Weco WF-103 User manual

Cod.006.0001.1040
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ENGLISH
WECO srl
Via S. Antonio, 22 - BELVEDERE
36056 TEZZE SUL BRENTA (VICENZA) ITALY
Tel.[phone] –Fax [phone]
www.weco.it - E-mail [e-mail]
WF-103
Instruction manual
GB

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1INTRODUCTION................................................................. 4
2FRONT PANEL................................................................... 4
3REAR PANEL..................................................................... 5
4INSTALLATION .................................................................. 5
4.1 PREPARING FOR MIG/MAG WELDING............................. 5
4.2 PREPARING FOR MMA WELDING ..................................... 5
4.3 WIRE SPOOL POSITIONING .............................................. 8
4.4POSITIONING THE WIRE IN THE WIRE FEEDER .............. 8
5USER INTERFACE ........................................................... 10
6UNIT POWER-UP.............................................................. 12
6.1 POWER SOURCE MANAGEMENT BY REMOTE CONTROL
......................................................................................... 12
7RESET (LOAD FACTORY SETTINGS) ............................. 12
7.1 TOTAL RESET.................................................................. 12
8SET-UP (INITIAL SET-UP OF THE WELDING POWER
SOURCE).......................................................................... 13
COOLER ACTIVATION ................................................................13
REMOTE CONTROLLER SELECTION......................................... 13
ADJUSTMENTS BLOCK SELECTION.......................................... 13
PUSH PULL .................................................................................13
SELECTION OF BURN TYPE.......................................................13
8.1 LOCKING PROCEDURE ................................................... 14
Enabling....................................................................................... 14
Disabling......................................................................................14
8.2 TORCH LOADING............................................................. 15
9ALARMS MANAGEMENT................................................. 15
AL. HEA. ......................................................................................15
AL. COO. .....................................................................................15
Err. C0 .........................................................................................15
Err. C1 .........................................................................................15
Err. C2 .........................................................................................15
Err. C4 .........................................................................................15
Err. C11 .......................................................................................15
Err. C12 .......................................................................................15
Err. C69 .......................................................................................15
AL. Cur.........................................................................................16
AL. Mot. .......................................................................................16
10 WELDING PARAMETERS ................................................ 17
10.1 PARAMETERS ACTIVATION ............................................ 18
Working voltage............................................................................18
Welding inductance ...................................................................... 18
WIRE FEED RATE....................................................................... 18
WELDING CURRENT...................................................................18
THICKNESS.................................................................................18
PROGRAMS ................................................................................18
Hot Start.......................................................................................18
Crater Filler ..................................................................................18
3 Levels Slope.............................................................................. 18
Soft Start......................................................................................18
Motor Slope.................................................................................. 18
Bourn Back ..................................................................................18
Post gas time ...............................................................................18
Pre gas time.................................................................................18
11 WELDING SETTINGS....................................................... 19
11.1 MIG/MAG WELDING ......................................................... 19
11.1.1 SETTING MIG/MAG PARAMETERS (MAIN WELDING
PARAMETERS) ...........................................................................19
11.1.2 MIG/MAG PARAMETERS SETTING (2ND LEVEL)....................... 20
11.1.3 MIG/MAG PARAMETERS SETTING (GAS MENU) .......................20
11.2 ELECTRODE WELDING (MMA) ........................................ 20
11.3 ARC AIR (DESEAMING).................................................... 20
12 JOBS MANAGEMENT ...................................................... 21
12.1 SAVING A JOB.................................................................. 21
12.2 LOADING A USER JOB OF FACTORY SET JOB .............. 21
12.3 DELETING A JOB ............................................................. 22
13 TORCH TRIGGER MODES ............................................... 22
13.1 2T MIG/MAG WELDING .................................................... 22
13.2 4T MIG/MAG WELDING .................................................... 22
13.3 3 LEVEL MIG/MAG WELDING ...........................................22
14 TECHNICAL DATA............................................................23
15 SPARE PARTS..................................................................24
15.1 WF-103..............................................................................24
15.2 WIRE FEEDER MOTOR ....................................................26
15.3 WIRE FEEDER ROLLS......................................................27
16 ELECTRICAL DIAGRAM...................................................28
16.1 WF-103..............................................................................28
16.2 POWER SOURCE → WF-103 CABLE...............................29
16.3 REMOTE CONTROLLER...................................................30
16.3.1 RC03: ELECTRICAL DIAGRAM....................................................30
16.3.2 RC04: ELECTRICAL DIAGRAM....................................................30
16.3.3 RC05: ELECTRICAL DIAGRAM....................................................31
16.3.4 RC06: ELECTRICAL DIAGRAM....................................................31

