Praxair PHOENIX 401 BASIC PULS forceArc, Operating Instructions Manual

Page 1: ...us 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 P...

Page 2: ...tion 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 p...

Page 3: ...d 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 e...

Page 4: ...u 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 ...

Page 5: ...ional 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 MA...

Page 6: ...achine cooling 51 6 6 Workpiece lead general 51 7 Maintenance 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 re...

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

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

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

Page 10: ... 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 coo...

Page 11: ...m min to 24 m min Standard WF roller fitting 1 0 1 2 mm for steel wire Drive 4 roller 37 mm Torch connection Euro central or Dinse central Protection classification IP 23 Ambient temperature 10 C to 40 C Dimensions LxWxH mm 680 x 460 x 265 690 x 300 x 410 Weight incl intermediate tube package 1 5 m approx 24 kg approx 20 5 kg Constructed to standards IEC 60974 EN 60974 VDE 0544 EN 50199 VDE 0544 P...

Page 12: ...Machine description PHOENIX 401 BASIC PULS forceArc 12 Item No 099 004838 PRA01 4 Machine description 4 1 PHOENIX 401 BASIC PULS forceArc 4 1 1 Front view Figure 4 1 ...

Page 13: ... reset a triggered fuse 7 Conveyor rolls guide castors 8 Coolant tank 9 Coolant tank cap Connection socket welding current MIG MAG welding Workpiece connection MMA welding Workpiece or electrode holder connection 10 TIG welding Welding current connection for welding torch Connection socket welding current MMA welding Workpiece or electrode holder connection 11 TIG welding Workpiece connection 12 C...

Page 14: ...SIC PULS forceArc 14 Item No 099 004838 PRA01 4 1 2 Rear view The maximum possible machine configuration is given in the text description If necessary the optional connection may need to be retrofitted see Accessories chapter Figure 4 2 ...

Page 15: ... plug welding current Welding current connection on wire feed unit 6 Connection socket welding current MIG MAG welding Workpiece connection MIG MAG cored wire welding Welding current connection on wire feed unit 7 Coolant return from the DV device red rapid action closure coupling 8 Coolant water supply to the DV device blue rapid action closure coupling 9 Conveyor rolls fixed castors 10 Cooling a...

Page 16: ...Machine description PHOENIX BASIC DRIVE 4L 16 Item No 099 004838 PRA01 4 2 PHOENIX BASIC DRIVE 4L 4 2 1 Front view Figure 4 3 ...

Page 17: ...ool casing 7 Control Operating elements see chapter Function specification 8 Spool holder 9 Wire delivery unit 10 Euro central connector welding torch connection Welding current shielding gas and torch trigger included 11 Control Operating elements see chapter Function specification 12 Changeover switch remote control on off 13 19 pole connection socket analogue For connecting analogue remote cont...

Page 18: ...Machine description PHOENIX BASIC DRIVE 4L 18 Item No 099 004838 PRA01 4 2 2 Rear view Figure 4 4 ...

Page 19: ...kage strain relief 2 19 pole connection socket analogue Wire feed unit control lead connection 3 Connecting nipple G shielding gas connection 4 Rapid action closure coupling red coolant return 5 Rapid action closure coupling blue coolant supply 6 Connector plug welding current Welding current connection on wire feed unit ...

Page 20: ... HOLD AMP HOLD After each completed welding process the last parameter values used for the welding process are shown on the display in the main program the signal light is on 2 LCD display 3 digit left Display of the parameters and values Welding current material thickness wire speed hold values 3 m min Wire speed welding parameter setting rotary dial Infinitely adjustable setting of the wire spee...

Page 21: ...m number rotary dial Arc length correction from 9 9 V to 9 9 V Setting the program number 0 15 not possible if accessory components such as program torches is connected 7 LCD display 3 digit right Display of the parameters and values Welding voltage program number coolant low temperature error Parameter selection button right VOLT Welding voltage actual nominal and hold values PROG Program number ...

Page 22: ...F min to WF max Setting range for arc length correction 9 9 V to 9 9 V 7 DYN LED Dynamics Setting range 40 to 40 8 sec LED Duration of main program PA Absolute setting range 0 0 sec to 20 0 sec 0 1s increments for superpulse 9 LED Reduced main program PB Wire speed setting range 1 to 200 of main program PA Setting range for arc length correction 9 9 V to 9 9 V 10 sec LED Duration of reduced main p...

