H&S HSM250 Operator's Manual
IMPORTANT: Read this Owner’s Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
distributor if you do not fully understand this manual.
M250 DOUBLE-PULSE SYNERGIC
MULTI-MIG WELDING SYSTEM
OPERATORS’ MANUAL
CONTENT
I
CONTENT
§1 Safety ......................................................................................................... 1
§1.1 Symbols Explanation ................................................................................... 1
§1.2 Machine Operating warnings! ..................................................................... 1
§1.3 EMC device classification ........................................................................... 8
§1.4 EMC measure ............................................................................................... 9
§1.5 Warning label ............................................................................................. 10
§2 Overview .................................................................................................. 11
§2.1 Features ....................................................................................................... 11
§2.2 Technical Data ............................................................................................ 12
§2.3 Brief Introduction ....................................................................................... 12
§2.4 Duty Cycle and Over-heat.......................................................................... 13
§2.5 Working Principle....................................................................................... 14
§2.6 Volt-Ampere Characteristic ....................................................................... 14
§3 Panel Functions & Descriptions ............................................................ 15
§3.1 Machine Layout Description ..................................................................... 15
§3.2 Control panel of welding machine ............................................................ 16
§4 Installation & Operation ......................................................................... 25
§4.1 Installation & Operation for MMA/Stick Electrode Welding..................... 25
§4.1.1 Set-Up Installation .............................................................................................. 25
§4.1.2 MMA/Stick Electrode Welding ........................................................................... 26
§4.1.3 MMA Welding Fundamentals ............................................................................. 27
§4.2 Installation & Operation for TIG Welding.................................................. 29
§4.2.1 Set-Up for TIG Welding ....................................................................................... 29
§4.2.2 DCTIG Welding .................................................................................................... 32
§4.2.3 TIG Welding Fusion Technique ......................................................................... 33
§4.2.4 Tungsten Electrodes ........................................................................................... 35
§4.2.5 Tungsten Preparation ......................................................................................... 37
§4.2.6 TIG Torch Switch Controls ................................................................................. 39
§4.3 Installation & Operation for MIG Welding ................................................. 40
§4.3.1 Set up installation for MIG Welding (Gas shielded wire) ................................ 40
§4.3.2 Wire Feed Roller Selection ................................................................................. 42
CONTENT
II
§4.3.3 Wire Installation and Set-Up Guide ................................................................... 44
§4.3.4 Set up for MIG Welding- Aluminum or Silicone Bronze Wire ......................... 46
§4.3.5 MIG Torch Liner Installation ............................................................................... 46
§4.3.6 MIG Torch Liner Types and Information ........................................................... 48
§4.3.7 Torch & Wire Feed Set-Up for Aluminum Wire ................................................. 49
§4.3.8 Set-Up Installation for Spool Gun ..................................................................... 50
§4.3.9 MIG Welding ........................................................................................................ 51
§4.3.10 Spool Gun Control NEED NEW TORCH INFO!! ......................................... 58
§4.4 Standard Welding Programs & Settings Chart......................................... 59
§4.5 Welding Parameters ................................................................................... 61
§4.6 Operation Environment ............................................................................. 63
§4.7 Operation Notices ...................................................................................... 63
§5Diagram for Guns ..................................................................................... 64
§5.1 MIG Torches AK15 (Cu/Si), AK25 (Fe) & AK26 (Al) ................................... 64
§5.2 TIG Torch .................................................................................................... 67
§5.3 Spool Gun (Optional) ................................................................................. 68
§6 Welding Trouble Shooting ..................................................................... 69
§6.1 MIG Welding - Trouble Shooting ............................................................... 69
§6.2 MIG Wire Feed - Trouble Shooting ............................................................ 71
§6.3 DC TIG Welding - Trouble Shooting .......................................................... 73
§6.4 MMA Welding - Trouble Shooting ............................................................. 75
§7 Maintenance & Troubleshooting ........................................................... 77
§7.1 Maintenance ............................................................................................... 77
§7.2 Troubleshooting ......................................................................................... 78
§7.3 List of Error Codes..................................................................................... 80
§7.4 Electrical Schematic Drawing ................................................................... 81
§7.5 Replacement Parts Drawing ................................................................ ...... 82
SAFETY
-1-
§1 Safety
Welding and cutting equipment can be dangerous to both the operator and
people in or near the surrounding working area, if the equipment is not
correctly operated. Equipment must only be used under the strict and
comprehensive observance of all relevant safety regulations. Read and
understand this instruction manual carefully before the installation and
operation of this equipment.
