Lampert PUK U4 User manual

Operating ManualPUK U4

OPERATING MANUAL (translation)
"PUK U4" with welding microscope "USM"
Dear Customer,
This operating manual is intended to familiarise you with the commissioning process and operation of your "PUK U4" as
well as the associated "USM" welding microscope. Please read the operating instructions carefully and follow the advice
given here diligently. Disruptions and operational faults will thus be avoided. Your personal safety, constant availability and
long service life can be assured by this.
THE COMMISSIONING OF THE DEVICE MUST ONLY BE UNDERTAKEN BY TRAINED SPECIALISTS AND ONLY
WITHIN THE SCOPE OF APPROPRIATE USE. THE MANUFACTURER ACCEPTS NO LIABILITY FOR DAMAGES
CAUSED THROUGH INAPPROPRIATE USE AND IMPROPER OPERATION. THE “GENERAL SAFETY
REQUIREMENTS” AND "PERSONAL BODY PROTECTION" CHAPTERS MUST BE READ BEFORE COMMISSIONING.
Please keep these operating instructions safe.
The equipment produced by “Lampert Werktechnik GmbH” fulfils the conformity requirements of the CE mark and is
constructed in accordance with the VDE guidelines. The device safety of the PUK04 is certified by the DGUV (German
statutory accident insurance) test and documented by the GS (tested safety) mark. The eye protection systems used on the
"SM04" welding microscope are tested and certified by DIN-CERTCO (DIN department for eye protection).
Only use original spare parts for maintenance and overhaul work. Our customer service department will naturally be happy
to help you.
THE DEVICE MUST ONLY BE OPENED OR MODIFIED BY AUTHORISED CUSTOMER SERVICE PERSONNEL,
OTHERWISE ALL GUARANTEES AND WARRANTIES ARE VOID.
LAMPERT WERKTECHNIK GMBH
June 2016

© Lampert Werktechnik GmbH 2015 2
TABLE OF CONTENTS
1 WARNING AND INFORMATION SIGNS Pg. 2
2 FIELD OF APPLICATION Pg. 3
3 SAFETY REQUIREMENTS
3.1 General safety requirements Pg. 3
3.2 Installation conditions
for multiple welding sets Pg. 4
3.3 Personal body protection and hazards Pg. 4
3.4 Risk of allergic reactions Pg. 4
3.5 Hazards of shielding gas cylinders Pg. 4
4 SETUP AND INSTALLATION
4.1 Set-up of the device Pg. 5
4.2 Description of the rear of the device Pg. 5
4.3 Connection of eye protection and
LED illumination of the microscope USM Pg. 5
4.4 Connect shielding gas supply Pg. 6
4.5 Inserting the electrodes into the hand piece Pg. 6
4.6 Connect power supply Pg. 6
4.7 Commissioning the welding microscope Pg. 7
5 COMMISSIONING
5.1 Description of the front-side controls Pg. 8
5.2 Description of menu items Pg. 9
5.3 Switching on the device Pg. 10
5.4 Adjusting for the correct gas volume Pg. 10
5.5 Control level “settings” Pg. 10
6 SELECTION OF THE WELDING PARAMETERS
AND PROGRAM MEMORY
6.1 Selection of the TIG-welding parameters Pg. 11
6.2 Help function Pg. 12
6.3 Programming Pg. 12
6.4 Loading saved WIG-welding programs Pg. 13
6.5 Resistance welding mode Pg. 13
7 WELDING INSTRUCTIONS
7.1 Introduction to TIG-welding Pg. 13
7.2 TIG-welding with foot switch Pg. 14
7.2.1 Resistance welding instructions Pg. 14
7.3 Basics and tips Pg. 14
7.4 Sharpening the electrodes Pg. 15
8 CARE OF THE SYSTEM COMPONENTS
8.1 Care of the welding equipment Pg. 15
8.2 Care of the microscope Pg. 15
9 TECHNICAL DATA Pg. 16
10 TROUBLESHOOTING Pg. 18
11 SPARE PARTS LIST Pg. 19
12 DISPOSAL INFORMATION Pg. 20
13 EC-DECLARATION OF CONFORMITY Pg. 20
Warning!
“Warning” identifies a potentially dangerous situation. If this is not avoided, the consequences can be death or
severe injuries.
Caution!
"Caution!" identifies a potentially hazardous situation. If this is not avoided, the consequences can be slight or
minor injuries as well as property damage.
Note!
“Note” identifies the product at risk from the hazard and possible damage to the equipment.
Important!
"Important!" designates user tips and other especially useful information. This is not a signal word for hazardous or
dangerous situations.
1. WARNING AND INFORMATION SIGNS

