EWM Phoenix 500 TG is a MIG/MAG power source in a split layout: the M3.10 Synergic Expert panel sits in the source and the wire feeder stands apart. The current reaches 500 A at a 60% duty cycle at a temperature of 40°C and 400 A at a 100% duty cycle. The supply is 3 x 400 V with a tolerance from -25% to +20%, and the cooling is run by a COOL71 U40 module.
What this machine is for
Here 500 A is not a peak value for a moment but a parameter the machine works with at a 60% duty cycle, while in continuous work it gives 400 A. This is equipment for many hours of welding and hardfacing, where a stop for cooling costs. The split build lets you leave the heavy source below or outside and pull the light feeder up to the station, within 20 to 30 m of the source.
The first field is shipyards and offshore structures, where the feeder goes inside the hull. The second is halls and steel structures: forceArc lets you weld plate over 15 mm with a smaller bevel angle. The third is aluminium and acid resistant stainless steel, where pulse and superPuls give welds without pores and a face close to a TIG bead in transport parts.
The M3.10 panel is a base of welding characteristics called JOB. You choose the base material and the gas, set the arc dynamics with the electronic choke, and a matrix of diodes shows the active gas and the wire diameter, so that the settings are not mixed up in the hall. The feeder has simple knob control, so the welder corrects the voltage and the feed without taking off his gloves, while the process engineer sets the process at the source.
Splitting the roles between source and feeder has a practical meaning in the hall: the process is set once at the source, and at the part the welder changes only the voltage and the feed. The matrix of diodes on the panel shows the active gas and the wire diameter, so a mistake is visible before the arc is struck, not after the first bead.
Features and equipment
- M3.10 Synergic Expert panel: hundreds of JOB characteristics, a choice of material and gas, arc dynamics set with the electronic choke, support for CuSi braze welding and duplex steel.
- forceArc: a spray arc with modulated plasma pressure, which gives deep penetration also with a long free wire stick out and lets you drop the bevel angle from 60 to 30 degrees.
- superPuls: cyclic switching between two energy levels, for vertical up welding without the weaving technique and for a neat face on aluminium.
- rootArc: a process for root runs and for bridging gaps.
- COOL71 U40 cooling module with a centrifugal pump: a high fluid pressure gives a turbulent flow in the torch head, which prevents vapour locks, and a large tank steadies the temperature in three shift work.
- Separate 4 roll feeder with analogue and digital control: correction of the voltage and the feed right at the part.
- MMA and gouging with a carbon electrode: a reserve of power and a high open circuit voltage for repair work and for removing faulty welds.
- The forceArc arc is little sensitive to a change in the distance from the torch to the material: it helps with long welds run semi automatically.
- JOB programs for structural steels, acid resistant steels, aluminium alloys, CuSi wires and duplex steel.
Technical data
| Brand | EWM |
|---|---|
| Model | Phoenix 500 TG |
| Source control | M3.10 Synergic Expert panel |
| Maximum welding current | 500 A |
| Duty cycle at 40°C | 60% at 500 A, 100% at 400 A |
| Supply voltage | 3 x 400 V, tolerance from -25% to +20% |
| Cooling | liquid, COOL71 U40 module with a centrifugal pump |
| Wire feeder | separate, 4 roll, analogue and digital control |
| Working reach of the feeder | from 20 to 30 m from the source |
| Processes | MIG/MAG pulse, superPuls, forceArc, rootArc, MMA, gouging |
What to watch out for
The supply is 3 x 400 V with a tolerance from -25% to +20%, so the machine takes a weaker mains, but the socket and the fuse have to match a current of 500 A. The COOL71 U40 cooler needs a check of the fluid level, the tightness of the couplings and the flow through the hoses, because at currents of the order of 450 A the circuit runs without a break. Spreading the feeder out to 20 or 30 m means a longer liner, so the rolls, the guide liner and the pressure have to be chosen with care, otherwise the wire starts to jam.
For gouging you need a separate carbon holder and compressed air. Before you buy settle which torch and interconnection cable belong to this item, how long the earth cable is and which wire diameters you want to feed, because the set of rolls depends on that.
When working with forceArc count in the preparation of the joints as well: the gain from less bevelling appears only when the edges are cut repeatably and the gap is constant. With superPuls and the vertical position plan a trial on scrap, because the machine carries heat differently than a normal arc and the torch technique has to be matched to it.
How we sell used machines
This unit was checked in our service workshop in Krotoszyn with measurements to PN-EN 60974-4 and a load test. The price includes the first year of the basic service package: an inspection with cleaning of the machine and a validation measurement. Further years can be added. We ship across the European Union, collection in person by appointment.
