LOKERMANN GRAND MIG 400 PULSE User manual

USER MANUAL
GRAND MIG
400/500/600
PULSE
IMPORTANT: Read this OPERATOR MANUAL together
with PRESCRIPTION AND COMPLIANCE MANUAL before
to use this equipment. In case of loss one of two parts
contact immediately your dealer.
Allow the operator to consult this manual.

Contents
1 Safety Warning........................................................................................................................................3
2 Product....................................................................................................................................................8
2.1 Product Introduction......................................................................................................................8
2.2 Technical Data..............................................................................................................................8
2.3 Panel Instruction.........................................................................................................................11
2.4 Function Description...................................................................................................................23
3 Opening Inspection...............................................................................................................................39
4 MIG/MAG Welding................................................................................................................................40
4.1 Standard Configuration...............................................................................................................40
4.2 Installation Instruction.................................................................................................................41
4.3 Connection Diagram...................................................................................................................47
4.4 Welding Operation......................................................................................................................49
5 TIG Welding...........................................................................................................................................56
5.1 Accessories.................................................................................................................................56
5.2 Welding Operation......................................................................................................................56
6 STICK/MMA Welding............................................................................................................................57
6.1 Accessories.................................................................................................................................57
Welding Operation......................................................................................................................59
7 Arc Gouging Welding............................................................................................................................60
7.1 Installation Instruction.................................................................................................................60
7.2 Connection Diagram...................................................................................................................60
7.3 Welding Operation......................................................................................................................60
8 Welding Environment and Problems.....................................................................................................62
8.1 Environmental Condition.............................................................................................................62
8.2 Connection to the Main Supply...................................................................................................62
8.3 Welding Problems.......................................................................................................................62
9 Routine Maintenance............................................................................................................................64
10 Trouble Shooting.................................................................................................................................65
Appendix A Circuit Diagram.....................................................................................................................75
6.2

1 Safety Warning
Security Definitions
It indicates that neglecting safety warnings may result in serious
accidents, even death or serious injury.
It indicates that neglecting safety warnings may result in minor
injury to personnel or property damage.
It indicates that neglecting safety warnings may result in equipment
failure or damage.
Personal Protection Precautions
Personnel with professional qualifications or relevant knowledge and skills are
requested to install, operate, maintain and repair the power source.
Installation, inspection and repair of power source must be carried out by
electricians, and temporary construction points should be connected by
electricians.
 Supervisors shall be provided for working in high altitude or narrow places, such
as boxes, boilers, cabins, etc.
Personal protective equipment, such as protective masks, overalls, insulating
gloves and insulating shoes, should be worn when working.
Those who use cardiac pacemakers shall not approach the power source in use
and welding workplaces without the permission of a physician.
Installation Operation Precautions
The power source shall not be used for pipeline thawing, battery
load or motor start-up.
Beware of Electric Shocks
3

 Before welding, the yellow-green grounding wire in the power line must be
grounded and the insulation of the welding cable must be ensured.
During welding operation, do not touch live parts such as workbench, welding
parts, earth clamp, electrode holder or welding torches.
 Rubber insulation pads should also be laid on the ground near the operating table
for welding operations with high no-load voltage and in wet working places.
In the welding process, do not open the machine house and side cover.
 Do not touch the electrically charged parts.
 Do not use cables with insufficient cross-section, damaged insulation sheaths or
exposed conductors.
Maintenance operation should be carried out after 5 minutes of disconnection of
the power supply until the power indicator is completely turned off, otherwise there
is a risk of electric shock.
 Turn off all input power when transferring work place, replacing fuse, repairing or
not using the equipment.
Beware of welding fume and harmful gases
When welding steel plates with coatings or coatings, harmful fumes and gases will
be produced. Full ventilation or exhaust facilities should be used to keep fumes
and toxic gases away from the breathing area. If necessary, wear breathing
protection tools.
 When working in narrow places, such as boxes, boilers, cabins, etc., please
accept the inspection of supervisors. In order to prevent hypoxia, we should fully
ventilate and wear respiratory protective equipment.
Keep ventilation system of welding machine unblocked. The minimum distance
between power source and surrounding place should be greater than 0.5m. Do not
cover the inlet and outlet of equipment to ensure smooth circulation of cooling air.
Welding Sparks May Cause Fire or Explosion
Corresponding protective measures should be taken in the welding area to avoid
fire caused by welding mars.
4

