Top Gun SYN 2500 PULSE User manual

USER MANUAL
SYN 2500 PULSE

SYN 2500 PULSE USER MANUAL
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Please read carefully this user manual before using this machine
Keep it for the future use.
MANU
SAFETY 3
APPLICATION 6
DESCRIPTION OF THE MACHINE 6
TECHNICAL DATA OF THE DEVICE 6
DEVICE CONNECTION - WELDING POLARITY SETTING 7
PANEL OPERATION-GENERAL 12
-SYNERGY MODE FOR MAG/MIG 15
-MIG OPERATION 17
-TIG OPERATION 24
-MMA OPERATION 26
ERROR CODE 28
ELETRICITY SAFETY GUIDLINES 29
ELECTRICITY DIAGRAM 30

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1. Safety
It is imperative that you read the following signs and safety rules to protect your own and other people's health
and life.
Read the instructions before starting the device. Use only original equipment supplied by
the manufacturer.
Some components may explode. Always use a face shield and protective clothing with
long sleeves.
Static voltage can damage electronic components.
Use approved face shields and welding shields. Always use protective clothing designed for
welders. Metal splinters can damage your eyes. Always use safety glass.
Electric shock can result in death. Do not touch electrical components when the device is
connected to power. Use dry and complete protective gloves and protective clothing.
Gases and vapors can be hazardous to health. Welding gases and fumes are emitted during
the welding process. Inhalation of these substances can be hazardous to health.
Eye protection with welding filters. Depending on the current used, use protective shields
with appropriate filters.
Moving parts of the device can cause injuries.
Continuous operation for too long can cause device to overhear. Wait until the device cools
down.

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Damaged technical gas cylinders may explode. The cylinders contain high pressure gas.
Make sure that cylinders are handled and stored in accordance with health and safety and
fire protection requirements.
Welded parts may burn.
The protruding wire from the torch is sharp and can cause skin puncture.
Danger of fire and explosion. During welding work, a fire may result. The welding station
must be remote and protected against flammable and explosive materials.
The magnetic field can disrupt the functioning of pacemakers. Consult a doctor before
starting work.
Do not weld at height without proper protection.
A device falling or falling over may cause injury.
◼ Before starting work, specify the place where the device is to be operated.
◼The device should be connected to the network so that it can be freely manipulated at all times.
◼The power cord should not be taut during operation.
◼Do not use the device on a surface that may cause it to tip over.
◼To move the device, use only the handle on the front of the device. Do not pull on the welding or power
cord.
◼Moving and transporting the device and cylinders with technical gases should be carried out separately.
Only carry the machine using the factory carrying handles.
◼ Incorrect use is prohibited.

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ATTENTION!
The heating test was carried out at ambient temperature and the duty cycle (load factor) at 25℃ was
determined as a result of the simulation.
The device is intended for conducting professional welding works in industrial conditions by personnel
having valid qualification certificates in accordance with applicable standards.
The device should be operated in accordance with the Regulation of the Minister of Economy of April
27, 2000. on health and safety at work during welding (Journal of Laws No. 40 item 470)
Keeping this user manual and following the guidelines outlined in it will allow for proper maintenance
of the device in the future. The following warnings are intended to ensure user safety and
environmentally friendly operation. Read the entire manual carefully before installing and using the
device.
◼After opening the packaging, check that the device has not been damaged during transport. If in
doubt, contact our service department.
◼The device should only be used by a trained employee or consumer.
◼When installing the appliance, you should entrust all electrical activities to a qualified
electrician.
!
!
WARNING: This Class A equipment is not intended for use in residential areas where electricity is
supplied through the public low voltage network system. There may be potential difficulties in
ensuring electromagnetic compatibility at these locations due to conducted and radiated
disturbances.

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2. APPLICATION
SYN 2500 PULSE devices are used for manual arc welding in the GMAW (Gas Metal Arc Welding),
GTAW (Gas Tungsten Arc Welding) and SMAW (Shielded Metal Arc Welding) methods.
3. DESCRIPTION OF THE MACHINE
SYN 2500 PULSE devices are modern inverter sources offering very high welding versatility. Their main
advantage is the possibility of welding using single or double pulse current in MIG or MAG mode. Thanks
to the use of modern IGBT technology and high-quality components, they are ideal for works related to
the automotive industry, steel constructions, welding of aluminum alloys and others.
Reliability, a wide range of applications (the ability to carry out work in three welding methods:
MIG / MAG, TIG-LIFT DC, MMA make the device satisfy even the most demanding users.
4. TECHNICAL DATA OF THE DEVICE
Characters
SYN 2500 PULSE
Rated input voltage[V]
220V
Frequency[Hz]
50/60
Security[A]
20
Output current range[A]
MMA
30-250
TIG
10-250
MIG/MAG
40-250
Output voltage
MMA
21.2-32
TIG
10.4-22
MIG/MAG
16-32
Duty cycle[%]
（at ambient temperature 40°C）
30% 250 [A]
Rated input power [kVA]
13.9
Power factor
0.93
Work piece thickness[mm]
0.5-6
Feeder type
2R
Welding wire diameter[mm]
0.8/1.0/1.2
Insulation class
F
Protection class
IP21
Net weight [kg]
29
Dimensions [mm]
270X600X540

