Forside

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Forside
Flex 4000
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Flex overboks
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Flex kortlæser
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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.
5
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.
6
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.
7
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.
8
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.
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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.
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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.
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Choice of welding proces
Alternatives MIG/MAG or MMA welding Flex 4000
is a multi process welding machine.
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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.
13
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.
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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.
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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.
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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.
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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.
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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.
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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

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Smart card reader
A MIGATRONIC smart card containing up to 50
standard or tailor-made 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
Migatronics program data bank. The light
beside the smart card indicates when the machine
is using the card.
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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.
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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.
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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
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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
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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.
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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.
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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.
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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
V-dial 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).
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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Welding voltage
The welding voltage LED lights for safety reasons
when the MIG torch or the MMA electrode is under
voltage.
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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.
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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.
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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.
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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.
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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.
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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.
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Sequence
Use the dial under the left display for setting
the number of sequences
Use this key pad to switch between sequences
Display shows the chosen sequence
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.
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Hot start
Hot start can be used in MMA welding MIG/MAG
welding
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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ContentsIn plain words

• Applications
• Configurations
• Marketing material
• Technical data
• USP - Arguments
• Why choose Migatronic?
• Program data bank
• Service and maintenance

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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.

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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.

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Marketing materialon a large scale

• Migatronic offers a variety of marketing
  materials
• 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

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Technical dataMeasurable data

• Power source
• Duty cycle 100 / 270 A 60 / 330 A 45 / 400
  A
• Open circuit voltage 85-90 V
• Primary voltage/fuse 400 V /- 15 - 20 A
• IP class IP 23
• Control system MigaNet digital internal control
  circuit
• Data monitoring Datalog and statistics via
  MigaConsole
• Type H-Bro inverter 50 kHz soft switch P.
  Mosfet technology
• Wire feed units
• Type Closed wire feed units with 4-roll wire
  feed system (MWF31)
• Choice of wire 0.6 - 1.6 mm. V - U or U-shaped
  goove - Ø 300 mm.
• Cooling module
• Cooling efficiency at 60C 1250 W - 1.75 l/min/
  1.2 bar
• IP class IP 23

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USP - ArgumentsConvincing facts

• Property
• Roller menu control
• Smartcard programming
• Program data bank
• Advanced controls

• Profit
• 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.

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USP - ArgumentsConvincing facts

• Property
• 100 digital (DSP)
• Self-calibrating arc
• Self-regulating frequency
• Gas flow adjusted to program

• Profit
• 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.

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USP - ArgumentsConvincing facts

• Property
• MIGAnet communication
• MIGAconsole datalog
• Reproducibility
• Quattro Pulse Process

• Profit
• Light guides ensure stable data transfer and
  precision.
• Pc based program for super users and technicians.
  Fault-finding and data collection.
• Ensures uniformity in programs and machines.
• Decisive for the appearance of the weld. Gives a
  colder mean current.

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USP - ArgumentsConvincing facts

• Property
• Plug and Play
• Self-detecting
• Standby functions
• Low current consumption

• Profit
• 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).

63
USP - ArgumentsConvincing facts

• Property
• Pin code facilities
• Fine arc characteristics
• Simple and user-friendly
• Service-friendly

• Profit
• 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.

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USP - ArgumentsConvincing facts

• Property
• Start performance
• Robot interface
• Large range of accessories
• Auto transformer 220V-500V

• Profit
• 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.

65
USP - ArgumentsSummed up

• 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

• 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

66
Why choose Migatronic?Synonymous with welding

• One of Europes 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

67
Program data bankMigatronics 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.

68
Service and maintenancePrevention rather than
cure

• 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