Page 23: ...lay or selection of the job number 17 JOBLIST key button Selection of the welding task JOB from the JOB list 18 Wire inching button See also Commissioning Inching the Wire Electrode chapter Gas test rinse button Gas test For setting the shielding gas quantity 19 Rinse For rinsing longer tube packages See also Commissioning Shielding Gas Supply chapter ...

Page 24: ...Functional characteristics Machine control Operating elements 24 Item No 099 004838 PRA01 5 1 1 2 JOB list Figure 5 3 ...

Page 25: ...ng the gas flow Pressing the key button once causes shielding gas to flow for approx 25 seconds The button can be pressed again at any time to cancel the process This ensures a high standard of safety for the welder by preventing accidental ignition of the arc 2 Wire inching button For inching the wire electrode when changing the wire spool speed 50 of set wire speed The welding wire is inched int...

Page 26: ...e digit JOB number on the machine control There are presets for other welding parameters such as gas pre flow free burning etc for numerous applications however these can be changed as necessary The parameters and functions described here can also be programmed by PC using the PHOENIX PCM 300 welding parameter software 5 2 2 Selecting MIG MAG welding tasks 5 2 2 1 Basic welding parameters Select t...

Page 27: ...g parameters button until on off Sup appears on the display on off Sup m min Switches function on or off on off Sup Super puls The signal light indicates when the function has been activated 5 2 2 6 Wire burn back Prevents fusing of the wire electrode in the molten pool Wire back burn set too high large drops developing on the wire electrode result in poor ignition properties or the wire electrode...

Page 28: ...ory setting there is an automatic cut out There are optimum pre sets for welding parameters such as gas pre flow and free burn etc for numerous applications although these can also be changed if required 5 2 3 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I Welding output Wire electrod...

Page 29: ... gas is expelled gas pre flows Wire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Change over to pre selected wire speed main program PA Step 2 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses ...

Page 30: ... creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 2 Release torch trigger Super pulse function is ended WF motor stops Arc is extinguished after the preselected wire bur...

Page 31: ...d gas pre flows Wire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART for the time tstart Slope to main program PA Step 2 Release torch trigger Slope to end program PEND for the time tend WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses ...

Page 32: ... feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART spot time starts Slope on main program PA After the set spot time elapses slope goes to end program PEND WF motor stops Arc is extinguished after the pre selected wire burn back time elapses Gas post flow time elapses Step 2 Release torch trigger Rel...

Page 33: ...kes contact with the workpiece welding current is flowing start program PSTART for the time tstart Slope on main program PA Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 2 Release torch trigger Super pulse function is ended Slope to end program PEND for the time tend WF...

Page 34: ...d motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Change over to pre selected WF speed main program PA Step 2 Release torch trigger no effect Step 3 Press torch trigger no effect Step 4 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Gas post flow time elapses ...

Page 35: ...electrode makes contact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 2 Release torch trigger no effect Step 3 Press torch trigger no effect Step 4 Release torch trigger Super pulse function is ended WF motor stops Arc is extingu...

Page 36: ... earliest after the set time tSTART elapses and at the latest when the torch trigger is released Tapping 1 can be used to change over to the reduced main program PB Repeated tapping will switch back to the main program PA Step 3 Press and hold torch trigger Slope to end program PEND Step 4 Release torch trigger WF motor stops Arc is extinguished after the preselected wire burn back time expires Ga...

Page 37: ...lding current is flowing start program PSTART for the time tstart Step 2 Release torch trigger Slope on main program PA Start the super pulse function beginning with main program PA The welding parameters change at the specified times between main program PA and the reduced main program PB Step 3 Press the torch trigger Super pulse function is ended Slope in the end program PEND for the time tend ...

Page 38: ...ding process immediately open circuit voltage or welding current wire feed and shielding gas are shut off 5 2 5 Standard MIG MAG torch The torch button on the MIG welding torch is normally used for starting and stopping the welding process Several additional functions are possible using the Powercontrol RETOX or Up Down torch Operating elements Functions 1 torch trigger Welding On Off Special latc...