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5. DEVICE CONNECTION - WELDING POLARITY SETTING
MIG/MAG WELDING
Select the correct welding polarity as shown above.
Positive polarity welding (MIG / MAG gas shielded solid wire welding)
Welder's current plug connected to the positive + socket (EURO)
Earth handle connected to the negative socket -
Welding with negative polarity - （welding with flux cored wire - FCAW)
Welder's current plug connected to the negative socket - （EURO）
Earth clamp connected to the positive socket +
WARNING!
To start working with self-shielding wire, change the polarity inside the device - on the wire feeder.
BEFORE YOU WORK:

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Check the voltage, number of phases and frequency of the power supply before connecting the
device to the mains.
Power supply voltage parameters are given in the chapter with technical data and on the rating
plate of the device.
Check the connection of the grounding wires of the device to the mains.
Ensure that the power supply network can provide coverage of the input power demand for this
device under normal operating conditions. The fuse size, the parameters of the power cord are
given in the technical data and on the rating plate. Connection and replacement of the power cord
and plug should be made by a qualified electrician.
Remove all flammable materials from the welding area.
◼Use appropriate protective clothing for welding: gloves, apron, work boots, mask or visor with
appropriate certificates.
DEVICE CONNECTION FOR THE MIG / MAG METHOD
To extend the service life and ensure reliable operation of the device, observe the following rules:
The device should be placed in a well-ventilated room with free air circulation.
Do not place the device on wet ground.
Use an electrode wire with diameter and spool weight in accordance with the manufacturer's
instructions (D200, max. 15 kg). Check the technical condition of the device and welding cables on
an ongoing basis.
Welding wire spool assembly:
SYN 2500 PULSE device is equipped with professional wire feeder, it has 4 rolls feeder enabling work
with 2 handles max 4mb when welding with steel wire and with 3mb when welding with aluminum
alloy wire, The welding wire holder allows the installation of reels with a diameter of 300mm-15kg.
5kg wire coil 15kg wire coil
◼Lift the side cover of the semi-automatic housing.
◼Ensure that the rollers fitted in the drive unit match the type and diameter of wire used. Rolls
should be used for steel wires with "V" shaped grooves, while for aluminum wires with "U" type
grooves.

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◼Apply welding wire spools to the spool clamping mechanism, paying attention that the unwinding
direction of the wire is consistent with the direction of the wire's entry into the drive unit. Lock
the spools before slipping by tightening the nut on the spool mounting body.
◼The end of the wire should be straightened or cut off a bent section.
◼To feed wire into the feeder, release the pressure of the feed rollers.
◼Insert the end of the wire into the guide located at the back of the feeder and route it over the
drive roller by inserting it into the welding gun stub.
◼Tighten the wire in the drive roller groove and tighten.
◼Remove the gas nozzle from the burner and unscrew the contact tip.
◼Turn the device on.
◼Unwind the welding gun cable so that it is straight. ATTENTION! Do not drive the
welding torch ends towards the face or other people.
◼Press the welding button on the welding gun and hold it until the wire appears behind the torch.
◼When the end of the welding wire passes through the connector in the torch, release the button
approx. 5 cm and replace the contact tip and gas nozzle.
◼Adjust the clamping force by turning the knob, clockwise-increases the clamping force, to the left-
decreases the clamping force. Too low clamping force will cause the drive roller to slip. Too much
pressure increases the feed resistance and deforms the wire.
We recommend placing the wire into the welding gun with the valve on the shielding gas cylinder
closed. This will reduce its unnecessary losses.
Installation of shielding gas cylinders:
A cylinder with a suitable shielding gas must always be properly secured against falling over. If
possible, attach to an approved welding carriage with the MIG / MAG device. The trolley is not
standard equipment of the set.
Connect the semi-automatic machine to the cylinder with a suitable hose.
Unscrew the regulator valve before starting to weld. Always close the cylinder valve after welding.
6.
MIG/MAG welding process
Arc welding in gas shields (marked MIG / MAG) is one of the most commonly used processes in the
production of welded structures. The abbreviation MAG (Metal Active Gas) includes in its description
types of active protective gases. The abbreviation MIG (Metal Inert Gas) refers to inert gas shields.

