot ective caps

before

lifting by crane!

• Use the correct number of hoisting equipment of the right size in the correct position! Observe craning principle (s ee figure)!

• For machines with lifting eyes: always lift all l ifting eyes simultaneously

• When using retrofitted craning frames etc.: always use at least two lifting points positioned as far apart as possible – observe option description.

• Avoid any jerky movements!

• Ensure that the load is

distributed evenly! • Use chain hoists and

chain slings of the same length only!

• Stay outside the danger zone underneath the machine!

• Observe the regulations regarding occupat ional safety and accident

prevention for the respective country.

Craning principle

Risk of injury due to unsuitable lifting eye! In case of improper use of lifting eyes or the use of unsuitable lifting eyes, persons can

be seriously damaged by falling equipment or add-on components!

• The lifting eye must be completely screwed in!

• The lifting eye must be positioned flat onto and in f ul l contact with the supporting surfaces!

• Check that the lifting eyes are securely fastened before use and check for any damage

(corrosion, deformation)!

• Do not use or screw in damaged lifting eyes!

• Avoid lateral loading of the lifting eyes!

Safety instructions

Transport and installation

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2.4.2 Ambient conditions

CAUTION

Installation site! The machine must not be operated in the open air and must only be set up and

operated on a suitable, stable and level base!

• The operator must ensure that the ground is non-slip and l evel, 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 gri nding 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!

2.4.2.1 In operation Temperature range of the ambient air:

• -25 °C to +40 °C

Relative air humidity:

• Up to 50% at 40 °C

• Up to 90% at 20 °C

2.4.2.2 Transport and storage Storage in an enclosed space, temperature range of the ambient air:

• -30 °C to +70 °C

Relative air humidity

• Up to 90% at 20 °C

Intended use

Applications

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3 Intended use

WARNING

Hazards due to improper usage!

Hazards may arise for persons, animals and materi al 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 prope r usage and by trained or expert staff!

• Do not modify or convert the equipment improperly!

3.1 Applications

3.1.1 MIG/MAG standard welding

Metal arc welding using a wire electrode whereby ga s f rom an external source surrounds the arc and the molten pool to protect them from the atmosphere.

3.1.1.1 forceArc

Heat-reduced, directionally stable and powerful a rc with deep penetration for the higher performance range. Non-alloyed, low-alloy and high-alloy steel s and high-tensile fine-grained steels

3.1.1.2 rootArc

Short arc with perfect weld modelling capabilities for effortless gap bridging and positional welding

3.1.2 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.

3.1.2.1 forceArc puls

Effective addition to the forceArc arc, perfect f or welding final passes in all performance classes and al l positions.

3.1.2.2 rootArc puls

The perfect enhancement for focused heat input for the higher performance range

3.1.3 TIG (Liftarc) welding

TIG welding process with arc ignition by means of workpiece contact.

3.1.4 MMA welding

Manual arc welding or, for short, MMA welding. It i s characterised by the fact that the arc burns between a melting electrode and the molten pool. There is no ex ternal protection; any protection against the atmosphere comes from the electrode.

3.1.4.1 Air arc gouging

During air arc gouging, bad welding seams are heat ed with a carbon electrode and then removed with compressed air. Special electrode holders an d carbon electrodes are required for air arc gouging.

3.1.5 Voltage reduction device – VRD machine version

To increase safety, particularly in hazard ous environments (like shipbuilding, pipe construction or mining), the machine is equipped with the VRD (Voltage-reducing device) .

The VRD signal light is illuminated, when the voltage reducing device is operating without fault and the output voltage is reduced to a value specified in t he relevant standard (see technical data).

Intended use

Use and operation solely with the following machi nes

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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!

Phoenix Progress

351-451

551

351-551 D

351-551 2DV

miniDrive

drive 200C



  

drive 300C



  

drive 4



  

drive 4 HS







 

drive 4L



  

drive 4L RE



  

drive 4D



  

drive 4X



  

drive 4X LP



  

Intended use

Documents which also apply

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3.3 Documents which also apply

3.3.1 Warranty

NOTE

For more information refer to the "Warranty registration" brochure supplied and our

information regarding warranty, maintenance and testing at www.ewm-group.com!

