FRO­NIUS PullMig User manual

Operating
Instructions
PullMig
42,0410,1958 004-28102022
EN Operating Instructions
RU Руководство по эксплуатации
ZH 操作说明书

General
Device concept PullMig is a wire feed unit for manual welding using soft welding wires and with
long hose packs. Two toothed precision rolls ensure large-surface power trans-
mission. This leads to outstanding wire feed even with very soft aluminium and
CuSi wires and very long hose packs. The many different versions of PullMig
available are one of its distinguishing features.
Thus there are several variations of torch connections available with both extern-
al and internal coolant connections. A variety of pipe bend designs ensures excel-
lent weld accessibility.
Proper use The MIG/MAG manual welding torch is intended solely for MIG/MAG welding in
manual applications.
Any use above and beyond this purpose is deemed improper. The manufacturer
shall not be held liable for any damage arising from such usage.
Proper use includes:
-Carefully reading and following all the instructions given in the operating in-
structions
-Performing all stipulated inspection and maintenance work.
Safety WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
▶All the work and functions described in this document must only be carried
out by technically trained and qualified personnel.
▶Read and understand this document in full.
▶Read and understand all safety rules and user documentation for this device
and all system components.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
▶Before starting work, switch off all devices and components involved and dis-
connect them from the grid.
▶Secure all devices and components involved so they cannot be switched back
on.
▶After opening the device, use a suitable measuring instrument to check that
electrically charged components (such as capacitors) have been discharged.
WARNING!
Danger from electric current due to defective system components and incor-
rect operation.
This can result in serious personal injury and damage to property.
▶All cables, leads and hosepacks must always be securely connected, undam-
aged and correctly insulated.
▶Only use adequately dimensioned cables, leads and hosepacks.
3
EN

WARNING!
Danger due to emerging wire electrode.
This can result in serious personal injuries.
▶Hold the welding torch so that the tip of the welding torch points away from
the face and body.
▶Wear suitable protective goggles.
▶Do not point the welding torch at people.
▶Ensure that the wire electrode does not touch any electrically conductive ob-
jects.
WARNING!
Danger due to hot system components and/or equipment.
Can result in serious burns or scalding.
▶Before starting work, allow all hot system components and/or equipment to
cool to +25°C/+77°F (e.g., coolant, water-cooled system components,
wirefeeder drive motor, etc.)
▶Wear suitable protective equipment (e.g., heat-resistant gloves, safety
goggles, etc.) if cooling down is not possible.
CAUTION!
Danger from operation without coolant.
This can result in damage to property.
▶Never operate water-cooled welding torches without coolant.
▶During welding, ensure that the coolant is circulating correctly – this will be
the case for Fronius cooling units if a regular return flow of coolant can be
seen in the coolant container of the cooling unit.
▶The manufacturer will not be liable for any damages due to non-observance
of the above mentioned points. All claims against the warranty are void.
CAUTION!
Danger due to exposed mechanically moving parts.
This can result in personal injury and damage to property.
▶Only operate the device when all covers are closed and/or completely moun-
ted.
System require-
ments
Power source
-TS 4000 / 5000
-TPS 2700 / 4000 / 5000
Software
-Power source: Software version 3.10.22 or higher
-Wire feed: Software version 1.70.16 or higher
Options
-Installation set „PMR4000 PullMig TS/TPS 2700-5000 (4,100,217)“
-Software „FS Drive (4,061,113)“
4

Installation and commissioning
Mounting the
torch neck
1
2
4
3
IMPORTANT! Risk of coolant leakage
(on water-cooled welding torches) or
damage from overheating (on gas-
cooled welding torches). When mount-
ing the torch neck, make sure that the
swivel nut is fixed firmly.
Assemble wire
guidance insert
1
1
1
1
2
2
2
When cutting the inner liner to length, make sure that
-no burr (sharp edges) protrudes into the inner liner at the cut location.
-Hold the side-cutting pliers at a slight angle (the burr is then pulled towards
the outside).
-Grind off the burr
* Contact tube with centering bore
** Contact tube without centering bore
Ø 4 mm (.16 in.): 40,0002,0014; 40,0002,0015
Ø 4,7 mm (.19 in.): 40,0002,0004; 40,0002,0017
5
EN

Assemble Inner
Liner (Fronius
connection
without wire-
guidance nozzle
2
1
1
1
2
3
2
12
3
5
4
6
7
3
1
4
2
1
5IMPOTRTANT! Bring the inner liner as
close as possible to the wirefeed
rollers, but without touching them.
Before threading in the welding wire,
round off the ends of the wire.
6

Assemble Inner
Liner (Fronius
connection with
wire-guidance
nozzle)
2
1
1
1
3
4
5
2
2
1
3
2
1
4
Only use wire guidance nozzles corresponding to diameter of wire. The following
wire guidance nozzles are available:
-0,8 mm (.030 in.)
-1,0 mm (.040 in.)
-1,2 mm (.045 in.)
-1,6 mm (1/16 in.)
Before threading in the welding wire, round off the ends of the wire.
7
EN

Assemble Inner
Liner (Euro con-
nection without
wire-guidance
nozzle)
4
3
2
1
6
1
1
234
5
2
3
1
2
2
3
(.04 - .08 in.)
1-2 mm
*
1
2
4
5
1
4
2
3
5
1
1
6
* Optional infeed nozzle (42,0001,5421)
IMPORTANT! Bring the inner liner / the infeed nozzle as close as possible to the
wirefeed rollers, but without touching them. Before threading in the welding wire,
round off the ends of the wire.
8

Connecting up
the welding
torch
2
3
3
1
4
4
2
3
3
1
4
4
* Standard plug (Standard or Up/Down torches)
** JobMaster plug (JobMaster welding torches)
Replace Feed
Rolls
(1)
(3)
(4)
(5)
(6)
(2)
1Unscrew pressure lever (1)
2Unscrew axle (2) using slotted screwdriver
3Remove complete unit (3)
4Fix drive roll (4) using driving gear key (5) provided
5Unscrew hexagon nut (6) using open-ended spanner - spanner size 10 mm
(.394 in.)
6Remove drive roll (4)
9
EN

Set Electrode
Pressure
(1)
(2)
(3)
1hard (e.g. CrNi)
2medium (e.g. AlMg / CuSi)
3soft (e.g. AlSi)
Replace Wire In-
let Nozzle
(2)
(1)
1Unscrew hexagon nut using open-ended spanner (1)
-spanner size 10 mm (.394 in.)
2Unscrew and remove wire inlet nozzle using Allen key (2)
-key width 2.5 mm (.099 in.)
10