Praxair PHOENIX 401 BASIC PULS forceArc User manual

GB
Operating instructions
Machines for MIG/MAG and MMA welding
PHOENIX 401 BASIC PULS forceArc;
PHOENIX BASIC DRIVE 4 / 4L
N. B. These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machines may only be operated by personnel who are familiar with the appropriate safety
regulations.
The machines bear the conformity mark and thus comply with the
• EC Low Voltage Directive (73/23/EEC)
• EC EMC Directive (89/336/EEC)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.
© 2006 Subject to alteration. Item No.: 099-004838-PRA01 Dated: 10.04.06

Declaración de Conformidad CE
EU - Conformity declaration
Déclaration de Comformidité UE
Declaraçao de Conformidade CE
Nombre del Fabricante: PRAXAIR SOLDADURA, S.L.
Name of manufacturer: C/ Orense, 11 - 9ª planta
Nom du fabricant: 28020 MADRID
Nome do fabricante:
Dirección del Fabricante:
Address of manufacturer:
Adresse du fabricant:
Direcçao do fabricante:
Por la presente declaramos
que el diseño y la
construcción de la/s
máquina/s indicada/s
cumple/n las directivas funda-
mentales de seguridad para
bajo voltaje de la UE. Esta
declaración no tendrá validez,
en el caso de cambios no
autorizados, reparaciones ina
decuadas o modificaciones
que no hayan sido expresa
mente aprobadas por
PRAXAIR SOLDADURA, S.L.
We herewith declare that the
machine described below
meets the standard safety
regulations of the EU - low
voltage guideline in its
conception and construction,
as well as in the design put
into circulation by us, in case
of unauthorized changes
improper repairs and/or
modifications, which have not
been expressly allowed by
PRAXAIR SOLDADURA, S.L.
This declaration will lose its
validity.
Par la présente, nous déclarons
que la conception et la
construction ainsi que le modéle,
mis sur le marcha par bous, de
l'appareil decrit ci dessous
correspondent aux directives
fondamentales de securité de la
UE regissant les basses tensions.
En cas de chargements non
autorisés, de reparations
inadiquates et/ou de modifications
prohibeés, qui n'ont pas été
autorisés expressement par
PRAXAIR SOLDADURA, S.L.
cette declaration devient caduque.
Pela presente declaramos que
o desenho e a construçao
da(s) máquina(s) indicada(s),
cumprem as directivas
fundamentais de segurança
para vaisa voltagem da UE.
Esta declaraçao nâo terá
validade, no caso de trocas
nâo autorizadas, reparaçôes
inadequadas ou modificaçôes
que nâo tenham sido
aprovadas pela PRAXAIR
SOLDADURA, S.L.
Descripción de la máquina :
Description of the machine:
Déscription de la machine:
Descriçao da máquina:
Tipo de máquina:
Type of machine
Type de machine
Tipo da máquina:
Número de Código:
Article number:
Numero d'article:
Número de Código:
Número de Serie:
Serial number:
Numéro de série:
Número de série:
Normas aplicadas:
Used co-ordinated norms:
Normes harmonisées appliquées:
Normas aplicadas:
EN 60974 - 1 / IEC 60974 – 1 / VDE 0544
73/23/CE
89/336/CE
Firma del Fabricante:
Signature of manufacturer:
Signature du fabricant:
Assinatura do fabricante:
Director de Producción
Production Manager
Directeur de Production
Director de Produçao

Estimado Cliente,
¡Enhorabuena! Usted acaba de elegir un producto de calidad de PRAXAIR
SOLDADURA.
Con los equipos de PRAXAIR se consiguen unos resultados de la máxima perfección,
gracias a su calidad SUPERIOR.
¡Nosotros desarrollamos y producimos calidad! Desde los componentes individuales
hasta el producto final, conservamos la exclusiva responsabilidad sobre nuestros
equipos.
Todos los componentes de nuestros equipos de soldar incorporan una tecnología
puntera del máximo nivel de calidad. Cada uno de nuestros productos es
cuidadosamente comprobado para poder garantizar unos materiales y productos libres
de defectos.
Estas instrucciones de funcionamiento contienen todo lo necesario para la puesta en
funcionamiento del equipo, notas de seguridad, mantenimiento y cuidado, datos
técnicos. Rogamos presten especial atención a las mismas para así asegurar unos
largos años de trabajo con el equipo en las mejores condiciones de seguridad.
Les agradecemos la confianza depositada en nosotros, y quisiéramos expresarles
nuestra gran ilusión de mantener con ustedes una relación a largo plazo en el espíritu
de “UNA VEZ PRAXAIR – SIEMPRE PRAXAIR”.
Un cordial saludo,
PRAXAIR SOLDADURA,S.L.