§1.1 Symbols Explanation
The above symbols mean warning!
Notice! Running parts, getting an electric shock or making contacts with
thermal parts will cause damage to your body and others. The underline
message is as follows:
Welding is quite a safe operation after taking several necessary
protection measures!
§1.2 Machine Operating warnings!
The following symbols and words explanations are for some damages to
your body or others, which could happen during the welding operation. While
seeing these symbols, please remind yourself and others to be careful.
Only people who are trained professionally can install, debug, operate,
maintain and repair the welding equipment covered with this Operator’s
Manual!
During the welding operation, non-concerned people should NOT be
around, especially children!
After shutting off the machine power, please maintain and examine the
SAFETY
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equipment according to §7 because of the DC voltage existing in the
electrolytic capacitors at the output of the power supply!
ELECTRIC SHOCK CAN KILL.
Touching live electrical parts can cause fatal shocks or severe burns. The
electrode and work circuit is electrically live whenever the output is on. The
input power circuit and internal machine circuits are also live when power is
on. In Mig/Mag welding, the wire, drive rollers, wire feed housing, and all
metal parts touching the welding wire are electrically live. Incorrectly installed
or improperly grounded equipment is dangerous.
Never touch live electrical parts.
Wear dry, hole-free gloves and clothes to insulate your body.
Be sure to install the equipment correctly and ground the work or metal to
be welded to a good electrical (earth) ground according to the operation
manual.
The electrode and work (or ground) circuits are electrically “hot” when the
machine is ON. Do not touch these “hot” parts with your bare skin or wet
clothing. Wear dry, hole-free gloves to insulate hands.
In semiautomatic or automatic wire welding, the electrode, electrode reel,
welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
Insulate yourself from work and ground using dry insulation. Make certain
the insulation is large enough to cover your full area of physical contact with
work and ground.
Be Careful when using the equipment in small places, falling-off and wet
circumstance.
Always be sure the work cable makes a good electrical connection with the
metal being welded. The connection should be as close as possible to the
area being welded.
Maintain the electrode holder, work clamp, welding cable and welding
SAFETY
-3-
machine in good, safe operating condition. Replace damaged insulation.
Never dip the electrode in water for cooling.
Never simultaneously touch electrically “hot” parts of electrode holders
connected to two welders because voltage between the two can be the total
of the open circuit voltage of both welders.
When working above the floor level, use a safety belt to protect yourself
from a fall should you get an electric shock!
FUMES AND GASES CAN BE DANGEROUS.
Smoke and gas generated whilst welding or cutting can be harmful to
people’s health. Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
Do not breathe the smoke and gas generated whilst welding or cutting, keep
your head out of the fumes. Use enough ventilation and/or exhaust at the arc
to keep fumes and gases away from the breathing zone. When welding with
electrodes which require special ventilation such as stainless or hard facing
or on lead or cadmium plated steel and other metals or coatings which
produce highly toxic fumes, keep exposure as low as possible and below the
Threshold Limit Values using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a respirator may be
required. Additional precautions are also required when welding on
galvanized steel.
Do not weld in locations near chlorinated hydrocarbon vapors coming from
degreasing, cleaning or spraying operations. The heat and rays of the arc can
react with solvent vapors to form phosgene, a highly toxic gas, and other
irritating products.
Shielded gases used for arc welding can displace air and cause injury or
death. Always use enough ventilation, especially in confined areas, to insure
breathing air is safe.
SAFETY
-4-
Read and understand the manufacturer’s instructions for this equipment
and the consumables to be used, including the material safety data sheet and
follow your employer’s safety practices.
ARCRAYS: Harmful to people’s eyes and
skin.
Arc rays from the welding process produce intense visible and invisible
ultraviolet and infrared rays that can burn eyes and skin.
Use a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when welding or observing open arc welding.
Use suitable clothing made from durable flame-resistant material to protect
your skin and that of your coworkers from the arc rays.
Protect other nearby personnel with suitable, non-flammable screening and
/or warn them not to watch the arc nor expose themselves to the arc rays or to
hot spatter or metal.
