ALWAYS THE RIGHT CHOICE WHATEVER THE APPLICATION!

Transcription

1 EXPERT STANDARD HIGH-TECH IN NUMEROUS VARIATIONS EXPERT PULS 500 RC PULS PHOENIX EXPERT STANDARD / PULS Multi-functional Designs PHOENIX 330** PHOENIX 400 PHOENIX 500/500 RC Setting range Welding current 5 A 330 A 5 A 400 A 5 A 500 A Welding voltage 14.3 V 30.5 V 14.3 V 34.0 V 14.3V 39.0 V MMA 20.2 V 33.2 V 20.2 V 36.0 V 20.2V 40.0 V TIG 10.2 V 23.2 V 10.2 V 26.0 V 10.2 V 30.0 V Duty cycle (dc) at ambient temperature 20 C 40 C 20 C 40 C 20 C 40 C 25 % dc A % dc 300 A % dc A 500 A 500 A 45 % dc A % dc 260 A 250 A A 475 A 450 A 65 % dc A % dc 220 A 210 A 300 A 300 A 390 A 340 A Open circuit voltage 103 V (400 V) 92 V (400 V) 79 V (400 V) V (460 V) Mains voltage (tolerances)* 3 x 400 V (-25 % +20 %) 3 x 400 V (-25 % +20 %) 3 x 400 V (-25 % +20 %) 3 x 415 V (-25 % +15 %) 3 x 415 V (-25 % +15 %) 3 x 415 V (-25 % +15 %) x 460 V (-25 % +10 %) Mains frequency 50/60 Hz 50/60 Hz 50/60 Hz Mains fuse (safety fuse, slow-blow) 3 x 16 A 3 x 35 A 3 x 35 A Max. connected power 15 kva 21.5 kva 29.0 kva Recommended generator power 20.5 kva 29.0 kva 39.2 kva Cos phi/efficiency 0.99/89 % 0.99/89 % 0.99/89 % Dimensions L x W x H [mm] 605 x 335 x x 335 x x 335 x 620 Weight 42.5 kg 55 kg 58 kg KONZEPT/REALISATION: MANUAL OR AUTOMATED EXPERT ALWAYS THE RIGHT CHOICE WHATEVER THE APPLICATION! PULS STANDARD Cooling unit COOL71 U40 COOL71 U42 Cooling capacity at 1 l/min 1200 W 1600 W Tank contents approx. 7 l 7 l Max. flow rate 5 l/min 20 l/min Max. output pressure 3.5 bar 4.5 bar Coolant with frost protection KF 23 E (-10 C to +40 C) oder KF 37 E (-20 C to +10 C) Dimensions L x W x H [mm] 685 x 370 x x 370 x 255 Weight (without coolant) 22.5 kg 25 kg PHOENIX wire feed Compact** DRIVE 4L/4LP DRIVE 4/4P DRIVE 4 ROB Wire feed speed 0.5 m/min 24 m/min 0.5 m/min 24 m/min Drive 4 rollers, ø 37 mm 4 rollers, ø 37 mm Standard WF roller fitting mm (steel) mm (steel) Torch connection choice between Euro-central or Dinse-central choice between Euro-central or Dinse-central Dimensions L x W x H [mm] (without accessories) x 300 x x 460 x x 205 x 245 Weight kg 24.0 kg 9.8 kg Transport vehicle TROLLY 75 TROLLY 70-2 TROLLY 70-2 DF TROLLY 70-3 Dimensions L x W x H [mm] 980 x 505 x x 500 x x 500 x x 500 x 1325 Weight 34 kg 46 kg approx. 49 kg 47 kg Control panel PHOENIX RC 1 Dimensions L x W x H [mm] 285 x 315 x 115 Weight 2.5 kg General data Ambient temperature -10 C to +40 C Standards IEC 60974, EN 60974, EN for arc welding equipment Signs IP 23 protection classification for increased protection e.g. for outdoor welding S -Sign Welding with increased electrical hazard, e.g. in boilers CE mark In accordance with EC Directive: EMC Directive (89/336/EWG) Low Voltage Directive (73/23/EWG) * Other mains voltages e.g. 3 x 230 V, 460 V, 500 V, 575 V are possible using MULTIVOLT multi-voltage mode. ** Integrated wire feed. Please feel free to find out about our PHOENIX PROGRESS machines with their exceptional ease-of-use (PHOENIX PROGRESS brochure). Sales, Advice, Service WM Subject to alteration. EWM Hightec Welding GmbH 2005 THE UNIVERSAL ALL-ROUNDERS OF THE PHOENIX SERIES: IN MANUAL OR AUTOMATED MODE WITH HIGHEST FLEXIBILITY FOR CONSISTANTLY OPTIMAL WELDING RESULTS! MMA welding MAG MAG IMPULS standard welding pulse arc welding - -welding S I M P L Y M O R E EWM HIGHTEC WELDING GmbH Dr.-Günter-Henle-Strasse 8 D Mündersbach Phone +49(0) Fax +49(0) click info@ewm.de TIG welding Liftarc S I M P L Y M O R E

