Operation Manual

MULTIMIG 400puls

ELEKTRON-BREMEN Fabrik für Elektrotechnik GmbH x Postfach 10 59 60 x D - 28059 Bremen

Telefon +49 / (0)421 / 54 90 6-0 x Telefax +49 / (0)421 / 54 90 619 x vertrieb@elektron-bremen.de x www.elektron-bremen.de
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 1 Safety precautions  Secure the gas cylinder with a chain against falling over.
GB
 Please take off the gas cylinder from the machine for trans-
Use and maintenance of welding and cutting portation.
machines can be dangerous. Please draw
 Disconnect the plug from the mains before changing the
user´s attention to follow the safety precau- welding area or repairs at the machine.
tions to avoid injuries. Welding and cutting
machines must be used appropriate and *) Please follow the current safety regulations corresponding
only by specialist staff. Please inform your- to your country.
self constantly about the valid safety pre-
cautions and regulations of accident pre-
vention by working with this machine*.
2 Machine elements
Remove all flammable material from the weld- 5 Facility for transportation
ing area for fire prevention before welding. 6 Handle
Do not weld at containers which were filled up 7 Operating panel
before with flammable materials (fuel).
8 Connections
All inflammable material in the welding area
which could be inflamed by sparks must be re- 9 Air outlet
moved. 10 Transport rollers
Check after welding the place conforming UVV. 11 Main switch
Do not expose the unit to rain, steam and do not 12 Display of welding current and welding voltage
spray water in it. 14 Connection socket for ground cable
15 Protective cover, operation panel

Do not weld without protection shield. Keep at-

tention to protect other persons in the welding 3 General regulation of use
area against arc-rays.
This unit is for welding steel, aluminium and their alloys, for
commercial as well as for industrial use.
Please use absorbers or other systems to ab-
sorb the gases. 4 Unit protection
It is not possible to absorb all the gases correct-
ly please use a breathing apparatus. This unit is protected electronically against overloading.
Close the side lid before welding.
Stop operation immediately at a defect or
damaging of the mains cable. Do not touch Connect the workpiece with the groundcable to the unit.
the cable. Unplug the unit before each serv- Remove welding spatter from the inside of the gas nozzle with
ice or repair. Do not use the machine if the a special pair of pliers. Spray with anti spatter spray inside the
mainscable is defect. gas nozzle to avoid adherence of spatters. Spray sloping to
Place an extinguisher near the welding area. avoid the obstruction of the gasoutlet.
Check the welding area against fire after weld- At transportation of the unit only use the purposed transpor-
ing. tation facilities 5, do not use a fork-lift truck or something sim-
ilar at the machine case.

Never try to repair a defect pressure reducer.

Replace the defect one.

 Keep attention to connect the ground cable near the weld-

ing location. Welding current through chains, ball-bearing
or steel-cables may destruct or melt it.
 Lock the brake on the transport rollers 10 when the ma-
chine is at the welding site.
 Secure yourself and the unit at higher or inclinational plac-
es.
 Connect the unit only at mains with correct connection to
ground / earth and at prolongations and sockets too.
 Wear correct protective clothing, gloves and leather apron.
 Protect the welding area with curtains or mobile walls
against rays.
 Do not thaw frozen waterpipes or conductions with this
unit.
 In high electrical risk areas (in confined spaces) it is only
allowed to use machines with S -sign.
 Switch off the machine at breaks and close the valve of the
gas cylinder.

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 5 Emission of sound 7 Electromagnetic compatibility (EMV)
The sound level of the unit is smaller as 70 dB (A) measured This product is manufactured conform to the current EMV
at standard load conforming EN 60 974 at the max. work- standard. Please notice following items:
point.  The unit is for welding under commercial or industrial con-
ditions. The use in other surroundings (for example in res-
6 UVV inspection (UVV = regulations idential areas) may disturb other electric devices.
for prevention of accidents)  During welding electromagnetic problems can be caused
at:
Depending on the operation, users of commercially operated – Mainscables, controlcables, connections for telecom-
welding systems are obliged to have safety inspections of the munication
equipment carried out regularly in accordance with – TV / Radio
VDE 0544-207. ELEKTRON recommends inspection periods
of 12 months. – Computer and other similar devices
A safety inspection must also be carried out after alterations – Protection devises as for example alarm systems
or repair of the system. – Pacemakers and hearing aids
! Caution ! : Improperly carried out UVV inspections can de-
– Devices for measure and calibrate
stroy the system.
For more information on UVV inspections of welding systems, – Devices with less protection against disturbances
please contact your authorized service center. If other devices are disturbed it may be necessary to pro-
tect additionally.
 The affected area can be bigger than your premises /
property depends of the building etc.
Please use the unit conform to the instructions of the manu-
facturer. The user is responsible for installation and use of the
machine. Furthermore the user is responsible to eliminate the
disturbances caused by electromagnetic fields.

