PullMig Operating Instructions

PullMig is a wire feed unit for manual welding using soft welding wires and with long hose packs. Two toothed precision rolls ensure large-surface power transmission. This leads to outstanding wire feed even with very soft aluminium and CuSi wires and very long hose packs. The many different versions of PullMig available are one of its distinguishing features.

Thus there are several variations of torch connections available with both external and internal coolant connections. A variety of pipe bend designs ensures excellent weld accessibility.

PullMig is a wire feed unit for manual welding using soft welding wires and with long hose packs. Two toothed precision rolls ensure large-surface power transmission. This leads to outstanding wire feed even with very soft aluminium and CuSi wires and very long hose packs. The many different versions of PullMig available are one of its distinguishing features.

Thus there are several variations of torch connections available with both external and internal coolant connections. A variety of pipe bend designs ensures excellent weld accessibility.

The device has been manufactured in line with the state of the art and according to recognized safety standards.

The MIG/MAG manual welding torch is intended exclusively for MIG/MAG welding in manual applications. Utilisation for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended use.

Intended use also includes:

Following all the instructions contained in the operating instructions
Performing all stipulated inspection and maintenance work

WARNING!

Danger due to incorrect operation and incorrectly performed work.

This can result in serious injury and damage to property.

All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

Fully read and understand this document.

Read and understand all safety rules and user documentation for this device and all system components.

WARNING!

Danger from electric current.

This can result in serious injury and damage to property.

Before starting maintenance or servicing work, switch off all the devices and components involved and disconnect them from the mains.

Secure all the devices and components involved to prevent unintentional restarting.

After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

WARNING!

Danger from electric current due to defective system components and incorrect operation.

This can result in serious personal injury and damage to property.

All cables, leads and hosepacks must always be securely connected, undamaged and correctly insulated.

Only use adequately dimensioned cables, leads and hosepacks.

CAUTION!

Danger due to emerging wire electrode.

This can result in personal injury.

Hold the welding torch with the end directed away from the face and body.

Wear suitable protective goggles.

Do not point the welding torch at people.

Ensure that the wire electrode can only intentionally make contact with electrically conductive objects.

CAUTION!

Danger due to hot system components and/or equipment.

This can result in burns or scalding.

Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.).

Wear suitable protective equipment if cooling down is not possible (e.g., heat-resistant gloves, safety goggles, etc.).

CAUTION!

Danger due to operation without coolant.

This can result in damage to property.

Never operate water-cooled devices without coolant.

During welding, ensure that there is a proper coolant flow. When using Fronius cooling units, this is the case if a proper coolant return flow can be seen in the coolant container of the cooling unit.

CAUTION!

Danger due to exposed mechanically moving parts.

This can result in personal injury and damage to property.

Only operate the device when all covers are closed and/or completely mounted.

Power source

TS 4000 / 5000
TPS 2700 / 4000 / 5000

Software

Power source: Software version 3.10.22 or higher
Wire feed: Software version 1.70.16 or higher

Options

Installation set „PMR4000 PullMig TS/TPS 2700-5000 (4,100,217)“
Software „FS Drive (4,061,113)“

IMPORTANT! Risk of coolant leakage (on water-cooled welding torches) or damage from overheating (on gas-cooled welding torches). When mounting the torch neck, make sure that the swivel nut is fixed firmly.

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2

When cutting the inner liner to length, make sure that

no burr (sharp edges) protrudes into the inner liner at the cut location.
Hold the side-cutting pliers at a slight angle (the burr is then pulled towards the outside).
Grind off the burr

* Contact tube with centering bore
** Contact tube without centering bore

Ø 4 mm (.16 in.): 40,0002,0014; 40,0002,0015
Ø 4,7 mm (.19 in.): 40,0002,0004; 40,0002,0017

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5

IMPOTRTANT! Bring the inner liner as close as possible to the wirefeed rollers, but without touching them.