2 MAG IMPULS pulse arc welding MAG - -welding standard welding MMA welding TIG welding Liftarc PHOENIX OFFERS ALL THE FEATURES YOU COULD EVER WISH FOR THE FULLY DIGITAL MODULAR SYSTEM ALWAYS HAS THE RIGHT SOLUTION FOR EVERY TASK THE PHOENIX machine series offers all possible applications to the welder: It covers the entire spectrum of welding tasks from manual via mechanized application through to robot applications. The completely digital EWM system guarantees the usual perfect and reproducible welding results and is at the same time very easy to operate. Integration into automated systems is easy as well. The product range of the PHOENIX series meets every requirement of the welder: The PHOENIX STANDARD machines offer a cost effective solution enabling you to access the world of high-end digital welding machines. And still, all options are open to you, since you can simply upgrade to a pulse unit for more complex welding tasks. PHOENIX PULS machines are the all-rounders for almost every application. Additionally, the machines offer the forcearc technology for faster and better welding as a standard feature what more could you ask for. Our PHOENIX RC machines are the perfect robot power sources. Their varied integration options are particularly impressive and they can be controlled from anywhere using their flexible control panel. Numerous accessories both for manual as well as automated application complete the PHOENIX system. EXPERT STANDARD EXPERT PULS 500 RC PULS HIGHLIGHTS EXPERT STANDARD SIMPLY OPERATE Pre-programmed JOBs for all applications, so that you can concentrate more closely on your actual welding tasks Switch on and start machine is ready to weld immediately after being switched on Clear, user-friendly layout of the operating elements SIMPLY PERFECT WELDING Excellent results for all welding tasks even with threshold areas and with difficult materials 100 % reproducible welding results with the highest level of quality thanks to the fully digitised welding system SIMPLY MORE POWER FOR YOUR MONEY Four or five full-scale welding processes in one machine process: faster and better welding for thicker metal sheets (EXPERT PULS) The latest inverter technology with a high level of economy thanks to optimum efficiency and cos phi Manual, mechanised and robot operation and control via PC using just one machine Multi-voltage compatible 400 V; 415 V and PHOENIX 500 also 460 V as a standard SIMPLY EASY-TO-USE EXPERT PULS 500 RC PULS Modular design Uncomplicated and fast combination of cooling module, transport vehicle or wire feed unit, for example no specialist / servicing personnel or tools required, no need to open the unit Flexible upgrading thanks to modification options designed to meet all possible future requirements PLUG & WELD all components are detected automatically and you can start welding straight away RETOX the multi-functional MIG welding torch guarantees easy working directly at the welding site: Individual selection of 99 programs, operating modes and welding processes, Up/Down function, etc. PHOENIX 500 RC PULS the machine system optimized for automated applications PCM 300 Software create and modify welding characteristics without additional accessories, software etc. and also update simple welding parameter world-wide via modem SIMPLY UNIVERSAL 100 % suitable for construction sites, e.g. thanks to high mains voltage tolerance (+20% to -25%) for safe operation on a generator, long mains leads and weak mains, protection classification IP23 and S safety sign, welding under increased electrical hazard, protected layout of operating elements APPLICATIONS Production and repair work: Chemical and foodstuffs industry, machine and plant construction, vehicle, automobile, railway vehicle and ship construction, container, closed container and equipment construction, steel and metal construction work, offshore, etc. Workshop, construction site and assembly work in trade and industry Robot, industrial bus and mechanised applications Special customized welding tasks SIMPLY RELIABLE Reduced noise thanks to temperature-controlled fans Overload protection from integrated thermal monitor Minimum contamination of the electronic elements due to location in low-dust compartment and temperature-controlled fans Easy to service and maintain thanks to internal modular design with few individual components MATERIALS Solid and fluxed-core wire electrodes ( mm), coated electrodes: Rutile, basic, PHOENIX 500 also suitable for cellulose Non-alloy, low-alloy and high-alloy steels, aluminium alloys, copper and its alloys, special alloys (standard machines: restrictions on high-alloy steels and aluminium alloys)

