EWM Phoenix 521 is a MIG/MAG power source with an M3.19 Expert panel, described on the card at 520 A and 420 A. The panel runs synergic welding with one knob, with access to the forceArc and superPuls processes. The machine handles wires from 0.8 to 1.6 mm and is liquid cooled.
What this machine is for
The M3.19 Expert panel picks the voltage and the inductance of the electronic choke from the material, the wire diameter and the shielding gas. The material list covers SG2 and SG3 structural steels, CrNi acid resistant steels, AlMg, AlSi and Al99 aluminium alloys and CuSi and CuAl braze welding wires. Handling 1.6 mm wire and three component mixes with helium or hydrogen puts this source in the class of machines for the heaviest tasks, hardfacing among them.
The first field of use is heavy industry and bridge structures: wires 1.2 mm and 1.6 mm together with the forceArc process give deep penetration in thick walled plate. The second is precision sheet metal work and the motor industry, where the braze welding programs with CuSi and CuAl wires join galvanised sheet without tearing the coating. The third is hardfacing and reclamation, that is laying wear resistant layers on parts of working machines with little mixing with the parent material.
forceArc changes the arc shape from conical to cylindrical and raises the plasma pressure. On structures thicker than 10 mm you drop the bevel angle from 60 degrees to 30 or 40 degrees, which means a smaller weld volume, less wire and lower shrinkage stress. superPuls mixes different ways of metal transfer in one cycle, for example the spray arc with the short arc, which orders the heat put into the material and lets you weld thin aluminium in the vertical position without the pool running out.
Handling unusual gas mixes is part of the class of this panel. Helium has a higher ionisation potential than argon and brings more heat energy into the pool, which helps with materials that carry heat away well, such as copper or thick aluminium. An addition of hydrogen on austenitic steels reduces the oxides and raises the arc temperature, so you weld faster and get a smoother face. The controller corrects the arc voltage by itself, making up for the differences in plasma resistance with these gases.
Features and equipment
- M3.19 Expert panel: synergic control with one knob, with a JOB program memory and special program slots SP1, SP2 and SP3.
- forceArc: a focused, cylindrical arc with high plasma pressure, for deep penetration and less bevelling of the edges.
- superPuls: sequential switching of the ways of metal transfer in one cycle, for vertical welding and a neat ripple on aluminium.
- Handling of wires 0.8, 0.9, 1.0, 1.2 and 1.6 mm: from thin sheet to fast filling of thick joints.
- Synergic curves for SG2 and SG3 steels, CrNi steel, CuSi and CuAl wires and AlMg, AlSi and Al99 aluminium.
- Handling of CO2, Ar/CO2 and Ar/O2 gases, pure argon, Ar/He mixes and mixes with hydrogen: the controller corrects the arc voltage for the differences in the plasma.
- MSG-Löten braze welding with CuSi3 and CuAl8 wires at a temperature of the order of 900 to 1000°C: joining coated sheet with limited evaporation of zinc.
- Hardfacing: a characteristic with little penetration into the parent material and a high deposition rate.
- Extra processes: TIG Lift, MMA and gouging.
- Adjustment of the electronic choke inductance: you pick the hardness of the arc for the gas and the welding position.
- Special programs in the SP1, SP2 and SP3 slots: you call up unusual settings without setting the gas, the wire and the material from scratch.
Technical data
| Brand | EWM |
|---|---|
| Model | Phoenix 521, M3.19 Expert panel |
| Welding current per the card | 520 A, 420 A |
| Control type | synergic, one knob |
| Processes supported | MIG/MAG, pulse, superPuls, forceArc, TIG Lift, MMA, gouging |
| Wire diameters | 0.8 / 0.9 / 1.0 / 1.2 / 1.6 mm |
| Materials | SG2 and SG3 steel, CrNi, CuSi, CuAl, AlMg, AlSi, Al99 |
| Shielding gases | CO2, Ar/CO2, Ar/O2, Ar, Ar/He, mixes with hydrogen |
| Braze welding | MSG-Löten, from 900 to 1000°C |
| Supply voltage | 400 V |
| Cooling | liquid |
| Memory | JOB programs, SP1, SP2, SP3 slots |
What to watch out for
The supply is 400 V from a power socket and the cooling is liquid, so you check the fluid level and the flow before the shift, and the torch has to match the current you weld with. Work with 1.6 mm wire needs rolls and a liner for that diameter, and with aluminium a guide liner for soft wire. Mixes with helium and hydrogen mean a different regulator and different flow settings, so plan that together with the choice of programs.
The Expert panel gives many options, but the gain from it shows only after you build your own JOB programs for repeatable parts. Before you buy settle which feeder, torch and earth cable belong to this item and which set of rolls is fitted.
Braze welding with CuSi3 and CuAl8 wires runs at a temperature from 900 to 1000°C, that is below the melting point of steel. This process needs a low arc voltage and steady guidance, otherwise the zinc evaporates and pores appear in the weld. Hardfacing is set the other way round than structural welding: you want little penetration into the parent material and a large amount of deposited material, so choose the program with intent, not from the list for steel.
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.