Before threading in the welding wire, round off the ends of the wire.

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4

Only use wire guidance nozzles corresponding to diameter of wire. The following wire guidance nozzles are available:

0,8 mm (.030 in.)
1,0 mm (.040 in.)
1,2 mm (.045 in.)
1,6 mm (1/16 in.)

Before threading in the welding wire, round off the ends of the wire.

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* Optional infeed nozzle (42,0001,5421)

IMPORTANT! Bring the inner liner / the infeed nozzle as close as possible to the wirefeed rollers, but without touching them. Before threading in the welding wire, round off the ends of the wire.

* Standard plug (Standard or Up/Down torches)
** JobMaster plug (JobMaster welding torches)

1Unscrew pressure lever (1)

2Unscrew axle (2) using slotted screwdriver

3Remove complete unit (3)

4Fix drive roll (4) using driving gear key (5) provided

5Unscrew hexagon nut (6) using open-ended spanner - spanner size 10 mm (.394 in.)

6Remove drive roll (4)

1hard (e.g. CrNi)

2medium (e.g. AlMg / CuSi)

3soft (e.g. AlSi)

1Unscrew hexagon nut using open-ended spanner (1)

- spanner size 10 mm (.394 in.)

2Unscrew and remove wire inlet nozzle using Allen key (2)

- key width 2.5 mm (.099 in.)

Set welding output using Up/Down function

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3

Select and set desired parameter using JobMaster function

IMPORTANT! Refer to MIG/MAG Torch Operating Instructions, chapter headed „JobMaster“ for more detailed information on the JobMaster function.

No number („PPU“) selectable for PullMig (PushPull Unit)

Cause:	„PMR4000 PullMig“ installation set is not installed
Remedy:	Install installation set

Number for PullMig (e.g. „PPU | 5“), for PushPull equalisation is not selectable

Cause:	Power source does not have „FS Drive“ software
Remedy:	Provide power source with „FS Drive“ software

PullMig feed rolls are not turning

Cause:	PullMig control plug is not plugged in
Remedy:	Connect PullMig control plug at torch control connection
Cause:	PullMig connection cable damaged
Remedy:	Check cable and replace if necessary

Irregular wire speed

Wire electrode forms a loop between feed rolls and wire inlet nozzle

Cause:	Feed rolls not suitable for wire electrode being used
Remedy:	Use appropriate feed rolls
Cause:	Wrong electrode pressure of PullMig or 4-roll drive
Remedy:	Optimise electrode pressure

Welding wire is deformed or breaks off

Cause:	Electrode pressure of PullMig or 4-roll drive set too high
Remedy:	Set electrode pressure of PullMig or 4-roll drive correctly
Cause:	PullMig turns too fast or too slow
Remedy:	Select right number (e.g. „PPU \| 5“) for PullMig during PushPull equalisation

PullMig becomes too hot

Cause:	Inadequate cooling; water circulation too low or non-existent in cooling unit
Remedy:	Check whether PullMig is properly connected; check cooling unit and bleed if necessary; check coolant throughflow for PullMig

EFd | xx.x, EFd | 8.1

Cause:	Wire drive blocked/faulty
Remedy:	Inspect/replace motor for wire drive

EFd | 8.2

Cause:	Fault in wire feed system (overcurrent in PullMig drive)
Remedy:	Lay hose pack out in as straight a line as possible; check liner for kink or dirt; check contact pressure of PullMig feed rolls

EFd | 9.1

Cause:	External supply voltage: supply voltage has dropped below tolerance range
Remedy:	Check external supply voltage

EFd | 9.2

Cause:	External supply voltage: supply voltage has exceeded tolerance range
Remedy:	Check external supply voltage

