Lampert PUK U5 User manual

Operating manual
PUK U5

Lampert Tools USA 2020
OPERATING MANUAL (translation)
"PUK U5" with welding microscope "SM5.1"
Dear Customer,
This operating manual is intended to familiarize you with the commissioning process and operation of your PUK U5 as well
as the associated SM5.1 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 eye protection systems used on the "SM5.1" 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.
January 2020

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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 Personal body protection and hazards Pg. 4
3.3 Hazards of shielding gas cylinders Pg. 4
3.4 Risk of allergic reactions Pg. 4
4 SETUP AND INSTALLATION
4.1 Set-up of the device Pg. 4
4.2 Installation conditions for multiple welding sets
4.3 Description of the rear of the device Pg. 5
4.4 Connection of eye protection and
LED illumination of the microscope SM5.1 Pg. 5
4.5 Connect shielding gas supply Pg. 6
4.6 Inserting the electrodes into the handpiece Pg. 6
4.7 Connect power supply Pg. 6
4.8 Configuration of 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. 9
5.4 Adjusting for the correct gas flow Pg. 10
5.5 Control level “settings” Pg. 10
6 SELECTION OF THE WELDING PARAMETERS
AND PROGRAM MEMORY
6.1 Selection of the welding parameters Pg. 11
6.2 Expert menu Pg. 13
6.3 Help Function Pg. 13
6.4 Programming Pg. 13
6.5 Loading saved programs Pg. 13
6.6 Tack welding mode Pg. 14
6.7 Micro Pg. 14
6.8 Resistance welding mode Pg. 14
7 WELDING INSTRUCTIONS
7.1 Introduction to welding Pg. 14
7.2 Speed mode (only PUK U5+) Pg. 15
7.3 Welding with the foot switch Pg. 15
(optional accessory)
7.3.1 Fixation welding Pg. 15
7.3.2 Resistance welding Pg. 16
7.4 Basics and tips Pg. 16
7.5 Sharpening the electrodes Pg. 16
8 CARE OF THE SYSTEM COMPONENTS
8.1 Care of the welding equipment Pg. 17
8.2 Care of the microscope Pg. 17
9 TECHNICAL DATA
9.1 Technical data welding device Pg. 17
9.2 Technical data microscope Pg. 18
9.3 Optical data microscope Pg. 18
9.4 Technical data LCD shutter Pg. 18
9.5 Type plate Pg. 18
9.6 Warning notices Pg. 19
10 TROUBLESHOOTING
10.1 Welding device Pg. 19
10.2 Microscope Pg. 20
11 SPARE PARTS LIST Pg. 21
12 DISPOSAL INFORMATION Pg. 21
13 EC-DECLARATION OF CONFORMITY Pg. 21
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.
1. WARNING AND INFORMATION SIGNS

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Important!
"Important!" designates user tips and other especially useful information. This is not a signal word for hazardous or
dangerous situations.
2. APPROPRIATE USE (FIELD OF APPLICATION)
•Outdoor operation is impermissible. Use this device only
in dry rooms!
•Welding on all metals and alloys that are suitable for arc
welding.
GENERALLY NO LIABILITY IS ACCEPTED FOR THE DURABILITY OF THE WELDING. WE RECOMMEND
THAT THE WELDING BE CHECKED IN EVERY CASE
•SM5.1: Observation and microscopic viewing of objects
through the ocular of the microscope and illumination of
the working area.
•The SM5.1 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 20 CM 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. 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.
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.
The highest and thus the most dangerous voltage in the
welding circuit is the no-load voltage. The highest
permissible no-load voltages are recorded in the national
and international regulations in accordance with the type of
welding current, construction of the current source and the
extent of the electrical hazard to the workplace.
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 must, as standard, be operated with a mains
voltage of 115 V~.
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 115 V!
This means that as a result of the tolerance range +/-10%,
the system can also be operated at 110 V~. Devices
configured to voltages other than 115 V 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! MAINS PLUGS
MUST CORRESPOND TO THE MAINS VOLTAGE AND
POWER CONSUMPTION OF THE WELDING
EQUIPMENT (see technical data!)
THE FUSING FOR THE MAINS SUPPLY MUST BE
MATCHED TO THE POWER CONSUMPTION OF THE
WELDING EQUIPMENT!
ONLY USE THE SUPPLIED MAINS CABLE!

