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 MIG/MAG manual welding torch is intended solely for MIG/MAG welding in manual applications.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal 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.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this device and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
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.
Danger due to emerging wire electrode.
This can result in serious personal injuries.
Hold the welding torch so that the tip of the welding torch points away from the face and body.
Wear suitable protective goggles.
Do not point the welding torch at people.
Ensure that the wire electrode does not touch any electrically conductive objects.
Danger due to hot system components and/or equipment.
Can result in serious 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 (e.g., heat-resistant gloves, safety goggles, etc.) if cooling down is not possible.
Danger from operation without coolant.
This can result in damage to property.
Never operate water-cooled welding torches without coolant.
During welding, ensure that the coolant is circulating correctly – this will be the case for Fronius cooling units if a regular return flow of coolant can be seen in the coolant container of the cooling unit.
The manufacturer will not be liable for any damages due to non-observance of the above mentioned points. All claims against the warranty are void.
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
Software
Options
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.
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.
When cutting the inner liner to length, make sure that
* 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
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.
Only use wire guidance nozzles corresponding to diameter of wire. The following wire guidance nozzles are available:
Before threading in the welding wire, round off the ends of the wire.
* 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)
IMPORTANT! Refer to MIG/MAG Torch Operating Instructions, chapter headed „JobMaster“ for more detailed information on the JobMaster function.
Cause: | „PMR4000 PullMig“ installation set is not installed |
Remedy: | Install installation set |
Cause: | Power source does not have „FS Drive“ software |
Remedy: | Provide power source with „FS Drive“ software |
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 |
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 |
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 |
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 |
Cause: | Wire drive blocked/faulty |
Remedy: | Inspect/replace motor for wire drive |
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 |
Cause: | External supply voltage: supply voltage has dropped below tolerance range |
Remedy: | Check external supply voltage |
Cause: | External supply voltage: supply voltage has exceeded tolerance range |
Remedy: | Check external supply voltage |
I (Amp.) 10 min/40° C | 40 % d.c.* 280 | ||||||
I (Amp.) 10 min/40° C | 40 % d.c.* 330 | ||||||
[m] | 6 / 8 / 10 | ||||||
[V] DC | 42 | ||||||
[A] | 0,8 | ||||||
[m/min] (ipm) | 0,5 - 18 | ||||||
[mm] | 0,8 - 1,6 | ||||||
* d.c. = duty cycle |
I (Amp.) 10 min/40° C | 40 % d.c.* 280 | ||||||
I (Amp.) 10 min/40° C | 40 % d.c.* 330 | ||||||
[m] | 6 / 8 / 10 | ||||||
[V] DC | 42 | ||||||
[A] | 0,8 | ||||||
[m/min] (ipm) | 0,5 - 18 | ||||||
[mm] | 0,8 - 1,6 | ||||||
* d.c. = duty cycle |
I (Amp.) 10 min/40° C | 100 % d.c.* 400 | ||||||
I (Amp.) 10 min/40° C | 100 % d.c.* 500 | ||||||
[m] | 6 / 8 / 10 | ||||||
Pmin | [W]** | 1450 / 1800 / 2000 W |
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Qmin | [l/min] | 1 |
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pmin | [bar] | 3 |
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pmin | [bar] | 5,5 |
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[V] DC | 42 | ||||||
[A] | 0,8 | ||||||
[m/min] (ipm) | 0,5 - 18 | ||||||
[mm] | 0,8 - 1,6 | ||||||
* d.c. = duty cycle | |||||||
** Minimum cooling power in accordance with standard IEC 60974-2 |
| AL216 | AL236 | AL306 | AL406 | ||
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| I (Amp.) 10 min/40° C | 35 % 180 | 40 % 200 | 40 % 260 | 40 % 350 | |
I (Amp.) 10 min/40° C | 35 % 210 | 40 % 230 | 40 % 300 | 40 % 400 | ||
[mm] | 0,6-1,0 | 0,6-1,0 | 0,8-1,2 | 1,0-1,6 |
| AL2300 | AL2400 | AL3000 | AL4000 | ||
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| I (Amp.) 10 min/40° C | 40 % 200 | 40 % 200 | 40 % 250 | 40 % 350 | |
I (Amp.) 10 min/40° C | 40 % 230 | 40 % 240 | 40 % 400 | 40 % 400 | ||
[mm] | 0,6-1,0 | 0,6-1,0 | 0,8-1,2 | 1,0-1,6 | ||
*d.c. = duty cycle |
| AW252 | AW332 | AW335 | AW352 | ||
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| I (Amp.) 10 min/40° C |
| 60 % 200 | 60 % 200 |
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I (Amp.) 10 min/40° C |
| 60 % 250 | 60 % 250 |
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[mm] | 0,6-1,2 | 0,8-1,2 | 0,8-1,2 | 1,0-1,6 |
| AW502 | AW652 | ||||
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| I (Amp.) 10 min/40° C |
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I (Amp.) 10 min/40° C |
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[mm] | 1,0-1,6 | 1,0-2,4 |
| AW2500 | AW4000 | AW5000 | AW7000 | ||
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| I (Amp.) 10 min/40° C |
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I (Amp.) 10 min/40° C |
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[mm] | 0,6-1,2 | 0,8-1,2 | 1,0-1,6 | 1,0-1,6 | ||
* d.c. = duty cycle |
The product complies with standard IEC 60974-7.
PushPull equalisation is adjusted in accordance with the Power Source Operating Instructions, chapter headed „PushPull Unit“