© Lampert Werktechnik GmbH 2015 3
2. APPROPRIATE USE
(FIELD OF APPLICATION)
•Outdoor operation is impermissible. Use this device
only in dry rooms!
•PUK U4: The application of spot welds on precious
metals and precious metal alloys, steel and steel alloys
as well as titanium and various non-ferrous metals.
NOT APPROVED FOR WELDING DENTAL PROTHESIS! (DENTAL TECHNOLOGY)
GENERALLY NO LIABILITY IS ACCEPTED FOR THE DURABILITY OF THE WELDING. WE RECOMMEND
THAT THE WELDING BE CHECKED IN EVERY CASE.
•USM: Observation and microscopic viewing of objects
through the ocular of the microscope and illumination of
the working area.
•The USM unit may only be used for welding if it has
been properly connected to a PUK fine-welding device.
3. SAFETY INSTRUCTIONS
3.1 GENERAL SAFETY REQUIREMENTS
PERSONS WHO WEAR ACTIVE IMPLANTS (HEART PACEMAKERS) MUST MAINTAIN A SAFETY
DISTANCE OF 20CM BETWEEN THE WELDING CURRENT CABLE / SOURCE OF THE WELDING
CURRENT AND THE IMPLANT.
The opening of the device is only permitted when
undertaken by an electrician of the authorised
customer service. Before opening remove the
mains cable and ensure that the device is de-energised.
Discharge any components in the device that could hold
electrical charge.
In case of doubt or uncertainty, always consult with a
specialist. Our customer support department is naturally
always available to assist you with their professional
trained personnel, appropriate tooling and equipment.
Always use the original cables and ensure that workpiece
clamps are properly attached.
Both the mains and welding currents can be a source of
danger.
Always remove the mains plug when exchanging the LED
unit. (Only use original replacement LED units from
Lampert).
The device must be isolated from the mains power when
undertaking any repair or maintenance work on the power
source. The power socket is to be clearly blocked when
undertaking any work on the system beyond minor
manipulations where it is necessary to leave the
workplace, even for brief periods.
If it can be assumed that risk-free operation is no longer
possible, the unit must be put out of operation and
secured against being unintentionally restarted.
It can be assumed that risk-free operation is no longer
possible, if
•the equipment shows visible signs of damage,
•malfunctions occur,
•or the equipment is no longer working.
The PUK U4 must, as standard, be operated with a mains
voltage of 115V~.
Yellow-green wire = protective earth terminal (PE). The
other wires L1 and N are to be connected to the phase
and neutral conductors of the power plug.
The welding device is factory-adjusted to 115V!
This means that as a result of the tolerance range +/-10%,
the system can also be operated at 110V~. Devices
configured to voltages other than 115V will be designated
as such by means of a label.
THE DEVICE MUST ONLY BE OPENED BY
AUTHORISED SERVICE PERSONNEL!
IF THE DEVICE HAS BEEN CONFIGURED FOR A
CUSTOM VOLTAGE, THE TECHNICAL DATA ON THE
DEVICE SPECIFICATION PLATE APPLY!
THE FUSING FOR THE MAINS SUPPLY MUST BE
MATCHED TO THE POWER CONSUMPTION OF THE
WELDING EQUIPMENT!
ONLY USE THE SUPPLIED MAINS CABLE!
THE PUK U4 IS A PIECE OF ELECTRICAL EQUIPMENT. NATIONAL REGULATIONS ON TESTING
INTERVALS AND THE SCOPE OF REQUIRED RECURRING SAFETY-RELATED TESTS MUST BE
OBSERVED.

© Lampert Werktechnik GmbH 2015 4
3.2 INSTALLATION CONDITIONS FOR THE PUK IN WELDING WORKSHOPS WITH MULTIPLE WELDING SETS
To avoid the electrical interconnection of two or
more welding sets, there must be no electrical
connection between sets (e.g. by way of a shared,
electrically conductive welding table)!
This could result in a cumulative no-load voltage on the
welding sets that exceeds the permitted voltage and
causes danger to personnel!
There is also a risk of damage occurring to the welding
sets involved.
Welding sets with HF ignition (high voltage ignition)
generate a strong electric field (radiation), which
could damage electrical devices in the vicinity.
When using welding sets with HF
ignition (high voltage ignition), be sure to
observe a spatial separation from the
PUK, in order to rule out the possibility of interference and
damage.
Also pay attention in this regard to the instructions from
the manufacturer of the welding set with HF ignition!
3.3 HAZARDS AND PERSONAL BODY PROTECTION
Protective gloves should be worn on both hands
whenever possible when welding, as sparks and
spatters can never be completely excluded when
welding. The protective gloves must not contain a high
proportion of easily melting plastic fibres.
Uncovered areas of the skin are exposed to UV radiation
produced during welding, which can cause skin damage.
Wear suitable clothing; do not wear articles of clothing
made with synthetic fibres.
The workpiece and electrode tip can become extremely
hot during welding operation - risk of burns.
The tip of the electrode fastened into the hand piece can
present a risk of injury (stab injuries and scratches e.g. to
the hands, face and eyes)
EYE PROTECTION WHEN WELDING:
Never look into the arc without eye protection; always use
a welding mask with certified protective glass. (min.
protection class 10)
In addition to light and thermal radiation, which can cause
dazzling and burning, the electric arc also emits UV
radiation. With insufficient protection this invisible
ultraviolet radiation causes very painful conjunctivitis,
which can first be noticed hours later.
The USM welding microscope with its integrated LCD
protective welding screen offers reliable protection against
these risks and
provides permanent protection from UV / IR rays in both
light and dark state. The protective class of the filter is
defined such that dazzling by the arc is effectively
prevented.
Persons who are nearby to the electric arc and assistants
must also be informed of the dangers and equipped with
the appropriate protection; if necessary set up protective
partition walls.
EYE PROTECTION WHEN OPERATING THE LED
ILLUMINATION:
Never look into the LED lamp or its reflections without
eye protection; always use a welding mask with
certified protective glass (min. protection class 3).
When welding, especially in small spaces, it is necessary
to ensure that there is an adequate fresh air supply as
smoke and hazardous gases can arise.
It is not permitted to carry out welding on containers that
have been used for storing gases, propellants, mineral oils
or similar, even if they have been empty for a long time, as
there is a risk of explosions caused by residues.
Particular regulations apply to fire and explosion
endangered spaces.
3.4 RISK OF ALLERGIC REACTIONS:
Please note that the device's raw materials that
could come into contact with the operator's skin
may cause allergic reactions in susceptible people.
3.5 HAZARDS OF SHIELDING GAS CYLINDERS
Observe all applicable safety measures when
handling gas cylinders as well as the safety
regulations for handling gases. Gas tanks must especially
be secured against falling over / falling down and heat
(max. 50°C); it is particularly important to ensure they are
not subjected to sunlight for extended periods and that
they are protected from severe frost.

