Download USP - Arguments

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Flex kortlæser
Mains error indicator
The LED lights in case of over voltage or under
voltage, under or over 15% variation, and will be lit
for 5 seconds after correction of the error.
The LED for mains error will flash, if the power
source is defective, to indicate that service must be
sent for.
Overheating of torch
Indicates interruption of welding due to overheating
of the torch. After sufficient cooling of the torch
welding can be resumed.
The LED lights for 5 seconds after the torch has
cooled and flashes if the torch is defective.
Error in wire feed motor
Indicates interruption of welding due to overloading of
wire feed motor. The LED is lit for 5 seconds after
correction of the error.
The LED flashes if the wire feed motor is defective.
The LED flashes simultaneously with the LED for
temperature error, if the error is caused by
overconsumption of current in the wire feed motor.
The LED flashes to indicate that service must be sent
for.
Gas pressure error
Indicates interruption of welding due to too low or too
high pressure on the gas supply. The LED lights for 5
seconds after correction of the error.
In synergic programs the gas flow regulator will
automatically regulate the correct gas flow as a
parameter.
The LED flashes in case of errors in the gas flow
regulator to indicate that service must be sent for.
Overheating of power source
Shows interruption of welding due to overheating of
the power source. The LED lights for 5 seconds after
correction of the error.
The LED flashes simultaneously with the LED for wire
feeding error if the error is caused by
overconsumption of current in the wire feed motor.
The LED flashes to indicate that service must be sent
for.
Adjustment of current and wire
Used for setting the welding current or wire feed speed.
The function of the dial depends on choice of program, i.e.
a synergic or a manual welding program.
The dial is infinite and moves in clicks. A click to the right
increases the digit on the display, and a click to the left
reduces the digit.
Setting of parameter
Used for setting all parameters except welding current
and wire feed speed.
The function of the dial depends on the chosen
adjustable parameter. Trim and welding current (V)
are set by pressing the button next to the dial.
The dial is infinite and moves in clicks. A click to the
right increases the digit on the display, and a click to
the left reduces the digit.
Choice of welding proces
Alternatives: MIG/MAG or MMA welding
Flex 4000 is a multi process welding machine.
Key pad method
Key pad method can be chosen in MIG/MAG. By
pressing the key pad, either two-stroke or four-stroke
control of the welding process is chosen.
With or without pulse
This function can be used in MIG/MAG when a
synergic program has been chosen in the program
unit.
The function changes between welding with or without
pulse, but with the same wire and gas set-up.
Shifts between synergic pulse and no pulse during
welding is possible in connection with the use of
sequential shifts.
Two-stroke or four-stroke
Two-stroke
Welding is started by pressing down the torch trigger.
Welding will continue until the trigger is released, after
which slope down will begin. The machine can be
reactivated during slope-down and gas post-flow.
Four-stroke
Welding is started by pressing down the torch trigger.
Welding will continue after the trigger is released. The
next press on the trigger activates slope down and
interrupts the welding process.
Setting of control
By pressing the button for setting of control you will get the
following alternatives: internal control, remote control or
Migatronic Dialog torch control.
If you choose a MIG/MAG synergic welding program, only
the requested welding current is set. In MIG/MAG manual
mode, wire feed speed and voltage are set.
In MMA mode only the requested welding current is set.
Machine control
The dial at the right side of the control panel is for
setting the current or wire feed speed.
The dial at the left side is for setting the voltage (v)
manually; the same dial is used as a trim function of
voltage if a synergic welding program is chosen.
Remote control
Flex 4000 can be fitted with remote control for
adjustment of wire and voltage.
If remote control is chosen, the internal dials for
adjustment of current and wire feed speed are
deactivated.
Dialog torch
Torch control can be chosen and utilized in the MIG/MAG
process if the machine is fitted with Migatronic Dialog torch.