3.3.2 Declaration of Conf or m ity

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 repetiti on test and / or non-permitted

conversion work not specifically authorised by t he m anufacturer. 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 h azard.

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 aut horised 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 admissi ble tolerances. Recommended calibration interval: 12 months

Machine description

– quick overview

Front vi

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4 Machine description – quick overview

4.1 Front view

Figure 4-1

Machine description – quick overview

Front view

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Item

Symbol

Description 0

Lifting lug

2 VRD

Voltage reduction device (VRD)

The VRD signal light is illuminated, when the voltage redu ct ion device is operating without fault and the output voltage is reduced to a value specified in the relevant standard- See 8 Technical data chapter. The voltage r eduction device is only active on

VRD machine versions.

Ready for operation signal light

Signal light on when the machine is switched on and ready for operation

Main switch, machine on/off

Carrying handle

6 Cooling air inlet

Wheels, guide castors

Coolant tank

Coolant tank cap

Automatic cut-out of coolant pump key button

press to reset a triggered fuse

Connection socket, “-” welding current

Connection socket, “+” welding current

Machine description

– quick overview

Rear view

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4.2 Rear view

NOTE

The maximum possible machine configuration is given in the text description. If necessary, the optional connection may need to be retrofitted- See 9 Accessories

chapter.

4.3 Rear view

Figure 4-2

Machine description – quick overview

Rear view

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Item

Symbol

Description 0

7-pole connection socket (digital)

For connecting digital accessory components

7-pole connection socket (digital)

Wire feed unit connection

PC interface, serial (D-Sub connection socket, 9-pole)

19-pole mechanised welding interface (analogue)

- See 7.4.1 Interface for automated welding chapter

Connection socket, “+” 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

Quick connect coupling (red)

coolant return

Quick connect coupling (blue)

coolant supply

Wheels, fixed castors

Bracket for shielding gas cylinder

Cooling air outlet

Mains connection cable

- See 5.7 Mains connection chapter

Securing elements for shielding gas cylinder (strap/chain)

Key button, Automatic cutout

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

Intermediate hose package strain relief

Design and function

General

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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 page s 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 hol der, 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 cur

rent 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 sho ck and lead to accidents.

• Wear dry and undamaged protective clothing (s hoes wit h rubber soles/ weld er' 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 i nsulated 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 of injury due to moving parts!

The wire feeders are equipped with moving parts, which can trap hands, hair, cl othing or tools and thus injure persons!

• Do not reach into rotating or moving parts or drive com ponents!

• Keep casing covers or protective caps closed during operation!

Risk of injury due to welding wire escaping in an unpredictable manner! Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may

escape in an uncontrolled manner and injure persons!

• Before mains connection, set up the complete wire guide system from the wire spool to the welding torch!

• Remove the pressure rollers from the wire feede r i f no welding torch is fitted!

• Check wire guide at regular intervals!

• Keep all casing covers or protective caps closed during operation!

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.

Design and function

Installation

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CAUTION

Damage due to incorrect connection!

Accessory components and the po wer 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 automati call y after the power source is switched on.

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 t here i s 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

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 l evel, and provide sufficient lighting for the place of work.

• Safe operation of the machine must be guaranteed at al l times.

5.3 Machine cooling

To obtain an optimal duty cycle from the power com ponents, 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 retu rn lead for the welding current!

• Take care to ensure faultless power connections!

Design and function

Notes on the installation of welding current l eads

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5.5 Notes on the installation of welding current leads

NOTE

Incorrectly installed welding current leads can cause faults in the arc (flickering).

Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel.

Lay the workpiece lead and hose package of power sources with HF igniter (TIG) for as

long as possible in parallel with a distance of 20 cm to avoid HF sparkover.

Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences.

Figure 5-1

Design an

d function

Notes on the installation of welding current l eads

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NOTE

Use an individual welding lead to the workpiece for each welding machine!