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1INTRODUCTION
IMPORTANT!
This handbook must be consigned to the user prior to
installation and commissioning of the unit.
Read the "General prescriptions for use" handbook supplied
separately from this handbook before installing and
commissioning the unit.
The meaning of the symbols in this manual and the associated
precautionary information are given in the "General
prescriptions for use”.
If the "General prescriptions for use" are not present, it is
mandatory to request a replacement copy from the
manufacturer or from your dealer.
Retain these documents for future consultation.
KEY
This symbol identifies an action that occurs automatically as
a result of a previous action.
This symbol identifies additional information or a reference to
a different section of the manual containing the associated
information.
§
This symbol identifies a reference to a chapter of the manual.
This symbol accompanies important information concerning
the execution of the relevant operations.
Wire feeder WF-103 is designed for connection to a power source for
MIG/MAG welding.
The welding modes and procedures available are those indicated in
the table.
MODE
PROCEDURE
MMA
ARC AIR
MIG/MAG
TWO STEP (2T)
FOUR STEP (4T)
THREE LEVEL (3T)
2FRONT PANEL
1 2 3 4 5 6
1: EURO TORCH welding socket.
2: Connector for coolant hose.
Power source Torch
3: Connector for coolant hose.
Torch Power source
4: Pre-arrangement for flowmeter to adjust the gas (l/min) at the
torch outlet (purchasing and installing the relative kit).
5: Remote controller connector.
6: MMA clamp welding socket.

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3REAR PANEL
1 2
3 4 5
1: Gas rear connector. This is for the connection of the gas pipe
coming from the bundle of cables.
2: Cable bundle signal connector.
3: Male socket for the connection of the power cable coming from
the bundle of cables.
4: Connector for coolant hose.
Power source Cooler
5: Connector for coolant hose.
Cooler Power source
4INSTALLATION
WARNING!
Lifting and positioning
Read the warnings highlighted by the following symbols in the
“General prescriptions for use”.
Assemble the various units as described in the instruction manual of
the power source trolley.
4.1 PREPARING FOR MIG/MAG WELDING
1. Set the welding power source ON/OFF switch to “O” (unit de-
energized).
2. Connect the power source mains supply cable to the mains socket
outlet.
3. Secure the cable bunch connectors to the wire feeder.
4. Secure the cable bunch connectors to the welding power source.
5. Connect the power supply cable of the cooling unit to the auxiliary
power socket on the power source.
6. Connect the MIG/MAG torch coolant outlet and return hoses to
the coolant fittings on the wire feeder.
7. Connect the MIG/MAG torch coolant outlet and return hoses of
the cable bunch to the fittings on the cooling unit and on the wire
feeder.
8. Secure the cable bunch by fastening the locking device.
9. Connect the earth clamp plug to the power source earth socket.
10. Connect the earth clamp to the workpiece being processed.
11. Connect the MIG/MAG torch plug to the EURO TORCH welding
socket.
12. Set the welding power source ON/OFF switch to “I” to switch on
the unit.
13. Select the following welding mode on the user interface:
MIG/MAG.
4.2 PREPARING FOR MMA WELDING
1. Set the welding power source ON/OFF switch to “O” (unit de-
energized).
2. Connect the power source mains supply cable to the mains socket
outlet.
3. Secure the cable bunch connectors to the wire feeder.
4. Secure the cable bunch connectors to the welding power source.
5. Secure the cable bunch by fastening the locking device.

