EWM Phoenix 351 Expert 2.0 puls MM FDW User manual

Operating instructions
EN
Welding machine
Phoenix 351 Expert 2.0 puls MM FDW
Phoenix 401 Expert 2.0 puls MM FDW
Phoenix 451 Expert 2.0 puls MM FDW
Phoenix 551 Expert 2.0 puls MM FDW
099-005329-EW501 Observe additional system documents! 13.06.2016
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the site of operation.
• Safety and warning labels at the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to the state of the art and any regulations and
standards applicable. It may be operated, serviced and repaired by trained personnel only.
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 [phone].
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of
liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Str. 8
D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change, errors excepted.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents.................................................................................................................................................. 3
2Safety instructions.................................................................................................................................6
2.1Notes on the use of these operating instructions ..........................................................................6
2.2Complete documentation............................................................................................................... 7
2.3Explanation of icons.......................................................................................................................8
2.4General ..........................................................................................................................................9
2.5Transport and installation ............................................................................................................13
2.5.1Lifting by crane .............................................................................................................14
2.5.2Ambient conditions .......................................................................................................15
2.5.2.1In operation ...................................................................................................15
2.5.2.2Transport and storage...................................................................................15
3Intended use .........................................................................................................................................16
3.1Use and operation solely with the following machines ................................................................16
3.2Applications.................................................................................................................................. 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
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Welding torch cooling system ...................................................................................................... 24
5.5.1List of coolants.............................................................................................................. 24
5.5.2Maximal hose package length...................................................................................... 24
5.5.3Adding coolant.............................................................................................................. 25
5.6Mains connection ......................................................................................................................... 26
5.6.1Mains configuration ......................................................................................................26
5.7Notes on the installation of welding current leads ....................................................................... 27
5.8Intermediate hose package connection ....................................................................................... 29
5.9Shielding gas supply (shielding gas cylinder for welding machine)............................................. 30
5.9.1Connection ...................................................................................................................31
5.9.2Setting the shielding gas volume (gas test)/rinse hose package .................................32
5.10MIG/MAG welding........................................................................................................................33
5.10.1Connection for workpiece lead ..................................................................................... 33
5.10.2Welding task selection..................................................................................................33
5.11TIG welding.................................................................................................................................. 34
5.11.1Welding torch connection ............................................................................................. 34
5.11.2Connection for workpiece lead ..................................................................................... 35
5.11.3Welding task selection..................................................................................................35
5.12MMA welding ............................................................................................................................... 36
5.12.1Connecting the electrode holder and workpiece lead ..................................................36
5.12.2Welding task selection..................................................................................................37
5.13Remote control............................................................................................................................. 37
5.14Interfaces for automation .............................................................................................................38
5.14.1Automation interface ....................................................................................................38
5.14.2RINT X12 robot interface.............................................................................................. 39
5.14.3BUSINT X11 Industrial bus interface............................................................................39
5.15PC Interfaces ...............................................................................................................................39
6Maintenance, care and disposal.........................................................................................................40

Contents
Notes on the use of these operating instructions
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6.1General.........................................................................................................................................40
6.2Maintenance work, intervals ........................................................................................................40
6.2.1Daily maintenance tasks...............................................................................................40
6.2.1.1Visual inspection ...........................................................................................40
6.2.1.2Functional test ...............................................................................................40
6.2.2Monthly maintenance tasks ..........................................................................................41
6.2.2.1Visual inspection ...........................................................................................41
6.2.2.2Functional test ...............................................................................................41
6.2.3Annual test (inspection and testing during operation) ..................................................41
6.3Disposing of equipment................................................................................................................41
6.3.1Manufacturer's declaration to the end user ..................................................................41
6.4Meeting the requirements of RoHS..............................................................................................41
7Rectifying faults....................................................................................................................................42
7.1Error messages............................................................................................................................42
7.2Checklist for rectifying faults ........................................................................................................44
7.3Vent coolant circuit.......................................................................................................................45
7.3.1Automation interface.....................................................................................................45
8Technical data.......................................................................................................................................46
8.1Phoenix 351 FDW ........................................................................................................................46
8.2Phoenix 401 FDW ........................................................................................................................47
8.3Phoenix 451, 551 FDW ................................................................................................................48
9Accessories ..........................................................................................................................................49
9.1System components.....................................................................................................................49
9.2General accessories ....................................................................................................................49
9.3Options.........................................................................................................................................49
9.4Remote control/connecting and extension cable .........................................................................50
9.4.17-pole connection .........................................................................................................50
9.5Computer communication ............................................................................................................50
10Appendix A............................................................................................................................................51
10.1Overview of EWM branches.........................................................................................................51

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 imminent
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
• The risk is explained using a symbol on the edge of the page.
Special technical points which users must observe.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.

Safety instructions
Complete documentation
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2.2 Complete documentation
This document is part of the complete documentation and valid only in combination with the
"Control" operating instructions for the product being used!
Read and observe the operating instructions for all system components, especially the safety
instructions!
Figure 2-1
The illustration shows a general example of a welding system.
Item Documentation
A.1 Wire feeder
A.2 Conversion instructions
A.3 Power source
A.4 Cooling unit, voltage converter, tool box etc.
A.5 Trolley
A.6 Welding torch
A.7 Remote control
A.8 Control
A Complete documentation

Safety instructions
Explanation of icons
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2.3 Explanation of icons
Symbol Description Symbol Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/tip
l
0
Switch off machine Release/do not activate
l
0
Switch on machine Press and hold
switch
Wrong Turn
Correct Numerical value – adjustable
Menu entry Signal light lights up in green
Navigating the menu Signal light flashes green
Exit menu Signal light lights up in red
4s
Time representation (e.g.: wait
4 s/activate)
Signal light flashes red
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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2.4 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 discharged!
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 due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
• Carefully read the safety instructions in this manual!
• Observe the accident prevention regulations and any regional regulations!
• Inform persons in the working area that they must comply with 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 appropriate safety level (depending on the
application)!
• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
• Protect persons not involved in the work against arc beams and the risk of glare using
safety curtains!
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!

