EWM OW ASM 2.DV PHOENIX PROGRESS K User manual

EWM
HIGHTEC WELDING GmbH
Dr. Günter-Henle-Straße 8 • D-56271 Mündersbach
Fon [phone] • Fax [phone]
www.ewm.de • [e-mail]
GB
Supplementary Sheets to the Standard
Operating Instructions
Factory-fit option
OW ASM 2.DV PHOENIX PROGRESS K
OW ASM 2.DV PHOENIX PROGRESS D
N. B. These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machines may only be operated by personnel who are familiar with the appropriate safety
regulations.
The machines bear the conformity mark and thus comply with the
• EC Low Voltage Directive (2006/95/ EG)
• EC EMC Directive (2004/108/ EG)
©The content of the operating instructions does not constitute grounds for any claims on the part
of the buyer.
The copyright to these operating instructions remains with the manufacturer.
Reprinting, including extracts, only with written approval.
© 2009 Subject to alteration. Item No.:099-OW0008-EWM01 Revised: 14.01.2009

Contents
For your safety
Item No.:099-OW0008-EWM01 3
1Contents
1Contents..................................................................................................................................................3
2Safety instructions.................................................................................................................................4
2.1 For your safety...............................................................................................................................4
2.2 Proper usage .................................................................................................................................4
3General....................................................................................................................................................5
3.1 Meaning of the type designation....................................................................................................5
3.2 Machine variants............................................................................................................................6
3.2.1 OW ASM 2. DV PHOENIX PROGRESS K ....................................................................6
3.2.2 OW ASM 2. DV PHOENIX PROGRESS D....................................................................6
4Technical data ........................................................................................................................................7
5Commissioning ......................................................................................................................................7
5.1 General..........................................................................................................................................7
5.2 Connecting the intermediate tube package to the power source..................................................8
5.2.1 OW ASM 2. DV PHOENIX PROGRESS K ....................................................................8
5.2.2 OW ASM 2. DV PHOENIX PROGRESS D..................................................................10
5.2.2.1 Setting up the wire feed units........................................................................10
6Functional characteristics...................................................................................................................12
6.1 Basic settings for operation with two wire feeds..........................................................................12
6.2 Changing over between wire feeds .............................................................................................13

Safety instructions
For your safety
4 Item No.:099-OW0008-EWM01
2Safety instructions
2.1 For your safety
CAUTION
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
DANGER
Validity of this document!
This document is only valid in combination with the operating instructions for the power
source being used (welding machine)!
• Read the operating instructions, in particular the safety instructions for the power source
(welding machine)!
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
Obligations of the operator!
In the European Economic Area (EEA), the relevant national version of the basic
guidelines must be followed and observed!
• National version of the basic guidelines (89/391/EEC) as well as the relevant individual
guidelines.
• In particular the Directive (89/655/EEC) on the minimum regulations for safety and health
protection when staff members are using equipment during work.
• The accident prevention regulations of the relevant country (e.g. in Germany, BGV D 1).
• Check at regular intervals that users are working in a safety-conscious way!
2.2 Proper usage
This machine has been manufactured according to the latest developments in technology and current
regulations and standards. It must only be operated in line with the instructions on correct usage.
CAUTION
Hazards due to improper usage!
Hazards may arise for persons, animals and material objects if the equipment is not used
correctly. No liability is accepted for any damages arising from improper usage!
• The equipment must only be used in line with proper usage and by trained or expert staff!
• Do not modify or convert the equipment improperly!

General
Meaning of the type designation
Item No.:099-OW0008-EWM01 5
3General
CAUTION
These supplementary sheets are valid in addition to the standard document!
These supplementary sheets are only valid in combination with the relevant standard
operating instructions and expand on or replace a section in the corresponding
standard descriptions.
Additional connection sockets have been fitted on the rear of the unit to operate a second wire feed unit.
OW ASM 2. DV PHOENIX PROGRESS K also includes
• OW 2 BOTTLE
− wide trolly with a bracket for two shielding gas cylinders.
• OW REINFORCED PUMP TP
− reinforced welding torch cooling.
OW ASM 2.DV PHOENIX PROGRESS D also includes
• OW 2 DRIVE 4L
− wide trolly with a bracket for two shielding gas cylinders.
− support for setting up two wire feeds on the welding machine.
• OW REINFORCED PUMP TP
− reinforced welding torch cooling.
3.1 Meaning of the type designation
OW ASM 2. DV PHOENIX PROGRESS K < > D
|||||< > |
||||Compact < > Decompact
|||Machine series
||2. Wire feed unit
|Connection option
Factory-fit option

General
Machine variants
6 Item No.:099-OW0008-EWM01
3.2 Machine variants
3.2.1 OW ASM 2. DV PHOENIX PROGRESS K
Figure 3-1
3.2.2 OW ASM 2. DV PHOENIX PROGRESS D
Figure 3-2

Technical data
General
Item No.:099-OW0008-EWM01 7
4Technical data
NOTE
The weights given should be added to the weights for the relevant machine given in the
standard operating instructions!
Only the modified data is given.
Type 301, 351, 421 K 301, 351, 421, 521 D
Cooling output at 2 l/min¹1500 W
Max. flow rate¹20 l/min
Max. coolant output pressure¹4.5 bar
Dimensions L x W x H in mm 1100 x 680 x 950
Weight +18 kg +24 kg
(¹) Machines with integrated welding torch cooling
5Commissioning
5.1 General
DANGER
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
• Follow safety instructions on the opening pages of the operating instructions.
• Commissioning may only be carried out by persons who have the relevant expertise of
working with arc welding machines!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
CAUTION
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of
products!