8 Technical data
Type MULTIMIG 400puls
Welding
Welding range (I2min-I2max/ A/V 25 – 320/
U2min-U2max) 15.2 – 30
No load voltage V 81
Voltage adjustment continuously variable
Slope characteristic constant / falling
Duty cycle 100 % 40 °C A 250
Duty cycle 60 % 40 °C A 270
Duty cycle at max. current 40 °C % 35
weldable wire steel Ø mm 0.6 – 1.2
weldable wire alu Ø mm 1.0 – 1.2
welding electrodes Ø mm 1.0 – 6.0
Wire-feed speed m/min 0.1 – 25
Mains
Mains voltage 3~ (50/60 Hz) V 400
Mains voltage tolerance range % +/- 15
Input power S1 (100 %/40 °C) kVA 10.7
Input power S1 (60 %/40 °C) kVA 12.6
Input power S1 (max. current) kVA 15.1
Current input I1 (100 %/40 °C) A 15.5
Current input I1 (60 %/40 °C) A 18.2
Current input I1 (max. current) A 21.8
Power factor (at I2max) cos ϕ 0.99
Mains fuse A/tr 16
Mains plug CEE16
Unit
Protection class (EN 60 529) IP23
Insulation class F
Cooling method F
Noise emission dB (A) <70

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 Type MULTIMIG 400puls
Dimensions and weights
Dimension power source (LxWxH) mm 745x340x498
Weight of power source A vers. kg 35
Standard equipment
Wire feed unit Rollers 4
Wire diameter mm 1.0/1.2
Torch type ML 2400 PM

9 Short instructions
) Please refer to chapter 10 “Before operation” and
chapter 11 “Setting into operation” for a full descrip-
 Insert welding wire.
 Turn on main switch 11.
tion.
 Press push-button 51 and push-button 48 (gas type)
 Place gas cylinder 3 on machine and secure with safety (solenoid valve is activated) and adjust gas amount on the
chain 35. pressure reducer
 Remove screw cap from gas cylinder and open gas cylin- (rule of thumb: wire diameter x 10 = gas flow).
der valve 34 briefly (blow-off).  Keep the wire insert switch pressed until the welding
 Connect pressure reducer 2 to gas cylinder. wire protrudes approx. 10 mm out of the gas nozzle on the
 Connect gas hose 31 from machine to pressure reducer torch neck.
and open gas cylinder.  Select welding material by pressing button 44.
 Plug mains plug in socket.  Select wire diameter by pressing button 46.
 Connect ground cable 22 to ground connection 14 (–) and  Select shielding gas type by pressing button 48.
attach ground clamp 13 to workpiece.  Select 2-stroke mode by pressing button 52.
 Insert wire feed roller 29 to wire feeder to fit welding wire  Press push-button 56 until the center LED for material
selected, set contact pressure to position 2. thickness lights up and adjust the thickness of the material
 Connect torch 1 (central socket 16, water connections 20 to be welded with the rotary pulse encoder 53.
red-blue) and mount contact tip to fit welding wire selected.  Hold down torch button to weld.
 Release torch button to stop welding process.
 If required, the arc length can be corrected with the rotary
pulse encoder 58.

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 10 Before operation How to connect at the mains
Plug in the plug into the mains socket. The fusing should be
Torch connection corresponding to the technical data.
Plug in the centralplug 17 of the torch 1 into the central socket
16. At machines with water-cooling: Connect additionally the How to insert the wirespool
waterconnections 20 of the torch with the sockets 18 and 19. Open the lid at the machine or at the wire-feed case 2 and
Please keep attention at the colour labelling. screw off the nut 26 from the wire-coil pick-up 24.
Red = water back-run 19 Put on the wire coil at the wire-coil pick-up and pay attention
Blue = water fore-run 18 that the tappet is well insert at the coil 23.
By use of small wire coils please use the adapter.
Adjust the brake 25 by releasing the torch button the wire coil
16 do not continue to turn.

17 23
18 24
19 25
20
26

How to connect the ground cable

Connect the ground cable 22 at the groundconnection 14 and
fasten it turning to right and connect the ground clamp 13 to
the workpiece or at the welding table.
Insert of the wire electrode
Screw out the contact tip at the torch 1.
Open the lid at the unit or at the wire feeder 2.
The diameter of the wire should correspond to the diameter of
14 the feeding rolls. This is readable on the front at the built in
feeding roll 29.
Lift the lever 27 and thread in the wire electrode trough the in-
22 let nozzle 28 and the central connection 16.

How to connect the ground clamp

Fasten the ground clamp 13 near the welding location, this 27 27
avoids that the current will flow trough machineparts or con-
trols. 28 16
Please keep attention that the connections between ground
clamp and workpiece is constant. 29
L1(R)
L2(S)
L3(T)
Close the lever 30 and fasten it with the sweep levers 27.
N(MP)
PE

1 1

1 30 30
27 27
2

1 Do not place the ground clamp on the welding machine or

gas cylinder, otherwise welding current is conducted via Switch on machine at main switch 11, stretch torch cable and
the protective conductors and will destroy them. press button wire insert on operating panel. Adjust the
pressure at the modulation screws 27 that the wire-feed rolls
2 Connect the ground clamp tightly to the welding bench or
29 even still are turning by holding the wire coil. The wire
to the workpiece.
should not be clamped or deformed.

