EWM Phoenix 355 Expert 2.0 puls MM TDM User manual

Operating instructions
EN
Power source
Phoenix 355 Expert 2.0 puls MM TDM
Phoenix 405 Expert 2.0 puls MM TDM
Phoenix 505 Expert 2.0 puls MM TDM
099-005352-EW501
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13.01.2016
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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 components!
•Observe accident prevention regulations!
•Observe all local regulations!
•Confirm with a signature where appropriate.
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
1Contents..................................................................................................................................................3
2Safety instructions.................................................................................................................................6
2.1 Notes on the use of these operating instructions ..........................................................................6
2.2 Explanation of icons.......................................................................................................................8
2.3 General..........................................................................................................................................9
2.4 Transport and installation ............................................................................................................13
2.4.1 Ambient conditions.......................................................................................................14
2.4.1.1 In operation...................................................................................................14
2.4.1.2 Transport and storage...................................................................................14
3Intended use.........................................................................................................................................15
3.1 Documents which also apply.......................................................................................................15
3.1.1 Warranty.......................................................................................................................15
3.1.2 Declaration of Conformity.............................................................................................15
3.1.3 Welding in environments with increased electrical hazards.........................................15
3.1.4 Service documents (spare parts and circuit diagrams)................................................15
3.1.5 Calibration/Validation ...................................................................................................15
4Machine description –quick overview ..............................................................................................16
4.1 Front view ....................................................................................................................................16
4.2 Rear view.....................................................................................................................................18
5Design and function.............................................................................................................................20
5.1 General........................................................................................................................................20
5.2 Transport and installation ............................................................................................................22
5.3 Machine cooling...........................................................................................................................22
5.4 Workpiece lead, general..............................................................................................................22
5.5 Mains connection.........................................................................................................................23
5.5.1 Mains configuration ......................................................................................................23
5.6 Notes on the installation of welding current leads.......................................................................24
5.7 Welding torch cooling system......................................................................................................26
5.7.1 List of coolants..............................................................................................................26
5.7.2 Maximal hose package length......................................................................................26
5.7.3 Cooling module connection..........................................................................................27
5.8 Aligning the cable resistance.......................................................................................................28
5.9 Connecting the intermediate hose package to the power source ...............................................30
5.9.1 Intermediate hose package strain relief.......................................................................30
5.9.2 Intermediate hose package connection .......................................................................31
5.9.3 Shielding gas supply (shielding gas cylinder for welding machine).............................32
5.10 Welding torch holder....................................................................................................................33
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.....................................................................................35
5.13 MMA welding ...............................................................................................................................36
5.13.1 Connecting the electrode holder and workpiece lead..................................................36
5.14 Remote control.............................................................................................................................37
5.15 Interfaces.....................................................................................................................................37
5.15.1 Automation interface ....................................................................................................38
5.15.2 RINT X12 robot interface..............................................................................................39
5.15.3 BUSINT X11 Industrial bus interface............................................................................39
5.16 PC Interfaces...............................................................................................................................39
6Maintenance, care and disposal.........................................................................................................40
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

Contents
Notes on the use of these operating instructions
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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
7Rectifying faults....................................................................................................................................42
7.1 Checklist for rectifying faults........................................................................................................42
7.2 General operating problems ........................................................................................................43
7.2.1 Interface for automated welding...................................................................................43
7.3 Vent coolant circuit.......................................................................................................................43
8Technical data.......................................................................................................................................44
8.1 Phoenix 355 TDM ........................................................................................................................44
8.2 Phoenix 405.................................................................................................................................45
8.3 Phoenix 505.................................................................................................................................46
9Accessories ..........................................................................................................................................47
9.1 Wire feed units.............................................................................................................................47
9.2 Options.........................................................................................................................................47
9.3 Welding torch cooling system......................................................................................................47
9.4 Transport systems........................................................................................................................47
9.5 Remote control / connection cable...............................................................................................47
9.5.1 7-pole connection .........................................................................................................47
9.6 General accessories ....................................................................................................................47
10 Appendix A............................................................................................................................................48
10.1 Overview of EWM branches.........................................................................................................48