SELF-PROTECTION
Keep all equipment safety guards, covers and devices in position and in
good repair. Keep hands, hair, clothing and tools away from V-belts, gears,
fans and all other moving parts when starting, operating or repairing
equipment.
Do not put your hands near the engine fan. Do not attempt to override the
governor or idler by pushing on the throttle control rods while the engine is
running.
DO NOT add any fuel near an open-flame welding arc or
when the engine is running. Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine
parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up
SAFETY
-5-
and do not start engine until fumes have been eliminated.
WELDING SPARKS can cause fire or
explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause
them to explode. Flying sparks from the welding arc, hot work piece, and hot
equipment can cause fires and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or fire. Check and be sure
the area is safe before doing any welding
Remove fire hazards material from the welding area. If this is not possible,
cover them to prevent the welding sparks from starting a fire. Remember that
welding sparks and hot materials from welding can easily go through small
cracks and openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
Where compressed gases are to be used at the job site, special precautions
should be used to prevent hazardous situation.
When not welding, make certain no part of the electrode circuit is touching
the work or ground. Accidental contact can cause overheating and create a
fire hazard.
Do not heat, cut or weld tanks, drums or containers until the proper steps
have been taken to insure that such procedures will not cause flammable or
toxic vapors from substances inside. They can cause an explosion even
though they have been “cleaned”.
Vent hollow castings or containers before heating, cutting or welding. They
may explode.
Sparks and spatter are thrown from the welding arc. Wear oil free protective
garments such as leather gloves, heavy shirt, cuff less trousers, high shoes
and a cap over your hair. Wear earplugs when welding out of position or in
confined places. Always wear safety glasses with side shields when in a
SAFETY
-6-
welding area.
Connect the work cable to the work as close to the welding area as practical.
Work cables connected to the building framework or other locations away
from the welding area increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create
fire hazards or overheat lifting chains or cables until they fail.
Rotating parts may be dangerous.
Use only compressed gas cylinders containing the correct shielding gas for
the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application
and maintained in good condition.
Always keep cylinders in an upright position securely chained to an
undercarriage or fixed support.
Cylinders should be located:
- Away from areas where they may be struck or subjected to physical
damage.
- At a safe distance from arc welding or cutting operations and any other
source of heat, sparks, or flame.
Never allow the electrode, electrode holder or any other electrically “hot”
parts to touch a gas cylinder.
Keep your head and face away from the cylinder valve outlet when opening
the cylinder valve.
Valve protection caps should always be in place and hand tight except
when the cylinder is in use or connected for use.
Gas Cylinders.
Shielding gas cylinders contain gas under high pressure. If damaged, a
SAFETY
-7-
cylinder can explode. Because gas cylinders are normally part of the welding
process, be sure to treat them carefully. CYLINDERS can explode if
damaged.
Protect gas cylinders from excessive heat, mechanical shocks, physical
damage, slag, open flames sparks, and arcs.
Insure cylinders are held secure and upright to prevent tipping or falling over.
Never allow the welding electrode or earth clamp to touch the gas cylinder,
do not drape welding cables over the cylinder.
Never weld on a pressurised gas cylinder, it will explode and kill you.
Open the cylinder valve slowly and turn your face away from the cylinder
outlet valve and gas regulator.
Gas build up.
The buildup of gas can cause a toxic environment, deplete the oxygen
content in the air resulting in death or injury. Many gases use in welding are
invisible and odourless.
Shut off shielding gas supply when not in use.
Always ventilate confine spaces or use approved air-supplied respirator.
Electric and Magnetic Fields.
Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). The discussion on the effect of EMF is ongoing in the
entire world. Up to now, no material evidences show that EMF may have
effects on health. However, the research on the effect of EMF is still ongoing.
Before any conclusion, we should minimize exposure to EMF as few as
possible.
In order to minimize EMF, we should use the following procedures:
Route the electrode and work cables together – Secure them with tape
when possible.
SAFETY
-8-
All cables should be put away and far from the operator.
Never coil the power cable around your body.
Make sure welding machine and power cable to be far away from the
operator as far as possible according to the actual circumstance.
Connect the work cable to the workpiece as close as possible to the area
being welded.
The people with heart-pacemaker should be away from the welding area.
Noise can damage hearing.