 Do not carry out welding operations in degreasing, cleaning and spraying areas.
Do not weld gas-filled pipes, sealing grooves (boxes) and other devices, otherwise
explosions or fires are likely to occur.
 Do not weld near flammable gases or devices with flammable substances,
otherwise explosion or fire may occur.
When not welded, make sure that any component in the wire circuit does not
contact the workpiece or the earth, otherwise it may cause overheating and fire.
 When the welding operation is stopped, remove the electrode in the welding pliers
or cut off the welding wire in the nozzle of the welding torch.
Electrical Base Field May be Dangerous
Those who use cardiac pacemakers shall not approach the power source in use
and welding workplaces without the permission of a physician.
 It is strictly forbidden to place or wrap welded cables around the body.
Do not place the body between the welding wire and the workpiece cable. If the
welding wire cable is on the right side of the body, the workpiece cable should also
be on the right side of the body.
Arc Rays May Cause Burns
When welding or supervising welding, please wear protective appliances with
adequate shading.
 Protective barriers are set around the welding site to prevent arc or welding spatter
from injuring others.
Avoiding Electromagnetic Interference
Users should ensure that the welding power supply and other equipment in the
5

environment do not produce electromagnetic interference, otherwise
corresponding shielding and protection measures should be taken.
 According to the manufacturer's suggestion, the power source should be
connected to the main power supply line.
The length of welded cables should be shortened as far as possible to make them
close to each other and to the ground.
 Safety of all metal assemblies assembled by welding and the assemblies
connected with them should be confirmed.
The yellow-green grounding wire in the power line must be grounded, and the
workpiece must be well connected with the ground clamp.
 Users should be responsible for the interference caused by welding.
Noise Produced during Welding can Easily Cause Hearing Loss
In order to avoid the harm of noise to you and others, please wear the prescribed
protective equipment.
Cautions for Hoisting
The power source with strap or hand is prohibited from using strap or hand for
lifting.
When lifting power source with lifting forklift truck, in order to prevent dumping,
please fork-fit and fix it from side.
 When lifting power source with crane, the cable should be tied to the suspension
ring, and the angle between the cable and the vertical direction should not exceed
15 degrees.
When the power source with cylinder and wire feeder is hoisted, the two
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equipments should be unloaded from the power supply first. When moving the
power source on the ground, it is necessary to fix the cylinder with a strap or chain
to prevent dumping and injuring people.
If the wire feeder is hoisted by lifting lugs for welding, it is necessary to ensure that
it is firm and insulated.
7

2 Product
2.1 Product Introduction
The GRAND MIG PULSE series is digital multi-function welding machine designed based
on the inverter technology.
The multi-function of the product meet the requirements of customers, including pulse
MIG/MAG welding, double pulse MIG/MAG welding, MIG/MAG welding, TIG welding with
lift start function, STICK/MMA welding with VRD and arc air gouging.
It is applies to the metals as aluminum, aluminum alloy, copper alloy, titanium alloy, steel
and special material, etc.
2.2 Technical Data
Power source GRAND MIG 400 PULSE GRAND MIG 500 PULSE
Power supply 3 phase 380V / 460V (-
15~+10%)
3 phase 380V / 460V (-
15~+10%)
Rated input current (A) 27A (380V)
27A (460V)
38A (380V)
31.5A (460V)
Frequency (Hz) 50/60 50/60
Rated power 17.5 KVA 25 KVA
No load voltage (with VRD) 7.5 V±10% 7.5 V±10%
No load voltage (without VRD) 92.2 V (Max) 92.2 V (Max)
Rated duty cycle (10 min) 400A-100% 500A-60%
MIG/Lift-TIG/MMA/Gouging
output current adjustment (A)
MIG: 18~400 Lift-TIG: 5~400
MMA: 20~400 Gouging: 120~400
MIG/MAG output voltage (V) 14.9-34 14.9~39
TIG output voltage (V) 10.2~26 10.2~30
MMA output voltage (V) 20.8~36 20.8~40
Gouging output voltage (V) 24.8~36 24.8~40
Protection class IP23 IP23
Insulation class H H
EMC class A A
Weight (kg) 56 56
Dimensions (L×W×H) 770×340×505 770×340×505
MIG: 18~500 Lift-TIG: 5~500
MMA: 20~500 Gouging: 120~500
8