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6. Connect the earth clamp plug to the power source earth socket.
7. Connect the earth clamp to the workpiece being processed.
8. Choose the electrode based on the type of material and thickness
of the workpiece to be welded.
9. Insert the electrode in the electrode holder.
10. Connect the electrode holder clamp plug to the following welding
socket: MMA clamp welding socket.
11. Set the welding power source ON/OFF switch to “I” to switch on
the unit.
12. Select the following welding mode on the user interface: MMA
Installation

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4.3 WIRE SPOOL POSITIONING
1. Open the unit side door to gain access to the spool compartment.
2. Unscrew the cap of the spool holder.
3. If necessary, fit an adapter for the wire spool.
4. Fit the spool in the spool holder, ensuring it is located correctly.
5. Adjust the spool holder braking system by tightening/loosening the
screw in such a way that the wire feed force is not excessive and
when the spool stops rotating no excess wire is released.
6. Refit the plug.
4.4 POSITIONING THE WIRE IN THE WIRE FEEDER
1. Lower the wire feeder pressure devices.
2. Raise the wire feeder pressure arms.
3. Check that the feed rolls are suitable for the wire gauge.
§ 15.3 WIRE FEEDER ROLLS
The diameter of the roll groovemust be compatible with the
diameter of the welding wire.
The roll must be of suitable shape in relation to the composition of
the wire material.
The groove must feature a "U" profile for soft materials
(Aluminium and its alloys, CuSi3).
The groove must be "V" shaped for harder materials (SG2-SG3,
stainless steels).
Rolls with a knurled groove profile are available for flux-cored
wire.
4. Feed the wire between the wire feeder rolls and insert it into the
MIG/MAG TORCH connector plug.
5. Make sure the wire is located correctly in the roll grooves.
6. Close the wire feeder pressure arms.
7. Adjust the pressure system so that the arms press the wire with a
force that does not deform it while also ensuring constant feed
rate without slipping.
8. Set the welding power source ON/OFF switch to “I” (unit
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9. Feed the wire through the torch until it protrudes from the tip,
pressing button on the unit front panel.

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5USER INTERFACE
CODE
SYMBOL
DESCRIPTION
L1
When this LED illuminates the following parameter can be set: WIRE FEED RATE
The value appears on the following display: D1
L2
When this LED illuminates the following parameter can be set: WELDING CURRENT
The value appears on the following display: D1
L3
This LED illuminates to show an anomaly in the operating conditions.
An alarm message appears on the following display: D1-D2
§ 9 ALARMS MANAGEMENT
L4
When this LED illuminates the following parameter can be set: WELDING THICKNESS
(Reference is made to "T" fillet welds on identical thicknesses. The relative value is purely guideline).
The value appears on the following display: D1
L5
When this LED illuminates the following parameter can be set: WELDING PROGRAM
The value appears on the following display: D1
L6
Illuminates to show the last voltage and current values measured during welding.
The LED switches off when a new welding procedure is started, or when any of the welding settings is modified.
The value appears on the following displays: D1-D2
L7
Illuminates to show a value in the following unit of measurement: METRES PER MINUTE
Illuminates together with the following LED:
The value appears on the following display: D1
L8
Illuminates to show a value in the following unit of measurement: AMPERES
The value appears on the following display: D1
L9
Illuminates to show a value in the following unit of measurement: MILLIMETRES
Illuminates together with the following LED:
The value appears on the following display: D1
L10
This LED illuminates to confirm the presence of power on the output sockets.
L11
Illuminates to show that the cooling unit pressure switch does not detect any pressure.
L12
Illuminates to show a value in the following unit of measurement: SECONDS
The value appears on the following display: D2
L13
Illuminates to show a value in the following unit of measurement: VOLTS
The value appears on the following display: D2
L14
Illuminates to show a value in the following unit of measurement: PERCENTAGE
The value appears on the following display: D2
L15
Illumination shows that the following function has been activated: 2 times procedure
§ 13.1 2T MIG/MAG WELDING
L16
Illumination shows that the following function has been activated: 4 times procedure
§ 13.2 4T MIG/MAG WELDING

