Lampert PUK 6 User manual

OPERATING MANUAL PUK 6
Lampert Werktechnik GmbH
Fine welding device
Issue EN 2022/05

Product : Fine welding device
Type: PUK 6
Manufacturer: Lampert Werktechnik GmbH
Ettlebener Strasse 27
97440 Werneck
Telefon: [phone] – 0
Telefax: [phone] – 100
E-Mail: [e-mail]
Website: www.lampert.info
Revision index: –
Date of revision: –

Contents
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Contents
1About this operating manual ............................................................................6
1.1 General....................................................................................................................6
1.2 Presentation of information....................................................................................7
Handling instructions ...................................................................................................................7
Application tip ..............................................................................................................................7
1.3 Structure of the warnings.......................................................................................8
2General safety regulations............................................................................. 10
2.1 Principles.............................................................................................................. 10
2.2 Intended use ........................................................................................................ 10
2.3 Foreseeable misuse............................................................................................. 11
2.4 Safety instructions............................................................................................... 11
General information ...................................................................................................................11
Personal protective equipment..................................................................................................11
Handling protective gas cylinders .............................................................................................12
During transport .........................................................................................................................12
During installation......................................................................................................................12
During commissioning................................................................................................................12
During operation.........................................................................................................................13
Maintenance and inspection work............................................................................................13
During disassembly ....................................................................................................................14
2.5 Residual risks for device operation ..................................................................... 14
2.6 Selection and qualification of personnel ............................................................ 14
2.7 Safety devices...................................................................................................... 15
2.8 Safety signs ......................................................................................................... 16
3Structure and function .................................................................................... 18
3.1 Functional description ......................................................................................... 18
Scope of delivery........................................................................................................................18
3.2 General overview................................................................................................. 19

Contents
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3.3 PUK 6.................................................................................................................... 20
3.4 Handpiece with connection cable ....................................................................... 24
3.5 Optional electrode grinding motor (item number 100 858) ................................ 25
3.6 Optional foot switch (item number 100 850) ...................................................... 26
3.7 Type plate ............................................................................................................ 27
4Transport and storage ..................................................................................... 28
4.1 Transport.............................................................................................................. 28
4.2 Storage................................................................................................................. 28
5Commissioning ................................................................................................. 29
5.1 Setting up the device........................................................................................... 29
5.2 Establishing supplies ........................................................................................... 29
5.3 Connect eye protection........................................................................................ 30
5.4 Insert the electrode into the handpiece.............................................................. 30
5.5 Adjusting the electrode length............................................................................ 31
5.6 Connecting the handpiece................................................................................... 32
5.7 Connecting the contact clamp............................................................................. 32
5.8 Connecting optional accessories......................................................................... 32
6Graphical user interface................................................................................. 33
6.1 Main menu........................................................................................................... 33
Material selection ......................................................................................................................34
Welding power and pulse duration...........................................................................................35
Menu bar ....................................................................................................................................37
Geometry selection ....................................................................................................................38
Speed levels ...............................................................................................................................39
6.2 Micro mode.......................................................................................................... 39
6.3 Fixation mode....................................................................................................... 40
6.4 Settings menu...................................................................................................... 41
6.5 Update menu........................................................................................................ 42

Contents
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6.6 Standby mode ...................................................................................................... 43
7Using the PUK 6 ................................................................................................ 44
7.1 Adjusting the gas flow ........................................................................................ 44
7.2 Switching on the PUK 6....................................................................................... 44
7.3 Welding with the PUK 6 ...................................................................................... 45
7.4 Switching off the PUK 6 ...................................................................................... 47
7.5 Basic information and tips................................................................................... 47
8Help with faults ................................................................................................ 48
9Care and inspection work .............................................................................. 49
9.1 Care and inspection schedule ............................................................................. 49
9.2 Carry out care and inspection work .................................................................... 49
Cleaning the PUK 6.....................................................................................................................49
Regrinding electrodes ................................................................................................................49
10 Disposal and recycling ................................................................................... 50
11 Dimensions and technical data .................................................................... 51
11.1 Device dimensions............................................................................................... 51
11.2 Technical data for the device .............................................................................. 52
12 Appendix............................................................................................................ 53
12.1 Service address.................................................................................................... 53
12.2 Spare and wear parts .......................................................................................... 53
12.3 CE conformity....................................................................................................... 54

1 About this operating manual
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1About this operating manual
Before operating the device for the first time or starting any other work on
the device, you are required to read these operating instructions carefully.
Pay particular attention to the chapter 2 "General safety regulations".
1.1 General
These operating instructions are intended to help you get to know the de-
vice and use it as intended. They contain important information on how to
operate the device safely and properly.
The operating instructions must
•Be fully read and applied by any person assigned to work on the device.
•Be stored in such a way that they are accessible at all times to all users
at the place of use of the device.
•Be handed over to third parties together with all necessary documents
when the device is passed on.
Observance of the operating instructions helps
•Avoiding dangers.
•Reduce repair costs and downtime.
•Increase the reliability and service life of the device.
In addition to the operating instructions, the accident prevention and envi-
ronmental protection regulations applicable in the country of use and at the
place of use must also be observed.
Safety and danger notices on the device must be kept in legible condition
and must not be removed, covered or damaged.