3 THE ENTIRE BANDWIDTH FROM MANUAL TO AUTOMATED PHOENIX EXPERT STANDARD / PULS 400 or 500 INTERMEDIATE TUBE PACKAGE TROLLY 75 TROLLY 70-2* PHOENIX EXPERT STANDARD / PULS 400 or 500 INTERMEDIATE TUBE PACKAGE AUTOMATION PHOENIX DRIVE 4 ROB Welding machine 1.5 m, 5 m, 10 m, 20 m Simple assembly as all connections are plug-in or screw-on (compact) + wire feed unit TRANSPORT VEHICLE Features: Secure, stable, can be crane-lifted*, large wheels Welding machine 2.5 m, 5 m, 10 m Simple assembly as all connections are plug-in or screw-on, optimised for automation, designed for high bending and torsional loads Robot wire feed unit Optimised for use with robots, especially lightweight and compact, constant, reproducible wire feed PHOENIX DRIVE 4L / 4L P PHOENIX EXPERT STANDARD / PULS 330 Compact welding machine Wire feed unit Wire spool D300 (15 kg), easier to transport, simple change of wire spool and constant, reproducible wire feed Wheel set TROLLY 70-2 DF* + wire feed unit + 2 gas cylinders TROLLY 70-3* + 2 accessories modules + wire feed unit PHOENIX 500 RC PULS Welding machine PHOENIX RC 1 Control panel Robot application in JOHN DEERE production COOL71 U40 or COOL71 U42 PHOENIX DRIVE 4 / 4 P PHOENIX DRIVE 4Z COOL71 U40 or COOL71 U42 MULTIVOLT COOL71 U40, cooling module Modular, efficient centrifugal pump, plug-in and snapon connections or COOL71 U42, reinforced cooling module especially high coolant delivery rate Wire feed unit Wire spool D300 (15 kg), easier to transport, simple change of wire spool and constant, reproducible wire feed Wheel set Intermediate drive unit Safe wire feed (push/pull) across extended distances TUBE PACKAGE INTERMEDIATE DRIVE UNIT 10 m or 20 m, easy assembly (central connector) and friction-free wire feed (Bikox cable) COOL71 U40, cooling module Modular, efficient centrifugal pump, plug-in and snapon connections or COOL71 U42, reinforced cooling module especially high coolant delivery rate Multi-voltage module For regional mains voltages: 3 x 230 V, 460 V, 500 V, 575 V TROLLY 70-2 ROB PHOENIX R10 PHOENIX R40 RETOX COM PCINT X10 WELD QAS RINT X11 BUSINT X10 DVINT X11 DIN ISO 9000 WELD QAS Manual MIG remote control Operating point Infinitely adjustable operating point setting (one-dial operation/synergic) Arc length correction Manual MIG remote control Program Create, save and call up MIG welding programs Display for welding data MIG multi-functional welding torch, Gas / water cooled Individual setting and display options Call-up of 99 welding programs Up/Down function Display for welding data MIG welding torch Gas / water cooled Standard torch Program torch Up/Down torch Push/pull torch TIG Kombi- Welding torch Gas / water cooled Analogue Interface for mechanised welding Current flows, emergency stop, U actual, I actual, etc. Serial PC interface (as standard) Interface + PHOENIX PCM300 software welding parameters Welding data Documentation PCINT X10 interface, Q-DOC 9000 software Welding data monitoring and documentation Interface + software WELD QAS Robot interface Industrial bus interface Wire feed Interface e.g. for special wire feed units Further information regarding automation components can be found in the following sections

4 SIMPLY... EVEN BETTER RESULTS, EVEN FASTER SIMPLY... ALL IMPORTANT OPERATING ELEMENTS AVAILABLE AT THE SITE OF WORK The PHOENIX EXPERT control has been designed to be very easy and quick to operate, but still provides all the functions one could ever need. No additional re-training time thanks to the identical control interface for the STANDARD and PULS machines. PHOENIX EXPERT MACHINE CONTROLS The main focus in developing the PHOENIX wire feed control was on simple and fast operation directly at the site of work. They are available in 2 versions: The basic control (M 3.00) and the program control (M 3.70) with selection of the special JOBs and 16 welding programs as well as suitable parameter and welding data display. PHOENIX WIRE-FEED CONTROL PROGRAM Display Display