Top Gun SYN 2000 PULSE User manual

SYN 2000 PULSE

SYN 2000 PULSE
OPERATION MANUAL

Contents
SAFETY.............................................................................................................. 1
CAUTION .......................................................................................................... 3
SYN 2000 PULSE TECHNICAL DATA................................................................... 5
MIG INSTALLATION .......................................................................................... 6
LIFT TIG INSTALLATION..................................................................................... 8
MMA INSTALLATION ........................................................................................ 9
OPERATION PANEL INSTRUCTION.................................................................. 10
MEMORY FUNCTION...................................................................................... 16
LIFT TIG SETTING GUIDE................................................................................. 18
MMA SETTING GUIDE..................................................................................... 20
TROUBLE SHOOTING...................................................................................... 23
MAINTENANCE............................................................................................... 25
CIRCUIT .......................................................................................................... 26
WARRANTY INFORMATION............................................................................ 27

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Machine Operating Safety
• Do not switch the function modes while the machine is operating. Switching of the function modes
during welding can damage the machine. Damage caused in this manner will not be covered under
warranty.
• Disconnect the electrode-holder cable from the machine before switching on the machine, to avoid
arcing should the electrode be in
contact with the work piece.
• Operators should be trained and or qualified.
Electric shock: It 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.
• Connect the primary input cable according to regulations.
• Avoid all contact with live electrical parts of the welding/cutting circuit, electrodes and wires with
bare hands.
• The operator must wear dry welding gloves while he/she performs the welding/cutting task.
• The operator should keep the work piece insulated from himself/herself.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged,
bare wiring is dangerous and can kill.

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• Do not use damaged, under sized, or badly joined cables.
• Do not drape cables over your body.
• We recommend (RCD) safety switch is used with this equipment to detect any leakage of current to
earth.
Fumes and gases are 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
• Keep the working area well ventilated, use fume extraction or ventilation to remove welding/cutting
fumes and gases.
• In confined or heavy fume environments always wear an approved air-supplied respirator.
• Welding/cutting fumes and gases can displace air and lower the oxygen level causing injury or death.
Be sure the breathing air is safe.
• Do not weld/cut in locations near de-greasing, cleaning, or spraying operations. The heat and rays of
the arc can react with vapours to form highly toxic and irritating gases.
• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give off
toxic fumes when welded/cut. Do not weld/cut these materials unless the area is very well ventilated,
and or wearing an air supplied respirator.
Arc rays: harmful to people’s eyes and skin. Arc rays from the welding/cutting process produce
intense visible and invisible ultraviolet
and infrared rays that can burn eyes and skin.Always wear a welding helmet with correct shade of
filter lens and suitable protective clothing including welding gloves whilst the welding/cutting
operation is performed.
• Measures should be taken to protect people in or near the surrounding working area. Use
protective screens or barriers to protect
others from flash,glare and sparks; warn others not to watch the arc.
Fire hazard. Welding/cutting on closed containers, such as tanks,drums, or pipes, can cause them to
explode. Flying sparks from the
welding/cutting 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/cutting.
• The welding/cutting sparks & spatter may cause fire, therefore remove any flammable materials
well away from the working area. Cover flammable materials and containers with approved covers if

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unable to be moved from the welding/cutting area.
• Do not weld/cut on closed containers such as tanks, drums, or pipes, unless they are properly
prepared according to the required Safety Standards to insure that flammable or toxic vapours and
substances are totally removed, these can cause an explosion even though the vessel has been
“cleaned”. Vent hollow castings or containers before heating, cutting or welding. They may explode.
• Do not weld/cut where the atmosphere may contain flammable dust, gas, or liquid vapours (such as
petrol)
• Have a fire extinguisher nearby and know how to use it. Be alert that welding/cutting sparks and
hot materials from welding/cutting can easily go through small cracks and openings to adjacent areas.
Be aware that welding/cutting on a ceiling, floor, bulkhead, or partition can cause fire on the hidden
side.
Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can
explode. Because gas cylinders are normally part of the welding/cutting 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/cutting electrode or earth clamp to touch the gas cylinder, do not drape
welding cables over the cylinder.
• Never weld/cut 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 build up of gas can causes a toxic environment, deplete the oxygen content in the
air resulting in death or injury. Many gases use in welding/cutting are invisible and odourless.
• Shut off shielding gas supply when not in use.
• Always ventilate confined spaces or use approved air-supplied respirator.
Electronic magnetic fields. MAGNETIC FIELDS can affect Implanted Medical Devices.
• Wearers of Pacemakers and other Implanted Medical Devices should keep away.
• Implanted Medical Device wearers should consult their doctor and the device manufacturer before
going near any electric welding, cutting or heating operation.
Noise can damage hearing. Noise from some processes or equipment can damage hearing.