Datos del Equipo y de la Empresa
Rogamos introduzca los datos del equipo PRAXAIR así como los de su empresa en los campos
correspondientes
CE
TYP:
ART:
SNR:
PROJ:
GEPRÜFT/CONTROL:
Nombre de Cliente / Compañía
Dirección
Código postal / Ciudad
País
Sello / Firma distribuidor PRAXAIR
Fecha de compra
Nombre de Cliente / Compañía
Dirección
Código postal / Ciudad
País
Sello / Firma distribuidor PRAXAIR
Fecha de compra

Contents
PHOENIX 401 BASIC PULS forceArc
Item No.: 099-004838-PRA01 5
1Contents
1Contents..................................................................................................................................................5
2Safety instructions.................................................................................................................................7
3Technical data ......................................................................................................................................10
3.1 PHOENIX 401 BASIC PULS forceArc.........................................................................................10
3.2 PHOENIX BASIC DRIVE 4 / 4L...................................................................................................11
4Machine description ............................................................................................................................12
4.1 PHOENIX 401 BASIC PULS forceArc.........................................................................................12
4.1.1 Front view.....................................................................................................................12
4.1.2 Rear view......................................................................................................................14
4.2 PHOENIX BASIC DRIVE 4L........................................................................................................16
4.2.1 Front view.....................................................................................................................16
4.2.2 Rear view......................................................................................................................18
5Functional characteristics...................................................................................................................20
5.1 Machine control – Operating elements........................................................................................20
5.1.1 Wire feed machine control............................................................................................20
5.1.1.1 Covered operating elements.........................................................................22
5.1.1.2 JOB list..........................................................................................................24
5.1.2 Operating elements in the machine..............................................................................25
5.2 MIG/MAG welding........................................................................................................................26
5.2.1 Definition of MIG/MAG welding tasks...........................................................................26
5.2.2 Selecting MIG/MAG welding tasks...............................................................................26
5.2.2.1 Basic welding parameters.............................................................................26
5.2.2.2 Operating mode ............................................................................................26
5.2.2.3 Welding type .................................................................................................26
5.2.2.4 Choke effect / dynamics................................................................................27
5.2.2.5 Superpulses..................................................................................................27
5.2.2.6 Wire burn-back..............................................................................................27
5.2.3 MIG/MAG functional sequences / operating modes.....................................................28
5.2.3.1 Explanation of signs and functions ...............................................................28
5.2.3.2 Non-latched mode.........................................................................................29
5.2.3.3 Non-latched operation with superpulse.........................................................30
5.2.3.4 Special, non-latched......................................................................................31
5.2.3.5 Spots.............................................................................................................32
5.2.3.6 Special, non-latched with superpulse ...........................................................33
5.2.3.7 Latched mode ...............................................................................................34
5.2.3.8 Latched mode with superpulse.....................................................................35
5.2.3.9 Latched special.............................................................................................36
5.2.3.10 Special, latched with superpulse.................................................................37
5.2.4 MIG/MAG automatic cut-out.........................................................................................38
5.2.5 Standard MIG/MAG torch.............................................................................................38
5.2.6 Special parameter, “DRIVE 4 P wire feed units”..........................................................39
5.2.6.1 Special parameters list..................................................................................39
5.2.6.2 Selecting, changing and saving parameters.................................................39
5.2.6.3 Reset to factory settings ...............................................................................40
5.2.6.4 Ramp time for wire creep (P1)......................................................................40
5.2.6.5 Program "0", releasing the program block (P2) ............................................40
5.2.6.6 Display mode torch power control (P3).........................................................40
5.2.6.7 Program limit (P4).........................................................................................40
5.2.6.8 Special cycle in the operating modes special latched and non-latched
(P5).....................................................................................................................40
5.2.6.9 Enabling special JOBs SP1 to SP3 (P6).......................................................40
5.2.6.10 Correction operation, threshold value setting (P7) .....................................41
5.2.6.11 Program changeover with standard torch (P8)...........................................42
5.2.7 Interfaces......................................................................................................................43
5.2.7.1 PC interfaces.................................................................................................43

