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EWM PHOENIX 521 EXPERT HIGHSPEED - User Manual

EWM PHOENIX 521 EXPERT HIGHSPEED
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EWM
HIGHTEC WELDING GmbH
Dr. Günter - Henle - Straße 8 • D-56271 Mündersbach
Phone: +49 2680 181 0 • Fax: +49 2680 181 244
www.ewm.deinfo@ewm.de
GB
Operating instructions
Machines for MIG/MAG, TIG and MMA welding
PHOENIX 301,351,421,521 EXPERT forceArc
PHOENIX 301,351,421,521 EXPERT PULS forceArc
PHOENIX 521 EXPERT HIGHSPEED
PHOENIX EXPERT DRIVE 4,4L,4HS
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)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.
© 2007 Subject to alteration.
Item No.: 099-004833-EWM01
Revised: 03.12.2007

Table of Contents

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Summary

Safety instructions

2.1 For your safety

Observe accident prevention regulations; ignoring safety procedures can be fatal.

2.2 Transport and installation

Guidelines for safely transporting and installing the welding machine.

2.3 Safety rules while lifting

Specific safety regulations and procedures for lifting the welding machine by crane.

2.4 Notes on the use of these operating instructions

Information on how to use the operating instructions and understand symbols.

Technical data

3.1 PHOENIX 301; 351 EXPERT forceArc

Technical specifications for PHOENIX 301 and 351 EXPERT forceArc welding machines.

3.2 PHOENIX 421; 521 EXPERT forceArc

Technical specifications for PHOENIX 421 and 521 EXPERT forceArc welding machines.

3.3 PHOENIX DRIVE 4; 4 L; PHOENIX EXPERT DRIVE 4; 4 L

Technical specifications for PHOENIX DRIVE 4/4L and EXPERT DRIVE 4/4L models.

3.4 PHOENIX EXPERT DRIVE 4 HS

Technical specifications for the PHOENIX EXPERT DRIVE 4HS model.

Machine description

4.1 PHOENIX 301; 351; 421; 521 EXPERT forceArc

Detailed description of the PHOENIX 301, 351, 421, 521 EXPERT forceArc series.

4.2 PHOENIX DRIVE 4 L; PHOENIX EXPERT DRIVE 4 L

Detailed description of the PHOENIX DRIVE 4L and EXPERT DRIVE 4L models.

4.3 PHOENIX DRIVE 4; PHOENIX EXPERT DRIVE 4

Detailed description of the PHOENIX DRIVE 4 and EXPERT DRIVE 4 models.

Functional characteristics

5.1 Machine control - Operating elements

Overview and description of the operating elements on the welding machine control.

5.2 MIG;MAG welding

Detailed explanation of MIG/MAG welding processes, tasks, and parameters.

5.3 TIG welding

Explanation of TIG welding processes, task selection, and operating modes.

5.4 MMA welding

Description of MMA welding tasks, current setting, and operational characteristics.

5.5 Interfaces

Information on various interfaces for connecting accessory components and external devices.

5.6 Key switch

Explanation of the key switch function for locking parameters and functions.

5.7 Operating time counter

How to display and read the operating time counter of the welding machine.

5.8 Remote control

Description of available remote control units and their connection.

5.9 Advanced functions on the welding machine control

Detailed explanation of advanced functions for the welding machine control.

5.10 Advanced functions on the wire feed unit control

Explanation of advanced functions and special parameters for the wire feed unit control.

Commissioning

6.1 General

General safety instructions and connection guidelines for commissioning the welding machine.

6.2 Area of application - proper usage

Defines the intended use of the welding machines and any improper usage.

6.3 Installation

Guidelines for properly installing the welding machine in a stable and secure position.

6.4 Mains connection

Instructions for correctly connecting the welding machine to the mains power supply.

6.5 Machine cooling

Precautions for ensuring optimal duty cycle through proper machine cooling.

6.6 Adding coolant

Procedure for adding coolant to the integrated cooling module, including checks.

6.7 Workpiece lead, general

Guidelines for preparing and connecting the workpiece lead correctly.

6.8 MIG;MAG welding

Specific commissioning steps and safety warnings for MIG/MAG welding.

6.9 TIG welding

Safety instructions and connection guidelines for TIG welding.

6.10 MMA welding

Safety instructions and connection guidelines for MMA welding.

6.11 Shielding gas supply

Instructions for connecting and testing the shielding gas supply system.

Maintenance and testing

7.1 General

General guidelines for maintenance, cleaning, and testing for warranty compliance.

7.2 Cleaning

Procedure for safely cleaning the welding machine's components and casing.

7.3 Test

Information on conducting operational tests according to relevant standards (IEC/DIN EN 60974-4).

7.4 Repair Work

Guidelines for authorized personnel performing repair and maintenance work.

7.5 Disposing of equipment

Information on the proper and environmentally friendly disposal of old equipment.

7.6 Meeting the requirements of RoHS

Confirmation that products comply with the RoHS Directive (2002/95/EC).

Warranty

8.1 General Validity

Details on the warranty periods for EWM machines, accessories, and spare parts.

8.2 Warranty Declaration

Conditions, exclusions, and limitations of the EWM warranty.

Operating problems, causes and remedies

9.1 Error messages (power source)

List of error codes, their possible causes, and recommended remedies for the power source.

Accessories, options

10.1 General accessories

List of general accessories available for EWM welding machines with their designations.

10.2 Remote control; connection cable

Catalog of remote control units and connection cables, including item numbers.

10.3 Options

List of optional retrofit kits and accessories for enhancing machine functionality.

10.4 Computer communication

Information on computer communication interfaces and software for welding machines.

Circuit diagrams

11.1 PHOENIX 301 EXPERT forceArc

Electrical circuit diagram for the PHOENIX 301 EXPERT forceArc welding machine.

11.2 PHOENIX 351 EXPERT forceArc

Electrical circuit diagram for the PHOENIX 351 EXPERT forceArc welding machine.

11.3 PHOENIX 421 EXPERT forceArc

Electrical circuit diagram for the PHOENIX 421 EXPERT forceArc welding machine.

11.4 PHOENIX 521 EXPERT forceArc

Electrical circuit diagram for the PHOENIX 521 EXPERT forceArc welding machine.

11.5 PHOENIX DRIVE 4; 4 L; PHOENIX EXPERT DRIVE 4; 4 L

Circuit diagrams for PHOENIX DRIVE 4, 4L, and EXPERT DRIVE 4/4L models.

11.6 PHOENIX EXPERT DRIVE 4 HS

Electrical circuit diagram for the PHOENIX EXPERT DRIVE 4HS welding machine.

Appendix A

12.1 Declaration of Conformity

Manufacturer's declaration confirming compliance with EC directives and safety requirements.

Appendix B

13.1 JOB Mapping

Table mapping JOB numbers to welding process, material, gas, and wire diameter combinations.

EWM PHOENIX 521 EXPERT HIGHSPEED Specifications

General IconGeneral
Mains voltage3 x 400 V
Mains frequency50/60 Hz
Protection classIP23
Insulation classF
Rated duty cycle500 A / 60%
Power supply voltage3 x 400 V
Welding processMIG/MAG
Welding current range5 A - 500 A

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