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 How to modify the machine for aluminium
welding
p p p
Change the wire roll to a aluminium wire roll.
Change the steel-torch against an aluminiumtorch or resp.
change the wire liner against a teflon liner.
Remove the capillary tube 42 at the central connection.
correct contact wrong Cut the teflon liner close to the end of the wire-feeding roll and
pressure too wire-feed pull the brasstube over the teflon liner with the corresponding
high roll length for stabilising it.
Fasten the torch and thread in the wire electrode.
Indication for 4 rolls feeding units: Adjust the pressure of the
wire rolls 29 at the side of the inlet nozzle 28 less then at the
side of the central connection 16, this provides that the wire
) The art.no. of the parts depends on the torch and wire-
diameter. Please see at the torch spare list.
will be hold correct in the wire-feed unit. 17 38 39 40 41 42 29
Press the button wire insert till the wire appears approx.
20 mm out of the torchneck.
Screw in the contact tip corresponding to the wirediameter
and cut off the sticked out wire end.
How to connect the gas cylinder
Put the gas cylinder 3 on the provided place at the back of the 17 Centralconnection
machine and protect against falling by fastening the chain 35. 38 Nipple for 4.0 mm and 4.7 external diameter
Open the gas valve 34 several times to blow out possible dirt 39 O-ring 3,5 x 1.5 mm to prevent gas outlet
particles. 40 Nut
Connect the pressure reducer 2 at the gas cylinder 3. Con- 41 Teflon and plastic liner
nect the gas hose 31 at the pressure reducer. Open the gas-
cylinder and adjust the gas flow at the set screw 36 of the 42 Sustainpipe for teflon and plastic liner with 4 mm exter-
pressure reducer while pressing the torch button. The quanti- nal diameter it substitute the capillary pipe in the central
ty will be shown at the flowmeter 32. This should be approx. connection.
wire diameter x 10 l/min. The content of the cylinder is shown At 4,7 mm no sustainpipe is required.
by the contentmanometer 33. 29 Wire-feed roll
33 2 32
34

35
31

36

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 11 Setting into operation 54 Digital multifunction display
For indication of the primary parameters such as welding
DP 20 operating panel current, material thickness (in mm), wire feed speed (in
m/min) or arc length correction.
43 44 45 46 47 48 49 50 51 55 “Primary parameter” LEDs
These show which primary parameter is currently indi-
cated in the multifunction display 54.
TT
Save
TT
Enter
Tiptronic 56 “Primary parameter” push-button
For switching between welding current, material thick-
ness, wire feed speed and arc length, as indicated in the
digital multifunction display 54.
57 “Downslope” push-button
(END) (+)
Switches the downslope function on or off. A lit LED next
Enter to the push-button indicates that the downslope is on.
Mode 58 “Arc length / wire speed correction” rotary pulse encoder
For correction of the arc length or wire speed (depend-
ent on setting menu extra “arc lenght control“). Up to +/-
40 % of the characteristic value can be corrected.
59 “Arc length / wire speed correction” LED indication
Indicates the degree of the correction. When the upper-
most center LED is lit, the programmed arc length/wire
mm
speed remains unchanged; “0” is indicated in the multi-
function display 54. Turn the rotary pulse encoder 58 left
to reduce the arc length/wire speed; turn the rotary pulse
encoder 58 right to enlarge the arc length/wire speed
.
52 53 54 55 56 57 58 59
60 61 62
43 “Mode” push-button
For switching between the operation modes Normal,
Pulse, TwinPulse and Electrode.
44 “Material” push-button
For selection of the material to be welded. The push-but-
ton is also used for the “Decrementing” (-) function, e. g.,
to reduce the value of a secondary parameter.
45 “TT Save” push-button (Tiptronic)
For storage of a job. 60 Torch display
46 “Welding wire diameter” push-button Indicates the current welding power, material thickness,
For diameter selection of the wire to be welded. The wire feed speed or arc length correction (identical with
push-button is also used for the “End” function, with the digital multifunction display 54). In Tiptronic mode,
which you can switch back to the display of the previous the current job set and the current job number are indi-
menu level. cated.
47 “TT Enter” push-button (Tiptronic) 61 Torch rocker
For acknowledgement when saving a job. For changing the welding power, material thickness or
48 “Gas type” push-button arc length (depending on which value is being indicated
For selection of the gas to be used. The push-button is in the digital multifunction display 54).
also used for the “increment” (+) function, e. g., to in- In Tiptronic mode, the rocker can be used to switch be-
crease the value of a secondary parameter. tween the active jobs or job sets.
49 “Tiptronic” push-button 62 Torch “Modus” push-button
For switching the Tiptronic mode on or off. Has the same function as the “Primary parameter” push-
50 Multi-function display button 56 on the DP20 operation panel.
For indication of all parameter values and messages. In Tiptronic mode this push-button can be used to switch
51 and push-buttons (Enter) between job selection and job-set selection.
For switching between the individual secondary param- Current / voltage display
eters. Pressing both push-buttons at the same time is
The actual welding voltage and welding current values are in-
used for acknowledgement (Enter).
dicated during the welding. After the welding procedure, the
52 “2-stroke / 4-stroke” push-button “Hold” LED lights up and the last welding voltage and welding
For switching between 2-stroke and 4-stroke operation current values are indicated. When the operator changes cer-
mode. A lit LED indicates the currently selected operat- tain welding adjustments (e. g. level, program, job), the “Hold”
ing mode. LED goes out and the reference values for current and volt-
53 Rotary pulse encoder for welding current / material thick- age are indicated.
ness
The rotary pulse encoder is used for adjustment of the
required welding current and material thickness. The ad-
justment range can be limited, depending on the select-
ed material-wire-gas combination.