© Lampert Werktechnik GmbH 2015 5
4. SETUP AND INSTALLATION
4.1 SET-UP OF THE DEVICE
The system is to be set up so that cooling air is able to
reach all of the surfaces of the housing without hindrance.
The device may not be covered! The device is to be
placed on a non-combustible surface! The device should
be set up on a base that is solid, level, and insulated -
ideally on a suitable workbench.
For additional information please refer to chapter 3.2
“Installation conditions for multiple welding sets”.
Fasten the two hand supports for the microscope with 2
Allen screws using the supplied Allen key by inserting the
screws into the designated holes from underneath the
microscope baseplate and into the hand supports.
4.2 DESCRIPTION OF THE REAR OF THE DEVICE
(Fig. 2)
(1) FUSEBOX ("Fuse")
(2) MASTER MAINS SWITCH as well as
AC POWER SOCKET
(for connecting the mains cable)
(3) CONNECTION SOCKET FOR EYE PROTECTION
SYSTEM
(4) CONNECTION SOCKET FOR FOOT SWITCH
(5) CONNECTION SOCKET FOR LED MICROSCOPE
ILLUMINATION
(6) TYPE PLATE
(7) SERIAL NUMBER
(8) PROTECTIVE GAS CONNECTION ("ARGON
GAS") for 6.0 mm diameter pressure hose
(9) APPROVED MAINS VOLTAGE FOR THIS DEVICE
(10) USB SOCKET FOR SERVICE CONNECTION
4.3 CONNECT EYE PROTECTION AND LED ILLUMINATION FOR THE USM WELDING MICROSCOPE TO THE
PUK U4:
The circular connector for the eye protection system
should be inserted into the connecting socket (3) marked
with the red eye protection symbol on the rear side of the
device and is to be tightened in place with the coupling nut
(hand tight). The LED illumination connector should be
inserted into the connecting socket (5) marked with the
yellow illumination symbol on the rear of the PUK welding
device. In doing so, observe the colour coding of the
connection cables.
Please shut down the device prior to removing the
LED illumination connector.
WARNING!
ONLY SUITABLE ORIGINAL EYE PROTECTION
SYSTEMS FROM LAMPERT MAY BE CONNECTED TO
THE WELDING SYSTEM!
OTHER EYE PROTECTION SYSTEMS ARE NOT
APPROVED AND CAN LEAD TO PERMANENT HEALTH
DAMAGE OR DAMAGE TO THE WELDING DEVICE.
ALWAYS OBSERVE THE OPERATING INSTRUCTIONS FOR THE CONNECTED EYE PROTECTION SYSTEM

© Lampert Werktechnik GmbH 2015 6
4.4 CONNECT SHIELDING GAS SUPPLY:
Fasten the suitable flow regulator to the shielding gas
tank. ATTENTION: In doing so, always observe the
enclosed special operating instructions provided. (Where
possible, use argon with min. 99.8% purity, e.g. "Argon
4.6"). The pressure hose is to be fastened by hand with
the help of the quick coupling adapter to the flow regulator
as well as the shielding gas connector (10) on the rear of
the device.
CHECK REGULARLY THAT ALL OF THE HOSE CONNECTIONS AND GAS HOSES ARE IN OPTIMAL
CONDITION, ARE PROPERLY FASTENED AND ARE AIRTIGHT!
4.5
INSERTING THE ELECTRODES INTO THE WELDING HAND PIECE:
PLEASE ALWAYS CHECK THAT THE MACHINE IS SWITCHED OFF, PRIOR TO EXCHANGING THE
ELECTRODES. THIS PREVENTS UNCONTROLLED TRIGGERING OF THE WELDING PROCESS.
(Fig. 3)
(Fig. 4)
(Fig. 5)
Lightly rotate the nozzle (12) back and forth and in doing
so, pull it off of the hand piece (15). It is only pushed-on,
not screwed in place.
Release the threaded electrode connection (14), insert a
well sharpened tungsten electrode (13) and tighten up
(hand-tight – do not use a tool to tighten).
The correct length for the electrode can easily be checked
and corrected if necessary by means of the milled marks
on the handpiece clamping arm (Fig. 4).
Now replace the nozzle.
The electrode must protrude approx. 4 - 6mm out of the
nozzle (Fig. 5).
ONLY USE THORIUM OXIDE FREE ORIGINAL ELECTRODES
Subsequently insert the connector of the hand piece as
straight as possible into the socket (28) on the front of the
PUK and fasten in place by tightening the coupling nut
hand-tight in a clockwise direction. Insert the connecting
cable used into one of the sockets (27) on the front side of
the housing.
4.6 CONNECT POWER SUPPLY:
Insert the power cable with the mains connector into the
corresponding socket (2) on the rear of the housing and
insert the mains plug into a suitable socket with the correct
mains voltage.
CAUTION!
AS SOON AS THE MASTER MAINS SWITCH ON YOUR
PUK U4 IS SWITCHED ON, THE VOLTAGE IS APPLIED
TO THE CONNECTED CROCODILE CLIPS OR CABLES.
IT IS TO BE ENSURED THAT THESE PARTS ARE NOT
ALLOWED TO COME INTO CONTACT WITH
ELECTRICALLY CONDUCTIVE OR EARTHED PARTS,
SUCH AS THE HOUSING, ETC. IN DOING SO, THERE
IS NO RISK FOR THE OPERATOR, WITH THE
EXCEPTION OF POSSIBLE CIRCUMSTANCES
ARISING FROM OPERATING ERROR.

