4-12. Selecting Synergic Pulsed MIG Welding
E1 | D1 | D2 | E2 |
L7
L8
P1 P2 P3
Set Synergic Pulsed MIG welding process on the power source. L7 is On.
Synergic Pulsed MIG welding is a high quality welding process that produces very little spatter. This process works well on thin metals such as stainless steel and aluminum. In Synergic Pulsed MIG mode, the operator may need to ad- just welding data (wire type, wire diameter, and gas type) and only one weld parameter. General- ly, wire feed speed is adjusted and the synergic process automatically sets appropriate weld voltage. Synergic welding also sets many sec- ondary welding parameters automatically for im- proved weld quality.
Trim parameter appears on D1 and D2:
D1 value is default trim setting of 0.0 T (range is −5.0 T to 5.0 T).
D2 value is default wire feed speed setting of 5.0 m/min (minimum (MIN), maximum (MAX), or de- fault (DEF) values are arbitrary based on set welding data). Use P2 and E2 to change this dis- play to amperes or to the thickness of the weld.
While Setting Parameters:
-L2 ON means that D1 shows Trim value.
-L3 ON means that D2 shows the wire speed in meter/min or inch/min.
-L4 ON means that D2 shows the set welding current in amperes.
-L5 ON means that D2 shows the thickness of material to weld.
While Welding:
-D1 shows the measured welding voltage in Volts. L1 is ON.
-D2 shows the measured welding current in am- peres. L4 is ON.
Set wire speed, welding current or material thick- ness and welding voltage with E2 and E1. Select trigger mode using P1 pushbutton (see Section
If necessary, use P2 to adjust the welding pa- rameters.
Purge air from gun hose using P3 pushbutton (see Section
Setting Trim
See Section
Synergic Pulsed MIG Welding Advanced Set- tings
L1 | L2 | L3 | L4 | L5 |
To change all values list, unit must be SETUP FULL. To set unit to SETUP FULL, proceed as follows:
Press P2 to enter SET UP menu.
Select SETUP FULL on D1 and D2 (see Section
Setting Main Welding Regulation
See Section
Setting Inductance in Synergic Pulsed MIG Welding
Press P2 to enter SET UP menu.
Use E1 to select on D1 ind. D2 shows 100.
If necessary, use E2 to adjust inductance value (range is 1% to 200%).
This parameter is related to Pulse Width. Higher values give a hotter welding arc.
.Change these parameters as little as pos-
sible because the factory settings are pre- ferred for most applications.
Big changes can affect the arc stability and weld performance.
In general, remain in the 70% to 130% range.
Wire Feed Speed Unit (only in SETUP FULL)
See Section
Setting
See Section
Setting
See Section
Setting Burnback (only in SETUP FULL)
See Section
Setting
See Section
Setting 3 Level Trigger Mode
See Section
Setting Synergic Double Pulsed MIG
.Synergic Double Pulsed MIG process is se-
lected at the power source or recalled in the wire feeder using Synergic Double Pulsed programs. All Double Pulse parameters are selected on the wire feeder. All other MIG parameters are the same as standard Pulsed MIG process.
Some metals weld better using the Synergic Pulsed Welding process due to the unique puls- ing of the welding arc. Heat generated in the workpiece is generally lower and the arc charac- teristics produce a better weld bead appearance especially on aluminum. The Synergic Double Pulsed MIG process allows control all parame- ters to produce high quality welds on aluminum.
.Incorrect settings in Synergic Double
Pulsed Welding process can result in a pro- gram with undesirable weld characteristics. Setup should only be used by operators fa- miliar with various welding processes and parameters. In some cases, standard Syn- ergic Pulsed MIG welding can produce bet- ter welds.
Press P2 to enter SET UP menu.
Use E1 to change D1 to 2P.F.
Use E2 to change D2 value.
The range of this setting is 0.1 Hz to 5.0 Hz. This setting allows changing double pulse frequency in hertz (cycles per second). A recommended frequency is approximately 1 hertz.
Use E1 to change D1 to 2P.C.
D2 value is default setting of 50%.
Use E2 to change D2 value.
The range of this setting is 25% to 75%. This set- ting allows changing the time that the pulse is at high output. A lower setting will produce less heating at the welding puddle.
Use E1 to change D1 to 2P.O. D2 value is default setting of 20%. Use E2to change D2 value. The range of this setting is 20% to 80%. This setting allows changing the difference in high wire feed speed and low wire feed speed in percent of the wire feed speed setting. For example, if the main wire feed speed is set at 5 M and 2P.0 setting in D2 is 40%, the wire feed speed will change be- tween 4 m/min and 6 m/min. A recommended setting is 20%.
Use E1 to change D1 to 2P.A. D2 value is the de- fault setting of 0.0. Use E2 to change D2 value. The range of this setting is −5.0 to 5.0.
This setting allows changing the low end of trim in double pulse and the main setting for trim will be the low end. A higher 2P.A setting will produce a longer and hotter arc and lower setting will pro- duce a shorter and cooler arc.