When torch control is chosen, current speed and wire feed
speed can be set both from the dial on the welding torch and
from the dial internally on the weldng machine.
In a synergic program the torch control can be used to either
turn on or turn down the welding current by up to
100 A from the current set on the machine, provided that
parameters are within the program range.
Also in a manual program it will be possible to turn down the
wire feed speed by up to 10 m/min. In torch control trim or
voltage are set with the dial like in internal control.
Program display
In the digital display the program is presented with name and the
following details:
 if the program is placed on smart card
 if the welding program is MIG or MMA process
 if the program is synergic
 if pulse is chosen
 if there are any errors
Additional details on the display:
 wire material
 diameter of the wire
 chemical composition and mixing proportion of the gas
 polarity of the MIG torch
 any other parameters
Smart card reader
A MIGATRONIC smart card containing up to 50 standard or tailormade welding programs can be inserted in the machine.
The digital system ensures full reproducibility of welding programs
which can easily be transferred between machines.
New smart cards with programs adjusted to all future applications
can be ordered via Migatronic’s program data bank.
The light beside the smart card indicates when the machine is
using the card.
Dial
The dial will display the programs available on the card
or factory-made programs when the dial is turned.
The program in the display switches by a click to the
right or to the left. Names of programs are presented
on the clear display as a rolling list.
Key pad for choice of program
A program is chosen by pressing the key pad for choice
of program.
The welding machine will only function if a program from
the program data bank is chosen.
If there is no smart card in the machine when starting, a
factory-made program is chosen.
The machine will automatically start in the program
chosen last time the machine was in use.
Units, left
A switch to one of these indicators when a parameter is
chosen will ensure harmony between parameter and units.
Possible units are:
- Display for current - A (ampere)
- Display for wire feed speed - m/minute
Units, right
A switch to one of these indicators when a parameter is
chosen will ensure harmony between parameter and units.
Possible units are:
- Display for trim / voltage / chosen parameter
- V - volt
- l/min - litre per minute
- S - seconds
- % - percentage
- mm - millimetre
Display, right
If the welder does not choose an adjustable parameter, either
voltage or volt trim is displayed in MIG/MAG, while in MMA
voltage is always displayed.
If a parameter is chosen, the value of the chosen parameter is
displayed.
When the arc is extinguished, the mean value of the voltage is
shown for five seconds in the display. If sequence is used, the
mean value for the latest welded sequence is displayed.
Display, right - continued
Adjusted trim and voltage have the same adjustment area, meaning that since trim can be
set between -9,9 V and 9,9 V, the voltage for a synergic voltage value of e.g. 24,0 V can
be set between 14,1 V and 33,9 V. It is possible to choose between adjustment of trim or
voltage by pressing down the V-dial for at least two seconds, when adjusted voltage or
trim is shown in the display.
In MIG manual mode without simple synergy, voltage is shown in the display when the
welding machine is not used. Voltage can be set between 10 V and 50 V.
During welding with MIG synergic pulse at frequences faster than 2 hz, a mean value of
the measured voltage is continuously shown. At frequences under 2 hz measured base
and pulse voltage in the respective periods are shown.
In MMA the measured voltage or output is shown whether the welding machine is in use
or not. In MMA voltage cannot be adjusted.
When the arc is extinquished, the weld mean value of the voltage is shown in the display
for 5 seconds. In sequential welding only the weld mean value of the latest welded
sequenc is displayed.
If the V-dial is pressed during the display of voltage or trim, and the machine is not in use,
the latest weld mean value for the voltage is displayed for five seconds. It is not possible
to change the value of trim or voltage as long as the weld mean value is displayed. It is
possible, however, to press the V-dial once more or to press one of the dials for the other
parameters while weld mean value is displayed. This will result in immediate interruption
of the display of the weld mean value.
Display, left
In MIG either the current or wire feed speed is shown in the display,
while in MMA the current is always displayed.
If a MIG synergy program without pulse is chosen, a mean value of the
measured current is continuously shown in the display during welding.