© Lampert Werktechnik GmbH 2015 7
4.7 CONFIGURATION OF THE WELDING MICROSCOPE:
ESSENTIAL PRIOR TO THE INITIAL WELDING OPERATION: PRECISE CONFIGURATION OF THE
MICROSCOPE OPTICS
FIRST STEPS
Align the handpiece holder so that you are able to
comfortably introduce a workpiece with your hands to the
tip of the hand piece mounted in the supporting arm. It
should be possible to comfortably place both hands and
palms on the baseplate hand supports. You also have the
option of changing the angle of inclination for the
microscope. In order to do so, release the locking screw
(16) on the stand, angle the
microscope to the desired
position and re-fasten the screw.
A metal pin extends from the
stand to support the microscope
on your working surface.
ADJUSTING THE INTEROCULAR DISTANCE
Look through the two oculars (19) and move the ocular
tubes (17) inwards or outwards by holding the prism
housing (20) still and moving them in or out. The
interocular distance is correct if the range of vision as
viewed through the two oculars is complete and is united
into a single image. The interocular distance should be
individually set for each user.
FOCUSING
Mount a welding handpiece
with clamped electrode into
the supporting arm. Rotate the
focusing knob (22) to a
medium focus range. Adjust
the mounting height of the
microscope head: Hold the
microscope head (21) with one
hand, without touching one of the lenses, and use the
other hand to release the screw on the head bracket. The
head can now be moved. Look through the oculars and
move the microscope head up or down until the object
appears focussed. The correct distance between the
handpiece holder and the microscope head amounts to
approx. 6 cm on the stand rod. Now re-tighten the
adjusting screw on the head bracket once more.
Subsequently use the focusing knob (22) to focus the
image.
DIOPTRE ADJUSTMENT
The sleeve for adjusting the dioptre (18) is fitted to the left-
hand ocular (19). In the normal position, the lower part of
the tube is aligned to the marking on the ocular tube. In
the event of differing vision in both eyes: Open the right
eye only, look into the right-hand ocular (17) and adjust
the focus using the focusing knob (22). Now look through
the left-hand ocular with your left eye and adjust the focus
by turning the dioptre control (18) on the left tube (20) until
the image appears focused.

© Lampert Werktechnik GmbH 2015 8
5. COMMISSIONING
5.1 DESCRIPTION OF THE FRONT-SIDE CONTROLS
(Fig. 1)
(24) TOUCHSCREEN DISPLAY
(25) PULSE DURATION / WELDING-TIME CONTROL
(26) WELDING POWER CONTROL
(27) SOCKET (+)
- 4 mm socket for connecting TIG-welding contact
elements such as welding bench, contact terminals
and clamps.
(28) SOCKET (+)
- 6 mm socket for connecting resistance welding
contact elements as well as resistance welding
devices.
(29) CONNECTION SOCKET FOR HAND PIECE (-)
(30) SOCKET (-)
6 mm socket for connecting the blue contact terminal
for resistance welding as well as resistance welding
devices.
TOUCHSCREEN
(29) Welding program (depending on user level)
(30) Scroll within the selected user level
(31) Pulse duration scale in milliseconds (ms)
(32) Output scale as a percentage (%)
(33) Indicator
(34) Pulse duration in milliseconds (ms)
(35) Welding output as %
(36) Preselect welding situation and pulse shape
(depending on user level)
(37) Foot switch display (when active)
(38) Recommended setting range
(only TIG-welding)

© Lampert Werktechnik GmbH 2015 9
5.2 EXPLANATION / OVERVIEW OF MENUS
(Fig. Schematic diagram of user levels)
ONCE IT IS SWITCHED ON, THE PUK U4 STARTS UP IN ITS SELECTED START LEVEL (a, b or c – see chapter 5.5).
THE FOLLOWING USER LEVELS CAN BE NAVIGATED AFTER PRESSING THE POWER REGULATOR (26):
a) TIG-welding:
Preselection of the material to be welded and
preselection of the welding situation with display of the
recommended settings range for welding power and
pulse duration
b) User TIG-welding programs and stored custom
settings
c) Resistance welding mode
d) Settings
In user level TIG-welding it is possible to use the arrow
keys to scroll back and forth between the various pages,
e.g. between the preconfigured programs or your custom
stored settings, depending on the selected user level.
Beginners using the PUK system are advised to remain
within the start level.
PRESSING THE WELDING-TIME CONTROL (25) CAUSES THE PROGRAMMING MENU TO BE LAUNCHED:
e) TIG-welding
Selection of the memory location and saving the settings.
Storing custom welding parameters (33 memory slots)
Resistance welding
Saving of parameters power, time and pulse form (1 memory slot)
Micro stud welding
Saving of parameters power and time (1 memory slot)