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THE PUK U5 IS A PIECE OF ELECTRICAL EQUIPMENT. NATIONAL REGULATIONS ON TESTING
INTERVALS AND THE SCOPE OF REQUIRED RECURRING SAFETY-RELATED TESTS MUST BE
OBSERVED.
3.2 HAZARDS AND PERSONAL BODY PROTECTION
Please also observe the relevant regulations of the respective country.
RISK OF INJURY FROM RADIATION OR HEAT:
Protective gloves must be worn when welding.
Uncovered areas of the skin must be protected from the
UV radiation generated during welding in order to avoid
skin damage.
Wear suitable dry protective clothing with no synthetic
fibers.
The workpiece and the electrode tip can become very
hot during welding –risk of burns.
Welding can cause sparks and spatters –risk of burns.
EYE PROTECTION WHEN WELDING:
Never look into the arc without eye protection; always
use a welding mask with certified protective glass.
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, and can also
cause permanent eye damage.
The Lampert eye protection systems 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; use protective shield or safety glasses
with suitable protective glass.
SMOKES AND GASES:
When welding, especially in small spaces, ensure that
there is an adequate fresh air supply or use an external
extractor fan, as smoke and hazardous gases occur.
EXPLOSION HAZARD –DANGER WHEN
WELDING ON CONTAINERS:
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.
OTHER DANGERS:
The electrode tip installed in the handpiece means a risk
of injury (stabbing and scratching of e.g. hand, face and
eyes).
3.3 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.
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.
4. SETUP AND INSTALLATION

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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. 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.

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4.2 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!
4.3 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
AND LED MICROSCOPE ILLUMINATION
(4) CONNECTION SOCKET FOR FOOT SWITCH AND
ELECTRODE GRINDING MOTOR (optional accessory)
(5) TYPE PLATE
(6) SERIAL NUMBER
(7) PROTECTIVE GAS CONNECTION ("Argon Gas")
For 6.0 mm diameter pressure hose (max. 4,0 bar / 58 psi)
(8) APPROVED MAINS VOLTAGE FOR THIS DEVICE
4.4 CONNECT EYE PROTECTION AND LED ILLUMINATION OF THE WELDING MICROSCOPE TO THE PUK:
The circular connector for the eye protection system and
the LED illumination should be inserted into the connecting
socket (3) on the rear of the PUK welding device (marked
in red and yellow colour) and is to be tightened in place with
the coupling nut (hand tight)..
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
1
3
5
4
2
8
7
6

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4.5 CONNECT SHIELDING GAS SUPPLY:
Fasten the suitable flow regulator with the corresponding
tool to the shielding gas tank. ATTENTION: In doing so,
always observe the enclosed special operating instructions
provided. (Where possible, use argon with min. 99.99%
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
(7) 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!
4.6 INSERTING THE ELECTRODES INTO THE WELDING HANDPIECE:
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 (10) back and forth and in doing so,
pull it off of the handpiece (13). It is only pushed-on, not
screwed in place.
Release the threaded electrode connection (12), insert a
well sharpened tungsten electrode (11) 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. 4–6 mm out of the
nozzle (Fig. 5).
ONLY USE THORIUM OXIDE FREE ORIGINAL ELECTRODES
Subsequently insert the connector of the handpiece as
straight as possible into the socket (23) 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 the socket (24) on the front side of the
housing.
4.7CONNECT 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 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.

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4.8 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 handpiece 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
(14) 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 (17) and move the ocular
tubes (15) inwards or outwards by holding the prism
housing (18) 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 the welding handpiece
with clamped electrode into
the supporting arm. Rotate the
focusing knob (20) to a
medium focus range. Adjust
the mounting height of the
microscope head: Hold the
microscope head (19) 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 focused. 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 (20) to focus the
image.
DIOPTRE ADJUSTMENT
The sleeve for adjusting the dioptre (16) is fitted to the left-
hand ocular (17). 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 (15) and adjust the
focus using the focusing knob (20). Now look through the
left-hand ocular with your left eye and adjust the focus by
turning the dioptre control (16) on the left tube (17) until the
image appears focused.