Page 39: ...tched latched 1 DV3 cycle for non latched latched 0 P6 Enable special JOBs SP1 to SP3 M3 70 only 0 no enabling 1 enabling of Sp1 3 0 P7 Correction mode limit value setting 0 correction mode switched off 1 correction mode switched on The control indicates that the correction operation is switched on by flashing the main program PA LED 0 P8 Program changeover with standard torch 0 normal previous la...

Page 40: ...al condition It can be switched over to a blinking display Then the program number and the welding type normal pulse are displayed alternately in the program operation In Up Down operation the Up Down settings and the Up Down symbol are displayed alternately 5 2 6 7 Program limit P4 The number of the absolute programs can be limited to above limit 5 2 6 8 Special cycle in the operating modes speci...

Page 41: ...lues To allow the welder also to perform wire and voltage correction in program mode the correction mode must be switched on and limit values for wire and voltage must be specified Setting of the correction limit value WFlimit 20 Ulimit 1 9 V Now the wire speed can be corrected by 20 8 0 up to 12 0 m min and the welding voltage by 1 9 V 3 8 V In the example the wire speed is set on 11 0 m min This...

Page 42: ...time expires Otherwise the control remains in absolute program 1 and switches to absolute program 2 after tstart elapses In the third cycle torch trigger pressed the machine switches to absolute program 3 After t3 elapses the control switches over automatically to absolute program 4 The functional sequence is only available if no other accessory components such as remote control or special torch a...

Page 43: ...ction leads The ideal tool for welding data documentation of for example Welding voltage and current wire speed and armature current WELDQAS welding data monitoring and documentation system Network compatible welding data monitoring and documentation system for the digital Phoenix and Tetrix machines 5 3 TIG welding 5 3 1 TIG arc ignition 5 3 1 1 Liftarc a b c Figure 5 16 The arc is ignited on con...

Page 44: ...imally preset for a multiplicity of applications can be adapted if required see chapter TIG Program sequence Program Steps mode In every operation mode the Superpulse function can be used 5 3 2 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger press briefly and release Shielding gas flowing I Welding output Gas pre flows Gas post flows ...

Page 45: ...3 Special non latched t t I 1 2 PA PEND PSTART Figure 5 18 Selection Select non latched special mode Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows The arc is ignited using liftarc Welding gas flows with pre selected setting in start program PSTART After the tstart ignition current time elapses the welding current rises with the set upslope time tS1 to the main program...

Page 46: ...t latched operating mode Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows The arc is ignited using liftarc Welding current flows with pre selected setting Step 2 Release torch trigger no effect Step 3 Press torch trigger no effect Step 4 Release torch trigger Arc is extinguished Gas post flow time elapses ...

Page 47: ...e on main program PA is given at the earliest after the set time tSTART elapses and at the latest when the torch trigger is released Tapping can be used to switch to the reduced main program PB Repeated tapping will switch back to the main program PA Step 3 Press the torch trigger Slope to end program PEND Step 4 Release torch trigger Arc is extinguished Gas post flow time elapses 5 3 3 TIG automa...

Page 48: ...o 40 5 4 2 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current a Hotstart time b Hotstart current I Welding current t Time 5 4 3 Antistick Anti stick prevents the electrode from annealing If the electrode sticks in spite of the Arcforce device the machine automatically switches over to the minimum current within about 1 second to prevent t...

Page 49: ...ched off The remote control is detected automatically when the welding machine is switched on 5 5 1 R10 manual remote control Figure 5 21 Item Symbol Description 0 1 0 5 1 1 5 2 2 5 3 3 5 4 5 6 7 8 9 10 11 12 13 14 15 16 18 20 m min Wire speed rotary dial Infinitely adjustable setting of the wire speed from min to max welding output one dial operation 2 0 1 1 2 2 3 3 7 7 5 5 10 10 V Arc length cor...

Page 50: ...m min Set the JOB number to be reset Confirm JOB reset If not pressed within approx 3 seconds the machine switches to the last parameters displayed and the JOB reset process is cancelled 5 6 2 Resetting all JOBs Operating element Action Result Display 3 sec Select JOB Reset m min Set All Reset after JOB 251 Confirm JOB reset If not pressed within approx 3 seconds the machine switches to the last p...