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.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
•The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
•The hazard is explained using a symbol at the edge of the page.
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
Notes on the use of these operating instructions
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WARNING
Validity of the document!
This document is part of the complete documentation and valid only in combination
with the "Power source"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 xxx
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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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the user
must observe.
Activate and release/tap/tip
Switch off machine
Release/do not activate
Switch on machine
Press and hold/switch
Wrong
Turn
Correct
Signal light off
Menu entry
Signal light on (e.g. green), colour code:
g=green, r=red, y=yellow
Navigating the menu
Signal light flashing (e.g. green), colour
code: g=green, r=red, y=yellow
Exit menu
Time representation (e.g.: wait
4 s/activate)
Tool not required/do not use
Interruption in the menu display (other
setting options possible)
Tool required/use

Safety instructions
General
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2.3 General
DANGER
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
•Observe the maintenance instructions - See 6 Maintenance, care and disposal chapter!
•Unwind welding leads completely!
•Shield devices or equipment sensitive to radiation accordingly!
•The correct functioning of pacemakers may be affected (obtain advice from a doctor if
necessary).
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
•Appoint only skilled persons for repair work (trained service personnel)!
Electric shock!
Welding machines use high voltages which can result in potentially fatal electric shocks
and burns on contact. Even low voltages can cause you to get a shock and lead to
accidents.
•Do not touch any live parts in or on the machine!
•Connection cables and leads must be free of faults!
•Switching off alone is not sufficient!
•Place welding torch and stick electrode holder on an insulated surface!
•The unit should only be opened by specialist staff after the mains plug has been
unplugged!
•Only wear dry protective clothing!
•Wait for 4 minutes until the capacitors have discharged!
WARNING
Risk of injury due to radiation or heat!
Arc radiation results in injury to skin and eyes.
Contact with hot workpieces and sparks results in burns.
•Use welding shield or welding helmet with the appropriate safety level (depending on the
application)!
•Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
•Protect persons not involved in the work against arc beams and the risk of glare using
safety curtains!
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
•Move containers with inflammable or explosive liquids away from the working area!
•Never heat explosive liquids, dusts or gases by welding or cutting!

Safety instructions
General
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WARNING
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent
vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to
the ultraviolet radiation of the arc!
•Ensure that there is sufficient fresh air!
•Keep solvent vapour away from the arc beam field!
•Wear suitable breathing apparatus if appropriate!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
•Check for fire hazards in the working area!
•Do not carry any easily flammable objects such as matches or lighters.
•Keep appropriate fire extinguishing equipment to hand in the working area!
•Thoroughly remove any residue of flammable substances from the workpiece before
starting welding.
•Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
•Connect welding leads correctly!
Risk of accidents 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!
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 leadshave
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 accident prevention for the respective country.
•Setting up and operating the machine according to IEC 60974-9.
•Check at regular intervals that users are working in a safety-conscious way.
•Regular checks of the machine according to IEC 60974-4.
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
•Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of
products!
•Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Damage to the machine due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage equipment and
electronic devices and cause overheating of components leading to fire.
•Make sure all welding leads are securely connected and check regularly.
•Always ensure a proper and secure electrical connection to the workpiece!
•Set up, attach or suspend all conductive power source components like casing, transport
vehicle and crane frames so they are insulated!
•Do not place any other electronic devices such as drillers or angle grinders, etc., on the
power source, transport vehicle or crane frames unless they are insulated!
•Always put welding torches and electrode holders on an insulated surface when they are
not in use!
Mains connection
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of
the operator, where necessary in consultation with the mains network operator, to ensure that
the machine can be connected.

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 Technical data 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
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 provided for them and secure with fixing
devices.
•Avoid heating the shielding gas cylinder!
Risk of accident due to improper transport of machines that may not be lifted!
Do not lift or suspend the machine! The machine can fall down and cause injuries! The
handles and brackets are suitable for transport by hand only!
•The machine may not be lifted by crane or suspended!
CAUTION
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10°
(according to IEC 60974-1).
•Set up and transport the machine on level, solid ground.
•Secure add-on parts using suitable equipment.
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
•Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
•Only transport and operate in an upright position!