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 12 Menu Structure

Main Level Level 1 Level 2 Remark

Gas pre-flow 0 – 10 sec.; not in electrode mode
Start current 20 % – 200 % of the welding current
Start current time 0 – 10 sec.; not in 4-stroke mode
Twin pulse frequency 0,5 – 5 Hz; only in Twinpulse mode
Twin pulse current change 5 – 50 % of the welding current; only in Twinpulse mode
Twin pulse relation 20 % – 80 %; only in Twinpulse mode
Welding current Adjustment range depends on the selected material-wire-
gas combination
Downslope 10 – 990 A/sec.; not in electrode mode, only when downs-
lope = on
Final current 10 % – 100 % of the welding current; not in electrode mode,
only when slope = on or in 4-stroke
Final current time 0 – 10 sec.; not in electrode mode, only for slope = on
Wire burnback time 20 % – 300 % of the programmed value; not in electrode
mode
Gas post-flow 20 % – 200 % of the programmed value; not in electrode
mode
Arc length correction 60 % – 140 % of the programmed value
Inductor effect 20 % – 200 % of the programmed value; only in normal
mode (short arc)
+/- 40% in manual mode (see “Manual mode” on page 11)
Arc dynamic 0 % – 100 % of the programmed value; only in electrode
mode
Job selection, indication of Set and job name are indicated only in Tiptronic mode
set and job name upon actuation of the “TT Enter” push-button 47 or the “Tip-
tronic” push-button 49
Edit mode for set and Move the cursor with the and push-buttons 51;
job name change the character with the pushbuttons 48 (+) and 44 (-
)
Extras 1Machine data Operating system Master Version number, operating system Master
Operating system Process Version number, operating system process
Operating system DMRs Version number, motor assembly (-ies)
Welding program version Version number, welding programs
Operating hour counter Indication of the welding duration in h, min, sec
Configuration Machine type and the recognized power module (with max.
current ) are indicated alternately
2 Diagnosis Last error message Indication of the last three error messages from the error
memory (0 = last error, 2 = oldest error)
Module temperatures Temperatures of the power modules in °C
Operating voltages Indication of the operating voltages (15 V / 24 V) of the
E-assembly DP-MAPRO
Flow rate, cooling unit Indication of the coolant flow rate in l/min
3 Language Selection of the menu language
4 Display contrast Contrast setting of the LCD display
5 Mode cooling system 0 normal cooling unit switches on, as soon as an arc is ignited
1 on cooling unit runs constantly
2 off cooling unit is deactivated
6 Lock function 0 All free
1 Welding current, mode and Tiptronic on/off free
2 Tiptronic on/off, job selection free
3 All locked except menu selection, gas and pump test
7 Arc lenght control voltage correct arc lenght with rotary pulse encoder 58
wire correct wire speed with rotary pulse encoder 58
8 Robot interface Menu item is only visible when the machine is equipped
with a robot interface (further details about setup/configura-
tion see operation manual INT)

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 Menu structure

enter menuitem by pres-

sing both keys 51 at the
same time

Gas pre-flow 1 Machine data Operating system Master

Start current Operating system Process

Start current time Operating system DMR

Twin pulse frequency change between me- Welding programs

nuitems with keys 48
(+) und 44 (-)
Twin pulse current change Operating hour counter

Twin pulse relation Configuration

Welding current 2 Diagnosis Last error messages

Downslope Module temperatures

Final current Operating voltages

Final current time flow rate cooling system

Wire burnback time 3 Language select language

Gas post-flow 4 Display contrast

Arc lenght correction 5 Mode cooling system 0 normal

Inductor effect 1 on

Arc dynamic 2 off

Job selection 6 Lock function 0

Extras 1

change between 3
parameters with
keys 51
7 Arc lenght control Voltage

11 Robot interface Wire

Secondary parameters (menu main level) Tiptronic

With the and 51 push-buttons you can switch between The Tiptronic function provides you with 100 independent
the secondary parameters. The currently selected parameter jobs (10 job set with 10 jobs each). A job stores all the settings
is indicated in the display 50. The value in the square brackets and corrections on the operating panel.
is a standard or suggested value. The best way to use the Tiptronic function is to assign job
Push-button 44 (-) is used to reduce the indicated parameter numbers to frequently recurring welding tasks or save the set-
and push-button 48 (+) is used to increase the value of the in- tings which individual welders use specifically for “their” jobs.
dicated parameter. By actuating the push-button 46 (END)
the system switches back to the material-wire-gas combina-
tion display. Programming jobs:
 Determine the optimal welding adjustment.
Extras menu
 Press the “TT Save” button 45 (Save LED flashes).
In addition to the secondary parameters, the Extras menu
item is also available; it offers the following functions:  Select the target job number with the push-buttons 44 (-)
and 48 (+) or with the torch rocker, and confirm with the
Push-buttons 44 (-) and 48 (+) are used to switch between the
“TT Enter” push-button 47 (if you do not press Enter, the
menu items. The different entries of the menu items are called
up by pressing the und push-buttons 51 at the same Save LED goes out after 10 s after the last keystroke and
time. Switching between the individual entries is also possible the save operation is aborted).
here with the push-buttons 44 (-) and 48 (+). To return, press  The Save and Enter LEDs flash briefly to confirm that pro-
push-button 46 (END). gramming is terminated.