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1.2 Presentation of information
Handling instructions
The instructions explain step by step which activities have to be carried out
and how to proceed.
In these operating instructions, handling instructions are marked with the
following symbols:
The steps marked with this activity symbol may be carried out in any or-
der.
1) Numbered steps must be carried out exactly in the given order.
The result symbol describes the result or intermediate result of an ac-
tion.
Application tip
The "TIP" indicates additional information for easy and safe use of the de-
vice.
TIP: Note on the optimal use of the device.

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1.3 Structure of the warnings
Signal word Avoidance of ... Possible consequences if
the warning is not heeded:
DANGER Personal injury
(imminent danger)
Death or severe injuries!
WARNING Personal injury
(potentially hazardous situation)
Death or severe injuries!
CAUTION Personal injury Light or minor injuries!
NOTE Property damage Damage to the device or its im-
mediate surroundings!
Tab. 1.1 Warning levels
The warnings are structured as follows:
•Warning sign with signal word in accordance with the warning level
(see Tab 1.1)
•Type of hazard (description of the hazard)
•Consequences of the hazard (description of the consequences of the
hazard)
•Hazard prevention (measures to prevent the hazard)
DANGER!
Type of hazard
Consequences of hazard

Hazard prevention

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Special warnings are given at relevant points. They are marked with the fol-
lowing pictograms.
General warning sign
This sign warns of personal injury.
In the case of a clearly identifiable source of danger, it is preceded by one
of the following pictograms.
Electrical voltage
Warning of possible electric shock, potentially with fatal conse-
quences.
Hand injuries
Warning about the danger of hand injuries.
Hot surfaces
Warning of hot surfaces.
Pressurised containers
Warning of fire and explosion hazard.
Optical radiation
Warning of optical radiation
.
Hazard due to electromagnetic radiation
Warning of electromagnetic fields.
Warning sign

2 General safety regulations
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2General safety regulations
2.1 Principles
The device shall be used only when in flawless condition and is intended
exclusively for work in accordance with the intended use.
2.2 Intended use
The device is intended for welding on all metals and alloys that are suitable
for arc welding.
Intended use also includes
•The complete reading and following of all instructions in the operating
manual
•The complete reading and following of all safety and hazard instructions
•Compliance with maintenance and servicing work.
The device is designed for use in industrial and commercial applications.
The manufacturer is not liable for damage resulting from use outside this
area of application.
Temperature range of the ambient air:
•during operation: -10 °C to + 40 °C (14 °F to 104 °F)
•during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
•- up to 50 % at 40 °C (104 °F)
•- up to 90 % at 20 °C (68 °F)
The ambient air should be free of dust, acids, corrosive gases or substances.

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2.3 Foreseeable misuse
The hardware and software of the device is designed in such a way that
misuse is largely avoided or reduced to a minimum by safety features. Nev-
ertheless, in exceptional cases, misuse by the user is possible and must be
avoided when operating the device:
•Welding of non-weldable metals or alloys
•Use of an inappropriate shielding gas
•Exerting too much pressure on the electrode
•Use of the device without personal protective equipment
2.4 Safety instructions
General information
•If the device shows signs of damage, it must be taken out of service.
•If malfunctions occur, the device must be taken out of service.
Personal protective equipment
The personal protective equipment listed below must be worn during every
welding operation:
•Gloves
•Eye protection
•Dry clothing (non-synthetic and flame retardant)
Furthermore, the workplace must be sufficiently ventilated. If this cannot be
ensured by fresh air supply, an exhaust system must be installed.

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Handling protective gas cylinders
Observe the relevant precautions when handling gas cylinders, as well as
the safety rules for handling gases.
In particular, gas cylinders must be secured against falling over and down
and protected against heating (max. 50°C), especially during prolonged ex-
posure to sunlight and against severe frost.
During transport
•Ensure that all connecting cables have been removed from the device to
prevent the operator from tripping and damaging the device.
•When transporting the device, ensure that it is always securely packed
and not dropped or knocked over.
During installation
•The device must be placed in a stable and non-slip position at the work-
place.
•The device must be placed on a non-combustible surface.
During commissioning
•The device must not be connected to a circuit in which devices (e.g. TIG
welders) that work with high frequency are operated at the same time.
This may cause irreparable damage to the device. In the case of simul-
taneous operation with equipment that operates at high frequency, al-
ways ensure that the device is operated on a separate, individually
fused circuit that is shielded and protected from high frequency input
from other equipment. In addition, physical separation and a minimum
distance of at least 5 meters from devices that work with high fre-
quency must always be maintained.
•The eye protection must be checked for correct fit and proper function.
Follow the instructions in the operating manual of the respective eye
protection system.
•Before each start-up of the device, make sure that the gas connection
on the back of the device as well as the connection on the flow regula-
tor have been hand-tightened without tools.