Power source GRAND MIG 600 PULSE
Power supply 3 phase 380V / 460V (-
15~+10%)
Rated input current (A) 49.5A (380V)
41A (460V)
Frequency (Hz) 50/60
Rated power 32.5 KVA
No load voltage (with VRD) 7.5 V±10%
No load voltage (without VRD) 92.2 V (Max)
Rated duty cycle (10 min) 600-40%
MIG/Lift-TIG/MMA/Gouging
output current adjustment (A)
MIG/MAG output voltage (V) 14.9~44
TIG output voltage (V) 10.2~34
MMA output voltage (V) 20.8~44
Gouging output voltage (V) 24.8~44
Protection class IP23
Insulation class H
EMC class A
Weight (kg) 56
Dimensions (L×W×H) 770×340×505
Wire Feeder Type GRAND FEEDER PULSE
Power supply 42V (50/60Hz)
Rated input current 2A
Wire feeding speed 1.5-24m/min
Gas pressure 0.5MPa
Wire dimension (min) Φ0.8mm
Wire dimension (max) Solid-cored Φ1.6mm
Flux-cored Φ1.6mm
Spool cover Axis diameter Φ50mm
External diameter Φ300mm
Width 103mm
Weight 18 kg
Protection class IP23
EMC class A
Weight (kg) 18
MIG: 18~500 Lift-TIG: 5~500
MMA: 20~500 Gouging: 120~500
Dimensions (L×W×H) 661×212×395mm
9

Water Cooler Unit Type GRAND COOLER PULSE
Power supply 380V (1~50/60Hz)
Q.max 8L/min (pump)
H.max 15m
Rated input current 0.5A
Protection class IP23
Weight (kg) 30
Dimensions (L×W×H) 658×360×260mm
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2.3 Panel Instruction
 Under the MIG/MAG mode, users need to set and operate both the power source and
wire feeder.
 Under the TIG welding, STICK/MMA welding and arc gouging welding mode, users
need to set and operate the power source.
Front/Back Panel of Power Source
No. Description No. Description
1 Crane eyelets 8 CO2 heater supply socket
2 Handle 9 Power supply cable
3 Control panel 10 Serial port
4 Main switch 11 Wire feeder communication
connector
5 Negative connector (-) 12 Positive connector (+)
6 Remote control connector
(5-pin)
13 Grid
7 Positive connector (+) / /
1
2
3
4
567
8
10
11
9
12
13
11

Control Panel of Power Source
No./Knob Description
1 Main adjusting knob
2 Software version/error code display
3Current display
It shows the error code, current value, set current
before welding, and real current in welding process.
4Voltage display
It shows the output voltage in welding process, and
shows the input voltage value when pressing the main
adjusting knob.
Selection button for STICK, TIG and ARC gouging
mode.
If the wire feeder unit is connected, press or turning any
of the knob or button on the wire feeder panel, the
power source turns into MIG/MAG mode.
Selection button for electrode type
Press it to select the type of electrode, including 6013/
RUTILE, 7018/ BASIC, 6010/ CEL, 4043/ ALU, CrNi/
RUTILE.
Selection button for arc force
Press it to set the value of hot start. And press it for 5
sec, it turns into the power limit status, and the right
display is shown "PL". Turn the main knob to adjust the
value from "0-100" or OFF.
Remote control LED
When the led lights on, the power source is under
remote control. When led is off, the power source is set
1
2
3
4
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No./Knob Description
by the panel.
Input power supply LED
The bus voltage has a feedback to the main control.
When the voltage is lower than 150V DC, the machine
stops working, the led of "DC BUS FAIL" on the power
source front panel will light on. And the main relay of
the power source would turn off
The fan cool LED
When the led lights on, the fan keeps working under
manual mode. When the LEDs are off, the fan start
working automatically.
The water cool LED
When the led lights on, the water cooler unit keeps
working under manual mode.
The LED of anti-sticking protection
Over heat protection
The LED of VRD function.
13