Contents
PHOENIX 401 BASIC PULS forceArc
6 Item No.: 099-004838-PRA01
5.3 TIG welding..................................................................................................................................43
5.3.1 TIG arc ignition .............................................................................................................43
5.3.1.1 Liftarc.............................................................................................................43
5.3.2 TIG function sequences / operating modes..................................................................44
5.3.2.1 Explanation of signs and functions................................................................44
5.3.2.2 Non-latched mode.........................................................................................45
5.3.2.3 Special, non-latched......................................................................................45
5.3.2.4 Latched mode................................................................................................46
5.3.2.5 Latched special .............................................................................................47
5.3.3 TIG automatic cut-out...................................................................................................47
5.4 MMA welding................................................................................................................................48
5.4.1 Arcforcing......................................................................................................................48
5.4.2 Hotstart .........................................................................................................................48
5.4.3 Antistick.........................................................................................................................48
5.5 Remote control.............................................................................................................................49
5.5.1 R10 manual remote control ..........................................................................................49
5.6 Resetting JOBs (welding tasks) to the factory settings................................................................50
5.6.1 Resetting a single JOB.................................................................................................50
5.6.2 Resetting all JOBs ........................................................................................................50
6Commissioning.....................................................................................................................................51
6.1 General.........................................................................................................................................51
6.2 Area of application – proper usage..............................................................................................51
6.3 Installation....................................................................................................................................51
6.4 Mains connection .........................................................................................................................51
6.5 Machine cooling ...........................................................................................................................51
6.6 Workpiece lead, general ..............................................................................................................51
7Maintenance and care..........................................................................................................................52
7.1 General.........................................................................................................................................52
7.2 Cleaning.......................................................................................................................................52
7.3 Repetition Test conforming to E VDE 0544-207, conforming to the German Ordinance on
Operational Safety .......................................................................................................................52
7.3.1 Test intervals and scope...............................................................................................53
7.3.2 Documentation of the test.............................................................................................53
7.3.3 Visual inspection...........................................................................................................53
7.3.4 Measurement of protective conductor resistance.........................................................53
7.3.5 Measurement of insulation resistance..........................................................................54
7.3.6 Measuring the leakage current (protective conductor and contact current).................54
7.3.7 Measuring the open circuit voltage...............................................................................54
7.3.8 Function test of the welding machine ...........................................................................54
7.4 Repair Work .................................................................................................................................55
8Operating problems, causes and remedies.......................................................................................56
8.1 Error messages (power source)...................................................................................................56
9Accessories, options ...........................................................................................................................57
9.1 General accessories ....................................................................................................................57
9.2 Remote control / connection cable...............................................................................................57
9.3 Options.........................................................................................................................................57
9.4 Computer communication............................................................................................................57
9.5 Welding data documentation........................................................................................................57
10 Circuit diagrams...................................................................................................................................58
10.1 PHOENIX 401 BASIC PULS forceArc .........................................................................................58
10.2 PHOENIX BASIC DRIVE 4 / 4L...................................................................................................60

Safety instructions
PHOENIX 401 BASIC PULS forceArc
Item No.: 099-004838-PRA01 7
2Safety instructions

Safety instructions
PHOENIX 401 BASIC PULS forceArc
8 Item No.: 099-004838-PRA01

Safety instructions
PHOENIX 401 BASIC PULS forceArc
Item No.: 099-004838-PRA01 9

Technical data
PHOENIX 401 BASIC PULS forceArc
10 Item No.: 099-004838-PRA01
3Technical data
3.1 PHOENIX 401 BASIC PULS forceArc
PHOENIX 401 PULSE forceArc
Setting range: Welding current / voltage
TIG 5 A / 10.2 V – 400 A / 26.0 V
MMA 5 A / 20.2 V – 400 A / 36.0 V
MIG/MAG 5 A / 14.3 V – 400 A / 34.0 V
Duty cycle at 20°C 40°C
60% DC - A 400 A
80% DC 400 A - A
100% DC 370 A 360 A
Load alternation 10 min (60% DC ∧6 min welding, 4 min break)
Open circuit voltage 92 V
Mains voltage (tolerances) 3 x 400 V (-25% to +20%)
Frequency 50/60 Hz
Mains fuse (slow-blow safety fuse) 3 x 35 A
Mains connection lead H07RN-F4G4
Max. connected power 21.5 kVA
Recommended generator rating 29.0 kVA
Cosϕ/ efficiency 0.99 / 89%
Insulation class / protection classification H / IP 23
Ambient temperature -10°C to +40°C
Machine / torch cooling Fan / gas or water
Cooling capacity at 1 l/min 1200 W
Max. flow rate 5 l/min
Max. initial coolant pressure 3.5 bar
Max. tank capacity 7 l
Coolant Ex works: KF 23E (-10°C to +40°C) or
KF 37E (-20°C to +10°C)
Workpiece lead 70 mm2
Dimensions L/W/H [mm] 1100 x 455 x 950
Weight 111.5 Kg
Constructed to standards IEC 60974 / EN 60974 / VDE 0544
EN 50199 / VDE 0544 Part 206 / /