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• Wear approved ear protection if noise level is high.
Hot parts. Items being welded/cut 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/cutting gun. Use insulated welding gloves
and clothing to handle hot parts and prevent burns.
CAUTION
1. Working Environment.
i. The environment in which this welding/cutting equipment is installed must be free of grinding dust, corrosive
chemicals, flammable gas or
materials etc, and at no more than maximum of 80% humidity.
ii. When using the machine outdoors protect the machine from direct sun light, rain water and snow etc; the
temperature of working environment
should be maintained within -10°C to +40°C.
iii. Keep this equipment 30cm distant from the wall.
iv. Ensure the working environment is well ventilated.
2. Safety Tips.
i. Ventilation
This equipment is small-sized, compact in structure, and of excellent performance in amperage output. The fan is used
to dissipate heat generated by this equipment during the welding/cutting operation. Important: Maintain good
ventilation of the louvres of this equipment. The minimum distance between this equipment and any other objects in
or near the working area should be 30 cm. Good ventilation is of critical importance for the normal performance and
service life of this equipment.
ii. Thermal Overload protection.
Should the machine be used to an excessive level, or in high temperature environment, poorly ventilated area or if the
fan malfunctions the
Thermal Overload Switch will be activated and the machine will cease to operate. Under this circumstance, leave the
machine switched on to
keep the built-in fan working to bring down the temperature inside the equipment. The machine will be ready for use
again when the internal
temperature reaches safe level.

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iii. Over-Voltage Supply
Regarding the power supply voltage range of the machine, please refer to “Main parameter” table. This equipment is
of automatic voltage
compensation, which enables the maintaining of the voltage range within the given range. In case that the voltage of
input power supply
amperage exceeds the stipulated value, it is possible to cause damage to the components of this equipment. Please
ensure your primary
power supply is correct.
iv. Do not come into contact with the output terminals while the machine is in operation. An electric shock may
possibly occur.
ATTENTION! - CHECK FOR GAS LEAKAGE
At initial set up and at regular intervals we recommend to check for gas leakage
Recommended procedure is as follows:
1. Connect the regulator and gas hose assembly and tighten all connectors and clamps.
2. Slowly open the cylinder valve.
3. Set the flow rate on the regulator to approximately 8-10 L/min.
4. Close the cylinder valve and pay attention to the needle indicator of the contents pressure gauge on the regulator, if
the needle drops away towards
zero there is a gas leak. Sometimes a gas leak can be slow and to identify it will require leaving the gas pressure in the
regulator and line for an
extended time period. In this situation it is recommended to open the cylinder valve, set the flow rate to 8-10 L/min,
close the cylinder valve and check
after a minimum of 15 minutes.
5. If there is a gas loss then check all connectors and clamps for leakage by brushing or spraying with soapy water,
bubbles will appear at the leakage
point.
6. Tighten clamps or fittings to eliminate gas leakage.
IMPORTANT! - We strongly recommend that you check for gas leakage prior to operation of your machine. We
recommend that you close the cylinder valve when the machine is not in use.

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SYN 2000 PULSE TECHNICAL DATA
Gas Metal Arc Welding (GMAW) is an arc welding process where a consumable wire is fed by motor driven feed rolls to
a welding gun, and where welding current is supplied from the welding power source. The welding arc is struck
between the work piece and the end of the wire, which melts into the weld pool. The arc and the weld pool are both
shielded by gas flow from the gun, or in the case of “self shielded” wires, by gases generated by the wire core. The
process is very versatile in that by selection of the correct wire composition, diameter and shielding gas, it can be used
for applications ranging from sheet-metal to heavy plate, and metals ranging from carbon steel to aluminum alloys.

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TECHNICAL DATA SYN 2000 PULSE
Power Supply / Phases
220/230/240V +/- 15% 50/60Hz
Rated input power
MIG:40-200
MMA:30-200
TIG:20-200
Duty cycle
60%
Feeding mode
ALL IN ONE
Wire feeding speed
2-15M/min
Welding plate Thickness
0.5-5mm
Welding wire diameter
0.8-1.2
Size (mm)
460x220x375mm
Weight (kg)
15.6kg

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MIG INSTALLATION
1.Connect the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it.
2.Insert the earth cable plug into the required polarity and tighten -negative for gas shielded wires positive for gas less
wires. + postive for gass wire. The weld power cable goes into the opposing negative or positive socket.
3.Connect Gas Line to Gas Regulator and connect the gas regulator to the Gas Cylinder. Carefully open the valve of the
gas cylinder, set the flow to 5 l/min. （When using gasless wire）
4.Fit the correct type and size of drive rollers (see the chapter of wire feed roller selection)
5.Place the Wire Spool onto the Spool Holder. Feed the wire into the wire feeder inlet guide tube through to the drive
roller.