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L17
Illumination shows that the following function has been activated: 3 levels procedure
§ 13.3 3 LEVEL MIG/MAG WELDING
L18
This LED illuminates to show that the following welding mode is selected: MIG/MAG
L19
This LED illuminates to show that the following welding mode is selected: MMA
L20
This LED illuminates to show that the following welding mode is selected: ARC AIR
D1
During illumination of the following LEDs: / / /
The display shows the value of the selected parameter.
Welding: The display shows the effective amperes value during welding.
HOLD function (at welding end): The display shows the latest measured current value.
Menu function: The display shows the acronym of the parameter or function to be adjusted.
Programs setting: The display shows the message P “program no.”.
D2
Data setting: The display shows the value, in Volts, of the selected welding voltage.
Welding: The display shows the effective voltage value during welding.
HOLD function (at welding end): The display shows the latest measured voltage value.
Menu function: The display shows the value of the parameter or function to be adjusted.
Programs setting: The display shows the acronym of the material to be welded on the basis of the selected synergic curve.
S1
Manual MIG/MAG mode: The button cycles through the following LEDs in sequence, selecting only one: /
Synergic MIG/MAG mode: The button cycles through the following LEDs in sequence, selecting only one: / / /
Data setting: Hold down the button for 3 seconds to gain access to the second level menu.
§ 11.1.2 MIG/MAG PARAMETERS SETTING (2ND LEVEL)
S2
This button activates wire feed to insert it through the MIG/MAG torch.
The insertion speed is 2 m/min for 3 seconds, subsequently increasing to 10 m/min.
This function produces a slower feed rate and hence greater precision when inserting the wire when it enters the torch nozzle.
S3
This button opens the gas solenoid valve to fill the circuit and calibrate the pressure with the regulator on the gas cylinder.
S4
Press the button once to open the JOB upload menu.
Hold down the button for 3 seconds to gain access to the JOB save/delete menu.
§ 12 JOBS MANAGEMENT
S5
This button selects the torch trigger procedure.
S6
This button selects the welding mode.
E1
Data setting: The encoder adjusts the main welding (and synergy) parameter, shown on the following display: D1
Menu function: The encoder selects the function or parameter to be adjusted.
E2
Manual MIG/MAG mode: The encoder adjusts the welding voltage, and the relative value is shown, in volts, on the following display: D2
Synergic MIG/MAG mode: The encoder is used to correct the factory-set value of the selected synergic curve, the value of which is shown on
the following display: D2
POT1
Manual MIG/MAG mode: The potentiometer sets the inductance value.
Synergic MIG/MAG mode: The potentiometer sets the inductance value from the minimum to the maximum permissible value in accordance
with the selected synergic curve.
K1
Control release: When the key is in this position all the functions of the machine can be changed.
K2
Control lock: When the key is in this position, some functions of the panel are disabled.
The functions disabled depend on the blocking status selected.
§ 8.1 LOCKING PROCEDURE

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6UNIT POWER-UP
Set the welding power source ON/OFF switch to “I” to switch on the unit.
SEt GEn
The message appears on the following displays: D1-D2
The message appears only when the wire feeder is not selected as the remote control on the power source.
6.1 POWER SOURCE MANAGEMENT BY REMOTE CONTROL
Hold down the button for 3 seconds.
OPERATION TO BE PERFORMED ON THE POWER
SOURCE USER INTERFACE
The following LED illuminates on the power source panel:
The following message appears on the power source displays:
---
The power source is managed by the remote control connected to it.
The welding power source sets up for welding.
First power-up or power-ups following a RESET procedure
The welding power source sets up for welding with the factory presets.
Subsequent power-ups
The welding power source sets up for welding in the latest stable welding configuration that was active at the time of power-off.
7RESET (LOAD FACTORY SETTINGS)
The reset procedure involves complete restoration of the default values, parameters and memory settings set in the factory.
Too many changes made to the welding parameters so user finds it difficult to restore defaults.
Unidentified software problems that prevent the welding power source from functioning correctly.
7.1 TOTAL RESET
The reset procedure involves complete restoration of the default values, parameters and memory settings set in the factory.
All memory locations will be reset and hence all your personal welding settings will be lost!
Set the welding power source ON/OFF switch to “O” to switch the unit off.
S2
S6
Hold down both buttons simultaneously.
Set the welding power source ON/OFF switch to “I” to switch on the unit.
SIMULTANEOUS ACTIONS
rEC FAC
The message appears on the following displays: D1-D2