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5. COMMISSIONING
5.1 DESCRIPTION OF THE FRONT-SIDE CONTROLS
(Fig. 1)
(21) TOUCHSCREEN-DISPLAY with slide function
(22) CONNECTION SOCKET FOR HANDPIECE (-)
(23) SOCKET (-)
For connecting the blue contact clamp for fixation welding
(24) SOCKET (+)
For connecting contact elements such as welding table, contact
terminals and clamps.
(25) ROTARY CONTROLLER
Select the welding power/time or switch to the next user level
•Pressing the rotary controller for a short time (< 1
second) switches from the power parameter (POWER)
to the pulse duration parameter (TIME).
(It jumps back to power automatically after 1 second)
•Turning the controller to the left or the right changes
the selected parameter.
•Pressing the controller for a longer time (> 1 second)
switches to the next user level, see chapter 5.2.
TOUCHSCREEN
29
(27) Select the material or welding program
(depending on the user level) by sliding to the left
or right within the selected user level. Press and
hold for 2 seconds to call the save menu.
(28) Foot switch activated (optional accessory)
(29) Speed function activated (only PUK U5+)
(30) Output scale as a percentage (POWER in %)
(31) Recommended setting range
(32) Pulse duration scale in milliseconds (TIME in ms)
(33) Preselect welding situation and pulse shape
(depending on user level)
21
25
23
24
22
28
27
30
31
32
33

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5.2 EXPLANATION / OVERVIEW OF MENUS
(Fig. Schematic diagram of user levels)
ONCE IT IS SWITCHED ON, THE PUK U5 STARTS UP IN ITS START LEVEL (MAIN MENU).THE FOLLOWING USER
LEVELS CAN BE NAVIGATED AFTER PRESSING LONGER (> 1 SEC.) THE ROTARY CONTROLLER (25):
a) Start level (main menu):
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) Expert level (if activated in the settings)
Arbitrary preselection of the various welding curves
c) Level micro
d) User programs and stored custom settings (if activated
in the settings)
e) Fixation welding (if activated in the settings)
f) Resistance welding (if activated in the settings)
g) Settings (Language, gas valve, lighting,…)
At the start level and in "Custom Programs", sliding in the
header bar on the display scrolls between the different
preset materials or stored programs depending on the
selected user level.
Beginners using the PUK system are advised to remain
within the start level.
PRESSING THE SELECTED MATERIAL (27) IN THE TOP OF THE DISPLAY FOR 2 SEC. CAUSES THE
PROGRAMMING MENU TO BE LAUNCHED:
h) Selection of the memory location and saving the
settings (if activated in the settings). Storing custom
welding parameters (20 memory slots)
i) Input and saving of the desired program (if activated in
the settings)
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 the
rotary controller or by touching the touchscreen.

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5.4 ADJUSTING FOR THE CORRECT GAS FLOW
PLEASE CONSIDER THAT GOOD WELDING RESULTS CAN ONLY BE ACHIEVED WITH A CORRECTLY
ADJUSTED GAS FLOW.
In order to configure the correct gas flow, activate the
"Gas valve" 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 - 3
litres/min. In doing so, also observe the instructions
provided with the flow regulator. Once the gas volume is
correctly adjusted, close again the "Gas valve" function 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 valve:
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. In addition, any other operation of the
device will automatically quit that function.
•Filter test:
Pressing this button causes a
shading of the eye protection filter.
This enables correct function of the eye protection filter to
be checked.
Pressing the button again quits the test.
•LED light:
Pressing the button enables the
brightness of the LED lamp on the
welding microscope to be adjusted in 3 steps or to be
switched off.
•Program memory:
You can activate or deactivate the
saving and calling functions for
programs that you created
yourself here. If this menu is
activated, it appears as an additional user level. The user
levels can be toggled by pressing the rotary controller for
1 second.
•Expert Menü:
The expert menu can be activated
here. If this menu is active, it
appears as an additional user
level. The user levels can be toggled by pressing the
rotary controller for 1 sec. or longer.
•Fixation:
Pressing this button activates or
deactivates the operating menu for
fixation welding. If this menu is
activated, it appears as an
additional user level. The user levels can be toggled by
pressing the rotary controller for 1 sec. or permanently.
•Micro:
The “micro” menu can be activated
here. If this menu is active, it
appears as an additional user
level. The user levels can be toggled by pressing the
rotary controller for 1 sec.
•Welding sequence:
You can press the button to
preselect a "standard" or "short"
basic welding sequence. If you
select "short", a shortened gas pre-
flow time results in a shorter time gap for triggering in a
series of welding points.
•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 English,
German, Spanish, French, Italian and Russian.