Page 51: ...ase refer to the Technical Data chapter The correct mains plug must be attached to the mains supply lead on the machine The connection must be made by a qualified electrician in compliance with the relevant local laws and regulations The phase sequence for three phase machines is optional and has no effect on the fans direction of rotation Insert mains plug of the switched off machine into the app...

Page 52: ...ast electronic components or circuit boards with compressed air but instead use suction from a vacuum cleaner for cleaning purposes 7 3 Repetition Test conforming to E VDE 0544 207 conforming to the German Ordinance on Operational Safety In addition to the regulations on the repetition test given here the relevant local laws and regulations must also be observed The repetition test must be conduct...

Page 53: ... and The results for later reference The machine must be marked if the test is successful e g with a test plate This plate must include the date of the next repetition test 7 3 3 Visual inspection Given below are the main points in the full test The points to be tested with the machine open are not required for the partial test 1 Torch stick electrode holder welding current return lead clamp 2 Lea...

Page 54: ... must meet the requirements of VDE 0404 2 For the frequency response measurement please refer to DIN EN 61010 1 Appendix A Measuring Circuit A1 For these measurements the welding machine must be switched on and supplying open circuit voltage 1 Protective conductor current 3 5mA 2 Contact current from welding sockets separately to PE 10mA 3 Contact current of accessible conductive parts not connect...

Page 55: ...en ordering spare parts please quote the machine type serial number and item number of the machine as well as the type designation and item number of the spare part We hereby certify that we have correctly followed the above mentioned servicing and maintenance guidelines and the above mentioned repetition test conforming to E VDE 0544 207 Date Stamp Signature Date Stamp Signature Date of next repe...

Page 56: ...chine connection voltages see Technical data chapter 1 Err 3 x Welding machine excess temperature Allow the machine to cool down main switch to 1 Err 4 x Coolant level low Top up the coolant Leak in the coolant circuit rectify the leak and top up the coolant Coolant pump is not working check excess current trigger on air cooling unit Err 5 x Error in WF case tachometer error Check the wire feed un...

Page 57: ...ion Name Item number ON RMSDV2 Retrofit option for DRIVE4L wheel assembly kit 090 008151 00000 ON RMSDDV1 Optional wheel assembly retrofit kit DRIVE4 4S 090 008035 00000 ON FSB WHEELS Retrofit option for locking brake for machine wheels 092 002110 00000 ON DK DRIVE L PHOENIX Retrofit option for TETRIX PHOENIX star handle 092 002112 00000 ON HOSE FR MOUNT Optional holder for tubes and remote contro...

Page 58: ...9 X1 18 X1 17 X1 16 X1 15 X1 14 X1 13 X1 12 X1 11 X1 10 Ringkern X11 1 X11 2 X11 3 X11 4 X11 5 X11 6 X11 7 X11 8 X6 Wasserkühler X12 DV Koffer X10 Tacho X12 1 X12 2 X12 3 X12 4 X12 5 X12 6 X12 7 X12 8 X12 9 X12 10 X12 11 X12 12 X12 13 X12 14 X12 15 X12 16 X12 17 X12 18 X10 2 X10 1 X10 4 X10 3 X6 1 X6 2 X6 3 X6 4 X6 5 X6 6 D Sub 15polig X7 X11 X4 Computer 1 2 4A F1 1 T 2 T 1 PE1 T 1 Motor 2 Motor 2...

Page 59: ...V 6 0V 7 Lüfter 9 Pumpe 11 0V 1 T 2 T 1 2 2 5A F2 1 Lüfter M2 1 2 1 PE Pumpe 1 M M3 1 C 2 NO 1 2 P 0 F3 1 Druckwächter 2 T 1 Pumpe 2 Lüfter 3 15V 4 Wassermangel 5 Wasserkühler 6 0V A 1 1 B 1 1 1 2 3 4 X3 T T T T bl sw gnge T C 9 1 Ausführung Wassergekühlt Datum Name gezeichnet geprüft Freigabe 27 02 2006 NIEDENTHAL Blatt 2 This drawing is protected by copyright It may not be reproduced or utilised...

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