© Lampert Werktechnik GmbH 2015 10
5.3 SWITCHING ON THE DEVICE
First, carefully open the gas tank valve. Then switch the
master mains switch (2) on the rear of the housing to the
“I” position – the display shows the safety prompt
regarding eye protection and the operating manual.
Confirm your compliance with the safety instructions by
pressing one of the rotary controllers or by touching the
display.
5.4
ADJUSTING FOR THE CORRECT GAS VOLUME
PLEASE CONSIDER THAT GOOD WELDING RESULTS CAN ONLY BE ACHIEVED WITH A CORRECTLY
ADJUSTED GAS FLOW.
In order to configure the correct gas volume, activate the
"Gas Test" in the "Settings" menu (see chapter 5.5). This
opens the gas valve in the welding device. Now set the
flow regulator to the correct flow rate of approx. 2
litres/min. In doing so, also observe the instructions
provided with the flow regulator. Once the gas volume is
correctly adjusted, quit the "Gas Test" by pressing the
corresponding button.
5.5
OPERATING LEVEL "SETTINGS"
The "Settings" user level can be used to modify basic settings and launch various test functions.
•Gas Test:
Pressing the corresponding button
causes the gas valve to be opened. This
function is important in order to set the
correct gas flow on the flow regulator (see chap. 5.4).
Pressing the button again causes the gas valve to be
closed once more. In addition, any other operation of the
device will automatically quit the gas test.
•Shield Test:
Pressing this button causes repeated
switch-over of the eye protection filter
from light to dark. This enables correct
function of the eye protection filter to be checked.
Pressing the button again quits the test.
•Home screen selection:
This menu allows to
preselect the start
screen of the PUK U4.
With the next start of the unit the selected home screen
(WIG welding, pin welding or resistance welding) appears.
•LED lamp:
Pressing the button enables the
brightness of the LED lamp on the
welding microscope to be adjusted in 3 steps.
•Language:
Pressing the button with
the country codes
enables the system
language for the welding device to be changed. The
system can be toggled between German, English,
Spanish, French and Italian.

© Lampert Werktechnik GmbH 2015 11
6.
SELECTION OF THE WELDING PARAMETERS AND PROGRAM SAVING
6.1 SELECTION OF THE TIG-WELDING PARAMETERS
BASIC INFORMATION ABOUT THE EFFECTS OF WELDING POWER AND WELDING TIME:
POWER:
The welding power or the strength of welding energy is set
with the power control (26).
The size and intensity of the welding points are controlled
in this way, i.e. the higher the power the larger the welding
point.
With very thin materials too high a power level can also
quickly result in damage, i.e. it makes sense to experiment
with samples for beginners with the PUK system to find
the optimum power level, starting at a power of 20% or
with very fine welding, even lower. Power settings
between 35 and 50% are considered medium welding
powers.
Other metals can be welded with higher power levels, just
as with stainless steel. Power levels above 70% are only
practical in the most unusual circumstances. There is a
danger of inhomogeneous welds and only experienced
users should move outside this range.
WELDING TIME OR PULSE DURATION:
The pulse duration / welding time control (25) determines
for how many milliseconds the welding power is applied,
i.e. a longer pulse duration results in a longer and deeper
application of the energy to the workpiece and thus
simultaneously a greater development of heat.
With very thin materials, wires or other heat-sensitive
materials it is recommended to use a shorter welding time.
Welding times of no more than 4ms are recommended
here.
With many alloys and other highly conductive metals a
longer welding time can be advantageous in order to avoid
hot cracks, starting at 10ms.
IMPORTANT FOR SUCCESSFUL OPERATION WITH THE PUK:
Welding power and pulse duration must be
considered in close context with each other in all cases!
The total energy applied to the workpiece is comprised of
these two parameter settings together - prior to welding
this must be considered carefully following an in-depth
analysis of the welding task, the materials and the
workpiece geometry.
SELECTION OF THE WELDING PARAMETERS ON PUK U4:
The welding parameters are set in two stages:
1.
In the upper area of the display, the metal to be welded is selected by means of pressing the arrow
buttons.
2.
Pressing one of the 5 buttons in the centre of the display selects the given welding situation.
This selection causes numerous settings to be made in the background. The important information for the user is then
shown on the display:
•A welding time is preselected and the recommended
setting range for the selected welding situation is
marked next to the scale by means of a blue bar (only
TIG-welding). Settings outside of the recommended
blue setting range are always possible, however, they
are not recommended for the selected welding situation.
•The power is also preselected and the recommended
setting range for the power is marked with a blue bar
(only TIG-welding). Settings outside of the
recommended blue setting range are always possible,
however, they are not recommended for the selected
welding situation.

