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LOKERMANN GRAND MIG 400 PULSE User Manual

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USER MANUAL
GRAND MIG
400/500/600
PULSE
IMPORTANT: Read this OPERATOR MANUAL together
with PRESCRIPTION AND COMPLIANCE MANUAL before
to use this equipment. In case of loss one of two parts
contact immediately your dealer.
Allow the operator to consult this manual.

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Summary of Contents for LOKERMANN GRAND MIG 400 PULSE

  • Page 1 USER MANUAL GRAND MIG 400/500/600 PULSE IMPORTANT: Read this OPERATOR MANUAL together with PRESCRIPTION AND COMPLIANCE MANUAL before to use this equipment. In case of loss one of two parts contact immediately your dealer. Allow the operator to consult this manual.

  • Page 2: Table Of Contents

    Contents 1 Safety Warning............................3 2 Product..............................8 2.1 Product Introduction........................8 2.2 Technical Data..........................8 2.3 Panel Instruction.........................11 2.4 Function Description........................23 3 Opening Inspection..........................39 4 MIG/MAG Welding..........................40 4.1 Standard Configuration.......................40 4.2 Installation Instruction.........................41 4.3 Connection Diagram........................47 4.4 Welding Operation........................49 5 TIG Welding............................56 5.1 Accessories..........................56 5.2 Welding Operation........................56 6 STICK/MMA Welding..........................57 6.1 Accessories..........................57...

  • Page 4: Safety Warning

    1 Safety Warning Security Definitions It indicates that neglecting safety warnings may result in serious accidents, even death or serious injury. It indicates that neglecting safety warnings may result in minor injury to personnel or property damage. It indicates that neglecting safety warnings may result in equipment failure or damage.
  • Page 5 Before welding, the yellow-green grounding wire in the power line must be grounded and the insulation of the welding cable must be ensured. During welding operation, do not touch live parts such as workbench, welding parts, earth clamp, electrode holder or welding torches. Rubber insulation pads should also be laid on the ground near the operating table for welding operations with high no-load voltage and in wet working places.
  • Page 6 Do not carry out welding operations in degreasing, cleaning and spraying areas. Do not weld gas-filled pipes, sealing grooves (boxes) and other devices, otherwise explosions or fires are likely to occur. Do not weld near flammable gases or devices with flammable substances, otherwise explosion or fire may occur.
  • Page 7 environment do not produce electromagnetic interference, otherwise corresponding shielding and protection measures should be taken. According to the manufacturer's suggestion, the power source should be connected to the main power supply line. The length of welded cables should be shortened as far as possible to make them close to each other and to the ground.
  • Page 8 equipments should be unloaded from the power supply first. When moving the power source on the ground, it is necessary to fix the cylinder with a strap or chain to prevent dumping and injuring people. If the wire feeder is hoisted by lifting lugs for welding, it is necessary to ensure that it is firm and insulated.

  • Page 9: Product

    It is applies to the metals as aluminum, aluminum alloy, copper alloy, titanium alloy, steel and special material, etc. Technical Data Power source GRAND MIG 400 PULSE GRAND MIG 500 PULSE Power supply 3 phase 380V / 460V (- 3 phase 380V / 460V (-...
  • Page 10 Power source GRAND MIG 600 PULSE Power supply 3 phase 380V / 460V (- 15~+10%) Rated input current (A) 49.5A (380V) 41A (460V) Frequency (Hz) 50/60 Rated power 32.5 KVA No load voltage (with VRD) 7.5 V±10% No load voltage (without VRD) 92.2 V (Max) Rated duty cycle (10 min) 600-40%...
  • Page 11 Water Cooler Unit Type GRAND COOLER PULSE Power supply 380V (1~50/60Hz) Q.max 8L/min (pump) H.max Rated input current 0.5A Protection class IP23 Weight (kg) Dimensions (L×W×H) 658×360×260mm...

  • Page 12: Panel Instruction

    Panel Instruction Under the MIG/MAG mode, users need to set and operate both the power source and wire feeder. Under the TIG welding, STICK/MMA welding and arc gouging welding mode, users need to set and operate the power source. Front/Back Panel of Power Source Description Description Crane eyelets...
  • Page 13 Control Panel of Power Source No./Knob Description Main adjusting knob Software version/error code display Current display It shows the error code, current value, set current before welding, and real current in welding process. Voltage display It shows the output voltage in welding process, and shows the input voltage value when pressing the main adjusting knob.
  • Page 14 No./Knob Description by the panel. Input power supply LED The bus voltage has a feedback to the main control. When the voltage is lower than 150V DC, the machine stops working, the led of "DC BUS FAIL" on the power source front panel will light on.
  • Page 15 Back Panel of Water Cooler Unit The water cooler unit consists of two parts, the kit water cooler slot and the housing kit for water cooler rack. The cooling agent is filled through coolant filling. Description Fast socket for water (blue) Fast socket for water (red) Coolant filling Handle...
  • Page 16 Front Panel / Back Panel / Side Panel of Wire Feeder Description Front panel of wire feeder Crane eyelets Cable clamp for connection hose package (CHP) Euro connector Remote control output connector Carriage (welding tractor) connector Fast socket for water (blue) Fast socket for water (red) Gas in connector Communication port for power source...
  • Page 17 Description Fast socket for water (red) Fast socket for water (blue) Parameter label Side panel Front Panel of Wire Feeder Icon Name Description Left display Display the current, voltage and so on. Right display Left knob Used to regulate welding parameters such as current, voltage and so on.
  • Page 18 Icon Name Description Wire check button Holding down the button, the wire feeder start to wire feeding back. Real current indicator The left display shows real current when the indicator light is on. Preset current indicator The left display shows preset current when the indicator light is on.
  • Page 19 Icon Name Description mode. 4T indicator The indicator light is on when wording in this mode. Workpiece’s thickness The right display shows workpiece’s thickness when the indicator light is on. Inductance indicator The right display shows inductance when the indicator light is on. Side Panel of Wire Feeder (inside) Press the MIG/MAG torch switch, the MIG/MAG light on the power source panel lit on.
  • Page 20 Knob Description Welding mode selection button Press the button, select the four modes: Manual MIG/MAG welding Synergic MIG/MAG welding Pulse MIG/MAG welding Double pulse MIG/MAG welding Welding cycle selection button Press the button, select the four types cycle: 2T: Operating mode 2-cycles is provided for short manual welds cycles: Press torch button Solenoid valve for shielding gas opens...
  • Page 21 Knob Description Start welding cycles: Release torch button Wire feed stops Weld voltage is switched off after expiration of the burn back time Arc extinguishes Solenoid valve closes after expiration of the gas post-flow time 4T: Operating mode 4-cycles is provided for long welding cycles: Press torch button Solenoid valve for shielding gas opens the gas flow...
  • Page 22 Knob Description Solenoid valve for shielding gas opens Weld start voltage is applied on wire electrode Wire feed starts with reduced speed and arc ignites Wire feed switches to the start level wire feeding speed Weld current flows cycles: Release torch button Change from start parameter to set parameter via a time function (Up-Slope) Continue welding...

  • Page 23: Function Description

    Knob Description button is released during the spot time. Selection button of wire material Selection button of wire diameter Selection button of protection gas Auto/ manual selection button of carriage (welding tractor) Manual start / stop command button for carriage (welding tractor) Test button of protection gas (inch gas button) Function Description 2.4.1 Standby...
  • Page 24 state, and the main display is shown as three lines "---". During this state, the fan normally doesn’t work. The fan works only when the machine needs to be cooled down. 2.4.2 VRD This function reduces the output no load voltage 7.5V±10%. The VRD function is always "on", the system grants efficient arc sticking even with a no load voltage <15V.
  • Page 25 In case voltage exceeds the mentioned limits (voltage peaks), machine functions stop. Reset the machine by switching the main ON/OFF knob. The three-phase version detects even the right presence of the three current phases and, should one of those fail for > 20 ms, machine functions stop and display will show "NO PHA", reset the machine by switching the main ON/ OFF knob.
  • Page 26 d) Once ensured the correct liquid flowing, restore the original hose. 2.4.5 Output Welding Conditions, Short Circuit or Welding Over Limits A circuit test is released every time you switch "ON" the machine. The correct output polarities are checked-out and in case of eventual short circuit detection, machine enters in alarm standby showing on the display: Once short circuit conditions are removed, machine test will continue correctly.
  • Page 27 2.4.8 Inch Wire/Gas Test Press the torch switch the rollers work normally and the machine starts wire inching at 2 m/min. After 5 sec, the front panel of wire feeder flashes as "inc". The machine stops wire inching. Release the torch switch and presses it again immediately, it starts wire inching at the speed 10 m/min.
  • Page 28 0~t1: The machine starts to exhale (pre-gas time) When pressing the torch button. t1~t2: The machine starts to wire feeding. t2: The machine starts to weld and the current reach to the rated welding current. t3~t4: When releasing the torch button, the controller automatically stops the welding process, the current goes to zero, and the machine continue to exhale for some time (post-gas time).
  • Page 29 0~t1: The machine starts to exhale (pre-gas time) When pressing the torch button. t1~t2: The machine starts to weld when releasing the torch button, and the current reach to the rated welding current. t2~t3: When pressing the torch button in second time, the controller automatically stops the welding process, the current becomes to zero, and the machine continue to exhale for some time (post-gas time).
  • Page 30 0~t1: The machine starts to exhale (pre-gas time) When pressing the torch button. t1~t2: The machine starts to wire feeding. t2~t3: The machine starts to weld at the start current. t3~t4: The current goes to the rated welding current when releasing the torch button with time function (Up-slope time).
  • Page 31 Parameters Min. Max. Default 0.1s 1.0s Pre-gas time 180% 135% Start current 0.1s 3.0s Upslope time 0.1s 3.0s Downslope time Stop Current Post-gas time 0.5s The display shows "Auto" that means the post-gas time is set automatically in synergy with the value of current and the time of the welding.
  • Page 32 0~t1: The machine starts to exhale (pre-gas time) When pressing the torch button. t1~t2: The machine starts to wire feeding t2: The machine starts to weld, and current reach to the rated welding current. t3: The welding process is immediately stopped if the torch button is released during the defined time, like the case1 at t3 point in the figure, and the machine continue to exhale for some time (post-gas time).
  • Page 33 2.4.11 Inductance The inductance is used to adjust arc stiffness. When the current is small, the arc stiffness can be increased, which can reduce arc breaking. When a large current, reduce the arc stiffness, can reduce the spatter (Inductance range: -50~+50, the larger the number, the more hard the arc stiffness is).
  • Page 34 AF has internal preset values that cannot be modified when synergy STICK/MMA mode is selected. 2.4.16 Arc Force Arc force is the auto increasing of the welding current when electrode is going to have a short circuit with consequent arc brake. The value of the current depends on the AF adjustment with the relation.
  • Page 35 2: synergic welding mode 3: pulsed welding mode 4: double pulsed welding mode 0-5s Only for 4S cycle Up-slope time When the welding mode (F02) is "1", "2", "3" or "4", it is effective. 60% -150% Only for 4S cycle Start current When the welding mode (F02) is "1", "2", "3"...
  • Page 36 F014 -50 -+50 Set the inductance modification Inductance When the welding mode (F02) is "1", "2", "3" or "4", it is effective. F015 -10 -+10 Set the BBT modification When the welding mode (F02) is "1", "2", "3" or "4", it is effective. F016 On/Off...
  • Page 37 The instructions for parameters current, pulse frequency, balance and level are shown in the following figure. The peak current value is adaptive, and its size is determined by the value of balance, level and preset current because the energy in the area A equals area B. Description for PRG You can set the PRG by the remote control unit.
  • Page 38 Material Wire Protection Gas 100% (CO 82%-18% (Ar-CO 92%-8% (Ar-CO 91%-4%-5% (Ar-O - CO 100% (CO 82%-18% (Ar-CO 92%-8% (Ar-CO 91%-4%-5% (Ar-O - CO 82%-18% (Ar-CO 92%-8% (Ar-CO 91%-4%-5% (Ar-O - CO CRNI 98%-2% (Ar-CO CRNI 98%-2% (Ar-CO CRNI 97%-3% (Ar-O CRNI 98%-2% (Ar-CO CRNI...
  • Page 39 Material Wire Protection Gas FLUXBS Special 82%-18% (Ar-CO FLUXBS Standard 82%-18% (Ar-CO FLUXBS Special 82%-18% (Ar-CO FLUXRU 82%-18% (Ar-CO FLUXRU 82%-18% (Ar-CO FLUXRU 82%-18% (Ar-CO Note: the numbers with * mean they are used only for synergistic. 2.4.18 Special Options Remote Control The GRAND MIG PULSE series can be matched with a remote control box, and the welding current is set by remote control.

  • Page 40: Opening Inspection

    3 Opening Inspection Note: Avoid dust or other impurities entering the equipment. 1. Open the package and place the equipment on a stable, dry horizontal surface. 2. Verify that the equipment and all its components are not damaged during transportation. 3.

  • Page 41: Mig/Mag Welding

    The standard configurations are shown in the tables below. Model Accessories Amount Marks (PCS) GRAND MIG 400 PULSE Power source Trolley GRAND MIG 500 PULSE Water cooler slot GRAND MIG 600 PULSE House kit for Water cooler...

  • Page 42: Installation Instruction

    Installation Instruction This document will introduce the installation of water cooler standard configuration of GRAND MIG PULSE power source (the installation of air cooling configuration can refer to the corresponding steps), the assembly diagram is shown below. Wire Feeder Kit Storage Power Source Water Cooler Unit Trolley...
  • Page 43 4.2.1 Install Kit Storage Take off the 4 plastic covers on the side of power source. Fix the kit storage to the side of power source with M6. M6×14 4.2.2 Install Water Cooler Unit and Trolley Remove the screws in the back side of housing kit for water cooler slot, and take off...
  • Page 44 M5×12mm Remove the screws in the two side of the housing kit. Pull open the two side covers of the housing kit. Remove the plastics cover on the top of the housing kit, and take out the terminal from the hole. Connect the 3 ground wires of the housing kit to the side cover, then close the side cover and tighten the screws.
  • Page 45 10 Remove the 6 screws in the two sides of power source. 11 Remove the plastics cover from the bottom of power source with a slotted screwdriver, and pull out the short connect terminal. 12 Connect the two terminals of the power source and housing kit. This operation requires three people to cooperate, two of them to lift the power source, the other one to connect the two terminals.
  • Page 46 14 Fix the two sides of the housing kit and power source with M5 screws, and tighten the 6 screws in the two sides of the housing kit. 15 According to users’ requirement, the gas cylinder support could be selected and installed to the power source.
  • Page 47 Assembly Steps (with wheel) 1. Fix the wheels and torch holder (optional), and than fix the wire feeder to the power source. M6×14m Install torch holder M5×12m M6×14m...

  • Page 48: Connection Diagram

    Connection Diagram Connection Diagram (back panel) When it is connected with the gas cool CHP, the blue and red fast sockets on the water cooler unit should be short connected with a bridge pipe. And the fast sockets on the wire feeder back panel are not connected. When it is connected with the water cool CHP, the blue and red fast sockets on the wire feeder front panel should be short connected with a bridge pipe if gas cool torch is used.
  • Page 49 When remote control box (optional) with two knobs is connected to wire feeder. Manual mode: a knob is use to adjust the wire feeding speed, and the other one is use to adjust voltage. Synergic mode: a knob is use to adjust the current, and the other one is use to adjust inductance.

  • Page 50: Welding Operation

    Welding Operation 4.4.1 Preparing for Welding Before welding operation, the operators should inspect the equipment components and confirm they are in normal condition. Water Flow Cycle Test Step 1 Fill the water tank with cooling liquid. The level of liquid should be at the maximum limit of the mark on the back panel.
  • Page 51 Connect to the blue fast socket of connection hose package Connect to the red fast socket of connection hose package Step 7 Switch on the machine. Step 8 Press the torch switch again to test the water flow cycle. The cooling liquid should flow normally.
  • Page 52 The external wire feeder must be connected to the machine in the MIG/MAG process by connection hose package (CHP). The option length of the cable includes 1.4m, 5m, 10m and 20m. Press the button on the MIG/MAG torch to push wire. The wire feeding speed is only selectable in the manual MIG/MAG process between the ranges of 1.5-24m/min, while automatic set by the software in the other three MIG/MAG process.
  • Page 53 4) Press the torch switch the rollers work normally and the machine starts wire inching at 2 m/min. After 5 sec, the front panel of wire feeder flashes as "inc". The machine stops wire inching. Note: Welding wire coming out of the current contact tube may hurt the hand, the eyes or the face.
  • Page 54 Accessories Description Action Checking point Cable Check if the cable is It is damaged or even Replace the cable. damage or not. broken up. Parts of the cable heats. Check if the connection The connection looses Fasten the is loose or not. or ever heats.
  • Page 55 1) Set the voltage value through the knob on the right side of the front control panel of the wire feeder. 2) The wire feeding speed is set by knob on the left side of the front control panel of the wire feeder. 3) Shortly press the knob on the right side of the front control panel of wire feeder, and then set the arc characteristics through the knob on the right side (range: -50~+50, the larger the number, the harder the arc, that is, the greater the...
  • Page 56 Holding down the right knob, and release it when the display shows as following figure. Press the right knob or button to save the configuration. After configuration, the machine can begin to work. Configured JOB Select the configured JOB number by of the front (JOB＞0) panel of the wire feeder.

  • Page 57: Tig Welding

    5 TIG Welding Accessories Remote control 5m connection cable (standard) (male/male) 5m/10m connection cable (optional) (male/female) Welding Operation NOTE Before welding operation, the operators should inspect the equipment components and confirm they are in normal condition. Step 1 Connect the power plug to the socket. You must ground the earth wire in the power supply cable.

  • Page 58: Stick/Mma Welding

    6 STICK/MMA Welding Accessories Remote control (type: RC 101) (standard) 5m connection cable(male/male) (optional) 5m/10m extension cable (male/female) Note: The remote control is standard equipped with 5m connection cable (male/male). And optional extension cables of two length, 5m or 10m Remote control 5m connection cable 5m/10m extension cable...
  • Page 59 4×screws 4×feet 1×sheet 1×magnet 1×RC101 Wrong Schematic Diagram Variant A with four feet Variant B with two feet Variant C without feet Variant D without feet, without magnet...

  • Page 60: Welding Operation

    Welding Operation NOTE Before welding operation, the operators should inspect the equipment components and confirm they are in normal condition. Step 1 Connect the power plug to the socket. You must ground the earth wire in the power supply cable. Step 2 Turn on the main switch.

  • Page 61: Arc Gouging Welding

    7 Arc Gouging Welding Installation Instruction The installation under arc gouging mode are the same as the STICK/MMA mode. Connection Diagram The power source could be connected with one knob remote control device to set welding current. Remote Control (optional) Welding Operation NOTE Before welding operation, the operators should inspect the equipment...
  • Page 62 Step 3 Select the arc gouging mode by pressing the button " ". Under this mode, the proper length of carbon electrode out of the clamp is 80- 100mm. Step 4 Set the current according to the diameter of the electrode, thickness of workpiece and welding position.

  • Page 63: Welding Environment And Problems

    8 Welding Environment and Problems Environmental Condition The external environment of the proposed welding is as follows: Please put the power source in the horizontal position. The inclination of power source should not exceed 10 degree. The environment of power source storage should be clean and dust-proof. Dust, acid, corrosive gas or substance in ambient air not exceeding normal content, which are produced by welding process.
  • Page 64 Black welding spot Welding spot is not prevented from oxidizing .User may check as following: Make sure the valve of argon cylinder is opened and its pressure is enough. Argon cylinder must be filled up to enough pressure again if pressure of cylinder is below 0.5Mpa .

  • Page 65: Routine Maintenance

    9 Routine Maintenance a) Remove dust regularly with dry compressed air. If the welding machine is used in surroundings with heavy smoke and polluted air, it is necessary to remove dust at least one time one month. b) The pressure of compressed air shall fall to required level to prevent damage to small components in the machine.

  • Page 76: Appendix A Circuit Diagram

    Appendix A Circuit Diagram Circuit Diagram of Power source Software key filter board heat sink Display board (T177) RX0027-08C-A00 T255-A01 RX0027-02A-A00 OUT - OUT + negative di s pl a y positive di s pl a y software ORANGE VIOLET CON4 BLACK main current feedback...
  • Page 77 Circuit Diagram of Wire Feeder T252 RX0027-02A- RX0027-03C- soft w are dow nl o ad board C Z 1 5402*2 G as bal v e OUTP UT+ 103/ 2 50M 5 hol e swi t c h hole...
  • Page 78 Circuit Diagram of Water Cooler Unit Tank Flow switch Pump PUMP heat Switch Heat switch exchange exchange Filter (Optional) Blue...
  • Page 80 LOKERMANN Srl, Via Produzione 16/18, 37044, Cologna Veneta, (VR)-Italy, Tel: +39 0442 1722469 lokermann@lokermann.eu - www.lokermann.eu...

This manual is also suitable for:

Grand mig 500 pulseGrand mig 600 pulse

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