Safety instructions
Transport and installation
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2.4.1 Ambient conditions
CAUTION
Installation site!
The machine must not be operated in the open air and must only be set up and
operated on a suitable, stable and level base!
•The operator must ensure that the ground is non-slip and level, and provide sufficient
lighting for the place of work.
•Safe operation of the machine must be guaranteed at all times.
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
•Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
•Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
•Observe the ambient conditions!
•Keep the cooling air inlet and outlet clear!
•Observe the minimum distance of 0.5 m from obstacles!
2.4.1.1 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
2.4.1.2 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
Documents which also apply
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3 Intended use
WARNING
Hazards due to improper usage!
Hazards may arise for persons, animals and material objects if the equipment is not
used correctly. No liability is accepted for any damages arising from improper usage!
•The equipment must only be used in line with proper usage and by trained or expert staff!
•Do not modify or convert the equipment improperly!
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).
A suitable wire feed unit (system component) is required in order to operate the welding
machine!
3.1 Documents which also apply
3.1.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.1.2 Declaration of Conformity
The designated machine conforms to EC Directives and standards in terms of its design
and construction:
•EC Low Voltage Directive (2006/95/EC),
•EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly
conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted
conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
3.1.3 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.
3.1.4 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.
3.1.5 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
The device configuration shown may differ in case of an additional ex works options or
retrofitting options- See 9 Accessories chapter.
4.1 Front view
Figure 4-1

Machine description –quick overview
Front view
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Item
Symbol
Description 0
1
Carrying handle
2
Ready for operation signal light
Signal light on when the machine is switched on and ready for operation
3
Main switch, machine on/off
4
Cooling air inlet
5
Machine feet
6
Connection socket, "+" welding current
•MIG/MAG cored wire welding: Workpiece connection
•TIG welding: Workpiece connection
•MMA welding: Workpiece connection
7
"-" welding current connection socket
•MIG/MAG welding: Workpiece connection
•MMA welding: electrode holder connection
8
Machine control, see the relevant control operating instructions
9
Torch holder

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

Machine description –quick overview
Rear view
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Item
Symbol
Description 0
1
Key button, Automatic cutout
Wire feed motor supply voltage fuse
(press to reset a triggered fuse)
2
Connection socket, 7-pole
Connection for peripheral devices with digital interface
3
7-pole connection socket (digital)
Wire feed unit connection
4
Connection socket, “+” welding current
•Standard MIG/MAG welding (intermediate hose package)
5
Connection socket, “-” welding current
Connection for welding current plug from intermediate hose package
•MIG/MAG flux cored wire welding
•TIG welding
6
Stirrup
Intermediate hose package strain relief
7
Cooling air outlet
8
8-pole connection socket
Cooling unit control lead
9
4-pole connection socket
Cooling unit voltage supply
10
Mains connection cable
- See 5.5 Mains connection chapter
11
PC interface, serial (D-Sub connection socket, 9-pole)
12
19-pole mechanised welding interface (analogue)
- See 7.2.1 Interface for automated welding chapter
13
LAN interface

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 pages of the operating instructions.
•Commissioning may only be carried out by persons who have the relevant expertise of
working with arc welding machines!
•Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
CAUTION
Insulate the arc welder from welding voltage!
Not all active parts of the welding current circuit can be shielded from direct contact. To
avoid any associated risks it is vital for the welder to adhere to the relevant safety
regulations. Even low voltages can cause a shock and lead to accidents.
•Wear dry and undamaged protective clothing (shoes with rubber soles/welder's gloves
made from leather without any studs or braces)!
•Avoid direct contact with non-insulated connection sockets or connectors!
•Always place torches and electrode holders on an insulated surface!
Risk of burns on the welding current connection!
If the welding current connections are not locked, connections and leads heat up and
can cause burns, if touched!
•Check the welding current connections every day and lock by turning in clockwise direction,
if necessary.
Risk from electrical current!
If welding is carried out alternately using different methods and if a welding torch and
an electrode holder remain connected to the machine, the open-circuit/welding voltage
is applied simultaneously on all cables.
•The torch and the electrode holder should therefore always be placed on an insulated
surface before starting work and during breaks.