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•If there are indications of leaks in the gas hose or gas connection (e.g.
audible hissing or whistling noise or unusually rapid loss of pressure in
the gas container), the device must be taken out of operation and defec-
tive components replaced.
During operation
•Always wear gloves when welding. Do not touch the workpiece without
gloves during or immediately after the welding process.
•During the welding process, parts of the skin must never be directly ex-
posed to the UV radiation that is generated by the welding process.
•The contact clamp for fixation welding must be removed from the blue
socket on the right hand side of the PUK 6 ( - ) again after fixation weld-
ing has been completed. In normal welding operation, always make
sure that the contact clamp for fixation welding is not connected to the
device.
•An extraction system must be installed at the workplace. In addition,
the workplace should be sufficiently ventilated without creating
draughts.
•The flow rate at the flow regulator must be between 2 - 3 litres/minute.
Maintenance and inspection work
•Disconnect the device from the power supply before carrying out
maintenance, inspection and cleaning work.
•The clamping nut on the handpiece must be hand-tightened after re-
placing the electrodes.
•When regrinding electrodes, wear protective gloves and do not touch
the rotating grinding wheel.
•When regrinding electrodes, make sure that the resulting grinding dust
is not inhaled.
•The device fuse may only be replaced by a qualified electrician and only
the fuse approved by the manufacturer for the respective mains voltage
may be used.

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During disassembly
•The valve on the gas cylinder must always be closed during decommis-
sioning and dismantling.
•When dismantling the device, disconnect it from the power supply.
•When dismantling, remove the electrode from the handpiece to avoid
puncture injuries.
2.5 Residual risks for device operation
In principle, it is not possible to exclude the following hazards:
•Puncture injury from electrode due to improper handling of the hand-
piece
•Danger from leaking or improperly connected protective gas cylinders
•Eye and skin damaging arc radiation on uncovered skin areas
2.6 Selection and qualification of personnel
The operator undertakes to only allow persons to work on the device who
•Are familiar with the basic regulations on occupational safety and acci-
dent prevention and have been instructed in the handling of the device
•Have read and understood this operating manual, in particular the "Gen-
eral safety regulations" chapter
•Are trained with regard to the requirements for the work results.
The safety-conscious working of the personnel must be checked at regular
intervals.
All persons who are instructed to work on the device undertake, before
starting work, to
•observe the fundamental regulations governing occupational safety and
accident prevention

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•confirm with their signature that they have read and understood this op-
erating manual, and in particular the chapter on “safety instructions”,
and that they will observe this information.
2.7 Safety devices
•The device has a thermal cut-off device that is activated if the heat
build-up is too high, preventing the device from overheating.

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2.8 Safety signs
Fig. 2.1 Safety signs on the back of the device
Safety sign Description
Electromagnetic fields may impair the function of pacemak-
ers.
Inhaling welding fumes can endanger your health.
Arcs can damage the eyes and injure the skin.
Welding sparks may cause an explosion or fire.

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In case a qualified electrician needs to open the device, the
main cable always needs to be unplugged before.
The union nut of the protective gas hose may only be tight-
ened by hand on the protective gas connection. The use of
tools (e.g. wrenches) can damage the protective gas con-
nection.
Tab. 2.1 Safety sign

3 Structure and function
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3Structure and function
3.1 Functional description
The PUK 6 is a micro-pulse TIG welder. The welding process is controlled by
the central control and regulation unit of the PUK 6. For a precise welding
process and a perfect result, the welding process is continuously monitored
and the target parameters are adjusted as required using control algorithms.
The energy pulses generated by the power source are transferred to the
workpiece via the handpiece included in the scope of delivery and its elec-
trode, thereby carrying out the welding process.
Scope of delivery
The scope of delivery of the device includes:
•Handpiece with connection cable
•Main cable
•3 m gas connection hose
•Contact cable with contact clamp
•Set of electrodes with electrodes in different specifications and dia-
mond grinding wheel

Structure and function 3
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3.2 General overview
Fig. 3.1 Overview of PUK 6 with handpiece
1. PUK 6
2. Handpiece with connection cable
2
1

3 Structure and function
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3.3 PUK 6
Fig. 3.2 PUK 6 Front
1. Display
2. Turn-push controller with tilt function
3. Socket (-) for contacting tools (fixation welding)
4. Handpiece connection socket (-) for the welding handpiece
5. Socket (+) for contacting tools (spot welding)
Displays the user interface of the operating software.
The Turn-push controller can be turned, tilted and pressed. Depending on
the software dialogue, the following actions can be triggered:
•Turn: Changing the welding parameters or the operating mode
•Tilt: Navigating the user interface
•Press: Confirm the selected choice
Display
Turn-push controller
1
2
5 4 3