Selection Selection and setting Operating modes: Non-latched / latched, non-latched / latched special puls arc (only PHOENIX EXPERT PULS) and Standard welding Setting Special functions Superpuls function Selection and setting Welding programs and parameters and their values e.g. M 3.70 Selecting the welding task (JOB) Welding process -, cored wire and GMAsurfacing, MSG brazing - forcearc welding - MMA Welding - TIG welding Material type Wire electrode diameter Type of gas e.g. M 3.10 Key switch (locking the control) Selecting further operating levels Operating point setting with one-dial operation/synergic e.g. using wire-feed rate / speed or panel thickness Arc length correction Apart from the welding parameters and functions optimally preset for most applications, the program control is also provided with special functions as well as non-standard setting options. Selection / display Selection Special JOBs SP1 to SP3 currentless wire inching No-power gas test Functions General standard, pulse and forcearc welding, TIG (Liftarc) and MMA Welding Non-latched / latched, special non-latched / latched, MIG spot Automatic cut-out, hold function Synergic one-dial operation Pre-selection of material type, seam type, electrode diameter 256 JOBs: 128 preset and 128 freely programmable for customised applications 3 special JOBs 16 programs per JOB Key-operated switches Displays 2 displays for welding parameters before, during and after welding: Welding current and voltage, panel thickness, a-measurement, motor current, program and JOB numbers etc. LEDs for status display (infinitely adjustable) MIG Wire speed Arc length correction Choke effect / dynamics Wire burn-back Wire creep Gas pre-flow and post-flow times Slope times: Main, reduced main and end program Start, main, reduced main and end program per JOB Superpuls: pulse and pause program TIG Welding current Gas pre-flow and post-flow times Up and down slope time Start, welding, secondary and end currents MMA Hotstart time and current Arcforcing Internally programmable Various torch and function modes Expert Mode for creating customised characteristics Accessories / options Torch Up/Down Program / JOB selection RETOX: UP/Down with display Push/Pull TIG Kombi Remote control Manual remote control: Current, program Program remote control Options Dinse central connector PHOENIX 330: Crane suspension Interfaces Analogue interface for mechanised welding Digital interfaces: PC, robot, industrial bus, cold wire feed, documentation Software PCM 300 welding parameter software Q-DOC 9000, WELD QAS welding data documentation software Miscellaneous Multi-voltage module (3 x 230 V, 460 V, 500 V, 575 V) Welding programs and their parameters, superpuls function, arc dynamics/choke effect etc. Functions General standard and pulse welding Non-latched, special non-latched, latched, special latched, MIG spot Automatic cut-out, hold function Synergic one-dial operation 3 special JOBs: 16 programs per JOB Currentless gas test and wire inching Intermediate connection capability Displays 2 displays for welding parameters before, during and after welding: Welding current and voltage, panel thickness, program number etc. LEDs for status display e.g. M 3.70 (cover open) (infinitely adjustable) MIG Wire speed Arc length correction Choke effect / dynamics Wire burn-back Wire creep Gas pre-flow and post-flow times Slope times: Main, reduced main and end program Start, main, reduced main and end program per JOB Superpuls: Pulse and pause program Internally programmable Various torch and function modes Accessories / options Torch Up/Down Program / JOB selection RETOX: UP/Down with display Push/Pull TIG Kombi Remote control Manual remote control: Current Program remote control Options Dinse central connector PHOENIX DRIVE wheel set