When the machine is not in use, the set current is displayed.
If a MIG synergy program with pulse mode is chosen, the set mean
welding current is shown when the machine is not in use. During
welding a mean value of the measured current is continuously
displayed.
If a manual MIG program is chosen, actual current is shown in the
display during welding, while the set wire feed speed is displayed when
the machine is not in use.
In MMA actual current is shown in the display during welding. When the
machine is not in use, the set current is displayed.
Display, left - continued
It applies especially to wire-inching that the measured values for wire feeding are displayed
as long as the function is maintained by pressing down the wire-inching key pad.
When the arc is extinguished, the weld mean value of the current is shown in the display for
five seconds.
The weld mean value is the average from establishment of the arc until extinction of the arc,
except if sequence is used, in which case the weld mean value is the average from start until
end of the sequence.
In case of sequential welding, only the weld mean value for the latest welding sequence is
shown. The weld mean value for the latest welding is also shown for five seconds, if the Vdial is pressed down and if voltage or trim is already shown in this display and if the machine
is not in use. It is possible to press once more on the V-dial or to press one of the dials for
the other parameters while the weld mean value is displayed. This will result in immediate
interruption of the display of the weld mean value.
In MMA the current can be set between a minimum current of 15 A and the maximum current
of the machine.
In synergic MIG pulse/no pulse mode the current can be set between the synergic minimum
and the synergic maximum current in the program, but not higher than the maximum current
of the machine. Wire feed speed in manual MIG can be set between 1 m/minute and the
maximum wire feed speed. If simple synergy is chosen, there are restrictions on wire feed
speed.
The current is set in whole ampere, i.e. without decimal points. Wire feed speed is set in
m/minute (with one decimal).
Arc power
Arc power is an arc enhancing function used to
stabilize the arc in MMA welding. This is done by
briefly increasing the welding current during the
unintended short circuits. The additional current is cut
out when there is no longer a short circuit. Arc power
can be set between 0 and 150 % of the pre-set
welding current.
Arc-adjust
Arc-adjust (electronic choke). An auxiliary function for
spatter-free welding, pleasant welding sound and fine
ignition properties.
Dip transfer:
In dip transfer Arc-adjust makes it possible to adjust the
reaction time for short circuits. Arc-adjust value varies
between 1 and 100.
Spray transfer:
In spray transfer there will be no short circuits, for which
reason Arc-adjust is not important.
Pulse welding:
Arc-adjust cannot be chosen in a pulse program, since
Arc-adjust is always in synergy in pulse welding.
Thickness of material
Thickness of material can be chosen in a synergic program.
This function is a help to adjust the synergic current on the basis
of the thickness of the material.
When thickness of material is chosen, a synergic current will be
adjusted automatically, corresponding to the specific thickness
of material in case of welding from above.
The synergic current can be adjusted subsequently.
As a principal rule the thickness of material is stated as standard
roller thicknesses for the actual material.
Extra line
With this extra line key pad it is possible in certain
programs to get further details about the program.
The next press on the extra line key pad will switch
back to the name of the program.
Machine lock
The user has the option of ”keying" a valid code by
turning the dial.
The code is chosen between 000 and 999. A turn to
the right gives value 0 - 999, and a turn to the left
gives values -999 - 0. The code is accepted by the
user by two short presses on the key pad.
The code prevents unintended use of the machine
and theft.
MigaNet
MigaNet is the internal electronic Can-Bus circuit
which continuously circulates digital signals in the
welding machine.
MigaNet is a self detecting system, meaning that any
possible set-up of the machine is adjusted and
registered automatically.
Cooling of torch
In MIG/MAG welding there are two alternatives: water
cooling or air cooling of torch and intermediary cables.
Cooling method is chosen, when the welding machine
is not in use.
It is to be recommended to choose water cooling of the
torch in severe operation, and in general, in case of
high current in the spray transfer area and in case of
pulse welding.