10

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 Selecting jobs: button 49.
 Switch the Tiptronic function on by pressing “Tiptronic” 49  Select the job number with the push-buttons 44 (-) and 48
(associated LED comes on). (+).
 Select the job number with the torch rocker (alternatively  Press the and push-buttons 51 at the same time (a
the job number can be selected with the push-buttons 44 flashing cursor appears in the display 50) in order to get
(-) and 48 (+)). into the edit mode.
 To exit the Tiptronic mode, press “Tiptronic” 49 (Tiptronic  The cursor is moved with the and push-buttons 51.
LED goes out). The parameters are reset to the values At the end of the line, the cursor jumps to the respective
that existed before you switched on the Tiptronic mode. next line.
 Select a character (number, letter or special character)
Setting a job inactive: with push-buttons 44 (-) and 48 (+).
 Switch the Tiptronic function on by pressing “Tiptronic” 49  The edit mode is ended by pressing push-button 46 (END)
(associated LED comes on). or by pressing the and push-buttons 51 at the same
 Select job number with the torch rocker 61 or with the time.
push-buttons 44 (-) and 48 (+) (an active job is indicated If you press the “Tiptronic” push-button 49 in edit mode
in the torch display 60 and in digital multifunction display (Tiptronic is switched off), then the text entries will not be
54 with a decimal point between the job set and the job saved.
number).
 Hold the Enter push-button 47 pressed for two seconds Texts can be programmed both for the job set (upper line in
(the decimal point in the torch display 60 and in the digital display 50) as well as for the job (bottom line in display 50).
display 54 goes out).
Setting a job active: Special functions
 Switch the Tiptronic function on by pressing “Tiptronic” 49
(associated LED comes on). Gas test
 Select the job number with the push-buttons 44 (-) and 48 Pressing the push-button 51 and the “Gas type” push-but-
(+) (with an inactive job, the decimal point between job set ton 48 at the same time activates the gas test function. The
solenoid valve of the system is activated and the gas supply
and job number is missing).
can be checked / adjusted. The function remains active for 30
 Hold the “TT Enter” push-button 47 pressed for two sec- seconds and is then ended automatically. By pushing the
onds (the decimal point between the job set and the job “Gas type” push-button 48 again, the gas test can be termi-
number lights up). nated prematurely.
Pump test
Reprogramming jobs: Pressing the push-button 51 and the “Material” push-but-
 Switch the Tiptronic function on by pressing „Tiptronic“ 49 ton 44 at the same time activates the pump test function. The
and select a job (see Selecting Jobs). water pump is switched on and runs for approx. one minute.
By pushing the “Material” push-button 44, the pump test can
 Change the settings as required.
be terminated prematurely.
 Press the “TT Save” button 45 (Save LED flashes).
 Press “TT Enter” button 47 to confirm. Resetting adjustments
 The Save and Enter LEDs flash briefly to confirm that pro- Pressing the push-button 51 and the “TT Enter” push-but-
gramming is terminated. ton 47 at the same time resets all secondary parameters to
the suggested values. When the Tiptronic mode is active, the
settings of the current job are reset. All adjustment in the Ex-
Copying jobs: tras menu (language, display contrast, etc.) remain un-
 Switch the Tiptronic function on by pressing “Tiptronic” 49 changed.
and select a job for copying (see Selecting Jobs).
 Press the “TT Save” button 45 (Save LED flashes). Manual mode
 Select the target job number with the push-buttons 44 (-) In manual mode the machine can weld independently from a
and 48 (+) and confirm with the “TT Enter” push-button 47 characteristic. Only welding voltage and wire feed speed are
(if the Enter push-button is not actuated, the Save LED set separately:
goes out 10 seconds after the last push-button actuation  switch to manual mode with button 43
and the saving procedure is cancelled). If the target job  set welding voltage (10V - 40V) with knob 53
number has not been occupied with a job yet, it will be in-  set wire feed speed (0,5 - 25 m/min) with knob 58
dicated flashing in the display. The following parameters are available in manual mode:
 The Save and Enter LEDs flash briefly to confirm that pro- – inductor effect (+/- 40%, select with button 56, LED arc
gramming is terminated. lenght 55 is lit)
The user-defined job texts are also copied onto the new – wire insert speed (0,5-15 m/min)
target job number.
– gas pre-flow (0-10 sec.)
– wire burnback time (5-300%)
Assigning job texts
– gas post flow (20-300%)
An individual text can be assigned to each job in order to spe-
cially mark it or allocate it more clearly.
 Switch on the Tiptronic function with the “Tiptronic” push-

11

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 Error codes
In case of a malfunction, an error code is indicated on the digital multifunction display 54 and the corresponding error description
appears on the LCD display 50. As long as an error code is indicated, welding operation is not possible.
Code Error description Remark Remedy
E00 no Prog No welding parameters for the selected Choose a different material-wire-gas
material-wire-gas combination (no sensible combination
combination)
E01 Thermal overload The system has been overheated Allow the system to cool down in standby;
check the ventilation
E02 Mains overvoltage Mains voltage too high Check mains voltage
E03 Overcurrent Output current too high Notify service technician
E04 Air-cooling error Flow rate of air too low Clean the air intake 9; check fan
E05 Faulty cooling circuit No or too little flow rate of water Check level of cooling liquid and coolant filter
E06 Overvoltage Output voltage too high Notify service
E07 EEProm checksum error Adjustment data faulty or not available Switch system off and then on again
E08 Wire feed / tacho Current input from feed motor too high Blow out torch package with compressed air
No tacho signal available and check wire feed unit
E09 Error v/a measuring Faulty current / voltage measuring systems Notify service
E10 Torch socket / cable Faulty torch switch cable or torch switch Check torch
socket
E11 Remote control socket Faulty remote control or socket of remote Check remote control
control
E12 Communication process Defective communication CAN-Bus (process) Switch system off and then on again
E13 Error, temperature sensor Thermo sensor not operative Notify service
E14 Supply voltage Internal supply voltage too low Check mains voltages
E16 Overcurrent protection 1 Allowable maximum power supply of power Notify service
unit 1 too high
E18 Overload protection Safety switch device for protection of Allow the system to cool down in standby
electrical components
E20 Overvoltage secondary Output voltage too high Notify service
E21 Output voltage / current Power unit delivers voltage / current without Notify service
drive
E22 Mains undervoltage 1 Mains voltage at power unit 1 too low Check mains voltages
E23 Mains overvoltage Mains voltage too high Check mains voltages
E24 Overcurrent protection 2 Power supply of power unit 2 too high Notify service
E25 Power-module detection Power unit not being recognized or unallowa- Notify service
ble combination of power units
E27 No program (DSP) Welding programs faulty or not available Notify service
E30 Mains undervoltage 2 Mains voltage at power unit 2 too low Check mains voltages
E31 Communication error Faulty communication CAN-Bus (master) Switch system off and then on again