Figure 5-2

NOTE

Fully unroll welding current leads, torch hose packages and intermediate hose

packages. Avoid loops!

Always keep leads as short as possible!

Lay any excess cable lengths in meanders.

Figure 5-3

Design and function

Welding torch cooling system

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5.6 Welding torch cooling system

CAUTION

Coolant mixtures!

Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void!

• Only use the coolant described in this manual (ov erv iew of coolants).

• Do not mix different coolants.

• When changing the coolant, the entire volume of li quid must be changed.

Insufficient frost protection in the welding torch coolant! Depending on the ambient conditions, different liquids are used for cooling the welding torch - See 5.6.1 List of coolants chapter. Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure

that the frost protection is adequate to prevent damage to the machine or the accessory

components.

• The coolant must be checked for adequate f rost protection with the TYP 1 frost protection tester .

• Replace coolant as necessary if frost protection is inadequate!

NOTE

The disposal of coolant must be carried out according to official regulations and observing the relevant safety data sheets (Germ an waste code number: 70104)!

• Coolant must not be disposed of together with ho usehold waste.

• Coolant must not be discharged into the sewera ge system.

• Recommended cleaning agent: water, if necessary wit h cleaning agent added.

5.6.1 List of coolants

The following coolants may be used - See 9 Accessories chapter:

Coolant

Temperature range

KF 23E (Standard)

-10 °C to +40 °C

KF 37E

-20 °C to +10 °C

5.6.2 Maximal hose package l engt h

Pump 3.5 bar

Pump 4.5 bar

Machines with or without separate wire feeder

30 m

60 m

Compact machines with additional intermediate

drive (example. miniDrive)

20 m 30 m

Machines with separate wire feeder and additional

intermediate drive (example: miniDrive)

20 m 60 m

Data as a rule refer to the entire hose package length including welding torch. The pump output is sho wn on the type plate (parameter: Pmax).

Pump 3.5 bar: Pmax = 0.35 MPa (3.5 bar) Pump 4.5 bar: Pmax = 0.45 MPa (4.5 bar)

Design and function

Welding torch cooling system

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5.6.3 Adding coolant

The unit is supplied ex works with a minimum level of coolant.

Figure 5-4

Item

Symbol

Description 0

Coolant tank cap

Coolant filter sieve

Coolant tank

"Min" mark

Minimum coolant level

• Unscrew and remove the coolant tank sealing cover.

• Check filter sieve insert for dirt, clean if necessary and reinsert into position.

• Top up coolant to the filter sieve insert, close sealing cover again.

NOTE

After the initial filling, wait for at least one minute when the machine is switched on so

that the hose package is filled with coolant completely and without bubbles. With frequent changes of torch and during the initial filling process, the cooling unit

tank should be topped up as necessary.

The level of coolant must never fall below the “min” mark. If there is less coolant in the coolant tank than the minimum required you may need to

vent the coolant circuit. In this case the welding machine will automatically shut down

the coolant pump and signal an error, "- See 7 Rectifyin g fau lts chapter".

Design and function

Mains connection

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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 i s 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 5-5

Legend

Item

Designation

Colour code

Outer conductor 1

brown

Outer conductor 2

black

Outer conductor 3

grey

Neutral conductor

blue

Protective conductor

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!

• - See 8 Technical data chapter!

• Insert mains plug of the switched-off machi ne i nto the appropriate socket.

Design and function

Intermediate hose package connection

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5.8 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 5-6

Item

Symbol

Description 0

Wire feed unit

Intermediate hose package

Intermediate hose package strain relief

7-pole connection socket (digital)

Wire feed unit connection

Connection socket, “+” welding current

• Standard MIG/MAG welding (intermediate hose package)

Connection socket, “-” welding current

• MIG/MAG cored wire welding:

Welding current to wire feed/torch

Quick connect coupling (red)

coolant return

Quick connect coupling (blue)

coolant supply

Design and function

Shielding gas supply (shielding gas cylinder for welding machine)

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• Insert the end of the hose package through t he st rain relief of the hose package and lock by turning to the right.