I (Amp.) 10 min/40° C M21 (EN ISO 14175)		40 % d.c.* 280 60 % d.c.* 220 100 % d.c.* 170
I (Amp.) 10 min/40° C C1 (EN ISO 14175)		40 % d.c.* 330 60 % d.c.* 270 100 % d.c.* 210
	[m] (ft.)	6 / 8 / 10 (19,6/26,2/32,8)
	[V] DC	42
	[A]	0,8
	[m/min] (ipm)	0,5 - 18 (19,69 - 787,40)
	[mm] (in.)	0,8 - 1,6 (.032 - .047)
* d.c. = duty cycle

I (Amp.) 10 min/40° C M21 (EN ISO 14175)		40 % d.c.* 280 60 % d.c.* 220 100 % d.c.* 170
I (Amp.) 10 min/40° C C1 (EN ISO 14175)		40 % d.c.* 330 60 % d.c.* 270 100 % d.c.* 210
	[m] (ft.)	6 / 8 / 10 (19,6/26,2/32,8)
	[V] DC	42
	[A]	0,8
	[m/min] (ipm)	0,5 - 18 (19,69 - 787,40)
	[mm] (in.)	0,8 - 1,6 (.032 - .047)
* d.c. = duty cycle

I (Amp.) 10 min/40° C M21 (EN ISO 14175)		100 % d.c.* 400
I (Amp.) 10 min/40° C C1 (ENISO 14175)		100 % d.c.* 500
	[m] (ft.)	6 / 8 / 10 (19,6/26,2/32,8)
P_min	[W]**	1450 / 1800 / 2000 W
Q_min	[l/min] (gal./min)	1 (.26)
p_min	[bar] (psi.)	3 (43.5)
p_min	[bar] (psi.)	5,5 (79.7)
	[V] DC	42
	[A]	0,8
	[m/min] (ipm)	0,5 - 18 (19,69 - 787,40)
	[mm] (in.)	0,8 - 1,6 (.032 - .047)
* d.c. = duty cycle
** Minimum cooling power in accordance with standard IEC 60974-2

			AL216	AL236	AL306	AL406
	I (Amp.) 10 min/40° C M21 (EN ISO 14175) - d.c.*	35 % 180 60 % 140 100 % 100	40 % 200 60 % 160 100 % 120	40 % 260 60 % 210 100 % 160	40 % 350 60 % 280 100 % 220
I (Amp.) 10 min/40° C C1 (EN ISO 14175) - d.c.*	35 % 210 60 % 160 100 % 120	40 % 230 60 % 190 100 % 150	40 % 300 60 % 240 100 % 190	40 % 400 60 % 320 100 % 250
	[mm] (in.)	0,6-1,0 (.024-.039)	0,6-1,0 (.024-.039)	0,8-1,2 (.032-.047)	1,0-1,6 (.039-.063)

AL216

AL236

AL306

AL406

I (Amp.) 10 min/40° C
M21 (EN ISO 14175) - d.c.*

35 % 180
60 % 140
100 % 100

40 % 200
60 % 160
100 % 120

40 % 260
60 % 210
100 % 160

40 % 350
60 % 280
100 % 220

I (Amp.) 10 min/40° C
C1 (EN ISO 14175) - d.c.*

35 % 210
60 % 160
100 % 120

40 % 230
60 % 190
100 % 150

40 % 300
60 % 240
100 % 190

40 % 400
60 % 320
100 % 250

[mm]
(in.)

0,6-1,0
(.024-.039)

0,8-1,2
(.032-.047)

1,0-1,6
(.039-.063)

		AL2300	AL2400	AL3000	AL4000
I (Amp.) 10 min/40° C M21(EN 439) - d.c.*		40 % 200 60 % 160 100 % 120	40 % 200 60 % 160 100 % 120	40 % 250 60 % 200 100 % 150	40 % 350 60 % 280 100 % 220
I (Amp.) 10 min/40° C C1 (EN ISO 14175) - d.c.*		40 % 230 60 % 190 100 % 150	40 % 240 60 % 200 100 % 160	40 % 400 60 % 320 100 % 250	40 % 400 60 % 320 100 % 250
	[mm] (in.)	0,6-1,0 (.024-.039)	0,6-1,0 (.024-.039)	0,8-1,2 (.032-.047)	1,0-1,6 (.039-.063)
*d.c. = duty cycle