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•Welding signal tone:
Pressing the button activates or
deactivates the acoustic signal that
notifies the triggering of the weld.
•Resistance welding:
Pressing the button activates or
deactivates the resistance
welding function. If this menu is
activated, it appears as an additional user level. The user
levels can be toggled by pressing the rotary controller for
1 sec. or permanently.
6. SELECTION OF THE WELDING PARAMETERS AND USER LEVELS
6.1 SELECTION OF THE WELDING PARAMETERS
Pressing for a short time (< 1 second) the rotary controller (25) or touching the POWER or TIME scales on the display
switches between the power (POWER) and pulse duration (TIME) parameters. It jumps back to power (POWER)
automatically after 1 second. Rotating the rotary controller or sliding the power (POWER) or pulse duration (TIME) scales
changes the relevant value.
BASIC INFORMATION ABOUT THE EFFECTS OF WELDING POWER AND WELDING TIME:
POWER:
With the parameter “welding power” the strength of welding
energy is set.
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.
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 welding time setting 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 4 msec are recommended
here.
With many silver alloys or other highly conductive metals a
longer welding time can be advantageous in order to avoid
hot cracks, starting at 10 msec.
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.

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SELECTION OF THE WELDING PARAMETERS ON THE PUK U5:
The welding parameters are set in two stages:
1) In the upper area of the display, select the metal to be welded by sliding over
the metal names.
2) Pressing one of the 5 buttons on the lower edge 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 under the scale by means of a blue bar.
Settings outside of the recommended blue setting
range are always possible.
•The power is also preselected and the recommended
setting range for the power is marked with a blue bar.
Settings outside of the recommended blue setting
range are always possible.
DESCRIPTION OF THE WELDING SITUATION WITH ASSOCIATED SYMBOL ON TOUCHSCREEN:
•In the start level, the meaning of the following symbols
is always the same for each of the preconfigured
materials.
•In the start 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 0.3 mm. This is well suited for most
applications (≥ 0.3 mm).
Setting for thin sheet metal or wire parts
equal to or less than ca. 0.3 mm (≤ 0.3 mm).
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.
Melting of welding wire. Use identical alloy
wire with a diameter of ca. 0.4 mm.
Particularly low-energy melting of thin
welding wire, a diameter of approx. 0.2 mm
is recommended.
PUSHING/TOUCHING THE RESPECTIVE BUTTON FOR 2 SEC. BRINGS UP AN INFO WINDOW ON THE
DISPLAY. SEE 6.3 "HELP FUNCTION"

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6.2 EXPERT MENU
>>>THE EXPERT MENU CAN BE ACTIVATED IN THE USER LEVEL "SETTINGS"
After activation,
the expert mode
appears as a
separate user
level, which can
be accessed by
pressing the
rotary controller
for 1 second or permanently. The various welding
characteristic curves are stored in the expert mode, which
have been developed and defined in the start level for the
preconfigured metals and welding geometries. However,
here they are shown without content-related assignment.
This mode is designed for experienced welders who want
to experiment with the various stored energy characteristic
curves (pulse modulations). In this user level it is possible
to choose between the various energy curves and store
these together with individual settings for the output and
time.
WHEN SWITCHING FROM THE MAIN MENU TO THE EXPERT MENU, THE RELEVANT SETTINGS ARE
CARRIED OVER FROM THE MAIN MENU. THIS MEANS THAT THE WELDING CURVES STORED IN THE
MAIN MENU CAN STILL BE VIEWED.
6.3 HELP FUNCTION
The buttons on the bottom
of the display are provided
with accessible info
screens in all user levels.
Touching / pressing the
button for 2 sec. 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.
6.4 PROGRAMMING
SAVING CUSTOM PROGRAMS
1. Pressing the metal
name for a longer time
(2 seconds) calls the
programming menu. In
the first step,
scroll/slide to the
left/right to select the
program slot into which you want to store your custom
settings.
2. Then save your data
by pressing the "next"
button. Saved data
cannot be deleted. It
can only be
overwritten.
3. The following screen
provides the option of
assigning a program
name to the stored
settings. The program
name can comprise
upper and lower case
letters and special characters. You can use
the arrow buttons on the display to select the active cursor
position and you can use the rotary controller (25) to select
the desired characters.
Once the name has been entered, confirm your entry by
pressing the "Save" button. After saving, you will be
returned to the "Custom Programs" user level
automatically, and the previously saved data is active.
6.5 LOADING SAVED PROGRAMS AND THE USER LEVEL "CUSTOM PROGRAMS"
All custom stored
programs are
summarised in the
"Custom Programs"
user level. In the
upper display area on
this user level, select the relevant custom program by
sliding to the left/right.