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8SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)
With locked status active it is not possible to access this function.
§ 8.1 LOCKING PROCEDURE
Set the welding power source ON/OFF switch to “O” to switch the unit off.
S1
Hold down the button.
Set the welding power source ON/OFF switch to “I” to switch on the unit.
SIMULTANEOUS ACTIONS
SEt UP
The message appears for a few seconds on the following displays: D1-D2
The acronym relative to the setting to be edited appears on the following displays: D1
The value relative to the selected setting appears on the following displays: D2
E1
Using the encoder, select the setting to be changed.
E2
Using the encoder, edit the value of the selected setting.
E1
Select the following setting with the encoder: ESC
S1
Press any button to save the setting and quit the menu.
Tab. 1 - Setup settings
ACRONYM
SETTING
MIN
DEFAULT
MAX
Coo
COOLER ACTIVATION
Aut
Aut
on
*1
rC
REMOTE CONTROLLER SELECTION
oFF
oFF
06
oFF
No control
03
n°1 potentiometer
04
n°2 potentiometers
05
n°1 UP/DOWN
06
n°2 UP/DOWN
LoC
ADJUSTMENTS BLOCK SELECTION
oFF
oFF
3
oFF
All adjustments enabled.
1
All adjustments are disabled with the exceptions shown in
Tab. 2 page 14.
2
All adjustments are disabled with the exceptions shown in
Tab. 2 page 14.
3
All adjustments are disabled with the exceptions shown in
Tab. 2 page 14.
PP
PUSH PULL
on
oFF
oFF
bb
SELECTION OF BURN TYPE
SPc (*2)
Std
Std (*3)
*1: Cooler activation
ON= The cooler is always running when the power source is switched on. This mode is preferable for heavy duty and automatic welding
procedures.
OFF= The cooler is always disabled because an air-cooled torch is in use.
AUT= When the unit is switched on the cooler is switched on for 15 s. During welding procedures the cooler runs constantly. When welding is
terminated the cooler continues to run for 90 s + a number of seconds equivalent to the average current value shown using the HOLD
function.
*2: Anti-sticking function present to prevent the wire from sticking.
*3: No wire sticking control, just final wire cut.

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8.1 LOCKING PROCEDURE
The procedure inhibits unit adjustments, allowing the user to modify only certain settings depending on the selected lock status.
The procedure is used to prevent accidental alteration of the unit settings and welding settings by the operator.
Enabling
If no locking status is selected (LOC = OFF) and if you wish to set up a limitation on use of the power source, display the LOC function in the
SETUP menu.
Open the Setup menu.
The acronym relative to the setting to be edited appears on the following displays: D1
The value relative to the selected setting appears on the following displays: D2
E1
Select the following setting with the encoder: LoC
E2
Use the encoder to select the required lock status.
E1
Select the following setting with the encoder: ESC
S1
Press any button to save the setting and quit the menu.
Tab. 2 - Functions not disabled by Locks
LOC
USER INTERFACE
RC03
RC04
RC05
RC06
oFF
All adjustments enabled.
Key K1 disabled.
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
1
Selection of torch trigger procedure (button S5)
Display of main welding parameters (button S1)
Arc correction (encoder E2)
Wire insertion (button S2)
Gas test (button S3)
Arc correction
(Potentiometer Pot2)
Arc correction (UP/DOWN
lever 2)
2
Selection of torch trigger procedure (button S5)
Display of main welding parameters (button S1)
Arc correction (encoder E2)
Synergy (encoder E1)
Wire insertion (button S2)
Gas test (button S3)
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
3
(*1)
Selection of torch trigger procedure (button S5)
Display of main welding parameters (button S1)
JOB selection (encoder E2)
Wire insertion (button S2)
Gas test (button S3)
Scroll JOBS (UP/DOWN
lever 1)
Scroll JOBS (UP/DOWN
lever 1)
*1: The LOC 3 setting becomes active only when a JOB is loaded. When no JOB is loaded, the user interface is completely unlocked.
Disabling
If a lock status is selected, you can only edit parameters permitted by the currently active lock status.
Open the Setup menu.
The acronym relative to the setting to be edited appears on the following displays: D1
The value relative to the selected setting appears on the following displays: D2
E1
Select the following setting with the encoder: LoC
E2
Select the following setting with the encoder: oFF
E1
Select the following setting with the encoder: ESC
S1
Press any button to save the setting and quit the menu.