5 SIMPLY... FASTER AND MORE PERFEKT -WELDING WITH SIMPLY MORE... Closed container construction Reliable operating point location thanks to synergic one-dial operation Simple selection of the welding task via the material type, gas type and wire diameter Optimised characteristics for all materials 100 % reproducible welding results thanks to the digital system Precise setting of all parameters by displaying the welding data before the welding process Optimum preset ignition and end pulse corresponding to the material Excellent ignition thanks to the start operating point Competitive because of its cost-effectiveness Simple transport thanks to the innovative inverter technology for compact machine size Universal machines can also be used for pulse and standard welding, as well as MMA and TIG (Liftarc) welding AREA OF APPLICATION Applications Machine and plant construction, vehicle, railway vehicle and ship construction, container, closed container and equipment construction, offshore, etc. Robot, industrial bus and mechanised applications SIMPLY BETTER WELDING Improved efficiency thanks to the higher welding speed in spray arc ranges Excellent fusion penetration properties thanks to the high arc pressure Simple handling even at higher output levels thanks to the steady arc with high directional stability Best possible seam quality thanks to the narrow and small heat affected zone Fast stabilisation of changes in length via the highly dynamic arc Minimum distortion thanks to the reduced energy per unit length No undercuts thanks to the short arc Virtually spatter-free welding thanks to the highly dynamic current regulation via the digital system SIMPLY BETTER MACHINE TECHNOLOGY Application example Steel construction Sheet metal thickness Material Welding WF parameter Welding speed Materials Low- and high-alloy steels, aluminium and aluminium-based alloys Sheet metal thickness 5 mm 6 mm StE 260 (construction steel) double fillet weld without seam preparation 11 m/min (1.2 mm SG2) Us 29.8 V Is 302 A 510 mm/min PHOENIX EXPERT PULS WITH DRIVE 4L P... ADVANTAGES OF THE DIGITAL SYSTEM Low-spatter welding and minimal finishing work thanks to microprocessor-controlled drip transition Precise adjustment and reproduction of welding parameters Stable arc when changing the position even in transition and fringe areas Optimum welding parameters, regardless of the intermediate tube package and mains cable lengths and mains voltage fluctuations Reproducible, precise wire feed even with difficult welding wires thanks to the digital incremental encoder for checking and controlling the wire-feed speed... WELDING TECHNOLOGY OPTIONS Pulse arc welding (PHOENIX EXPERT PULS only) Exceptional, lower-spatter pulse arc with defined, short circuit-proof drip transition for all materials across the entire power range Thin panels can be welded with thicker, more economical wire electrodes Aluminium: 100 % ignition success thanks to defined start and end pulse, reduction of cool points and bonding errors by the start program (special latched) High-alloy steels: Appropriately adjusted pulse shapes provide optimum heat feeding Ideal alternative for working in the mixed arc area, e.g. for low-spatter welding of unalloyed and low-alloy steels Excellent welding properties for all materials thanks to the pulse arc characteristic specified accordingly Short arc welding Low spatter formation, stable arc, lowest possible heat feeding at relatively high welding speeds thanks to defined short-circuits and resolution on drip transition Enlarged short arc range, limiting undesirable mixed arc area Used in the lower power range, for positional welding and in root welding Spray arc welding Powerful, low-spatter arc thanks to short circuit-proof material transfer of fine droplets Used in the upper power range with high fusion performance for large panel thickness Superpuls function Aluminium: Fine meshing of the weld seam, reduction of pores, better welding bath control High-alloy steels and heat-sensitive materials with controlled energy per unit length welding Alternative for TIG welding, e.g. for visible seams for aluminium and high-alloy steels welding seam visually as TIG Welding voltage Short arc PULSE ARC Mixed arc Spray arc Welding current