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6.6 FIXATION WELDING
>>> THE FIXATION WELDING MENU CAN BE ACTIVATED FROM THE "SETTINGS" USER LEVEL.
After activation (see
also point 5.5 /
Settings), the fixation
mode appears as a
separate user level,
which can be
accessed by pressing
the rotary controller several times for 1 sec. or
permanently.
This mode is used for the fixation of two work piece parts.
See also Chapter 7.3.1.
For using the fixation mode the foot switch is required
(optional accessory).
PLEASE NOTE: FIXATION WELDING IS PARTICULARLY WELL SUITED FOR METALS WITH LOW
ELECTRICAL CONDUCTIVITY, FOR EXAMPLE: TITANIUM AND STEEL.
6.7 MICRO
>>> THE MENU MICRO CAN BE ACTIVATED FROM THE "SETTINGS" USER LEVEL.
The micro menu can
be activated in the
settings user level.
After activation, the
micro menu appears
as a separate user
level, which can be
accessed by pressing and holding the multifunctional
controller.
In micro menu the welding paratmeters can be adjusted
much finer allowing the welding of wires and sheets with
material thickness down to less than 0.2 mm with even
greater control.
6.8 RESISTANCE WELDING MODE
The resistance welding mode appears as a separate user
level, which can be
accessed by
pressing the rotary
controller several
times for approx. 1
second.
The welding process is released via the foot switch
(optional accessory) 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 SPECIALIST
PERSONNEL.
7.1 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 is carried out. 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.
The welding process starts automatically as soon as the electrode touches the workpiece:
•Shielding gas flows around the welding area.
•A signal tone (if activated in the settings) notifies of the
arc.
•The welding protection filter is darkened.
•The arc is triggered with a slight delay and the
electrode partly withdraws into the handpiece.
•The welding protection filter is lightened and the
electrode returns to the initial position.
•The shielding gas supply stops or the welding process
is started again by touching the workpiece.
WORK ONLY WITH EXTREMELY LIGHT CONTACT AND WITHOUT ANY PRESSURE TO THE TIP OF THE
ELECTRODE!