Back Panel of Water Cooler Unit
The water cooler unit consists of two parts, the kit water cooler slot and the housing kit
for water cooler rack. The cooling agent is filled through coolant filling.
No. Description
1 Fast socket for water (blue)
2 Fast socket for water (red)
3 Coolant filling
4 Handle
5 Coolant valve for the water cooler unit
6 Coolant scale
7 Label of water cooler unit
1
2
3
4
5
6
7
14

Front Panel / Back Panel / Side Panel of Wire Feeder
No. Description
1Front panel of wire feeder
2Crane eyelets
3Cable clamp for connection hose package (CHP)
4Euro connector
5Remote control output connector
6Carriage (welding tractor) connector
7Fast socket for water (blue)
8Fast socket for water (red)
9Gas in connector
10 Communication port for power source
11 Positive input terminal for power source
1
2
3
4
5
6
78
9
10
0
11
1
12
2
13
3
14
4
15
5
15

No. Description
12 Fast socket for water (red)
13 Fast socket for water (blue)
14 Parameter label
15 Side panel
Front Panel of Wire Feeder
Icon Name Description
Left display Display the current, voltage and so on.
Right display
Left knob Used to regulate welding parameters such as
current, voltage and so on.
Right knob
JOB adjusting button Used to choose JOB number.
Wire check button Holding down the button, the wire feeder start
to wire feeding.
1
2
3
4
1 2
3 4
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Icon Name Description
Wire check button Holding down the button, the wire feeder start
to wire feeding back.
Real current indicator The left display shows real current when the
indicator light is on.
Preset current indicator The left display shows preset current when the
indicator light is on.
Wire feeding speed
indicator
The left display shows wire feeding speed when
the indicator light is on.
Real voltage indicator The right display shows real voltage when the
indicator light is on.
Set voltage indicator The right display shows preset voltage when
the indicator light is on.
Arc length indicator The right display shows arc length when the
indicator light is on.
Manual mode indicator The indicator light is on when wording in the
mode.
Synergic mode indicator The indicator light is on when wording in the
mode.
Pulse mode indicator The indicator light is on when wording in the
mode.
Double pulse mode
indicator
The indicator light is on when wording in the
mode.
Lift MIG mode indicator When set in "on" its LED lit on the front panel.
Gas indicator The indicator light is on when press the Gas
Check button on the wire feeder, it means the
air compressor works properly.
2T indicator The indicator light is on when wording in this
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Icon Name Description
mode.
4T indicator The indicator light is on when wording in this
mode.
Workpiece’s thickness The right display shows workpiece’s thickness
when the indicator light is on.
Inductance indicator The right display shows inductance when the
indicator light is on.
Side Panel of Wire Feeder (inside)
Press the MIG/MAG torch switch, the MIG/MAG light on the power source panel lit on.
The MIG/MAG welding process is controlled by the wire feeder control panel, which is
under right side cover.
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Knob Description
Welding mode selection button
Press the button, select the four modes:
Manual MIG/MAG welding
Synergic MIG/MAG welding
Pulse MIG/MAG welding
Double pulse MIG/MAG welding
Welding cycle selection button
Press the button, select the four types cycle:
2T: Operating mode 2-cycles is provided for short
manual welds
1st cycles: Press torch button
 Solenoid valve for shielding gas opens
 Weld voltage is applied on wire electrode
 Wire feed starts with reduced speed and arc ignites
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