Code lock function

The lock function in menu Extras is secured with a code lock. A three-digit code must be entered before the lock function can be
changed. Only after the correct code is entered, the lock function can be altered. After leving the menu, a new code number can
be set or the old code number is acknowledged. Code "000" is the default (factory setting) number.
Procedure:
 switch to menu Extras, lock function
 pressing button 44 (minus) or 48 (plus) question „change parameter ?“ is displayed
 acknowledge with button 51 (up)
 set three-digit code number with button 44 (minus), 48 (plus) or encoder 53
 acknowledge the code number with button 51 (up)
 set desired lock function number with buttons 44 (minus) or 48 (plus)
 leave menu with button 46 (END)
 if requested, set a new code number with buttons 44 (minus), 48 (plus) or encoder 53
 acknowledge the code number with button 51 (up)

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 13 Basic of the MIG / MAG welding Types of arc
process Short circuit arc
This type of arc is specially suitable for thin materials and po-
Principle of the MIG / MAG welding sitional welding due to a relative cool welding pool welded
The welding wire is fed from the wire coil to the contact tip due with very short arc, low arc voltage and low current. The sur-
to the wire-feeding rolls. The arc burns between the melting face tension of the welding pool helps to draw the drop into
wire electrode and the workpiece. The welding wire acts as the bath and to reignite the arc. This cycle is repeated again
arc carrier and filler material. Shielding gas flows through the and again so the short circuit and the arcing period is con-
gas nozzle and protects the arc against the atmospheregas. stantly alternating.

) The transition from the short circuit to spray arc de-

pends on the wire diameter and the gas mixture.
Wire-feed rolls
Transitional arc
Wire electrode
The transitional arc is especially suitable for medium thick-
ness sheet metals and for vertical-down welding. The transfer
of the electrode to the workpiece takes place partly in short
circuit and in free flight. Due to less short circuiting the weld-
ing pool is hotter than at the short circuit arc. Welding with
transitional arc provides higher electrode melt rate and is
Power source more economic than welding at short circuit arc.
Gas nozzle
Contact tip Long arc
Shielding gas Long arcs are typical at welding at the higher ampere range
Welding seam under carbondioxid and gases with a high CO2 content. It is
not particularly suitable for positional welding. In this type of
Arc Workpiece arc large drops are formed which falls into the welding pool
mainly by force of gravity. Due to that short circuits occasion-
ally occur, which by the increase of the current at the moment
of the short circuiting lead to spattering when the arc is reignit-
At metal shielded gas welding both, inert and active gases are ed.
used. The distinction is made between Metal Inert Gas (MIG)
and Metal Active Gas (MAG) welding. Spray arc
The spray arc is not suitable for positional welding, due to the
extremely liquid nature of the welding pool. The spraying arc
Welding Shielded gas forms by welding at the higher range of ampere using inert
process inert active gas or mixtures with high argon content. The most typical
characteristic of the spray arc is the short circuit free transfer
MIG Helium (He) of extremely fine droplets.
Argon (Ar)
Mixtures of Working range at MAG welding
Ar/He Long arc / Transitional Short
Wire diameter
Spray arc arc circuit arc
MAG-C Carbon dioxide mm A V A V A V
100 % CO2
0.8 140… 23… 110… 18… 50… 14…
MAG-M Mixtures of 180 28 150 22 130 18
Ar/CO2 1.0 180… 24… 130… 18… 70… 16…
Ar/O2 250 30 200 24 160 19
1.2 220… 25… 170… 19… 120… 17…
320 32 250 26 200 20
Further possible classification is by the type of arc. This
means the external form of the arc, is proneness to short- 1.6 260… 26… 200… 22… 150… 18…
circuiting, and the way of transfer to the workpiece. 320 34 300 28 200 21
Favourable welding characteristic are only possible if voltage and
It is not possible to select the arc force to each individual
current are correctly adjusted.
welding process. This is only limited possible for example at CO2 requires an arc voltage approx. 3 V higher than gas mixtures
the short circuiting arc. The mode of material transfer can be with a high argon content.
selected at all types of gas shielded metal arc welding by
choosing the suitable current and the corresponding arc volt-
age, although the short circuit frequency and the size of the
drops depends from the type of shielded gas used.