Tack welding
If tack-welding is chosen, the key pad method is
always two-stroke.
With this function it is possible to switch between
the actual welding program and tack-welding.
This function is often used for tack-welding of
workpieces prior to the actual welding job.
Welding voltage
The welding voltage LED lights for safety reasons when
the MIG torch or the MMA electrode is under voltage.
Indication of arc
The LEDs are placed in a graph indicating whether
the MIG process is in dip transfer, globular transfer or
spray transfer.
If a synergic program is chosen, the actual process
level will be indicated both before and during welding.
If a manual MIG program without synergy is chosen,
there will be no indication.
Gas flow
Gas flow means the protection gas flowing through
the gas nozzle during welding.
The gas flow can be set from minimum 3 litres per
minute up to maximum gas flow.
In synergic programs the gas quantity will be a
program parameter.
When gas flow is chosen, the actual gas flow is
displayed during welding.
Gas pre-flow
Gas pre-flow is the period of time for which gas
flows after the torch trigger is pressed and before
wire feeding begins.
In synergic programs gas pre-flow will be a
program parameter.
Gas pre-flow is adjustable and is set between 0.0
and 10 seconds.
Gas post-flow
Gas post-flow ensures protection of the weld pool
after welding, protects the wire end and cools the
torch.
In synergic programs gas post-flow will be a program
parameter.
The gas post-flow time is the period from the
extinction of the arc to the interruption of the gas
supply. Gas post-flow is adjustable and can be set
between 0 and 20 seconds.
Creep start
Creep start improves ignition properties
considerably, especially during welding with high
wire feed speed, since this function prevents the
wire from ”stopping”.
This key pad is used for setting the starting wire feed
speed. The speed can be set between 0.5 and the
actually chosen wire feed speed, or corresponding to
the chosen synergy current.
Welding process
This field visualizes and collects parameters essential
to the welding process in MIG/MAG and MMA.
By pressing the key pads the LEDs will light in the
individual welding phases.
When a LED switches on, this parameter can be read
and adjusted, if necessary.
Sequence
Use this key pad to
switch between
sequences
Display shows the
chosen sequence
Use the dial under
the left display for
setting the number
of sequences
Sequences can be used both in MIG/MAG and MMA and
can be chosen when internal control is chosen. Sequence
makes it possible to switch between different settings of
parameters during arc welding.
Hot start
Hot start can be used in:
MMA welding
MIG/MAG welding
Hot start time
Setting of hot start time
When this diode is on, the hot start time may be set
using the potentiometer below the right display.
The display will show the set hot start time in secs.
Hot start MMA
Hot start MMA is an auxiliary function for establishment of
the arc when welding starts. Especially when welding with
basic electrodes, hot start is very applicable.
This is done by automatically increasing the welding current
for some milliseconds when the electrode touches the
workpiece. The increased start amp is maintained after
which it decreases to the set value for welding current.
The hot start value can be set between 0 and 100% of the
set current.
Hot start MIG/MAG
Hot start is an auxiliary function for establishing the right
temperature in the weld pool when welding is started.
MIG/MAG hot start is applicable in two-stroke as well as
four-stroke.
In two-stroke the hot start function cannot be controlled
with the torch trigger and is therefore fixed as regards
time. In four-stroke hot start is controlled with the torch
trigger.
Burn-back
The burn-back function ensures that the wire does
not stick to the weld pool. Burn-back is set as a
value from 1 to 30 (with no unit).
Burn-back is the period of time from when the wire
feeding stops till the current is switched off.
This new Migatronic machine ”cuts” the wire on a
Peak in synergic pulse welding programs.
Sequence slope time
This parameter can be chosen if sequence is used.
Sequence slope time makes it possible to gradually
change parameters between sequences.
This will prevent development of craters in connection
with sequence shifts. Slope up/slope down takes place in
the period of time chosen in the parameter (0-10 secs).
