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6.0 Operation

Switch on the machine using the mains on/off switch, this lights the
front panel.

You can MIG weld in 2 modes Manual and Synergic the manual
mode takes more skill to setup.

Synergic MIG

Select the Synergic MIG mode using button

6.1 Operation Selecting the JOB

Press and hold JOB button for 5 seconds (7) until the left display
says JOB rotate the right hand knob until the correct JOB number is
displayed. Refer to the inside of the wire feeder door for lob list.

Note Job list is shorter with Rapid panel and you should select
material and wire size on the front panel using buttons 10 and 11.

Adjusting the Function. Press and hold the F button (3) for 5 seconds
and the left display will show the F number which can be adjusted
by rotating the left knob 4 and the value will be displayed in the right
display and can be adjusted with the right hand knob.

Press the F button (3) briefly to display wire speed, material
thickness or Amperage depending on your preference and then
rotate the left knob (4) until you reach the required value. You are
ready to weld, If you prefer to alter the welding voltage you can trim
it up or down by rotating the right knob (8) and the V+/- light will
illuminate.

Switch off the synergic light or with Rapid panel toggle off the using
F function.

Manually adjust the Wire speed and welding voltage using the rotary
knobs 4 and 8. Note in manual mode you must adjust the voltage
to increase or reduce penetration and the wire speed to balance
the heat input. (Synergic mode is preferred for operation in all
operations)

6.2 Operation (2T)

Select 2T operation on the front panel.

Depress the trigger and hold on.

Pre-gas will start (adjust with F30)

Then arc will start

At the end of the weld release the trigger and the arc stops.

The wire stick out can be adjusted by changing burn back time
(F41)

The post gas flow can be adjusted as required (F43)

12

6.3 Operation (4T)

Select 4T operation on the front panel

Depress the trigger and hold

Pre-gas will start and stay on

Release the trigger the arc will start and continue

At the end of the weld depress and hold the trigger, the final
current will start (F39) and will stay on until the trigger is
released which starts post gas (F43)

6.4 Operation (S4T)

Select 4T operation on the front panel

Depress the trigger and hold

Pre-gas will start and stay on (F30)

Hot start current will start (F32)

Release the trigger the arc will change to the normal power level
and continues

At the end of the weld depress and hold the trigger, the final
current will start (F39) and will stay on until the trigger is released
which starts post gas (F43)

6.5 Operation Smart Trigger

Smart trigger allows the user to change memory programs quickly
from the torch without having to return to the machine. Store the
required programs starting at memory location 01, 02 etc.

Using F47 set the number of memories you wish to use for smart
trigger. If you wish to use 4 different settings in memory 01, 02, 03
and 04 then set F47 value to 04 and smart trigger will only cycle
through memory 01 to 04.

Ensure the front panel of the machine is set to 4T or S4T operation.

Set the value of F46 to 01 to switch on smart trigger.

Now if you give the trigger a short press (less than 1 second) it will
select the next memory program within the limit set by F47. Another
short press moves to the next memory location etc.

I

Summary of Contents for Pulse-Expert M-400S

Page 1: ...www masterweld co uk M 400S M 500S M 600S Pulse Expert OPERATOR MANUAL ISSUE 1...

Page 2: ...achine Please take time to read the Safety precautions They will help you protect yourself against potential hazards in the workplace With proper maintenance this equipment should provide years of rel...

Page 3: ...Drive Roll Sets 10 5 10 Welding Wire Installation 10 5 11 Torch Installation 11 5 12 Work Return Lead Connection 11 5 13 Shielding Gas Connection 11 6 0 Operation 12 6 1 Operation Selecting the JOB 1...

Page 4: ...o manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to work piece or worktable as near the weld a...

Page 5: ...cemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipmen...

Page 6: ...ned AC and DC power unit 20 Internal combustion engine generator 21 Internal combustion engine generator rectifier 22 Supply circuit number of phases e g 1 or 3 alternating current symbol and declared...

Page 7: ...ont protector Rear View 1 Connection Trigger socket 2 Communication socket 3 Power supply welding current connection socket 4 Coolant back flow connection Red 5 Cooling water forward flow connection B...

Page 8: ...www masterweld co uk 4 3 Device Control 8 12 13 14 9 10 11 12 13 14 6 15 16 17...

Page 9: ...r MIG welding with GAS 5 5 Torch Cooling Coolant liquids The use of unsuitable coolants will result in damage and void the manufacturer s warranty Only use the coolants specified in this manual Do not...

Page 10: ...on the outward facing side of the roller as it is refitted NOTE Be sure that the torch liner and contact tip are also sized to match the selected wire size 5 10 Welding Wire Installation As a factory...

Page 11: ...er source 1 Remove the tip adaptor and contact tip 2 Inch the wire from the exit of the wire guide on the feed unit as Figure 1 Ensure that it does not short out on any machine panels Fig 2 3 Carefull...

Page 12: ...on 2T Select 2T operation on the front panel Depress the trigger and hold on Pre gas will start adjust with F30 Then arc will start At the end of the weld release the trigger and the arc stops The wir...

Page 13: ...r approximately 1 second to calibrate the circuit resistance The correction figure will be shown in the PH display millivolts Material thickness determines weld parameters 1 Convert Material Thickness...

Page 14: ...from vertical lift the torch up from the work piece to draw out an arc To prevent melting of the end of the tungsten so this in a smooth rapid movement 6 9 Additional Functions 6 9 1 Memory function...

Page 15: ...their alloys longer life more stable arc easier starting wider current range narrower more concentrated arc GREY Guide for Selecting Filler Wire Diameter Filler wire diameter DC current range 1 16 1...

Page 16: ...tion of synergic MIG programs available to the welding industry covering a wide range of materials and welding processes Please choose from the below list of Jobs that have been written for these mate...

Page 17: ...www masterweld co uk 17...

Page 18: ...Pulse Lower Arc Correction 9 9 9 9 Volts F39 Crater Fill 30 100 F40 Crater Fill Arc Correction 9 9 9 9 Volts F41 Burn Back Control 0 15 Range F42 Wire Stick Out 0 15 Range F43 Post Gas 0 5 0 Seconds F...

Page 19: ...wire feed speed Improper welding technique Place stringer bead in proper locations at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on gro...

Page 20: ...sive wire spool brake tension Incorrect liner Blocked liner Bird nesting Burn back Bird nesting Excessive feed roll pressure Incorrect or blocked liner Incorrect contact tip size Contact tip overheati...

Page 21: ...are parts the machine type serial number and model number of the machine type identification and product number of the spare part must be specified General This device is largely maintenance free and...

Page 22: ...uthorised Service centre E5 IGBT Thermic Error Ensure that the Power Unit Fan is operating Wait 15 20 minutes without welding machine on If the problem persists notify the Authorised Service E6 Diode...

Page 23: ...ections Max Outlet Pressure 3 0 Bar 8 2 Feed Rolls Part No Description Application MW 1810 0810V D ROLL 0 8 1 0 V GROOVE 0 8 1 0 Hard Wires MW 1810 1012V D ROLL 1 0 1 2 V GROOVE 1 0 1 2 Hard wires MW...

Page 24: ...400S Pulse Expert MasterWeld M 500S Pulse Expert MasterWeld M 600S Pulse Expert The above listed products are certified to be compliant with the RoHS directive with all homogeneous component parts bei...

Page 25: ...the product determined by MasterWeld to be defective MasterWeld makes no other warranty express or implied This warranty is exclusive and in lieu of all others including but not limited to any warran...

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