Commissioning
Connecting the intermediate tube package to the power source
8 Item No.:099-OW0008-EWM01
5.2 Connecting the intermediate tube package to the power source
NOTE
Observe the operating instructions for the wire feed unit and for the power source!
The steps
• connect the intermediate tube package to the wire feed unit,
• connect the welding torch,
• connect the wire supply,
• shielding gas connection
and other steps are described in the operating instructions for the wire feed unit and the power
source.
5.2.1 OW ASM 2. DV PHOENIX PROGRESS K
Figure 5-1

Commissioning
Connecting the intermediate tube package to the power source
Item No.:099-OW0008-EWM01 9
Item Symbol Description 0
1 Intermediate tube package strain relief
2
digital
7-pole connection socket (digital)
Wire feed unit connection
Connection socket for "+" welding current
3 Welding current connection for wire feed unit
4
Rapid-action closure coupling, red (coolant return)
5 Rapid-action closure coupling, blue (coolant supply)
• Insert the end of the tube package through the strain relief intermediate tube package and lock by
turning to the right.
• Insert cable plug on the control lead into the 7-pole connection socket and secure with crown nut (the
plug can only be inserted into the connection socket in one position).
• Insert the plug on the welding current lead into the welding current connection socket "+" and lock.
• Lock connecting nipples of the cooling water tubes into the corresponding rapid-action closure
couplings:
Return line red to rapid-action closure coupling, red (coolant return) and
supply line blue to rapid-action closure coupling, blue (coolant supply).

Commissioning
Connecting the intermediate tube package to the power source
10 Item No.:099-OW0008-EWM01
5.2.2 OW ASM 2. DV PHOENIX PROGRESS D
5.2.2.1 Setting up the wire feed units
NOTE
Included in the version for decompact units!
(OW ASM 2.DV PHOENIX PROGRESS D)
A B
Figure 5-2
Item Symbol Description 0
1 Internal unit feet
2 Recesses for unit feet
3 Support
for two wire feed units
4 External casing frame
5 Press arbor bracket
CAUTION
Risk of falling!
If the wire feeds are not set up correctly on the support, they may fall, become damaged
and as a consequence cause injury to persons.
• Always position internal wire feed feet in the relevant recesses!
• External casing frame of the wire feeds must be positioned level on the support! (see figure,
part "B")
• Check that the wire feeds are properly secured before any transport and every start-up
operation!
• Observe the safety instructions on transport and setup, as well as on lifting by crane, in the
operating instructions for the power source, or for the wire feed!
• Do not exert any tractive force on the torch tube package! If there is any possibility that
tractive forces may be unavoidable, the wire feeds must be removed from their support!
• The press arbor bracket must not be used (even with a single wire feed)!

Commissioning
Connecting the intermediate tube package to the power source
Item No.:099-OW0008-EWM01 11
Figure 5-3
Item Symbol Description 0
1 Intermediate tube package strain relief
2
digital
7-pole connection socket (digital)
Wire feed unit connection
Connection socket for "+" welding current
3 Welding current connection for wire feed unit
4
Rapid-action closure coupling, red (coolant return)
5 Rapid-action closure coupling, blue (coolant supply)
• Insert the end of the tube package through the strain relief intermediate tube package and lock by
turning to the right.
• Insert cable plug on the control lead into the 7-pole connection socket and secure with crown nut (the
plug can only be inserted into the connection socket in one position).
• Insert the plug on the welding current lead into the welding current connection socket "+" and lock.
• Lock connecting nipples of the cooling water tubes into the corresponding rapid-action closure
couplings:
Return line red to rapid-action closure coupling, red (coolant return) and
supply line blue to rapid-action closure coupling, blue (coolant supply).

Functional characteristics
Basic settings for operation with two wire feeds
12 Item No.:099-OW0008-EWM01
6Functional characteristics
6.1 Basic settings for operation with two wire feeds
NOTE
Before operating for the first time, the wire feed controls must be configured for
operation with a second unit.
• One wire feed needs to be set up as the master, and the second as a slave.
• Wire feed units with a key switch (optional) must be configured as the master.
The special parameter P10 is located in the not directly accessible menu levels on the wire feed or
welding machine control.
It determines the settings for single or dual operation of wire feeds.
P10 Meaning
0 Single operation (no second wire feed connected)
1 Dual operation as the master
2 Dual operation as the slave
The following settings should be carried out in sequence on both wire feeds (with compact units, on the
welding machine and wire feed), or checked:
• open the special parameters menu on the machine control,
• set special parameter P10 on a wire feed (or welding machine) to "Master" and
• set special parameter P10 on the other wire feed to "Slave".
The "Master" or "Slave" setting does not mean a difference in function. The unit configured as the master
is active after switching on. (Tapping the torch trigger on the inactive unit will change over units.)
Displays
Operating
element Action Result
Left Right
01
Switch off the welding machine -
HOLD
AMP
Keep the key button pressed -
01
Switch on welding machine -
HOLD
AMP
Release the key button
m/min
Parameter selection (P10)
Parameter setting (P10)
1 = Master
2 = Slave
1 x Save the special parameters
01 01
Switch off the welding machine and restart in
order to put the changes into effect. -

Functional characteristics
Changing over between wire feeds
Item No.:099-OW0008-EWM01 13
NOTE
Please note!
• The system is not designed for simultaneous welding.
• Do not connect any further accessories to the 7-pole connection socket.
• Set the wire feed control to single operation if no second wire feed is connected.
6.2 Changing over between wire feeds
On the welding torch of the inactive wire feed
• Tap torch trigger (press briefly)
Changeover is only carried out if no welding current is flowing!
NOTE
• Keep the conversion instructions with the machine documentation!
• When ordering spare parts, ensure that the item number and serial number of the
machine are quoted!