Noise from some processes or equipment can damage hearing. You must
protect your ears from loud noise to prevent permanent loss of hearing.
To protect your hearing from loud noise, wear protective ear plugs and/or ear
muffs. Protect others in the workplace.
Noise levels should be measured to be sure the decibels (sound) do not
exceed safe levels.
Hot parts.
Items being welded generate and hold high heat and can cause severe
burns. Do not touch hot parts with bare hands. Allow a cooling period before
working on the welding gun. Use insulated welding gloves and clothing to
handle hot parts and prevent burns.
§1.3 EMC device classification
Radiation Class A Device.
Only can be used in the industrial area
If it is used in other area, it may cause connection
and radiation problems of circuit.
SAFETY
-9-
Radiation Class B device.
It can meet the radiation requirements of residential area and industrial area.
It also can be used in residential area which power is supplied by public low
voltage circuit.
EMC device can be classified by power nameplate or technical data.
Hi-zone welding machines belong to Class A.
§1.4 EMC measure
In the special situation, the specified area may be affected,
the standard of radiation limit value has been complied with
(eg: The device, which is easy effected by electromagnetism,
is used at the installation location, or there is radio or TV near the installation
location). In this condition, the operator should adopt some appropriate
measures to remove interference.
According to the domestic and international standards, the ambient devices’
electromagnetism situation and anti-interference ability must be checked：
Safety device
Power line, Signal transmission line and Date transmission line
Date processing equipment and telecommunication equipment
Inspection and calibration device
The effective measures avoid the problem of EMC：
a) Power source
Even though the power source connection meet rules, we still need to take
additional measure to remove the electromagnetic interference. (eg: Use
the right power filter. )
b) The welding line
Try to shorten the length of cable
Put the cable together
Be Far away from other cable
SAFETY
-10-
c) Equipotential connection
d) Ground connection of work-piece
When necessary, use appropriate capacitance to connect the ground.
e) Shielding, when necessary
Shield the ambient devices
Shield the whole welding machine
§1.5 Warning label
The device with a warning label. Do not remove, destroy or cover this
label. These warnings are intended to avoid incorrect device operations that
could result in serious personal injury or property damage.
OVERVIEW
-11-
§2 Overview
§2.1 Features
⚫ New PWM technology and IGBT inverter technology for high efficiency operation.
⚫ Three dedicated wire feed systems for high productivity and no cross contamination.
⚫ MIG/MAG with Pulse Synergic / Dual Pulse Synergic, Manual and Synergic function
-Synergic programs for aluminum,
mild steel, stainless steel and silicone bronze
-JOB mode (Save and call 100 job records)
- 2T /4T/S4T/ & Spot Weld welding mode
- Function parameter adjustment
⚫ MMA function (Stick electrode)
- Hot start (improves electrode starting)
- Adjustable Arc Force
⚫ DC TIG
- Lift Arc ignition (No high frequency)
- 2T /4T Trigger Control
- Adjustable Up/Downslope
-Adjustable pre and post gas
⚫ Three internal 4-roll, gear drive wire feeders
with 4” (100mm) and 8” (300mm) spool holders.
⚫ Three euro-connect outputs for steel, aluminum, silicone bronze and spool gun
torches.
⚫ Dual cylinder supports and shield gas lines with four gas solenoid valves.
⚫ IP23 rating for environmental/safety protection
⚫ Spool gun connection (Allows controlled feeding of smallest diameter wire for thin
panels.
⚫ TIG torch connection (Independent of MIG gun connects for increased productivity.
⚫ MMA stick electrode connection with hot-start and arc-force adjustment.
OVERVIEW
-12-
§2.2 Technical Data
Note: The above parameters are subject to change.
§2.3 Brief Introduction
The DOUBLE PULSE SYNERGIC (DPS) series of welding machines is a new
inverter-based MIG/MMA/TIG Welding machine with Synergic Programs and Dual pulse
functions. The MIG function allows you to weld with Gas Shielded wire applications giving
excellent, professional welding results. Easy step-less adjustment of voltage and wire
feed coupled with integrated digital meters allows easy setting of welding parameters.