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 Holding and manipulating the torch Length of the wire electrode

) Metal shielded gas welding can be welded in all posi-

tions: horizontal, vertical-down, vertical-up, overhead
The distance between the torch and the workpiece should be
10 – 12 times the diameter of the wire. Altering the distance
and in horizontal-vertical position. of the torch will influence the length of the electrode end.
At horizontal welding hold the torch vertical to the workpiece A longer electrode end reduces the amperage and the pene-
(neutral torch position) or up to 30° “pushing” the torch. At tration.
thicker welds, a slight dragging motion is sometimes used. A shorter electrode end increases the amperage if the wire-
For best depth of penetration and covering of shielded gas is feed speed remains the same.
the neutral position of the torch the most suitable one. Please
notice if the torch is tilted to far, it could be that possible that
air will be sucked into the shielded gas atmosphere (injection
effect).
At vertical and overhead welding a slight pushing motion is re-
quired. Vertical down welding is most used for thin materials,
for this kind of weld hold the torch at the neutral or slightly
“dragging” position. For this kind of welding is some experi-
ence required cause the welding pool could run ahead and
cause some lacks welding. With thicker material there is a
danger of lacks of fusion cause the welding pool is very liquid Long electrode end Short electrode end
due to high voltage.

14 Basics of pulsed arc welding

Current and voltage pulses
Material transfer is achieved by current and voltage pulses
controlled at the same rate as the pulse frequency. The arc
power is changed by the ratio between basic and current
pulses, the pulse duty factor between basic and current puls-
es and the pulse frequency.
Welding direction pushing Welding direction dragging
Avoid extreme side to side movements to avoid that the weld-
ing pool will be damed up in front of the arc. This could cause
lacks of fusion due to the welding pool flows ahead of the
welding spot. The side to side motion should only be as wide us[v]
as is necessary to reach both sides of the joint. If the joint is
wide enough you should weld two parallel string beads.
At vertical-up position the side to side motion should describe Ug Um Up
the shape of an open triangle. t[s]
kritische Stromstärke
Length of the arc
Welding with a longer arc reduces the penetration, the weld-
ing bead is wide and flat with increased spattering. The weld-
is[A]
ing material is transferred with slightly larger drops than at
welding with a shorter arc. A longer arc is useful for welding a
fillet weld to form a flat or concave seam.
Welding with a shorter arc (at the same amperage) increases
the penetration, the welding bead is narrow and high with re-
tg tp lg lm lp
duced spattering. The welding material is transferred with
smaller drops as long as the welder is not welding with short t[s]
arc. Tp = 1/ fp

Long arc Short arc

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 Material transfer

 Benefits: Pulse voltage UP and pulse current IP

– Controlled, short-circuit-proof material transfer without Since welding with pulsed arc is based on the temporary uti-
spatter lisation of the pinch effect, the drop-separating pulse current
– Low thermal transfer due to low primary current must always be large enough to exceed critical current inten-
sity depending on wire diameter, wire material and shielding
 Disadvantages:
gas composition, etc. If this value is not achieved, material
– Special units with large number of setting parameters transfer takes place completely or partially in the short circuit
required with possible spatter.
– Only shielding gases without or with low CO2 content
Wire feed speed vD and pulse frequency fP
Forces acting during material transfer The main condition for a controlled material transfer with one
The amount of heat required to melt the wire electrode results drop per pulse is to set a defined drop volume. The volume of
from arc power and resistance heat build-up in the free wire the melted drop must then be identical with the volume of the
end. wire electrode fed in each pulse period. The necessary wire
feed speed vD results from the product of pulse frequency fP
A number of forces come into play in the resulting drop forma-
tion and separation. and the wire length l melted in each pulse period. From this
relationship you see that a change in wire feed speed re-
quires a linear change in pulse frequency. A rise in electrode
Wire electrode melt rate by increasing wire feed speed therefore needs a
Acceleration due
to gravity higher pulse frequency. The objective drop diameter should
be about 1.2 mm with a wire diameter of 1.2 mm.
Electromagnetic force
FL (pinch effect) Viscosity

Primary current
Constrict drops
Arc length ionisation must be maintained during the primary
Surface
tension S current phase, whose period results from the selected fre-
Force of inertia quency and pulse period. This requires currents ranging be-
Forces of tween 25 and 80 A depending on wire diameter, material and
repulsion (FR) of material thickness. The primary current can also be used to
Electrostatic evaporating
Forces material affect the arc and material transfer. At a constant ratio of wire
feed speed and pulse frequency, the arc length can be
Eddying forces changed by varying the primary current and the associated
Workpiece caused by
plasma flow voltage. Reducing the primary current causes a shorter arc.
This can be used to counteract arc deflection with fillet welds
or at high welding rates.
The time of drop separation can be affected by varying the ra-
tio of primary current to pulse current. Normally the objective
) The main force components for separating the drops are
electromagnetic forces (pinch effect).
is to separate the drop just after the current pulse in the pri-
mary current phase (on the Saprom 900, in the third pulse
current phase). This can be achieved by increasing the prima-
ry current and reducing the pulse current at the same time.
Welding parameters Remember that excessively high primary current will melt the
Pulse period tP free wire end too quickly. This will form very large drops which
The pulse period for separating the drop should be between can lead to spatter during the transition to the welding pool.
1.5 and 3.0 ms depending on wire diameter and the pulse cur-
rent setting IP.
If the pulse period is too long, material transfer only takes
place during the pulse phase.
Arc formation and drop rate can be affected by additional
pulse stages.