The chosen parameter will diplay whether the next
sequence is higher or lower than the previous sequence.
If no sequence slope time is set, the time will be 0 secs.
Slope-down
When welding is stopped by activating the trigger, the
machine will enter into slope-down. During this period
crater filling is carried out.
In synergic programs parameters are lowered from the set
current to the chosen stop Amp or lowest current in the
program.
In four-stroke it is not necessary to carry out slope-down in
the whole slope-down time, since slope-down is stopped if
the torch is deactivated.
Stop Amp
Stop Amp is set in synergic programs with or without pulse as a
percentage between 0 and 100% of the set synergic welding
current.
In manual programs without synergy stop Amp is set as stop Amp
wire feed speed and stop Amp voltage.
In four-stroke the stop Amp phase (period of time) is determined
by the stop Amp, since in the stop Amp phase the welder will weld
subsequently with the stop Amp until he stops pressing down the
torch. Then follows the burn-back and gas post-flow phases.
Spot welding time
Spot welding time is the period of time during which
welding takes place with the set current.
Add to this time for gas pre-flow, slope-up, slope-down,
burn-back and gas post-flow.
Often used to harmonize tack-weldings.
Spot welding time is set between 0.1 and 50 seconds.
Contents
In plain words
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Applications
Configurations
Marketing material
Technical data
USP - Arguments
Why choose Migatronic?
Program data bank
Service and maintenance
Applications
when quality welding is required
All industrial groups from light through medium to
professional heavy industry
Companies with heavy demands for quality and finish. Applied
for welding jobs in exotic materials, such as stainless steels,
aluminium or mild types of steel.
For manual, robot or automated set-ups.
Documentation and reproducibility of data will often be important
parameters for the choice.
Configurations
• Chief features of Flex 4000
– Multi process power source 400 A / 45 %
– Wire feed units with intelligent controls
– Program packages to your specification or standard
solutions
– MigaConsole documentation program via pc solution
– Robot connection via interface
– Fitted with PP or common torches
– With or without water cooling
– Working reach up to 50 metres from the power source
– Relief arm, torch holder, trolley, remote controls etc.
Marketing material
on a large scale
Migatronic offers a variety of marketing
materials
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CD-ROM and disc information
Homepage www.migatronic.dk
Complete machine catalogue with full range of products
Brochures and ”Welding Bible” in several languages
Standard configurations or choice via configurator
Training compendiums in several languages
Support via Migatronic customer centre
Manpower support for special events
Sales training
Posters and marketing material for mounting
Technical data
Measurable data
• Power source
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Duty cycle:
Open circuit voltage:
Primary voltage/fuse:
IP class:
Control system:
Data monitoring:
Type:
100% / 270 A
60% / 330 A
45% / 400 A
85-90 V
400 V +/- 15% - 20 A
IP 23
MigaNet digital internal control circuit
Datalog and statistics via MigaConsole
H-Bro inverter 50 kHz soft switch P. Mosfet
technology
• Wire feed units
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Type:
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Choice of wire:
Closed wire feed units with 4-roll wire feed system
(MWF31)
0.6 - 1.6 mm. V - U or U-shaped goove - Ø 300 mm.
• Cooling module
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Cooling efficiency at 60°C: 1250 W - 1.75 l/min/ 1.2 bar
IP class:
IP 23
USP - Arguments
Convincing facts
• Property:
• Profit:
• Roller menu control
• Will give the welder a quick
overview of programs.
• Always possible to update and
optimize Flex 4000 programs.
• Continuous development of data
bank parallel with development
of new processes, wires and
gases.
• All operative functions have an
advanced position in the wire
feed unit.
• Smartcard programming
• Program data bank
• Advanced controls
USP - Arguments
Convincing facts
• Property:
• Profit:
• 100% digital (DSP)
• Digital transfer of all signals
ensures uniformity and
immunity from interference.