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The semi-automatic welding process involves fusing the edges of the work piece and the consumable
electrode material with the heat of an electric arc glowing between the electrode in the form of a
solid wire and the welded part, in an inert or active gas shield.
The main protective gases used for MIG welding are inert gases such as argon, helium and MAG active
gases: CO2, H2, O2, N2 and NO, used separately or as additives to argon or helium.
The fusible electrode is in the form of a solid wire, usually 0.6 1.2 mm in diameter, and is fed in mm,
and is fed in m / min upwards. Welding torches can be cooled by liquid or shielding gas. Welding is
carried out mainly with direct current with positive polarity, as semiautomatic, mechanized welding,
direct current with positive polarity, as semi-automatic, mechanized, automatic or robotic welding
using specialized equipment. The shield of the welding arc glowing between the consumable
electrode and the material being welded ensures the formation of the weld under very favorable
thermal and chemical conditions. This type of welding can be used to make high-quality joints of all
metals that can be joined by arc welding. These include: carbon and low alloy steels as well as
corrosion resistant steels. Welding can be carried out in workshop and field conditions in all positions.
SINGLE PULSE MODE
MIG PULSE is an advanced form of welding that uses the best of the forms of the transfer of molten
electrode material to the work piece. Unlike short circuits, pulse welding does not produce spatter
and there is a risk of cold "leakage". Welding positions in the pulse are not limited because they are
derived from globular or spray forms, and their use is definitely more efficient. By cooling the spray
arc process, pulsed MIG is able to extend the welding range, and smaller heat input does not cause
a problem with burning thin materials. MIG PULSE is one of the best welding processes for a wide
range of applications and types of metal.
DOUBLE PULSE MODE
Welding with the MIG / MAG method with double pulse we get a high level of face appearance (husk
effect). In addition, the use of automatic wire feed affects welding performance. The MIG / MAG
method with double pulse allows the regulation of current pulsation (pulse balance) and adjustment
of the wire feed speed. Thanks to this, we improve the appearance of the weld. When MIG / MAG
welding with double pulse, current pulses occur in two ranges. The sequential system of our devices
automatically combines two levels of pulses.

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The benefits of using the MIG MAG method with double pulse are:
1. MIG / MAG double pulse welding is faster than TIG welding.
2. MIG / MAG double pulse welding achieves high aesthetics like the TIG method.
3. MIG / MAG double pulse welding results in less deformation than TIG.
7. PANEL OPERATION
A. DESCRIPTION OF THE CONTROL PANEL

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1. LCD display
2. Function selection button, to select the previous menu, holding for 5 seconds to save the
current setting in memory.
3. Button to return to the previous menu. (additionally held for 5 seconds to return to the factory
settings (RESET)).
4. Adjustment knob,
Turn - Select and Adjust.
Press - Confirm and Switch to next.
5. Button for Confirmation or Enter.
6. Function selection button, to select the next menu, holding for 5 seconds to recall memories;
The device has 18 memory programs.
Function
Function
Return
Execute
Min
Max
1
2
3
4
5
6

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B. LANGUAGE SELECTION
The device allows you to set the following control languages: English,
German, Dutch, French, Spanish.
Turn the red knob of the font panel to select the language then press for confirmation.
C. CHOICE OF WELDING METHOD
This page allows you to select welding methods as below:
Synergy, MIG, LIFT-TIG, MMA
Turn the red knob of the font panel to select the welding mode then press for confirmation.

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SYNERGY - synergic settings. The user selects the basic welding parameters such as the type of
material, thickness of the material to be welded, diameter of the welding wire. Other parameters of
the device are selected automatically using the database of uploaded programs.
MIG MODE - welding using individual user settings. The system suggests the selection of key welding
parameters, indicating the thickness of the welded material when adjusting them. This information
suggests to the user that the settings are correct.
LIFT-TIG - TIG lift mode (ignition of the arc by rubbing) - welding with a tungsten electrode in an inert
gas shield. In order to carry out welding by this method, it is necessary to retrofit the device TIG torch
with shielding gas control in the handle as in the photo below. This handle is not a standard
equipment of the set.
MMA MODE - welding with coated electrode. In addition to welding current adjustment, the user can
additionally set ARC-FORCE, HOT START and enable or disable the VRD protection system.
ARC FORCE - Stabilizes the arc regardless of fluctuations in its length, reduces the amount of spatter.
HOT-START - a function that makes welding easier. When the arc strikes, the welding current is
temporarily increased to heat up the material and electrode at the point of contact, and to properly
shape the penetration and weld face at the initial stage of welding.
VRD - the device has a VRD (Voltage Reduction Device) system, which for welding mode MMA with
electrodes reduces the open circuit voltage, which significantly increases the user's safety. In special
cases of using electrodes with high arc ignition current, problems with its initiation may occur.