• Insert the plug on the welding current lead into the welding current connection socket "+" and l ock.

• Insert cable plug on the control lead into t he 7-pole connection socket and secure with crown nut (the

plug can only be inserted into the connection socket in one position).

• Lock connecting nipples of the cooling water tubes into the corresponding quick connect coup l i ngs: Return line red to quick connect coupling, red ( coolant return) and supply line blue to quick connect coupling, blue (coolant supply).

5.9 Shielding gas supply (shielding gas cylinder for welding machine)

5.9.1 Connection

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!

• When using shielding gas cylinders smaller than 50 l itres, the ON

HOLDER GAS BOTTLE option must be retrofitted

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 addi tion, 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.

Design and function

Shielding gas supply (shielding gas cylinder for welding machine)

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Figure 5-7

Item

Symbol

Description 0

Pressure regulator

Shielding gas cylinder

Output side of the pressure regulator

Cylinder valve

• 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.

• Tighten gas hose on pressure regulator to be gas tight.

Design and function

Adjusting the ca

ble resistance

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5.10 Adjusting the cable resistance

The resistance value of cables can either be set directly or it can be matched using the power source. The factory setting of the power sources is 8 m-ohm. Thi s v al ue correponds to a 5 m earth cable, a 1.5 m intermediate hose package and a 3 m water-cooled welding torch. With other hose package lengths, it is necessary to carry out a +/- voltage correction to optimise welding properties. The voltage correction value can be set close to zero by means of re-adjusting t he cable resistance. It is recommended to match the electric cable resistance after replacing acce ss ories such as torches or intermediate hose packages.

In case a second wire feeder is used the (rL2) parameter has to be adjusted. For all other configurations it is sufficient to match the (rL1) parameter.

50mm

Figure 5-8

Design and function

Adjusting the cable resistance

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1 Preparation

• Switch off the welding machine.

• Unscrew the gas nozzle from the welding torch.

• Trim the welding wire, so that it is flush with t he contact tip.

• Retract the welding wire a little (approx. 50 mm ) on the wire feeder. There should now be no more

welding wire in the contact tip.

2 Configuration

• Press the "Welding parameter" push-butt on whi le simultaneously switching on the welding machine. Release the "Welding parameter" push-button (" Choke effect" push-button with drive 4X LP).

• The required parameter can now be selected using the 'Welding parameter setting' rotary knob. Parameter rL1 must be adjusted for all machine combinations. In case of welding systems with a second power cir cuit – if two wire feeders are to be operated from a single power source, for example – a second adjustment with parameter rL2 must be performed.

3 Adjustment/measurement

• Applying slight pressure, put the welding t orch in place with the contact tip on a clean, purged location on the workpiece and then press the torch trigger for approx. 2 seconds. A short-circuit current will

flow briefly, which is used to determine and display the cable resistance. The value can be between 0 mΩ and 40 mΩ. The new value is immediately saved without requiring further confirmat ion. If no value is shown in the right-hand display, then measurement failed. The measurement must be repeated.

4 Restoring welding standby mode

• Switch off the welding machine.

• Screw the gas nozzle onto the welding torch.

• Switch on the welding machine

• Insert the welding wire.

Design and function

MIG/MAG welding

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5.11 MIG/MAG welding

5.11.1 Connection for workpiece lead

NOTE

Note the polarity of the welding current! Some wire electrodes (e.g. self-

shielding cored wire) are welded using negative polarity.

In this case, the welding current lead should be connected to the "-" welding current socket, and the workpiece lead should be connected to the "+" welding current socket.

• Observe the information from the electrode manufacturer!

Figure 5-9

Item

Symbol

Description 0

Connection socket, "+" welding current

• MIG/MAG cored wire welding:

Workpiece connection

"-" welding current connection socket

• MIG/MAG welding:

Workpiece connection

Workpiece

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

Design and function

TIG welding

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5.12 TIG welding

5.12.1 Welding torch connection

NOTE

TIG welding torches to be connected to a Euro torch connector are available in two versions:

• TIG combi welding torches are connected to the Euro torch connector of the wire feeder and to the (-) welding current plug of the power sou rce.