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 Pulsed arc applications 15 Care and maintenance
The main application for pulsed arcs is unalloyed steels within
the performance range of the transition arc. At the lower end Please keep attention to the current safety regulations at all
of the performance range the pulsed arc cannot fully replace care and maintenance works.
the short-circuiting arc. The reason here is the continuous arc The machine requires minimum of care and maintenance.
that occurs in the primary current phase. This phenomenon Only a few items should be checked to ensure a trouble free
does not exist with the short-circuiting arc. An exception to long term operation:
this is when welding aluminium and aluminium alloys. Nor-
– Check the mains plug, mains cable, and the welding
mally, these materials can only be reliably welded using a
torch as well as the ground connection for damage from
pulsed arc. In the upper performance range, the pulsed arc is
time to time.
preferable to the sprayer arc, in particular for welding alumin-
ium materials and high-alloy steels. – Once or twice a year please clean the machine with dry
low compressed air. Switch off the machine and pull out
the plug first. Open the case of the machine and clean
also inside - please avoid to blow directly onto electronic
parts – they could be damaged.

16 Troubleshooting guide
Symptom Cause Remedy
Torch too hot Insufficient coolant through flow due to pollution into Swill the waterhoses of the torch in opposite
coolant direction
Contact tip is not tight Check it
No function when torch Nut of the torch hose is not tight Tighten it
button is pressed No connection of the control cable in the torch hose Check and change if necessary
Overload of the unit and thermal protection is in Allow unit to cool down at no load
function
Irregular wire feeding or Wire electrode is tight at the spool Check and change if necessary
wire welds to the con- Burr at the wire beginning Cut the wire beginning again
tact tip
Irregular wire feeding or Wrong contact pressure at the wire-feed rolls Adjust it as described in the manual
no wire feeding Torch defect Check and change if necessary
No brass pipe in the central connection or is dirty Install or clean the brass pipe
Bad quality of welding wire Check and change if necessary
Rust formation at the welding wire Check and change if necessary
Torch liner is dirty inside Disconnect the torch from the machine, screw
off the contact tip and clean the liner with com-
pressed air
Torch liner is dejected Check and change if necessary
Motor brake adjusted to strong Adjust as described in the manual
Unit switches off Duty cycle overloaded Allow the machine to cool down
To less cooling of unit parts Check the air in and outlet
Cooler or hoses defect Freezed systems due to less anti freezer liquid Contact the nearest service facility
or pump is damaged
Arc or short circuit Spatter built up inside the gas nozzle Remove it with special pliers
between contact tip
and gas nozzle
Unstable arc Wrong diameter of contact tip or worn out Change contact tip
The DP20 operating Phase missing Check the unit at another power outlet. Check
panel is completely dark power cable and mains fuses/circuit breakers
No shielded gas Gas cylinder empty Replace it
Defect torch Check and replace it
Pressure reducer dirty or defect Check and replace it
Valve of gas cylinder defect Replace the gas cylinder
Shielded gas switches Valve of gas cylinder dirty or does not close Remove torch and pressure reducer and clean
not off it with compressed air
Not sufficient shielded Wrong adjusted quantity of shielded gas Adjust right as described in the manual
gas Dirty pressure reducer Check valve
Torch, gashose blocked or not air-tight Check and change if necessary
Shielded gas is blow away from draught Avoid draught

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 Symptom Cause Remedy
Less welding Phase missing Check the unit at another power outlet. Check
performance power cable and mains fuses/circuit breakers
Poor ground connection Ensure best contact between ground clamp
and workpiece
Ground cable not right plugged in Fasten ground cable by turning the plug to the
right
Defect torch Repair or replace it
Hot plug of ground Plug was not tightened by turning to the right Check
cable
Higher wire wear out at Wire rolls does not fit to the wire diameter Install right wire rolls
wire-feeding unit Wrong contact pressure at wire feeding Adjust as described at the manual

17 Options
UD remote control RC 20 Push pull set
For correctional adjustments of the wire feed speed, level and For control of a push pull torch.
job with the RC 20 UD remote control.
Push pull torch
Manual control unit HR911 At longer torches as 5 m it is recommended to use a Push pull
Incl. 5 m power supply cable and CAN-BUS plug. In conjunc- torch. Due to an additional wire-feed motor at the torch a con-
tion with wire feeders without operation panel or Robko wire tinuous wire feed is provided.
feeder, the HR911 must be used as operating panel.
Robot interface INT
Interface for connection to automated welding appliances or
welding robots.

Wire-feed variations
Precise 4 rolls wire-feed unit for all applications
Roll Roll Roll
Table of variations Use
alu steel knurled
Standard Standard at 4 rolls feeding units. Due to the straightening effect of
the roll less wire friction in the torch. For use with thicker or hard
wires.
Knurled rolls ideal for flux cored wires.

Double drive Straightening effect and double drive. Less contact pressure due to
(special double drive provides less wire disshapes. For use with ticker and
accessory) hard wires resp. at longer torch hoses.
Knurled rolls ideal for flux cored wires.

Wire-feed rolls Rolls with double groove (above and below). No wire disshape.
with grooves Ideal for soft wires (Aluminium, bronze, copper,...).
above and
below
(special
accessory)

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 18 Service
ELEKTRON-Bremen GmbH
Postfach 10 59 60
D-28059 Bremen
Germany
Telefon: +49(0)421 54 90 6-0
Telefax: +49(0)421 54 90 6-19

Subject to change

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 Appendix - mounting torch holder

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 326601 06/05

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