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D. Synergy function (MIG/MAG )
In the SYNERGY mode, the user only selects the basic welding parameters such as the type of material, the
thickness of the material to be welded, and the diameter of the welding wire (0.8mm, 1.0mm and 1.2mm
available). Other parameters of the device are selected automatically using the database of uploaded
programs.
The SYNERGY mode only allows continuous welding, it has no possibility to adjust the PULS and dual
PULS settings.
You can manually correct the synergic settings.
NOTE: If the material type and thickness settings are changed, the system will return with the
remaining parameters to the factory default values.
Step 1-Choice of material
The user selects the welded material (and
welding wire) from the list of alloys available in
the program.
Step 2-Selecting the thickness of the work
piece
The user chooses the thickness of the welded
material. The device automatically selects the
intensity on this basis welding current, arc
voltage and feeder speed.
Step 3 Selecting the welding wire diameter
You choose the welding wire diameter you plan
to use.
ATTENTION!
The device automatically reduces or increases
its maximum power depending on the wire
diameter.

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Step 4 Selecting the welding wire diameter
You choose the welding wire diameter you
plan to use.
ATTENTION!
The device automatically reduces or increases
its maximum power depending on the wire
diameter.
Step 5 Selecting the welding wire diameter
You choose the welding wire diameter you
plan to use.
ATTENTION!
The device automatically reduces or increases
its maximum power depending on the wire
diameter.
According to the programmed welding parameters, the welding wire diameters selected by the
user directly influence the welding current and voltage, and wire feeder speed. For example,
choosing a 0.8mm wire will automatically limit the maximum welding current to e.g. 140A,
choosing a 1.0mm wire will allow welding 200A current. These actions are aimed at optimizing
the welding process and avoiding problems associated with burning the wire too quickly just
after the contact tip in a situation where it is no longer possible to increase the feeder speed.
The inability to set the maximum welding current is not a software error and results from the welding
wire diameter selected.

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E. MIG/MAG OPERATION
In MIG welding mode, the user sets all welding parameters one after the other. The system
suggests the selection of optimal welding parameters by indicating at their adjustment thickness of
the welded material (see table - setting the wire feeder speed). This information suggests to the
user that the settings are correct. Depending on the welding style (forced positions, fast welding
with higher current or slower current with lower intensity), these settings may require a slight
adjustment by the user.
Handle mode button operation
2-step, 4-step welding and spot welding
selection.
Welding current selection:
-continuous (without pulse)
-single pulse
(see chapter WELDING MIG / MAG WITH PULSE)
-double pulse
(see chapter WELDING MIG / MAG WITH
DOUBLE PULSE)
Choice of welding wire diameter
Choose the corresponding wire diameter.

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Choice of welded material (and wire)
From the list of alloys available in program.
Setting the wire feeder speed ATTENTION!
It will show automatically the estimated
thickness of the welded material in order to
select the optimal welding parameter.
Adjusting the arc voltage
Increasing or decreasing this value will lengthen
or shorten the arc length.
Inductance regulation
Properly selected welding inductance reduces
the amount of spatter. It depends on the wire
diameter welding, shielding gas used, current
and welding position. Reducing the inductance
makes the arc more stable and concentrated,
while increasing contributes to the formation of
a more fluid pool and reduces the amount of
spatter. Properly selected, it is characterized by a
stable arc, even transfer of liquid metal droplets,
maintaining a constant weld pool size and
characteristic repetitive sound without splashes
and explosions.

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Adjusting the arc voltage
Increasing or decreasing this value will lengthen
or shorten the arc length.
Inductance regulation
Properly selected welding inductance reduces
the amount of spatter. It depends on the wire
diameter welding, shielding gas used, current
and welding position. Reducing the inductance
makes the arc more stable and concentrated,
while increasing contributes to the formation of
a more fluid pool and reduces the amount of
spatter. Properly selected, it is characterized by a
stable arc, even transfer of liquid metal droplets,
maintaining a constant weld pool size and
characteristic repetitive sound without splashes
and explosions.