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8.2 TORCH LOADING
WARNING!
Make sure the torch in use is correctly sized in relation to the welding current required and for the available and selected cooling type. This
prevents the risk of burns to which the operator is potentially exposed, potential faults, and irreversible damage to the torch and the system.
If a torch is installed or replaced while the unit is running, the circuit of the newly installed must be filled with coolant to avoid the risk of damage
to the torch in the case of high voltage arc strikes without any liquid in the circuit.
Power-up with operation of the cooler set to "ON" or "AUTO" mode
AL. COO.
The message appears on the following displays: D1-D2
(any)
Press the button or torch trigger to repeat the checking procedure for an additional 15 seconds.
If the problem persists rectify the cause of the alarm.
Power-up with operation of the cooler set to "OFF"
Operation of the cooler and the cooler alarm are disabled.
Welding is performed without liquid cooling of the torch.
Torch change-over with operation of the cooler set to "AUTO"
Press and release the torch trigger.
This serves to start the cooler for 15 seconds to fill the torch cooling circuit.
9ALARMS MANAGEMENT
This LED illuminates if an incorrect operating condition occurs.
An alarm message appears on the following display: D2
Tab. 3 - Alarm messages
MESSAGE
MEANING
EVENT
CHECKS
AL. HEA.
Overheating alarm
Indicates tripping of the welding power
source thermal protection.
Leave the unit running so that the
overheated components cool as rapidly
as possible.
When the unit has cooled, the welding
power source will reset automatically.
All functions disabled.
Exceptions:
-cooling fan.
-cooler (if switched on).
-Make sure that the power required by the
welding process is lower than the maximum
rated power output.
-Check that the operating conditions are in
compliance with the welding power source data
plate specifications.
-Check for the presence of adequate air
circulation around the welding power source.
AL. COO.
Cooler alarm
Indicates insufficient pressure in the torch
liquid cooling circuit.
All functions disabled.
Exceptions:
-cooling fan.
The alarm message persists on the display until the first operation is
performed on the user interface.
Cooler ON: the alarm is signalled as long as the unit alarm is active
and the cooler presence signal persists.
Cooler OFF: the alarm is never signalled, irrespective of the
circumstances.
Cooler AUTO: the alarm is signalled at the times in which the unit is
running; the alarm signal occurs as long as the unit presence signal
persists.
-Check that the connection to the cooler is
correct.
-Check that the O/I switch is set to I and that it
illuminates when the pump is running.
-Check that the cooler is filled with coolant.
-Check that the cooling circuit is liquid tight,
notably the torch hoses and the internal
connections of the cooler.
Err. C0
Err. C1
Err. C2
Err. C4
Err. C11
Err. C12
CAN BUS Communication Alarm
Indicates the presence of problems in
data communication between the power
source and wire feeder.
When the unit has cooled, the welding
power source will reset automatically.
Exit the alarm state by performing one of
the following actions:
Switch the power source off.
All functions disabled.
Exceptions:
-cooling fan.
-cooler (if switched on).
-Check that the connecting cable between
power source and wire feeder is intact and
make sure the connectors are securely
tightened.
Err. C69
Software Incompatibility Alarm
It triggers when the WF-103 software
release is incompatible with the power
source.
All functions disabled.
Exceptions:
-cooling fan.
-cooler (if switched on).
-In this event, update the software of the power
source.

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AL. Cur.
Overcurrent alarm
Indicates tripping of the welding power
source current surge protection.
All functions disabled.
Exceptions:
-cooling fan.
An audible signal will sound (buzzer).
Muting the audible signal:
-in torch trigger procedure 2T, release the torch trigger.
-in torch trigger procedure 4T or 3L the alarm mutes automatically
after 5 seconds.
Exit the alarm state by performing one of the following actions:
-press any button.
-switch the power source off.
-Check that the programmed arc voltage value
is not too high in relation to the thickness of the
work to be welded.
AL. Mot.
Motor alarm
It indicates the intervention of the
protection for the blocking of the wire
feeder motor.
All functions disabled.
Exceptions:
-cooling fan.
-cooler (if switched on).
-Check if the wire feeder motor is blocked by
some object.