6 SIMPLY... OPTIMAL FOR ROBOT-APPLICATION SYSTEM SIMPLY... CREATING LINKS The PHOENIX facilitates universal integration options using a variety of accessory components and various interfaces such as analogue automated interface, digital interfaces for robot and industrial bus connections as well as welding data creation, monitoring and documentation. PHOENIX 500 RC PULS THE PERFECT ROBOT-POWER SOURCE Fully digital bus system for perfect and 100 % reproducible welding results Extended duty cycle for continuous use in multi-shift operation Modular design (easy to service and maintenance), Plug & Weld functionality Extensive integration options thanks to various digital interfaces for program and control voltage operation, industrial bus systems (Profibus, Interbus, CAN-BUS, Devicenet) and connection of WF units (cold wire, flat wire etc.) Primary-switched innovative inverter power unit for excellent economy thanks to the high level of efficiency PHOENIX RC 1 THE FLEXIBLE CONTROL PANEL FOR SYSTEM AND MACHINE OPERATION FROM ANYWHERE Efficient solution operation panel required for programming work, not for operation Lightweight plastic casing Clear operating interface to display all parameters and status conditions relating to the process Easy to set and change parameters using the rotary dial with large control button Fast and simple programming thanks to LED user support Direct access to 16 welding programs Easy to set and change all parameters for the welding task (JOB) Standard PC interface on the control panel PHOENIX RC 1 CONTROL Display Status, operating state PHOENIX 500 RC PULS PHOENIX RC 1 MECHANISED WELDING INTERFACE (in welding machine as standard) Ideally equipped for simplest mechanised applications. Current flow signal, emergency stop, U actual, I actual, etc. RINT X11 ROBOT INTERFACE (optional, retrofitting in the machine or externally by the customer) The digital standard interface for automated applications. Functions and signals: Digital inputs: Start/stop, operating mode, JOB and program selection, inching, gas test Analogue inputs: Control voltages for welding output, correction, dynamics Relay outputs: Current flows, welding data monitoring, ready for welding, etc. BUSINT X10 INDUSTRIAL BUS INTERFACE (optional, external installation by customer) The solution for convenient integration into automated production lines with, for example, Profi, CAN and Interbus systems DVINT X11 WIRE FEED INTERFACE (optional, retrofitting in the machine or externally by the customer) The all-rounder for flexible connection of special wire feed units, for example: Binzel (APD system), Dinse wire feed systems Selection and display Basic parameters of the welding programs Confirmation of the inputs Welding programs Parameters in the program sequence JOB Manager (organisation of the welding programs) Selection further operating levels Locking the operating panel by means of key switch Setting such as wire-feed rate / speed, dynamics, gas pre-flows / post flows, slope times M 3.40 WELDING PARAMETER MANAGEMENT: Q-DOC 9000 Welding data documentation WELD QAS Welding data documentation and monitoring PCINT X10 Q-DOC 9000 WELD QAS MOBILE WELD QAS STATION (Accessories: set with software, interface, connection leads) The ideal tools for documentation of welding data such as welding voltage and current, wire-feed rate / speed. Armature current WELDING PARAMETER SOFTWARE PC M 300 Creation, transfer and management of welding data (Accessories: set with software, interface, connection leads) Create all welding parameters quickly on the PC and easily transfer them to one or more welding machines: Simple... Operation via: Windows interface, structured control menus and levels for changing, specifying and programming all welding parameters Management of the 256 JOBs in a database with easy-to-use search options Exchange of JOBs from and to the PHOENIX welding machine Creation of customised welding characteristics Online process analysis, i.e. data is displayed on PHOENIX PCM 300 and directly used in the welding process