12
4. Connect the earth clamp to the workpiece.
5. Start to weld maintaining an arc length of
between 5 to 10 mm.
6. Regulate the wire speed (Knob Fig. 1 –
9).For best results regulate the speed (Knob 9)
until a loud, regular sizzling sound is heard (sim-
ilar to that of frying bacon). Always perform a
trial run using a metal sheet that is free of
grease, rust or paint.
For best results heed the following advice:
1. Keep the torch at a 45° angle to the work-
piece. Keep the gas nozzle (Fig.4A) app. 6 mm
away from the workpiece.
2. Move the torch smoothly.
3. Weld using small zigzag movements so as to be
able to regulate the size of the weld as desired.
4. Do not weld in windy surroundings. Draughts
can disperse the gas from the welding pool
causing porous welding results.
5. Ensure the wire is clean: never use rusty
welding wire.
6. Keep the torch cable straight.
7. Clean the wire-feed guide with compressed
air when changing spools.
8. Remove dust from the air intake grills regu-
larly, using low-pressure compressed air. Always
point the jet of air outwards to avoid dirt being
forced into the unit.
Pulsed mode:
Pressing button 12 of Fig.1 will set the unit in man-
ual pulsed MIG welding mode. LED 6 of Figure 1
will be on. This mode is for experienced operators
only. In fact it is mainly used as an alternative to syn-
ergic pulsed MIG welding under rare circum-
stances, e.g. for special materials and when satis-
factory results cannot be achieved using the prede-
fined settings. In this mode the potentiometer knob
(Fig. 1 – 10) regulates the welding current, knob 9
(Fig.1) sets the wire speed and knob 8 (Fig.1) regu-
lates the pulsing frequency.
8.2 SYNERGIC MIG WELDING
In synergic MIG welding (with gas) mode the
welder tunes itself automatically to suit the type
of material to be welded and the thickness of the
workpiece. Contrary to manual mode, a series of
predefined programmes to suit all requirements
are available.
It should be noted, however, that certain param-
eters can be set manually. More information in
this respect will be provided in later sections. A
choice of Short-Arc (Fig. 1, LED 6 off) or Pulsed
(Fig. 1, LED 6 on) synergic MIG welding is avail-
able. Press the
Pulse button (Fig.1 – 12) lightly to switch mode.
To select this mode, turn knob 7 (Fig.1) to one of
the SYNERGIC settings.
Proceed as follows for synergic MIG welding:
1. Select one of the following programmes
according to the type of material to be welded
(Selector knob 7, Fig1)
• Al-Mg 0.8: The permissible thickness range
is 0.8 to 4 mm.
• Al-Mg 5 1.0: The permissible thickness
range is 0.9 mm to 5 mm.
• Al-Si 12 1.0: The permissibile thickness
range is 0.8mm to 5 mm (Spool Gun welding is
recommended for this type of wire).
• ideal for welding stainless steel (Ni-Cr)
0.8mm in diameter. The permissible thickness
range is 0.8 mm to 5 mm.
• ideal for welding SG2 or SG3 materials
0.8mm in diameter. The permissible thickness
range is 0.8 mm to 3.2 mm.
• Cu-Si 3 0.8: Ideal for Cu-Si3 having a diam-
eter of 0.8 mm. Such materials can be braze
welded, particularly zinc-plates iron sheets to be
used by car manufacturers The permissible
thickness range is 0.8 to 4 mm.
2. Select the workpiece thickness using Knob
2 of Figure 10. The display panel (Fig. 1 – 1) will
display the selected thickness parameter (in
mm) for a few seconds.
3. Turn knobs 8 and 9 to a mid-way position.
4. Connect the earth clamp to the workpiece.
5. Start to weld maintaining an arc length of
between 5 to 10 mm.
A high-quality result is usually achieved in this
mode. However, the following instructions may help
you achieve even better results depending upon
whether Short-Arc or Pulsed mode is being used.
Short-Arc Mode:
6- If during welding the arc tends to decrease
excessively, turn knob 9 of Figure fig1 anti clockwise
to reduce the wire speed, which will also decrease
the weld pool. If, on the other hand, the arc tends to
over-lengthen, turn the knob clockwise.
7. If there is too much splatter while welding,
the electronic
inductance parameter needs to be increased. Do so
turning knob 8 of Figure 1 clockwise. If maintaining
an arc is difficult, turn the knob anti-clockwise.
Pulsed mode:
8. To vary the length of the arc fine-tune
knob 9 of Figure 1.
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