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10 WELDING PARAMETERS
Welding inductance
Consequences of a higher value:
"Softer welding".
Less spatter.
Less positive starting.
Consequences of a lower value:
"Harder welding".
More spatter.
More reliable starting.
Hot Start
This function is useful when using aluminium alloy welding wire.
Consequences of a higher value:
Greater heat output.
Greater penetration.
Consequences of a lower value:
"Cold" weld bead.
Crater Filler
This parameter serves to obtain a uniform deposit at the end of the
welding process to fill the crater with a reduced wire feed rate to
facilitate the deposition of filler material.
By keeping the torch trigger pressed during the 3rd time, the wire feed
rate is reduced (crater filler speed) thereby ensuring optimal crater
filling, until the POST GAS time is started by releasing the torch
trigger (4Th time).
Consequences of a higher value:
Difficult crater filling (values greater than 100%).
Consequences of a lower value:
Cold welding (values close to 1%).
3 Levels Slope
Establishes the duration of the slope between the 1st and 2nd time
and between the 3rd and 4Th time.
Soft Start
Determines the wire feed rate before the arc strike.
Calculated as a percentage of the programmed wire feed rate.
In Synergic welding the optimal soft start value (indicated with SYN)
varies in general with variations of the synergic parameters.
In Synergic welding, if the value soft start = SYN is selected the
welding power source will always have the optimal soft start value set
when the main welding parameter changes.
If you set a value other than SYN, this value is stored and fixed.
Consequences of a lower value:
The start of welding is "softer".
Consequences of a higher value:
The welding start may prove difficult.
Motor Slope
Time required to switch from SOFT START speed to welding speed.
Bourn Back
The burn back value is associated with the quantity of wire that is
burnt at the end of the welding procedure.
In Synergic welding the optimal burn back value (indicated with SYN)
varies in general with variations of the synergic parameters.
In Synergic welding, if the value burn back = SYN is selected the
welding power source will always have the optimal burn back value
set when the main welding parameter changes.
If you set a value other than SYN, this value is stored and fixed.
Consequences of a higher value:
Wire significantly retracted into the torch nozzle.
Consequences of a lower value:
Stick-out at welding start is longer.
Post gas time
Time of post gas delivery when the welding arc is extinguished.
This is useful when welding at high current values or with materials
that oxidise readily to cool the weld pool in an uncontaminated
atmosphere.
In the absence of specific requirements the value should generally be
kept low.
Consequences of a higher value:
More effective pickling (improved appearance of workpiece at the
end of the welding pass).
Higher gas consumption.
Consequences of a lower value:
Lower gas consumption.
Oxidation of electrode tip (more difficult arc strike).
Pre gas time
Time of gas delivery before the arc strike.
Consequences of a higher value:
This parameter allows a shielded environment to be created,
thereby eliminating contaminants at the start of the welding pass.

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10.1 PARAMETERS ACTIVATION
The welding parameters are available in accordance with the selected welding mode and procedure.
Certain parameters are available only after other parameters or functions of the unit have been enabled or set.
The table shows the settings required to enable each parameter.
: always available
1: not enabled with manual program P0.
MENU
MODE 

PROCEDURE 
PARAMETER 
-
Working voltage


1
-
Welding inductance


1
1°
WIRE FEED RATE


1
1°
WELDING CURRENT
1
1
1
1°
THICKNESS
1
1
1
1°
PROGRAMS


1
2°
Hot Start
1
2°
Crater Filler
1
2°
3 Levels Slope
1
2°
Soft Start


1
2°
Motor Slope


1
2°
Bourn Back


1
2°
Post gas time


1
2°
Pre gas time


1

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11 WELDING SETTINGS
11.1 MIG/MAG WELDING
S6
Use this button to select one of the following welding modes:
MIG/MAG
S5
Use this button to select one of the following torch trigger procedures:
2 STEP
4 STEP
3 LEVEL
11.1.1 SETTING MIG/MAG PARAMETERS (MAIN WELDING PARAMETERS)
S1
Press this button to scroll the list of settings to edit.
The LED associated with the selected setting will illuminate.
The value relative to the selected setting appears on the following displays: D1
The following settings are available:
WIRE FEED RATE
AMPERES
THICKNESS
PROGRAMS
E1
Using the encoder, edit the value of the selected setting.
The value is saved automatically.
E2
Using the encoder, edit the value of the following setting: WORKING VOLTAGE
The value is saved automatically.
POT1
Using the potentiometer, edit the value of the following setting: WELDING INDUCTANCE
Tab. 4 - Main welding parameters in MIG/MAG mode
PARAMETER
MIN
DEFAULT
MAX
WIRE FEED RATE
1.5 m/min
5.0 m/min
22.0 m/min
MIG/MAG WELDING CURRENT
-
Syn
-
*1
THICKNESS
-
Syn
-
*1
PROGRAMS
P0
P0
P40
WORKING VOLTAGE
10.0 V
20.0 V
40.0 V
WELDING INDUCTANCE
0
-
255
Tab. 5 - Programmed synergic curves
WIRE DIAMETER
ACRONYM
WIRE MATERIAL (GAS MIXTURE)
0.8
1.0
1.2
1.4
1.6
PROGRAMS
P0
P0
P0
P0
P0
MAn
MANUAL
P1
P2
P3
--
P4
FE
SG2/SG3 (80%Ar-20%CO2)
P5
P6
P7
--
P8
FE
SG2/SG3 (92%Ar- 8%CO2)
P9
P10
P11
--
P12
FE
SG2/SG3 (100%CO2)
P13
P14
P15
--
--
S.S.
INOX 308 (98%Ar-2%CO2)
P16
P17
P18
--
--
S.S.
INOX 316 (98%Ar-2%CO2)
--
P19
P20
--
P21
AL
AlMg5 (100%Ar)
--
P22
P23
--
P24
AL
AlSi5 (100%Ar)
P25
P26
P27
--
--
CU.S.
CuSi3 (100%Ar)
P28
P29
P30
--
--
CU.A.
CuAl8 (100%Ar)
--
--
P31
P32
P33
rFC
RFCW (80%Ar-20%CO2)
--
--
P34
P35
P36
bFC
BFCW (80%Ar-20%CO2)
--
--
P37
P38
P39
MFC
MFCW (80%Ar-20%CO2)
P40
P40
P40
P40
P40
nPr
FREE PROGRAMS
*1: SYN= By synergy we mean a simple and fast way to regulate the generator. Through this function, an optimum balancing of all the welding
parameters in every position can be granted, thus helping the user.
This is the reason why the synergic curves of most of the wire types have been introduced, however these curves can be easily modified so
as to allow the user to optimise his own welding procedure.
NOTE: The synergic curves were created with reference to a fillet weld in position PB (horizontal-vertical) with 10 mm stick-out (distance from
torch to workpiece).