• TIG welding torches of the EZA version are connected t o the Euro torch connector of the wire feeder only. To do so, the welding current l ead of the intermediate hose package must

be connected to the (-) welding current connection at the rear of the unit!

Figure 5-10

Item

Symbol

Description 0

Welding torch connection (Euro or Dinse torch connector)

Welding current, shielding gas and torch trigge r integrated

Quick connect coupling (red)

coolant return

Quick connect coupling (blue)

coolant supply

"-" welding current connection socket

• TIG welding:

Welding current connection for welding torch

Welding torch hose package

Welding torch

sign and function

TIG welding

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• Insert the central plug for the welding t orch into the central connector and screw toget her with crown nut.

• Insert the welding current plug of the co m bi welding torch into the (-) welding current connection socket and lock into place by turning to the right (only in case of a separate welding current connection).

If fitted:

• Lock connecting nipples of the cooling water tubes into the corresponding quick connect coup l ings: Return line red to quick connect coupling, red (coolant return) and supply line blue to quick connect coupling, blue (coolant supply).

5.12.2 Connection for workpiece lead

Figure 5-11

Item

Symbol

Description 0

Connection socket, "+" welding current

• TIG welding:

Workpiece connection

Workpiece

• Insert the cable plug on the work piece lead int o the "+" welding current connection socket and lock by turning to the right.

Design and function

MMA welding

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5.13 MMA welding

CAUTION

Risk of being crushed or burnt. When replacing spent or new stick electrodes

• Switch off machine at the main switch

• Wear appropriate safety gloves

• Use insulated tongs to remove spent stick elect rodes or to move welded workpieces and

• Always put the electrode holder down on an insulated surface.

5.13.1 Connecting the electrode holder and workpiece lead

NOTE

Polarity depends on the instructions from the electrode manufacturer given on the

electrode packaging.

Figure 5-12

Item

Symbol

Description 0

Connection socket, “+” welding current

Connection socket, “-” welding current

Workpiece

Electrode holder

Design and functio

MMA welding

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• 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.

Design and function

Voltage reducing device (VRD)

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5.14 Voltage reducing device (VRD)

To increase safety, particularly in hazard ous environments (like shipbuilding, pipe constru ct i on or mining), the machine is equipped with the VRD (Voltage-reducing device) voltage reduction device.

The VRD signal light is illuminated, when the voltage redu ct ion device is operating without fault and the output voltage is reduced to a value specified in t he relevant standard (see technical data). The v ol tage reduction device is only active on VRD machine versions.

The voltage reducing device is a requirement in some countries and in many internal company safety guidelines for power sources.

5.15 Remote control

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 (p ower sources, welding torches, electrode holders, remote controls, spare parts and repla cement parts, etc.) from our range of products!

• Only insert and lock accessory components into the relevant connection socket when the

machine is switched off.

NOTE

The remote controls are operated on the 7-pole remote control connection socket (digital).

Please note the relevant documentation of the accessory components.

5.16 Interfaces for automation

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)!

CAUTION

Damage due to incorrect connection! Accessory components and the po wer 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 automati call y after the power source is switched on.

Design and function

Interfaces for automation

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5.16.1 Automation interface

NOTE

These accessory components can be retrofitted as an option .

Input / output

Description

Diagram A

Output

PE Connection for cable shielding

Output (open

collector)

IGRO Current flows signal I>0 (maximum load 20

mA / 15 V)

0 V = welding current flows

+ R

Input 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

Output

0 V Reference potential

G/P

Output

I>0 Power relay contact, galvanically isolated

(max. +/-15 V / 100 mA)

Output Uist Welding voltage, measured against pin F,

0-10 V (0 V = 0 V; 10 V = 100 V)

Input

Str/Stp Start = 15 V / Stop = 0 V 1)

Output

+15 V Voltage supply (max. 75 mA)

Output

-15 V Voltage supply (max. 25 mA)

Output

0 V Reference potential

Output Iist Welding current, measured on pin F;

0-10 V (0 V = 0 A, 10 V = 1000 A)

) 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).