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The PUK U5 is equipped with a function to prevent the
electrode becoming welded to the workpiece by
incorrectly pressing too hard. If a welding point has
already been set and is pressed too hard to the
workpiece when it comes into contact again, the welding
point is not triggered; instead, an acoustic signal sounds
periodically to indicate that the electrode is pressing too
hard against the workpiece. The electrode's contact to
the workpiece must be stopped for a short time and the
welding process must be started again.
THE WELDING PROCESS CAN BE HALTED AT ANY TIME BY MEANS OF LIFTING THE ELECTRODE AWAY
FROM THE WORKPIECE.
7.2 WELDING WITH THE SPEED MODE (only PUK U5+)
You can press
the according
symbol on
the display for 1
second to
activate or
deactivate the speed mode. The speed mode can only be
activated on the start level, in the expert menu and on the
"Custom Programs" level. The speed mode enables a
faster welding sequence, e.g. for an increased heat input
into the workpiece. If the user switches to a different user
level, the speed mode must be reactivated if required.
7.3 WELDING WITH FOOT SWITCH (optional accessory)
With the PUK U5 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 the rotary controller or touching
the screen 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.). AN INFO MESSAGE
AND A BLUE SYMBOL APPEAR IN THE DISPLAY.
Connect a metallic blank
section of the workpiece
with the contact clamp.
Now lightly touch the
workpiece with the
electrode. The eye
protection system starts to turn periodically from its light to
its dark setting. 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 SYMBOL ON THE DISPLAY DISAPPEARS.
7.3.1 FIXATION 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 contact clamp, 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 handpiece 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.
AFTER WELDING HAS BEEN SUCCESSFULLY COMPLETED, AND BEFORE SWITCHING TO ANOTHER
USER LEVEL, PLEASE REMOVE THE BLUE CONNECTION CABLE!
NOTE: DURING FIXATION WELDING, THE FOOT SWITCH IS ALWAYS ACTIVE, AND CANNOT BE
DEACTIVATED! DURING FIXATION WELDING THE GAS PROTECTION IS DEACTIVATED!

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7.3.2. 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!
NOTE: DURING RESISTANCE WELDING, THE FOOT SWITCH FUNCTION IS PERMANENTLY ACTIVATED, AND
CANNOT BE DEACTIVATED!
NOTE: IF TOO LOW A FORCE IS APPLIED TO THE WORKPIECES TO BE CONNECTED, AN ELECTRIC ARC MAY BE
GENERATED, WHICH MIGHT DAMAGE BOTH THE WORKPIECE AND THE ELECTRODES OR OTHER CONTACTING
TOOLS IN USE.
The resistance welding mode can be an option for using
individual solutions, e.g. in combination with a force
controlled triggering of the weld. Corresponding
equipment has to be connected to the socket for the foot
switch*. The following welding curves are available (from
left to right):
1. Single pulse
2. Single pulse with pre-pulse
3. Single pulse with postheating
4. Single pulse with pre-pulse and postheating
5. Single pulse with increased pre-pulse and
postheating
*PLEASE NOTE: Any damage, resulted whilst external equipment or tools, not produced by LAMPERT, were being
connected to PUK-devices, is expressly not covered by our terms of guarantee!
BEFORE SWITCHING TO ANOTHER USER LEVEL, PLEASE REMOVE THE BLUE CONNECTION CABLE
FROM THE PUK U5!
7.4 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 SM5.1. 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 –3 litres per 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.
7.5 SHARPENING 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°.
See also the video “Electrodes” on
www.youtube.com/LampertWelding.

Lampert Tools USA 2020 17
8. CARE OF THE SYSTEM COMPONENTS
8.1 CARE OF WELDING DEVICE AND WELDING MICROSCOPE
Your PUK 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 A QUALIFIED ELECTRICIAN!
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 (17) from
the ocular tubes (15).
Clean the outer surfaces. In doing so, breathe 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.
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
400 VA
30 –43 V
43 V
80 %
0.8 sec.
min. ARGON 99,9 %
4 bar / 58 psi
I
B
IP 21S
8.52 kg (PUK U5)

Lampert Tools USA 2020 18
9.2. TECHNICAL DATA MICROSCOPE
Optical eye protection and illumination system for exclusive use with PUK fine welding devices.
Use only in dry rooms
9.3 OPTICAL DATA MICROSCOPE
Lens
Ocular
Working distance
Magnification factor
Field of view
1.0
10 x
140 mm
10 x
20 mm
9.4 TECHNICAL DATA LCD SHUTTER M11 (BL)
Light shade
Dark shade
Switching time
UV protection
IR protection
DIN 3
DIN 11
< 50 msec.
> 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
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 –60 Hz
Read
operating
manual
No-load
voltage
Mains voltage
Voltage at
nominal load
Tungsten
inert gas
welding
Earthing
Nominal
welding
current
Power
consumption
under max.
load
Power
consumption
under
nominal load
Cyclic
duration
factor
Single-phase
transformer
Keep away
from water
Operating temperature
Lamp "LED unit"
Protection class
Insulation class
Protection type
Weight
+5 °C bis +40 °C
3 W / 800 mA
III
B
IP 20
3.5 Kg