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11.1.2 MIG/MAG PARAMETERS SETTING (2ND LEVEL)
S1
Hold down the button for 3 seconds to gain access to the 2nd level menu.
The acronym relative to the setting to be edited appears on the following displays: D1
The value relative to the selected setting appears on the following displays: D2
E1
Use the encoder to scroll the list of settings to edit.
E2
Using the encoder, edit the value of the selected setting.
Press any button to save the setting and quit the menu.
Tab. 6 - 2nd level menu parameters in MIG/MAG mode
ACRONYM
PARAMETER
MIN
DEFAULT
MAX
H.-S.
HOT START
0 %
130 %
200 %
C.-F.
CRATER FILLER
0 %
80 %
200 %
S.3L.
3 LEVELS SLOPE
0.1 s
0.5 s
10.0 s
S.-S.
SOFT START
10 %
30 %
100 %
*1
SLO.
MOTOR SLOPE
0 ms
50 ms
200 ms
*1
b.-b.
BOURN BACK
0 ms
25 ms
100 ms
*1
11.1.3 MIG/MAG PARAMETERS SETTING (GAS MENU)
S3
Hold down the button for 3 seconds to gain access to the 2nd level menu.
The acronym relative to the setting to be edited appears on the following displays: D1
The value relative to the selected setting appears on the following displays: D2
E1
Use the encoder to scroll the list of settings to edit.
E2
Using the encoder, edit the value of the selected setting.
Press any button to save the setting and quit the menu.
Tab. 7 - Gas menu parameters in MIG/MAG mode
ACRONYM
PARAMETER
MIN
DEFAULT
MAX
Po.G.
POST GAS TIME
0.0 s
0.3 s
10.0 s
*1
Pr.G.
PRE GAS TIME
0.0 s
0 s
10.0 s
*1
*1: When a synergic program is loaded the default value of the parameter is defined automatically by the software and the message "SYN" will
be shown on the display.
11.2 ELECTRODE WELDING (MMA)
S6
This button serves to select the following welding mode:
MMA
E1
Using the encoder, edit the value of the following setting: WELDING CURRENT
Tab. 8 - Main welding parameters in MIMA mode
PARAMETER
MIN
DEFAULT
MAX
WELDING CURRENT
5A
80A
400A
*2
5A
80A
500A
*3
11.3 ARC AIR (DESEAMING)
S6
This button serves to select the following welding mode:
ARC AIR
E1
Using the encoder, edit the value of the following setting: DESEAMING CURRENT
Tab. 9 - Main welding parameters in ARC AIR mode
PARAMETER
MIN
DEFAULT
MAX
WELDING CURRENT
5A
80A
400A
*2
5A
80A
500A
*3
*2: In the 400 Ampere version.
*3: In the 500 Ampere version.