Synergic setting of welding machines features MIG welding with Synergic welding
programs designed for ease of use with your selected gas mixture. The operator selects
the gas mixture and wire diameter they are using then simply start welding. Once this is
done the operator can make fine adjustments to the voltage for even greater control of the
weld pool. The added Lift-Arc DC TIG capability delivers perfect arc ignition every time
and a remarkably smooth stable arc produces high quality TIG welds. TIG functionality
OVERVIEW
-13-
includes adjustable up/down slope & pre/post gas control. The stick welding (MMA)
capability delivers easy electrode welding with high quality results, including cast Iron,
stainless and low hydrogen with hot-start and arc-force adjustment. An additional feature
is the spool gun function that allows the simple connection of Spool Gun for the use of
thin or softer wires that don’t have the column strength to feed through MIG torches, such
as some aluminum and silicone bronze wires. In the JOB mode, 100 different JOB
records can be stored and recalled, improve the quality of welding process.
The DPS series of arc welding machine is an industrial quality machine that is suitable
for all positions welding for various plates made of stainless steel, carbon steel, alloyed
steel etc. Applications applied to automotive, petrochemical, architecture, industrial and
common steel fabrication.
The DPS series of welding machines has built-in automatic protection functions to
protect the machines from over-voltage, over-current and over-heat. If any one of the
above problems happens, the alarm lamp on the front panel will illuminate and output
current will be shut off automatically to protect machine and operator.
§2.4 Duty Cycle and Over-heat
The letter “X” stands for Duty Cycle, which is defined as the portion of the time a
welding machine can weld at maximum rated output current within a 10-minute cycle.
If the welding machine is operated beyond the rated duty-cycle, the IGBT heat sensor
will send a signal to the welding
machine control unit to switch the
output welding current OFF and light
the over-heat. The machine should not
be operated for 10-15 minutes to allow
cool down. When operating the
machine again, the welding output
current should be reduced to match the
duty cycle.
OVERVIEW
-14-
§2.5 Working Principle
The working principle of DPS series welding machine is shown as the following figure.
Single-phase 208-240VAC is rectified into DC, then is converted to medium frequency AC
(about 20KHz) by inverter device (IGBT), after reducing voltage by medium transformer
(the main transformer) and rectifying by medium frequency rectifier (fast recovery diodes),
and fine-tuned by inductance filtering. The circuit utilizes current feedback control
technology to insure current output stability when MMA or TIG and adopts to voltage
feedback control technology to insure voltage output stability when operating in MIG
mode.
Rectifier Inverter Transformer Rectifier Hall
Current
Feedback
control
Single-phase AC
DC
AC DC
220V 50Hz
AC DC
Welding current
regulate
(Wire feed speed)
Wire feeder
motor
PWM signal
CPU control
Voltage
Feedback
control
§2.6 Volt-Ampere Characteristic
DPS series of welding machines have an excellent volt-ampere characteristic as shown
in the following figure. The relation between the rated loading voltage (U2) and welding
current (I2) is defined as follows: U2=14+0.05I
2
(V)
44
14
0 600
Io（A）
Uo（V）
Working point
Volt-ampere characteristic
The relation between the rated loading
voltage and welding current
208-240V 60HZ
Current sensor
OPERATION
-15-
§3 Panel Functions & Descriptions
§3.1 Machine Layout Description
Front and rear panel layout of welding machine
1. MIG torch euro-connectors (3)
2. Main power ON/OFF Switch
3. Torch output “SELECT” switch (0-3)
4. Positive(+) welding power output
5. Negative(-) welding power output
6. TIG torch gas connector (5/8-18F).
7. Control circuit 9-pin connect plug.
8. Input power cord NEMA6-50P
(230VAC @ 50A Max.).
9. TIG Gas input connectors(above).
MIG Gas input connectors(below).