• Continuous adjustment of
the welding machine via
feedback from the arc
ensures regularity.
• Pulse frequency adjusts
itself to varying stickout and
gives a steady arc.
• Always correct gas quantity.
Protects against errors and
overconsumption.
• Self-calibrating arc
• Self-regulating frequency
• Gas flow adjusted to
program
USP - Arguments
Convincing facts
• Property:
• Profit:
• MIGAnet communication
• Light guides ensure stable
data transfer and precision.
• Pc based program for super
users and technicians. Faultfinding and data collection.
• Ensures uniformity in
programs and machines.
• Decisive for the appearance
of the weld. Gives a colder
mean current.
• MIGAconsole datalog
• Reproducibility
• Quattro Pulse Process
USP - Arguments
Convincing facts
• Property:
• Profit:
• Plug and Play
• Simple and safe construction
of the machine via modules
that alway harmonize.
• The configuration registers
and adjusts itself
automatically to its setting.
• After a few minutes out of
service the machine will
switch off the most current
consuming units.
• Low current consumption =
fine economy (only 20 amp.
fuses).
• Self-detecting
• Standby functions
• Low current consumption
USP - Arguments
Convincing facts
• Property:
• Profit:
• Pin code facilities
• The machine can be locked
to avoid unintended use.
• Due to the dynamic arc
physical and mechanical
tolerances are adjusted by
controls.
• Switch on, press and weld.
Logical controls based on
icons.
• Easy to service owing to the
simple and separated
construction of components
and modules.
• Fine arc characteristics
• Simple and user-friendly
• Service-friendly
USP - Arguments
Convincing facts
• Property:
• Profit:
• Start performance
• Unique start properties: soft
and spatter-free ignition.
• Flex 4000 can be connected to
robots and automated
machines.
• The welder can tailor his
machine for any requirement.
• Self-detecting autografo for the
use of mains fuses more than
3 x 400 V.
• Robot interface
• Large range of accessories
• Auto transformer 220V-500V
USP - Arguments
Summed up
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Roller menu control*
Program data bank*
Smartcard programming*
MIGAnet communication*
MIGAconsole datalog*
100% digital (DSP)*
Advanced controls*
Gasflow adjusted to program*
Self-calibrating arc *
Reproducibility*
Self-regulating frequency*
Quattro Pulse Process*
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Plug and Play*
Self-detecting*
Standby functions*
Pin code facilities*
Low current consumption*
Auto transformer 220V-500V*
Large range of accessories*
Simple and user-friendly*
Fine arc characteristics*
Service-friendly*
Start performance
Robot interface*
Why choose Migatronic?
Synonymous with welding
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One of Europe’s leading manufacturers within the inverter technology
Subsidiaries and importers throughout Europe
ISO 9001 certified with more than 450 employees in Europe
Original sales and service network with support throughout Europe
More than 30 years experience of manufacturing welding machines
Knowledge of arc welding processes
Sales training of distributors and large end users
Robust and reliable welding machines for industrial use
Large machine flexibility and high resale value of used equipment
Customers in the automotive industry, heavy offshore and shipbuilding
industry are included in our reference list
Program data bank
Migatronic’s objective with the data bank:
• To be in the lead in welding performance, with up-to-date
programs for existing and known materials and gases
• To have the necessary knowledge in order to be able to master
the art of converting and updating existing equipment to future
welding applications via software
• To be able to individually adjust welding programs on smart card
and in this way comply with specific customer requests and
requirements.
Service and maintenance
Prevention rather than cure
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Different levels of service subscription and service agreements
Full service guarantee on welding machines after repair
Systematic maintenance at fixed intervals
Application training for customers and distributors
Own service school with training in specific machines
Service vehicles finalizing 95% of all repairs on site
Specialists in environmental and customized application
solutions
• Always original spares and a large range of exchange products
• Repair of torches and cables as per agreement