Design and function

PC Interfaces

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5.16.2 RINT X12 robot interface

The standard digital interface for mechanised applications  (optional, retrofitting on the machine or external fitting by the customer)

Functions and signals:

• Digital inputs: start/stop, operating modes, JOB and program selection, inching, gas test

• Analogue inputs: control voltages, e.g. for welding performance, welding current, etc.

• Relay outputs: process signal, ready for welding, system composite fault, etc.

5.16.3 BUSINT X11 Industrial bus interface

The solution for easy integration with automated p roduction with e.g.

• Profinet/Profibus

• EnthernetIP/DeviceNet

• EtherCAT

etc.

5.17 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 (p ower sources, welding torches, electrode holders, remote controls, spare parts and repla cement 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 soft ware, interface, connection leads).

Q-DOC 9000 welding data documentation software

(Accessories: set consisti ng of software, interface, connection lead s) The ideal tool for welding data documentation of, for example:

welding voltage and current, wire speed and motor c urrent.

WELDQAS welding data monitoring and documentation system

Network-compatible welding data monitoring and documentation system f or di gi tal machines

Maintenance, care and disposal

General

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6 Maintenance, care and disposal

DANGER

Do not carry out any unauthorised repairs or modifications!

To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference.

• Appoint only skilled persons for repair work (trained service personnel)!

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 di scharged!

Repair and maintenance work may only be perfo rmed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all servic e m atters, always consult the dealer who supplied t he machine. Return deliveries of defective equipment subject to warranty may only be made through y our 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.

6.1 General

When used in the specified environmental condi tions and under normal operating conditions, this machine is largely maintenance-free and require s 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 che cking as described below, depending on the pollution level of the environment and the length of ti m e the unit is in use.

6.2 Maintenance work, intervals

6.2.1 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).

6.2.1.1 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

6.2.1.2 Functional test

• Check correct mounting of the wire spool.

• Welding current cables (check that the y are fitted correctly and secured)

• Gas cylinder securing elements

• Operating, message, safety and adju st m ent devices (Functional test)

Maintenance, care and disposal

Maintenance work, intervals

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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 i m purities

6.2.2.2 Functional test

• Selector switches, command devices, em ergency stop devices, voltage reducing devices, m essage and control lamps

• Check that the wire guide elements (inlet ni pple, wire guide tube) are fitted securely.

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 experien ce, 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 more information refer to the "Warranty registration" brochure supplied and our

information regarding warranty, maintenance and testing at www.ewm-group.com!

A periodic test according to IEC 60974-4 "Periodic in spection 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.

Maintenance, care and disposal

Disposing of equipment

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6.3 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!

6.3.1 Manufacturer's declaration to the end user

• According to European provisions (guideli ne 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 recycli ng in the waste separation systems provided for this purpose.

• According to German law (law governing the di st ri bution, taking back and environmentally cor rect disposal of electric and electronic equipment (E l ektroG) from 16.03.2005), used machines ar e to be placed in a collection system separate from unso rted municipal waste. The public waste management utilities (communities) have created collecti on points at which used equipment from private households can be disposed of free of charge.

• Information about giving back used equipm ent or about collections can be obtained from the respective municipal administration office.

• EWM participates in an approved waste di sposal 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 t hroughout Europe via EWM sales partners.

6.4 Meeting the requirements of RoHS

We, EWM AG Mündersbach, hereby confirm that al l products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU).

Rectifying faults

Checklist for rectifying faults

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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 authorise d 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

 Vent coolant circuit

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)

 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

Rectifying faults

Error messages (power source)

099-005325-EW501

05.12.2014

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 servi ce staff as necessary.

• If multiple errors occur, these are displa yed in succession.

Error

EWM Phoenix 351-551 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual