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LOKERMANN GRAND MIG 302 PULSE Operator's Manual

Inverter mig welding machine
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THANK YOU FOR USING OUR PRODUCTS
OPERATORS' MANUAL
GRAND MIG 302 PULSE
Inverter MIG Welding Machine
IMPORTANT: Read this Owner's Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
distributor if you do not fully understand this manual.

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  • Page 1 THANK YOU FOR USING OUR PRODUCTS OPERATORS’ MANUAL GRAND MIG 302 PULSE Inverter MIG Welding Machine IMPORTANT: Read this Owner’s Manual Completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.

  • Page 3: Table Of Contents

    CONTENT CONTENT §1 Safety §2 Overview §2.1 Features §2.3 Brief Introduction §2.2 Technical Data §2.4 Duty cycle and Over-heat §2.5 Working Principle §2.6 Volt-Ampere Characteristic §3 Panel Functions & Descriptions §3.1 Machine Layout Description §3.2 Layout for Control panel §3.2.1 MMA control panel §3.2.2 Lift TIG control panel §3.2.3 MIG Manual control panel §3.2.4 MIG (Dual) Pulse control panel...
  • Page 4 CONTENT §4.3.2 Wire Feed Roller Selection §4.3.3 Wire Installation and Set-Up Guide §4.3.4 MIG Torch Liner Installation §4.3.5 MIG Torch Liner Types and Information §4.3.6 Torch & Wire Feed Set-Up for Aluminum Wire §4.3.7 MIG Welding §4.4 Installation & Operation for Spool Gun §4.4.1 Set up installation for Spool Gun §4.4.2 Spool Gun Control §4.5 Welding Parameters...

  • Page 5: Safety

    SAFETY §1 Safety Notice: The instructions are for reference only. The manufacturer reserves the right to explain the differences between the description and the product due to product changes and upgrades!
  • Page 6 SAFETY...
  • Page 7 SAFETY...
  • Page 8 SAFETY...
  • Page 9 SAFETY...
  • Page 10 SAFETY...
  • Page 11 SAFETY...
  • Page 12 SAFETY This is also true for residential areas in which the energy is supplied from the public low-voltage mains. EMC device classification as per the rating plate or technical data.

  • Page 13: Overview

    OVERVIEW §2 Overview §2.1 Features  LCD screen for accurate setting & feedback of welding output.  New PWM technology and IGBT inverter technology.  Multi voltage input, can use with long extension lead.  MIG/MAG with Pulse SYN/Dual pulse SYN/Manual function -Synergic programs for aluminum, mill steel, stainless steel and CuSi -JOB mode (Save and call 10 different job records) 2T/4T/S4T/...

  • Page 14: Brief Introduction

    OVERVIEW §2.3 Brief Introduction MIG series of welding machines is a new inverter-based MIG/MMA/TIG Welding machine with Synergic Programs and Dual pulse functions. The MIG function allows you to weld with Gas Shielded wire applications giving excellent, professional welding results. Easy step-less adjustment of voltage and wire feed coupled with the screen allows easy setting of welding parameters.

  • Page 15: Technical Data

    OVERVIEW §2.2 Technical Data Models GRAND MIG 302 PULSE Parameters Input Voltage (V) 3-400±10% Frequency (HZ) 50/60 Input Current (A) 20.5 16.0 22.5 Input Power (kVA) 14.3 11.1 15.7 Welding Current (A) 20~300 10-300 No-load Voltage (V) Power Factor 0.69 Duty cycle (40°C)

  • Page 16: Duty Cycle And Over-Heat

    OVERVIEW §2.4 Duty cycle and Over-heat The letter “X” stands for Duty Cycle, which is defined as the portion of the time a welding machine can weld continuously with its rated output current within a certain time cycle (10 minutes). The relation between the duty cycle “X”...

  • Page 17: Volt-Ampere Characteristic

    OVERVIEW §2.6 Volt-Ampere Characteristic MIG series of welding machines has an excellent volt-ampere characteristic, whose graph is shown as the following figure. The relation between the rated loading voltage and welding current I is as follows: U =14+0.05I (V).

  • Page 18: Panel Functions & Descriptions

    PANEL FUNCTIONS & DESCRIPTIONS §3 Panel Functions & Descriptions §3.1 Machine Layout Description 1. MIG torch euro connector. 2. Remote connection plug. 3. Positive (+) welding power output connection socket. 4. MIG Torch Polarity Change Power Connection. 5. TIG torch gas connector. 6.
  • Page 19 PANEL FUNCTIONS & DESCRIPTIONS Further Controls Explained: Outlet (8) and inlet (9) The two nozzles on the same side of the intake (7) can be connected to the nozzles on welding torch. Blue corresponds to the outlet: cold water is delivered from the tank; red corresponds to the backwater inlet: hot water is flowed into the tank for cooling.

  • Page 20: Layout For Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS §3.2 Layout for Control panel §3.2.1 MMA control panel 1. Welding mode button: Press it to enter MMA welding mode. 2. L parameter knob: Rotate it to welding current. 3. R parameter knob: Press it to select Hot Start or Arc Force and rotate it to adjust values.

  • Page 21: Lift Tig Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS Arc force An MMA welding power source is designed to produce constant output current. This means with different types of electrode and arc length; the welding voltage varies to keep the current constant. This can cause instability in some welding conditions as MMA welding electrodes will have a minimum voltage they can operate with and still have a stable arc.

  • Page 22: Function Interface

    PANEL FUNCTIONS & DESCRIPTIONS 2. L parameter knob: Rotate it to adjust welding current. In function interface, rotate it to select parameters, such as trigger mode and Post Flow time. 3. R parameter knob: rotate it to adjust parameters of TIG function interface. 4.
  • Page 23 PANEL FUNCTIONS & DESCRIPTIONS Introduction: (1) 0: Press the gun switch and hold it. Electromagnetic gas valve is turned on. The shielding gas stars to flow. (2) 0～t1: Pre-gas time (0.1~2.0s) (3) t1～t2: Arc is ignited and the output current rises to the setting welding current (I ) from the min welding current.
  • Page 24 PANEL FUNCTIONS & DESCRIPTIONS series of welding machines also has more current control options that can be used in 4T mode. The start current and crater current can be pre-set. This function can compensate the possible crater that appears at the beginning and end of the welding. Thus, 4T is suitable for the welding of medium thickness plates.

  • Page 25: Mig Manual Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS (12) t7: Electromagnetic valve is closed and stop argon flowing. Welding is finished. §3.2.3 MIG Manual control panel 1. Welding mode button: Press it to enter MIG Manual welding mode. 2. L parameter knob: Rotate it to adjust wire feeding speed. In function interface, rotate it to select parameters.
  • Page 26 PANEL FUNCTIONS & DESCRIPTIONS Function interface: 1. Trigger mode: 2T/4T/ Spot weld. 2. Pre flow time: 0~5.0s. 3. Post flow time: 0~10.0s. 4. Burnback: 0~10. 5. Slow feed: 0~5. 6. Spool gun: On/OFF. 7. Spot welding time: 0.5~10.0s Burnback Short-circuit between welding wire and molten pool leads to the increase of current, which leads to the melting speed of welding wire too fast, and the wire feeding speed cannot keep up with, which makes the welding wire and workpiece disconnected.
  • Page 27 PANEL FUNCTIONS & DESCRIPTIONS Slow feed This function is used to regulate the speed of wire feeding increasing. Range: 0~5. 2T trigger mode: 4T trigger mode: Spot Weld trigger mode:...

  • Page 28: Mig (Dual) Pulse Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.4 MIG (Dual) Pulse control panel 1. Welding mode button: Press it to enter MIG (Dual) Pulse welding mode. 2. L parameter knob: Rotate it to adjust wire feeding speed. In function interface, rotate it to select parameters. 3.
  • Page 29 PANEL FUNCTIONS & DESCRIPTIONS 1. Trigger mode: 2T/4T/S4T(4T+) (SPOT for MIG Pulse). 2. Wire material: SS-metal solid-cored/Fe-metal solid-cored/Fe-metal flux-cored/CuSi/ Al-Mg solid-cored/ Al-Si solid-cored/ Al 99.5 solid-cored/ SS-metal flux-cored/ CuAl. 3. Wire diameter: 0.8~1.2mm. 4. Type of gas: Ar /80% Ar+20%CO /98% Ar+2%CO 5.

  • Page 30: Mig Syn Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS allowing puddle stability. It is mainly used in aluminum alloy welding for strong penetration with narrow bead and smooth surface. It can produce the ripple effect of a TIG weld without torch modulation. Dual pulse reference waveform as shown below: ...
  • Page 31 PANEL FUNCTIONS & DESCRIPTIONS 1. Welding mode button: Press it to select MIG SYN welding mode. 2. L parameter knob: Rotate it to adjust wire feeding speed. In functional parameter interface, rotate it to select parameters. 3. R parameter knob: Rotate it to adjust parameters. 4.

  • Page 32: Job Program Control Panel

    PANEL FUNCTIONS & DESCRIPTIONS Function interface: 1. Trigger mode: 2T/4T/ Spot weld. 2. Wire material: SS-metal solid-cored/Fe-metal solid-cored/Fe-metal flux-cored/CuSi. 3. Wire diameter: 0.8~1.2mm. 4. Type of gas: CO /Ar / 98%Ar+2%CO / 80%Ar+20%CO 5. Pre flow time: 0~5s. 6. Post flow time: 0~10s. 7.
  • Page 33 PANEL FUNCTIONS & DESCRIPTIONS 1. JOB button: Press it for 3s to enter JOB programs and press it for 1s to save parameters. 2. Parameters display: Here are all the selected parameter that you settings. 3. JOB number display. 4. L parameter knob: Rotate it to turn the page and press it to delete the parameters. 5.

  • Page 34: System Setting Panel

    PANEL FUNCTIONS & DESCRIPTIONS §3.2.7 System setting panel Press the functional parameter key and hold it for 3s to enter the system interface. Here you can adjust the language and the unit setting by L parameter knob and R parameter knob.

  • Page 35: Installation & Operation

    INSTALLATION & OPERATION §4 Installation & Operation §4.1 Installation & Operation for MMA Electrode Welding §4.1.1 Set-Up Installation (1) Connection of Output Cables: Two sockets are available on this welding machine, One Positive (+) and one Negative (-) polarity, to connect MMA/Electrode holder cable and earth clamp cable.

  • Page 36: Mma/Stick Electrode Welding

    INSTALLATION & OPERATION steady to maintain the arc. §4.1.2 MMA/Stick Electrode Welding One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’.

  • Page 37: Mma Welding Fundamentals

    INSTALLATION & OPERATION wire core and a flux coating. These electrodes are identified by the wire diameter and by a series of letters and numbers. The letters and numbers identify the metal alloy and the intended use of the electrode. The Metal Wire Core works as conductor of the current that maintains the arc.
  • Page 38 INSTALLATION & OPERATION 6013 electrode. Welding Current (Amperage) Correct current selection for a particular job Electrode Size Current Range ø mm (Amps) is an important factor in arc welding. With the 2.5 mm 60~95 current set too low, difficulty is experienced in 3.2 mm 100~130 striking and maintaining a stable arc.

  • Page 39: Installation & Operation For Tig Welding

    INSTALLATION & OPERATION Travel Speed The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all times. Excessive travel speeds lead to poor fusion, lack of penetration etc, while too slow a rate of travel will frequently lead to arc instability, slag inclusions and poor mechanical properties.

  • Page 40: Dctig Welding

    INSTALLATION & OPERATION twist to lock in place. (2) Plug the welding torch into the negative socket on the front panel and twist to lock. (3) Connect the control cable of torch switch to multipin receptacle on the front of the machine.
  • Page 41 INSTALLATION & OPERATION electrons, flow in only one direction from the negative terminal (-) to the positive terminal (+). In the DC electrical circuit there is an electrical principle at work which provides that, in a DC circuit, 70% of the energy (heat) is always on the positive side. This is important because it determines what terminal to connect the TIG torch.

  • Page 42: Tig Welding Fusion Technique

    INSTALLATION & OPERATION §4.2.3 TIG Welding Fusion Technique Manual TIG welding is often considered the most difficult of all the welding processes. Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the workpiece. Similar to Oxygen/Acetylene torch welding, TIG welding normally requires two hands and in most instances requires the welder to manually feed a filler wire into the weld pool with one hand while manipulating the...

  • Page 43: Tungsten Electrodes

    INSTALLATION & OPERATION forward. A “dabbing” technique can be used to control the amount of filler wire added. The wire is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly and evenly forward. It is important during the welding to keep the molten end of the filler wire inside the gas shield as this protects the end of the wire from being oxidized and contaminating the weld pool.
  • Page 44 INSTALLATION & OPERATION Thoriated tungsten should not get in contact with open cuts or wounds. The more significant danger to welder can occur when thorium oxide gets into the lungs. This can happen from the exposure to vapors during welding or from ingestion of material/dust in the grinding of the tungsten.

  • Page 45: Tungsten Preparation

    INSTALLATION & OPERATION AC or DC electrode negative with a pointed end, or they can be balled for use with AC sine wave power sources. Lanthanated tungsten maintains a sharpened point well, which is an advantage for welding steel and stainless steel on DC or AC from square wave power sources.
  • Page 46 INSTALLATION & OPERATION start before the tip and wander. Grinding longitudinally with the grain, the electrons flow steadily and easily to the end of the tungsten tip. The arc starts straight and remains narrow, concentrated and stable. Electrode Shape & Angle The shape of the tungsten electrode tip is an important process variable in precision arc welding.

  • Page 47: Installation & Operation For Mig Welding

    INSTALLATION & OPERATION  Have a narrower arc shape  Can handle more amperage without eroding. Sharper electrodes with smaller included angle provide:  Offer less arc weld  Have a wider arc  Have a more consistent arc Tungsten Diameter at Constant Included Current Range...

  • Page 48: Wire Feed Roller Selection

    INSTALLATION & OPERATION B- Insert the earth cable plug into the Positive (+) socket and twist to tighten. (Gasless wire) (2) Plug the MIG welding gun into MIG torch euro-connector on the front panel and tighten locking nut securely. (3) A- Insert the polarity switching cable plug into the positive socket on the front of the machine and tighten it.
  • Page 49 INSTALLATION & OPERATION welding wire and they have different types of grooves machined in them to accommodate the different types of wire. The wire is held in the groove by the top roller of the wire drive unit and is referred to as the pressure roller, pressure is applied by a tension arm that can be adjusted to increase or decrease the pressure as required.

  • Page 50: Wire Installation And Set-Up Guide

    INSTALLATION & OPERATION §4.3.3 Wire Installation and Set-Up Guide The importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough. The correct installation of the wire spool and the wire into the wire feed unit is critical to achieving an even and consistent wire feed. A high percentage of faults with MIG welders emanate from poor set up of the wire into the wire feeder.

  • Page 51: Mig Torch Liner Installation

    INSTALLATION & OPERATION §4.3.4 MIG Torch Liner Installation §4.3.5 MIG Torch Liner Types and Information MIG Torch Liners The liner is both one of the simplest and most important components of a MIG gun. Its sole purpose is to guide the welding wire from the wire feeder, through the gun cable and up to the contact tip.
  • Page 52 INSTALLATION & OPERATION the liner with compressed air. Small diameter welding wires, 0.6mm through 1.0mm have relatively low columnar strength, and if matched with an oversized liner, can cause the wire to wander or drift within the liner. This in turn leads to poor wire feeding and premature liner failure due to excessive wear.

  • Page 53: Torch & Wire Feed Set-Up For Aluminum Wire

    INSTALLATION & OPERATION §4.3.6 Torch & Wire Feed Set-Up for Aluminum Wire The same method is used for Teflon and/or Polyamide Liners (PA). §4.3.7 MIG Welding Definition of MIG Welding MIG (metal inert gas) welding also known as GMAW (gas metal arc welding) or MAG (metal active gas welding), is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun.
  • Page 54 INSTALLATION & OPERATION towards the un-melted work surface. This technique offers a better view of the weld joint and direction of the wire into the weld joint. Push technique directs the heat away from the weld puddle allowing faster travel speeds providing a flatter weld profile with light penetration - useful for welding thin materials.
  • Page 55 INSTALLATION & OPERATION Stick Out - Stick out is the length of the un-melted wire protruding from the end of the contact tip. A constant even stick out of 5-10mm will produce a stable arc, and an even current flow providing good penetration and even fusion. Too short stick out will cause an unstable weld pool, produce spatter and over heat the contact tip.
  • Page 56 INSTALLATION & OPERATION the weld pool allowing the base metal to melt sufficiently to create good penetration, fusion and wetting out of the weld pool producing a weld deposit of good quality. Gas selection - The purpose of the gas in the MIG process is to protect / shield the wire, the arc and the molten weld metal from the atmosphere.
  • Page 57 INSTALLATION & OPERATION WELDING WIRE DIAMETER CHART MATERIALTHICKNESS RECOMMENDED WIRE DIAMETERS 0.8mm 0.9mm 1.0mm 1.2mm 1.6mm 2.0mm 2.5mm 3.0mm 4.0mm 5.0mm 6.0mm 8.0mm 10mm 14mm 18mm 22mm For material thickness of 5.0mm and greater, multi-pass runs or a beveled joint design may be required depending on the amperage capability of your machine.

  • Page 58: Installation & Operation For Spool Gun

    INSTALLATION & OPERATION §4.4 Installation & Operation for Spool Gun §4.4.1 Set up installation for Spool Gun (1) Insert the earth cable plug into the Negative socket on the front of the machine and tighten it. (2) Connect the Spool Gun to the MIG torch connection socket on the front panel of the wire feeder, and tighten it.

  • Page 59: Spool Gun Control

    INSTALLATION & OPERATION Regulator. (6) Connect the gas line to gas connector on the rear panel. (7) Connect the power cable of welding machine with the output switch in electric box on site. (12) Select MIG Manual welding mode by pressing the welding mode button and enter the function interface to set “SPOOL GUN”...

  • Page 60: Welding Parameters

    INSTALLATION & OPERATION §4.5 Welding Parameters Process reference for CO butt welding of low carbon steel solid welding wire Process reference for CO corner welding of low carbon steel solid welding wire...
  • Page 61 INSTALLATION & OPERATION Low carbon steel, stainless steel pulse MAG welding process reference Welding process of aluminum alloy pulse MIG Welding Material Wire Welding Welding Welding Nozzle and Gas-flow position thickness diameter current voltage speed workpiece rate (MM) (MM) (CM/MIN) spacing(MM) (L/MIN) Butt-joint...

  • Page 62: Operation Environment

    INSTALLATION & OPERATION 250-300 25-26 60-65 18-22 16-24 12.0 300-400 26-28 65-75 18-22 16-24 §4.6 Operation Environment ▲ Height above sea level ≤1000 M. ▲ Operation temperature range: 14 ~ 104°F (-10 ~ 40°C). ▲ Air relative humidity is below 90%. ▲...

  • Page 63: Maintenance & Troubleshooting

    MAINTENANCE & TROUBLESHOOTING §5 Maintenance & Troubleshooting §5.1 Maintenance The operator must understand the maintenance procedure of inverter welding machine and carry on simple examinations, cleanings and inspections. Do your best to protect the machine from contamination environment and leaving unit ON when not in use to lengthen service life of inverter arc welding machine.

  • Page 64: Troubleshooting

    MAINTENANCE & TROUBLESHOOTING Monthly Using the dry compressed air to clear the inside of arc welding machine. examination Especially for clearing up the dusts on aluminium heat-sinks, inductors, IGBT modules, fast recover diodes, PCB’s, etc. Check the screws and bolts in the machine. If any are loose, please tighten. Check all torches, earth clamp and hose connections to insure they are securely in place.
  • Page 65 MAINTENANCE & TROUBLESHOOTING Troubles Reasons Solution Turn ON power but the power Switch damaged Change it light is not illuminated. Fuse damaged Change it Power cord damaged Change it After welding machine is over- Fan damaged Change it heat, the fan doesn’t work The cable is loose Screw the cable tight Press the gun...

  • Page 66: Mig Welding - Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING §5.2.1 MIG Welding - Trouble Shooting The following chart addresses some of the common problems of MIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. Trouble Possible Reason Suggested Remedy Excessive Wire feed speed set too high...

  • Page 67: Mig Wire Feed - Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING Missing or damaged gas diffuser Replace the gas diffuser MIG torch euro connect O-ring Check and replace the O-ring missing or damaged Holding the torch too far away Bring the torch closer to the work and Wire stubbing during welding maintain stick out of 5~10mm Welding voltage set too low...
  • Page 68 MAINTENANCE & TROUBLESHOOTING welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. Trouble Possible Reason Suggested Remedy No wire feed Wrong mode selected Check that the TIG/MMA/MIG selector switch set to MIG position Wrong torch selector switch Check that the Wire Feeder/ Spool Gun selector switch is set to Wire Feeder...

  • Page 69: Dc Tig Welding - Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING Wire crossed over on the spool or Remove the spool untangle the wire or tangled replace the wire Contaminated MIG wire Use clean, dry, rust free wire. Do not lubricate the wire. §5.2.3 DC TIG Welding - Trouble Shooting The following chart addresses some of the common problems of DC TIG welding.
  • Page 70 MAINTENANCE & TROUBLESHOOTING Contaminated filler wire Remove all grease, oil or moisture from filler metal Incorrect filler wire Check the filler wire and change if necessary Yellowish residue/ Incorrect Gas Use pure Argon gas smoke on the Inadequate gas flow Set the gas flow between 20~40 CFH alumina nozzle &...

  • Page 71: Mma Welding - Trouble Shooting

    MAINTENANCE & TROUBLESHOOTING §5.2.4 MMA Welding - Trouble Shooting The following chart addresses some of the common problems of MMA welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. Trouble Possible Reason Suggested Remedy No arc Incomplete welding circuit...

  • Page 72: List Of Error Codes

    MAINTENANCE & TROUBLESHOOTING Distortion − Excessive heat input Reduce the amperage or use a movement of base smaller electrode metal during Poor welding technique Use the correct welding technique or welding seek assistance for the correct technique Poor joint preparation and or Check the joint design and fit up, joint design make sure the material is not too...

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