© Lampert Werktechnik GmbH 2015 12
DESCRIPTION OF THE WELDING SITUATION WITH ASSOCIATED SYMBOL ON TOUCHSCREEN:
•In the TIG-welding level, the meaning of the following
symbols is always the same for each of the
preconfigured materials.
•The TIG-welding level shows in addition to the welding
power and pulse duration for each stored material also
the recommended working range in the respective
scales of the touchscreen, highlighted in colour.
Universal setting for material thicknesses
from 0.3mm. This is well suited for most
applications (≥0.3mm).
Setting for thin sheet metal or wire parts
equal to or less than 0.3mm (≤0.3mm). This
setting offers very low development of heat,
especially for short welding times.
Welding in sharp angles and tight joint
situations. Here it is IMPORTANT to use
short welding times of 2 to 5 ms.
Melting of welding wire. Use identical alloy
wire with a diameter of 0.3 to 0.4 mm.
Particularly low energy fusing of thin
welding wires of a max. 0.25 mm.
PUSHING/TOUCHING THE RESPECTIVE BUTTON FOR AN EXTENDED PERIOD
BRINGS UP AN INFO WINDOW ON THE DISPLAY. SEE 6.2 "HELP FUNCTION"
6.2 HELP FUNCTION
The buttons in the centre of the display are provided with
accessible info screens in all user levels. Touching /
pressing the button for an extended period causes the info
screen to appear for the respective button, which contains
explanatory information for the button's function. Touching
the display button again causes the active user screen to
be shown once more.
6.3 PROGRAMMING
SAVING CUSTOM PROGRAMS
Pressing the welding-time control
(25) causes the programming
menu to be launched. In the first
step, use the arrow key to select
the program slot into which you
want to store your custom
settings. Then save your data by pressing the button with
the blue dot. The process can be aborted at any time
without saving the data by pressing the welding time
regulator (25).

© Lampert Werktechnik GmbH 2015 13
6.4 LOADING SAVED TIG-WELDING PROGRAMS AND THE USER LEVEL "CUSTOM PROGRAMS"
All custom stored programs are
summarised in the "Own
Programs" user level. This user
level displays the settings in
"Expert Mode". This means that
the corresponding underlying
energy characteristic curve is shown in addition to the
settings for time and power.
The other controls within "Own Programs" function as
"Expert Mode". The individual energy characteristic curves
can be selected here in addition to welding duration and
welding power.
6.6 RESISTANCE WELDING MODE
The resistance welding mode
appears as a separate user level,
which can be accessed by
pressing the power regulator.
The welding process is released with the foot switch,
which is permanently activated in this welding mode.
7.
WELDING INSTRUCTIONS
NOTE!
PRIOR TO WELDING, ALWAYS CHECK THE
FUNCTION OF THE EYE PROTECTION FILTER AS
DESCRIBED IN CHAPTER 5.5 "FILTER TEST". IF THE
EYE PROTECTION FILTER (SHUTTER) FAILS TO
SWITCH OVER FROM LIGHT TO DARK, THEN IT MUST
BE IMMEDIATELY EXCHANGED BY AUTHORISED
CUSTOMER SERVICE PERSONNEL.
7.1 TIG-WELDING INSTRUCTIONS
•First connect a metallic blank section of the workpiece
with the contact clamp.
•Lightly touch the area to be welded with the tip of the
electrode until welding begins. In doing so, it is
important to remain in the position where initial contact
is made until welding begins, i.e. neither to follow the
electrode with the workpiece if it retracts slightly in the
handpiece, nor to pull back.
APPLY EXTREMELY LIGHT PRESSURE OR NO PRESSURE TO THE TIP OF THE ELECTRODE!
The welding process proceeds automatically:
•shielding gas flows around the welding point.
•A signal tone announces the arc.
•The arc triggers and the electrode retracts
slightly in the handpiece.
•The shielding gas supply cuts off.
THE WELDING PROCESS CAN BE HALTED AT ANY TIME BY MEANS OF LIFTING THE ELECTRODE AWAY
FROM THE WORKPIECE.

© Lampert Werktechnik GmbH 2015 14
7.2 TIG-WELDING WITH FOOT SWITCH
With the PUK U4 switched off, connect the foot switch to
the socket (4) marked with the blue foot switch symbol on
the rear of the device. Switch the device on, confirm the
safety prompt by pressing an arbitrary button and wait for
the self-test to conclude. The device is now ready for
operation.
THE FOOT SWITCH CAN BE ACTIVATED BY PRESSING AND HOLDING IT (APPROX. 2 SEC.). A BLUE DOT
APPEARS IN THE DISPLAY.
Connect a metallic
blank section of the
workpiece with the
contact clamp. Now
lightly touch the workpiece with the electrode, so that the
shielding gas flows out. If the foot switch is operated in this
mode, the welding process will begin automatically as
described in chapter 7.1.
PRESSING AND HOLDING THE FOOT SWITCH (APPROX. 2 SEC.) (WITHOUT TOUCHING A WORKPIECE) CAUSES
IT TO BE DEACTIVATED AND THE BLUE DOT ON THE DISPLAY DISAPPEARS.
7.2.1. RESISTANCE WELDING
THE BLUE CONNECTION CABLE MAY ONLY BE CONNECTED AFTER THE MODE HAS BEEN ACTIVATED.
AFTER WELDING IS COMPLETE, IT IS VITAL THAT THIS CABLE IS REMOVED AGAIN, BEFORE SWITCHING
TO ANOTHER MODE, IN ORDER TO AVOID FAULTY WELDS!
Connect both of the workpieces which are to be fixed at
an area of bare metal with a connection terminal, one to
the blue one and the other to the black. When the two
parts are touching, the welding process can be triggered,
using the foot switch. The hand piece is not used during
this process.
The required welding power is determined by the
strength of the connection desired as well as the
workpiece geometry. The welding time setting is of
secondary importance in this mode, and can only be
varied to a very limited extent.
BEFORE SWITCHING TO ANOTHER USER LEVEL, PLEASE REMOVE THE BLUE CONNECTION CABLE
FROM PUK U4!
NOTE: DURING FIXATION WELDING, THE FOOT SWITCH IS ALWAYS ACTIVE, AND CANNOT BE DEACTIVATED!
7.3 BASICS AND TIPS
IMPORTANT!
•Always work with a well sharpened electrode (see point
7-4 for information about sharpening the electrodes).
•Ensure extremely good contact between the workpiece
and the contact clamp, i.e. make contact between the
workpiece and the connection cable terminal at a point
which is metallically blank.
•Never weld "free hand", i.e. use the hand rests of the
microscope USM. Shaking hands can cause the
configured parameters to be falsified.
•Apply only light force to the electrode tip.
•Weld with the correct gas flow of 2 litres/minute and
check this regularly.
•With a little experience you will notice that the angle
with which you touch the workpiece with tip of the
electrode affects the "direction of flow" of the welding
point.
•The electrode can easily be clamped in somewhat
longer for welding recessed areas.
•In many cases it is helpful to work with welding wire as
a welding supplement, but never with solder.