Safety instructions
General
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WARNING
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
• Check for fire hazards in the working area!
• Do not carry any easily flammable objects such as matches or lighters.
• Keep appropriate fire extinguishing equipment to hand in the working area!
• Thoroughly remove any residue of flammable substances from the workpiece before
starting welding.
• Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
• Connect welding leads correctly!
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
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
• Observe the maintenance instructions > see 6.2 chapter!
• Unwind welding leads completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if
necessary).
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent
vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to
the ultraviolet radiation of the arc!
• Ensure that there is sufficient fresh air!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
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
EMC Machine Classification
In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic
compatibility classes > see 8 chapter:
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas,
including residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the
surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding equipment
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system

Safety instructions
General
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Obligations of the operator!
The respective national directives and laws must be observed for operation of the machine!
• National implementation of the framework directive (89/391/EWG), as well as the associated
individual directives.
• In particular, directive (89/655/EWG), on the minimum regulations for safety and health
protection when staff members use equipment during work.
• The regulations regarding work safety and accident prevention for the respective country.
• Setting up and operating the machine according to IEC 60974-9.
• Check at regular intervals that users are working in a safety-conscious way.
• Regular checks of the machine according to IEC 60974-4.
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Stray welding currents can destroy protective earth conductors, damage equipment and
electronic devices and cause overheating of components leading to fire.
• Make sure all welding leads are securely connected and check regularly.
• Always ensure a proper and secure electrical connection to the workpiece!
• Set up, attach or suspend all conductive power source components like casing, transport
vehicle and crane frames so they are insulated!
• Do not place any other electronic devices such as drillers or angle grinders, etc., on the power
source, transport vehicle or crane frames unless they are insulated!
• Always put welding torches and electrode holders on an insulated surface when they are not
in use!
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of the
operator, where necessary in consultation with the mains network operator, to ensure that the
machine can be connected.

Safety instructions
Transport and installation
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2.5 Transport and installation
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!
• Observe the instructions from the gas manufacturer and any relevant
regulations concerning the use of compressed air!
• Place shielding gas cylinders in the holders provided for them and secure
with fixing devices.
• Attach the fastening elements within the upper half of the shielding gas
cylinder!
• The fastening elements must tightly enclose the shielding gas cylinder!
• Do not attach any element to the shielding gas cylinder valve!
• 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 (avoid 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!
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 instructions
Transport and installation
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2.5.1 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 lifting 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 protective caps before
lifting by crane!
• Use the correct number of hoisting equipment of the right size in the
correct position! Observe craning principle (see figure)!
• For machines with lifting eyes: always lift all lifting 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 occupational 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 full 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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2.5.2 Ambient conditions
T he machine must not be operated in the open air and must only be set up and operated on a
suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient lighting
for the place of work.
• Safe operation of the machine must be guaranteed at all times.
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
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!
2.5.2.1 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
2.5.2.2 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
Use and operation solely with the following machines
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. 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 its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
Arc welding machine for standard and pulsed gas-shielded metal-arc welding with TIG welding and lift arc
(touch starting) or MMA welding as secondary process. It may be possible to expand the functionality by
using accessories (see the documentation in the relevant chapter).
3.1 Use and operation solely with the following machines
A suitable wire feed unit (system component) is required in order to operate the welding
machine!
Phoenix 351-551 miniDrive
drive 4X LP 
drive 4X LP MMA 
drive 4X HP 
drive 4X HP MMA 
drive 4X IC LP 
drive 4X IC HP 
3.2 Applications
Machine series Main process Secondary
process
Standard MIG/MAG
welding
Pulsed MIG/MAG
welding
TIG welding (lift arc) MMA welding Gouging forceArc rootArc coldArc pipeSolution forceArc puls rootArc puls coldArc puls
alpha Q puls MM 
Phoenix puls MM 
Taurus Synergic S MM 
possible
not possible

Intended use
Documents which also apply
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3.3 Documents which also apply
3.3.1 Warranty
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 Conformity
The labelled machine complies with the following EC directives in terms of its design and
construction:
• Low Voltage Directive (LVD) 2014/35/EC
• Electromagnetic Compatibility Directive (EMC) 2014/30/EC
• Restriction of Hazardous Substance (RoHS) 2011/65/EC
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which
have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the
specific declaration of conformity is included with every product.
3.3.3 Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
3.3.4 Service documents (spare parts and circuit diagrams)
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.3.5 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as
stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months

Machine description – quick overview
Front view
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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
1 Lifting lug
2
Ready for operation signal light
Signal light on when the machine is switched on and ready for operation
3
l
0
Main switch, machine on/off
4 Carrying handle
5
Cooling air inlet
6 Wheels, guide castors
7 Coolant tank
8 Coolant tank cap
9
Automatic cut-out of coolant pump key button
press to reset a triggered fuse
10 Connection socket, “-” welding current
•----------- MIG/MAG welding: workpiece connection
•----------- MIG/MAG cored wire welding: welding current connection for the
welding torch
•----------- MMA welding: electrode holder connection
11 Connection socket, “+” welding current
•----------- MIG/MAG welding: welding current connection for the welding torch
•----------- MIG/MAG cored wire welding: workpiece connection
•----------- MMA welding: workpiece connection
12 Machine control, see the relevant control operating instructions

Machine description – quick overview
Rear view
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4.2 Rear view
Figure 4-2