Wire feed cabinet (3) on welding
machine
10. Spool holder.
11. Wire feed tension adjustment (2x).
12. Wire feed tension arm (2x).
13. Wire feeder inlet guide.
14. Drive roller retainer (2x).
15. Wire drive roller (2x).
16. Wire feed motor.
OPERATION
-16-
§3.2 Control panel of welding machine
1. Synergic program indicator.
2. Welding voltage indicator.
3. RH digital multifunction display.
4. Arc length indicator.
5. Inductance indicator.
6. Material thickness indicator.
7. Wire feed indicator.
8. LH digital multifunction display.
9. Welding current indicator.
10. JOB indicator.
11. Power “ON” indicator.
12. Spool gun mode indicator.
13. Over-temp alarm indicator.
14. LH parameter select/adjust knob.
15. RH parameter select/adjust knob.
16. JOB button.
17. Program save/delete button.
18. Function button.
19. Trigger mode select button: Select 2T/4T/S4T/Spot Weld
20. Manual wire feed button.
21. Welding process select button.
22. Manual shield gas check button.
Arc Length (4)
If arc length is decreased, the arc cone becomes narrower and the arc more focused
resulting in a weld bead that is narrow with slightly decreased penetration. Conversely, if
arc length is increased, the arc cone and the arc are wider resulting in a weld bead that is
wider and flatter with slightly increased penetration. Wire speed must be constant (preset
synergic) for arc length adjustment to have the desired effect on the weld.
Inductance / Wave Form (5)
Inductance slows the rate of current rise. A high inductance setting (+10) increases the
time of each arc cycle creating more penetration. A low inductance setting (-10)
decreases the time of each individual arc cycle creating a narrow bead or less
blow-through on thin material.
OPERATION
-17-
Alarm Indicator (13)
Illuminates when the power supply has exceeded duty-cycle and entered an
over-temperature condition. The unit will automatically reset once cooled and lamp will go
off.
JOB program save (16)
In the JOB mode, 100 different JOB records can be stored and recalled. When leaving
the factory, has no saved JOB programs; therefore, operator must first save a program.
Saving the JOB program
⚫ Set JOB mode parameters (welding function, welding mode, welding parameters,
etc).
⚫ Press the JOB button (16) and LED will illuminate.
⚫ Select JOB number by the adjustment Knob (15) shown on the digital meter (8).
⚫ Press the Save/Delete button (17) to save the JOB under the selected number.
Recall the JOB program
⚫ Press the JOB button (16) and the JOB LED will illuminate.
⚫ Selectthe required JOB number by the adjustment Knob (15) as shown on the meter
(8).
⚫ Press the JOB button (16) again and the JOB LED is off that signals exit of JOB
mode.
Function button (18)
• Implicit parameter menu and parameter adjustment method for import and
export
a) Press the function button (18) indicator light “ON” indicates in parameter adjusting
mode.
b) Scroll through parameter codes turning knob (14). Codes are shown on meter (3).
Once parameter is selected, adjust the knob (15) with selection shown on the meter
(8).
c) Press the function button（18）again, light “OFF” signals exit parameter adjusting
mode.
OPERATION
-18-
DISPLAY
FUNCTION
ADJUSTABLE RANGE
MODE
PrG
PRE GAS
0-5S
PoG
POST GAS
0-10S
SFt
SLOW FEED TIME
0-10S
bub
BURN BACK
0-10
SPt
SPOT WELD TIME
0-10S
dPC
DELTA PULSE CURRENT
0-200A
DUAL PULSE
FdP
DUAL PULSE FREQUENCY
0.5-3.0Hz
dut
DUAL PULSE DUTY
10-90%
bAL
DUAL PULSE BASE CURRENT
ARC LENGTH
+10 / -10
SCP
START CURRENT PERCENT
1-200%
S4T
SAL
START CURRENT
ARC LENGTH
+10 / -10
ECP
END CURRENT PERCENT
1-200%
EAL
END CURRENT ARC LENGTH
+10 / -10
HdC
HYDROCOOLING
ON/OFF
SPG
SPOOL GUN
ON/OFF
HSt
HOT START
0-10
MMA
ACF
ARC FORCE
0-10
dSL
DOWN SLOPE
0-10S
TIG
Trigger mode select button (19)
2T mode (ON/OFF)
Pre Gas Time
Slow Feed Time
Post Gas Time
Welding conditions
Gun Switch
Gas Supply
Wire Feed
Output Voltage
Output Current
Burn back Time
OPERATION
-19-
4T mode (Latching)
S4T mode
Spot weld
Welding conditions
Gun Switch
Gas Supply
Wire
Output Voltage
Output Current
End Current conditions
Self-Locking
Gun Switch
Gas Supply
Wire Feed
Output Voltage
Output Current
Welding condition
Initial condition
End Current condition
Transition Time
Burnback Time
Gun Switch
Gas Supply
Wire Feed
Output Voltage
Output Current
Spot Weld Time
OPERATION
-20-
Program SELECT Indicator (21)
Synergic Function
The operator simply sets the welding current like MMA or TIG welding and the machine
calculates the optimal voltage and wire speed for the material type, wire type and size
and shielding gas being used. Obviously other variables such as welding joint type and
thickness, air temperature affect the optimal voltage and wire feed setting, so the program
provides a voltage fine tuning function for the synergic program selected. Once the
voltage is adjusted in a synergic program, it will stay fixed at this variation when the
current setting is changed. To reset the voltage for a synergic program back to factory
default, change to another program and back again
The synergic programs are given a number from 1-17, this is accessed on the L display
(3) using the L knob (14), indicator 'P'. To select the relevant program for the welding
application, check the chart printed on the inside door of the welding machine or further
on in this manual.