© Lampert Werktechnik GmbH 2015 15
7.4 ABRADING THE ELECTRODES
Please switch off the machine prior to exchanging
the electrodes. This prevents uncontrolled
triggering of the welding process.
If possible, the electrodes should be sharpened with a
diamond disk with fine or medium grain.
The recommended angle of grinding is approx. 15°.
8. CARE OF THE SYSTEM COMPONENTS
8.1 CARE OF WELDING DEVICE AND WELDING MICROSCOPE
Your PUK U4 as well as the welding microscope require a
minimum of maintenance under normal working
conditions. However, it is essential that a few points are
observed in order to guarantee the functionality and to
keep the spot welding device fully operational for years to
come.
•Check the mains plug and cable as well as all welding
and connection cables regularly for damage.
•Check that the moving parts of the handpiece move
easily.
•If necessary, clean the electrode threaded assembly on
the handpiece, in order to ensure optimal contact with
the electrodes.
•Clean the device occasionally with a suitable cloth.
•Use the supplied dust cover to cover up the microscope
after use.
IF WORK OR REPAIRS THAT ARE NOT DESCRIBED IN THESE OPERATING INSTRUCTIONS ARE NECESSARY
THEN CONTACT YOUR DEALER.
WARNING!
IF FUSES REQUIRE EXCHANGING, THEN THEY MUST BE REPLACED WITH FUSES OF THE SAME TYPES
AND VALUES.THE GUARANTEE IS VOID IN THE EVENT OF EXCESSIVLY HIGH FUSING!
THE DEVICE MAY ONLY BE OPENED BY AUTHORISED CUSTOMER SERVICE PERSONNEL!
8.2 CARE OF THE OPTICAL COMPONENTS
Do not attempt to disassemble optical components.
Please contact the local technical customer service
department for repairs which are not covered by this
manual.
Remove dust from the lens surface with a special brush
prior to cleaning. You can obtain suitable accessories in
any photography store.
Cleaning the oculars: Do not remove the oculars (19) from
the ocular tubes (17).
Clean the outer surfaces. In doing so, blow on them.
Subsequently dry the lens with suitable cloth or paper for
the purpose. Dry the lens with circular movements from
the centre to the outside. Do not wipe over a dried lens as
they can easily be scratched.
Cleaning and exchanging the protective glass of the eye
protection filter:
Never dismantle the eye protection filter
(shutter)!
Only clean the surface. Use a cotton cloth with glass
cleaner.
If the protective glass requires exchanging, slide it
forwards out of the bracket and insert a new protective
glass in the same manner.

© Lampert Werktechnik GmbH 2015 16
9. TECHNICAL DATA
9.1
TECHNICAL DATA WELDING DEVICE
Device suitable for welding in dry rooms
Mains voltage
Mains fusing
Power consumption
Closed-circuit voltage
No-load voltage
Duty cycle X
Max. charging time
Shielding gas
Maximum gas pressure
Protection class
Insulation class
Protection type
Weight
~115 V / 50-60 Hz +/-10%
T 6.3 A
400VA
30 – 43 V
43 V
80 %
0.8 s
min. ARGON 99.8%
4 bar
I
B
IP 21S
8.8 kg
9.2
TECHNICAL DATA MICROSCOPE
Optical visual protection and illumination unit for exclusive
use with PUK fine welding devices.
>>>Use only in dry rooms.
Operating temperature
Lamp "LED unit"
Protection class
Insulation class
Protection type
Weight
+5°C to +40°C
2.5W / 800mA
III
B
IP 20
3.6 Kg
9.3 OPTICAL DATA MICROSCOPE
Lens
Ocular
Working distance
Magnification factor
Field of view
1.0
10x
140 mm
10x
20 mm
9.4
TECHNICAL DATA LCD SHUTTER M11 (BL)
Light shade
Dark shade
Switching time
UV protection
IR protection
DIN 3
DIN 11
<50ms
>UV 11
>IR 11
MARKING ON THE LCD SHUTTER: 3/11 LWT 1/1/1/3/379
Protection shade number in open state
Protection shade numbers in closed state
Manufacturer identification code
Optical quality
Light scattering
Homogeneity
Angular dependence
Number of the standard
3
11
LWT
1
1
1
3
379
Notified body for CE testing of the LCD Shutter: DIN CERTCO, Alboinstrasse 56, 12103 Berlin