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6.At the wirefeed assembly, release the compression screw by swivelling it outwards. This allows the top roller arm to
spring to the open position.The end of the welding wire can now be passed through the inlet guide, over the bottom
driven roller, and into the output wire guide tube.
7.Check that the drive roll groove is correct for the wire in use. The appropriate size is stamped on the visible side of
the installed roller. Check also that the correct size contact tip is fitted at the gun end.
8.Return the top roller arm to the closed position and adjust the compression screw to provide sufficient clamping of
the drive roll to achieve constant wirefeed. Do not over tighten.
9.With the equipment energised, operate the gun switch to feed wire through the gun cable.
WIRE FEED ROLLER SELECTION
Solid Hard Wire - like Steel, Stainless Steel require a drive roller with a V shape groove for optimum grip and drive capability.
Solid wires can have more
tension applied to the wire from the top pressure roller that holds the wire in the groove and the V shape groove is more
suited for this. Solid wires are
more forgiving to feed due to their higher cross sectional column strength, they are stiffer and don’t bend so easy.
Soft Wire - like Aluminium requires a U shape groove. Aluminium wire has a lot less column strength, can bend easily and is
therefore more difficult to
feed. Soft wires can easily buckle at the wire feeder where the wire is fed into inlet guide tube of the torch. The U-shaped
roller offers more surface area
grip and traction to help feed the softer wire. Softer wires also require less tension from the top pressure roller to avoid
deforming the shape of the wire,
too much tension will push the wire out of shape and cause it to catch in the contact tip.
Accessories:

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V GROOVE DRIVE ROLLER - STEEL WIRE
1 x 0.8-1.0 V
U GROOVE DRIVE ROLLER - ALUMINUM WIRE
1 x 1.0-1.2 U

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LIFT TIG INSTALLATION
In the TIG (Tungsten Inert Gas) method, the electric arc strikes under an inert gas (argon) shield, between the welded
element and the non-fusible electrode made of pure tungsten or tungsten with additives.
The TIG method is especially recommended for aesthetic and high-quality joining of metals, without laborious
mechanical treatment after welding. However, this requires proper preparation and cleaning of the edges of both
welded elements. The mechanical properties of the additive material should be similar to the properties of the welded
parts. The role of shielding gas is always played by pure argon, supplied in quantities depending on the welding current
set.

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1.Connect the welding torch into the Euro Mig torch connection socket on the front panel, and tighten it.
2.Insert the earth cable plug into the positive socket. The TIG torch plug into negative socket.
3.Connect Gas Line from the torch to Gas Regulator and connect the gas regulator to the Gas Cylinder. Carefully open
the valve of the gas cylinder, set the flow to 5 l/min.

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MMA INSTALLATION
Arc welding is also called the MMA (Manual Arc Welding) method and is the oldest and most versatile arc welding
method.
The MMA method uses a coated electrode, consisting of a metal core covered with a lagging. An electric arc is created
between the end of the electrode and the material being welded. Arc ignition is created by touching the electrode with
the end of the workpiece. The welder feeds the electrode as it melts into the workpiece so as to maintain a constant
arc length and at the same time moves its melting end along the welding line. The melting coating of the electrode
gives off protective gases that protect the liquid metal from the influence of the surrounding atmosphere, and then
solidifies and forms a slag on the surface of the lake, which protects the coagulating weld from cooling too quickly and
harmful environmental influences.

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Connect the welding and mass leads to the appropriate output connectors of the welder, according to the polarity
recommended by the manufacturer of the electrodes you intend to weld.

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OPERATION PANEL INSTRUCTION
1
Function switch button to the left menu. Press over 5 seconds switch to data call page. Function
selection: When you choose a function, the relative icon will be highlighted.
2
Return button，switch to the parent menu，or return. Press over 5 seconds will back to factory
settings.
6
5
1
2
5
3
4

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3
Data adjusting knob. According left or right button, to switch the relative menu, and turn this
knob can adjust the data. Press to confirm current setting.
4
Execute button, press it can enter into sub-menu, or execute the current operation. Press over 5
seconds will save current data.
5
Function switch button to the right menu. Press over 5 seconds switch to data storage page.

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1.LANGUAGE SETTING
The welding machine offering 5 language options, operators can switch to English, German, Spanish and Russian
versions.
2.WELDING MODE SETTING