Single Pulse Function
Pulse allows the arc to enter spray transfer at lower currents and feed speeds than
manual allowing faster welding with high deposition and smaller heat effected zones due
to the extra arc energy provided at peak of pulse. Used for stainless or aluminum edge or
seam welds.
Double-Pulse Function
Double pulse allows more precise control of heat input as “peak” is offset by “base”
allowing puddle stability. It is mainly used in aluminum alloy welding for strong penetration
with narrow bead and smooth surface. It can produce the ripple effect of a TIG weld
without torch modulation. Dual pulse reference waveform as shown below:
Wire
Current
OPERATION
-21-
◼ DUAL PULSE FREQUENCY
Set pulse frequency, as shown in Figure regulating the value of time T, namely, ripple
pattern of density regulation. Higher Hz produces many short ripples with slightly lower
penetration.
◼ DUAL PULSE DUTY
Set strong pulse time T1 (peak) for penetration and low-frequency cycle T2 ratio
(cooling), namely the regulation of the proportion of the ripple pattern on weld puddle
surface and resulting depth in groove.
MIG Single-Pulse Synergic Function- Front Panel Description
1. Function Select: MIG Single-Pulse Synergic
2. Trigger Select: 2T/4T/S4T/Spot
3. Function Select: refer to§ 4.4
4. Synergic Program Select: refer to§ 4.4
4. Set: Voltage / Arc Length / Inductance
5. Set: Material Thickness / Current / Wire
Speed
6. Display: Program / Voltage / Arc Length /
Inductance
7. Display: Current / Wire Speed / Material
Thickness
8. Shield Gas Purge
9. Manual Wire Feed
OPERATION
-22-
MIG Double-Pulse Synergic Function- Front Panel Description
1. Function Select: MIG Double-Pulse Synergic
2. Trigger Select: 2T/4T/S4T/Spot
3. Function Select: refer to§ 4.4
4. Synergic Program Select: refer to§ 4.4
4. Set: Voltage / Arc Length / Inductance
5. Set: Material Thickness / Current / Wire
Speed
6. Display: Program / Voltage / Arc Length /
Inductance
7. Display: Current / Wire Speed / Material
Thickness
8. Shield Gas Purge
9. Manual Wire Feed
MIG Manual Function- Front Panel Description
1. Function Select: MIG Manual
2. Trigger Select: 2T/4T/S4T/Spot
3. Function Select: refer to§ 4.4
4. Set: Voltage / Inductance
5. Set: Thickness /Current / Wire Speed
6. Display: Voltage / Inductance
7. Display: Thickness / Current / Wire Speed
8. Shield Gas Purge
9. Manual Wire Feed
OPERATION
-23-
MIG Synergic Function-Front Panel
Description
1. Function Select: MIG Synergic
2. Trigger Select: 2T/4T/S4T/Spot
3. Function Select: refer to§ 4.4
4. Synergic Program Select: refer to§ 4.4
4. Set: Voltage / Arc Length / Inductance
5. Set: Material Thickness / Current / Wire
Speed
6. Display: Program / Voltage / Arc Length /
Inductance
7. Display: Current / Wire Speed / Material Thickness
8. Shield Gas Purge
9. Manual Wire Feed
MMA Mode - Front Panel Description
1. Display Code Parameter: Hot Start / Arc
Force
2. Display Welding Current: Hot Start / Arc
Force
3. Welding Current Indicator (Amps)
4. Function Select: MMA / Stick Electrode
5. Parameter Select: Hot Start / Arc Force
6. Code Parameter Select: Hot Start / Arc Force
7. Welding Current Set: Hot Start / Arc Force
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