© Lampert Werktechnik GmbH 2015 17
9.5 TYPE PLATE
Explanation of pictographs:
Current Voltage
Protection
type
Hertz
Alternating
current
(AC)
Direct
current
1 ~ 50-60Hz
Mains input
1 phase / AC
/ 50-60Hz
Read
operating
manual
No-load
voltage
Mains
voltage
Voltage at
nominal load
Tungsten
inert gas
welding
Earthing
(earth)
Nominal
welding
current
Power
consumption
under max.
load
Power
consumption
under
nominal load
Cyclic
duration
factor Single-phase
transformer
Keep away
from water
9.6 WARNING NOTICES:
Breathing welding fumes and gases can be hazardous to your health.
Welding sparks, hot workpiece, and hot equipment can cause fires and burns.
Arc rays from the welding process can burn eyes and skin.
Magnetic fields can affect pacemakers.

© Lampert Werktechnik GmbH 2015 18
10.
TROUBLESHOOTING
10.1 WELDING DEVICE
FAULT CAUSE REMEDY
1 No welding current
Mains master switch on,
display remains off
Mains cable interrupted Check mains cable and mains voltage
Device fuse blown Replace device fuse with identical
fuse (same type and value)
2 No welding current
Mains master switch on Welding cable connections interrupted
Check plugged connections
Poor or zero contact to the workpiece Establish connection to the workpiece,
fasten contact clamps directly to the
workpiece
3 No welding current
Mains master switch on
Fault due to leakage current Switch device off and back on again
If fault reoccurs,
arrange for servicing of device
4 Mains fuse blows or automatic
circuit breaker trips
Mains insufficiently fused or incorrect
automatic circuit breaker
Fuse mains properly
Mains protection trips during idling arrange for servicing of device
5 Poor welding characteristics Incorrect shielding gas Use inert shielding gas (Argon 4.6)
6 Poor ignition characteristics Electrode clamped loosely in hand
piece
Tighten the clamping nut in the
handpiece (chap.11, no.41) by hand,
however, tighten firmly.
7 Oxidation and rusting Excessive gas pressure Reduce flow rate - approx. 2 l/min is
recommended
8 Severe oxidation of the welding
points
Incorrect shielding gas Use inert shielding gas (Argon 4.6)
9 Tungsten inclusions in base
material
Excessive pressure of the electrodes
on the workpiece
Touch workpiece with extremely light
pressure.
10 Tungsten electrode welds to
workpiece
Excessive pressure of the electrodes
on the workpiece
Touch workpiece with extremely light
pressure.
11 Tungsten electrode melts off
immediately
Electrode sharpened too steeply Use the recommended angle of
grinding (approx. 15°)
12 Static discharge over the surface of
the device
Special local conditions Use special foot mat for the
workspace
13 Device begins to weld immediately
when touching the workpiece (no
gas pre-flow)
Fault Immediately shut down the device,
arrange for servicing.
10.2 MICROSCOPE
PROBLEMS WITH ELECTRICAL COMPONENTS
A
The LED illumination fails to
operate
Cable not connected. Connect the plug to the connecting
socket (5) marked with the yellow
illumination symbol on the PUK U4.
LED faulty Exchange LED unit (only use original
replacement LED units from Lampert)
B
Eye protection system (shutter)
fails to operate
Cable connected incorrectly Connect the plug to the designated
socket (3) marked with the red eye
protection symbol on the PUK U4.

© Lampert Werktechnik GmbH 2015 19
Eye protection filter faulty Arrange to have eye protection unit
replaced by authorised customer
service personnel
IMAGE QUALITY
D
Poor resolution
Oculars dirty. Clean oculars.
E
Marks or soiling in field of vision
Oculars dirty. Clean oculars.
Protective glass dirty Clean or exchange protective glass
* Note: Marks in the field of vision can also be caused by soiling in the interior of the oculars. For this reason, it is
recommended to have the lenses cleaned by an authorised customer service engineer
PROBLEMS WITH MECHANICAL COMPONENTS
F
Focus is not retained
The sight slides down Readjust the tension of the focusing
knob
REPAIR
If the stereo microscope requires repair or adjustment by
qualified personnel, we recommend sending it back to the
dealer (authorized customer service) in its original
packaging. Include a description of the problem or the
desired adjustment.
WARNING: THE DEVICE MAY ONLY BE OPENED BY AUTHORIZED CUSTOMER SERIVICE PERSONNEL!
11. SPARE
PARTS LIST
Hand piece
(40) Nozzle (D 3mm)
(41) Clamping nut
(42) Chuck
(43) Hand piece complete
Electrodes:
10 x electrodes D 0.5 mm (thorium oxide free),
incl. diamond grinding disk
10 x electrodes D 0.6 mm (thorium oxide free),
incl. diamond grinding disk
Grinding disk:
diamond grinding wheel
Gas hose:
3m gas hose 6x4mm
100 150K
100 152
100 151
100 100 04
100 400
100 401
100 701
100 153
PLEASE NOTE!
Nozzle(40), clamping nut (41), electrodes and clamping tongs (42) are wearing parts and are not covered by the
guarantee.