			AW252	AW332	AW335	AW352
	I (Amp.) 10 min/40° C M21 (EN ISO 14175) - d.c.*	100 % 220	60 % 200 100 % 150	60 % 200 100 % 150	100 % 300
I (Amp.) 10 min/40° C C1 (EN ISO 14175) - d.c.*	100 % 250	60 % 250 100 % 190	60 % 250 100 % 190	100 % 350
	[mm] (in.)	0,6-1,2 (.024-.047)	0,8-1,2 (.032-.047)	0,8-1,2 (.032-.047)	1,0-1,6 (.039-.063)

AW252

AW332

AW335

AW352

I (Amp.) 10 min/40° C
M21 (EN ISO 14175) - d.c.*

100 % 220

60 % 200
100 % 150

100 % 300

I (Amp.) 10 min/40° C
C1 (EN ISO 14175) - d.c.*

100 % 250

60 % 250
100 % 190

100 % 350

[mm]
(in.)

0,6-1,2
(.024-.047)

0,8-1,2
(.032-.047)

1,0-1,6
(.039-.063)

			AW502
	I (Amp.) 10 min/40° C M21(EN ISO 14175) - d.c.*	100 % 400	100 % 500
I (Amp.) 10 min/40° C C1 (EN ISO 14175) - d.c.*	100 % 500	100 % 600
	[mm] (in.)	1,0-1,6 (.039-.063)	1,0-2,4 (.039-.94)

AW502

AW652

I (Amp.) 10 min/40° C
M21(EN ISO 14175) - d.c.*

100 % 400

100 % 500

I (Amp.) 10 min/40° C
C1 (EN ISO 14175) - d.c.*

100 % 500

100 % 600

[mm]
(in.)

1,0-1,6
(.039-.063)

1,0-2,4
(.039-.94)

		AW2500	AW4000	AW5000	AW7000
I (Amp.) 10 min/40° C M21(EN ISO 14175) - d.c.*		100 % 220	100 % 350	100 % 400	100 % 550
I (Amp.) 10 min/40° C C1 (EN ISO 14175) - d.c.*		100 % 250	100 % 400	100 % 500	100 % 700
	[mm] (in.)	0,6-1,2 (.024-.047)	0,8-1,2 (.032-.047)	1,0-1,6 (.039-.063)	1,0-1,6 (.039-.063)
* d.c. = duty cycle

Voltage rating (V-Peak):

for manually guided torches: 113 V
for mechanically guided torches: 141 V

The product complies with standard IEC 60974-7.

PushPull equalisation is adjusted in accordance with the Power Source Operating Instructions, chapter headed „PushPull Unit“

PullMig

General

Device concept

Device concept

Intended use

Safety

WARNING!

WARNING!

WARNING!

CAUTION!

CAUTION!

CAUTION!

CAUTION!

System requirements

Installation and commissioning

Mounting the torch neck

Mounting the torch neck

Assemble wire guidance insert

Assemble Inner Liner (Fronius connection without wire-guidance nozzle

Assemble Inner Liner (Fronius connection with wire-guidance nozzle)

Assemble Inner Liner (Euro connection without wire-guidance nozzle)

Connecting up the welding torch

Replace Feed Rolls

Set Electrode Pressure

Replace Wire Inlet Nozzle

Up/Down

JobMaster

Troubleshooting

Troubleshooting

Troubleshooting

Technical data

PullMig hosepack gas-cooled

PullMig hosepack gas-cooled

PullMig hosepack water-cooled

PullMig torch neck gas-cooled

PullMig torch neck water-cooled

PullMig - hosepack / torch neck

PushPull Equalisation