HTP Pro Pulse 220 MTS, Owner'S Manual

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11
The Programs—Overview
The Pro Pulse 220 MTS offers 22 synergic programs, both with and without pulse, as well as a manual mode. The
manual mode operates just like a classic MIG machine with wire speed adjustment in IPM (from 55 to 629) and
voltage adjustment (from 13.0 to 35.0). Manual mode can be used for wire types not included in the synergic
programs list (e.g., cast iron wire). Please obtain the correct settings from your wire distributor or manufacturer.
The synergic, non-pulse programs sound very similar to classic MIG welding. These programs offer inductance
adjustments, which makes the arc crisp or soft. On inverter-based machines, changing the arc characteristics is a
desired feature, while on classic transformer-based machines, adjustments like this are not offered.
The pulse programs are also fully synergic (the wire speed/voltage ratio is synergic as well as all of the pulse
parameters), but they sound different than classic MIG welding; the sound when pulse welding changes with the
material thickness (wire feed speed). These programs offer a slope down function, which can be used to fill craters at
the end of aluminum welds.
Both pulse and non-pulse programs offer adjustment in start speed (wire run-in), speed and duration, along with burn
back and pinch. The start speed offers the ability to set a crisp arc ignition without a “machine gun” start. Burn back
determines how long the wire sticks out of the contact tip when the weld is completed and the machine has stopped
welding. The lower the number on burn back, the longer the stick out ( ATTENTION: High numbers can cause the
wire to burn back into the contact tip, destroying it ). Pinch r efers to the shape of the wire; when MIG welding
(classic), a ball usually forms at the end of the wire upon completion of the weld. Then, you typically trim the ball off
with a pair of pliers. However, the Pro Pulse 220 MTS can do that for you, electrically, by setting the pinch. The
higher the pinch number, the more the wire gets trimmed electrically ( ATTENTION: The number required will
change by type and diameter of wire. Also, numbers higher than 75 can cause burn back when welding with
aluminum wire ).
Regardless of whether you are running a synergic or a pulsed program, the pre– and post– gas flow can also be
adjusted. Pre-flow ensures shielding gas is already in place when the welding arc starts, which minimizes or
eliminates porosity, discoloration, and/or peppering. Post-flow shields hot, glowing wire from contamination through
ambient air and also protects the weld (as long as the torch is kept in place for the post-flow duration after the weld is
completed). This function is extremely helpful when welding stainless steel and aluminum.
Welding Aluminum with the Pro Pulse 220 MTS
The Pro Pulse 220 MTS offers several different programs for welding aluminum. All of the programs are designed to
get the best results using 100% Argon gas. For aluminum welding, the use of a shallow or wide V-shaped (sometimes
referred to as U-shaped) drive roll is required, and the tension on the wire feed unit has to be properly adjusted.
Aluminum wire requires very little tension. A setting just less than 1 will be absolutely sufficient. If higher settings
are chosen, wire feed issues, such as deformation of the wire, wire getting stuck in the contact tip, burn backs, and
birds nesting, will arise. Aluminum shavings will also be deposited in the liner, which will clog up the liner.
The use of long-life contact tips is strongly recommended. Contact tips that are not specifically labeled AL for
aluminum welding can be used but need to be .005” bigger than normal (e.g., .040” tips for .035” wire). When using
contact tips labeled AL, use the tip size that matches your wire diameter size; the tip manufacturer already
compensated the actual size versus the nominal size.
Aluminum wire should be fed through a designated gun if cross contamination is a concern. While 5356 alloy
aluminum wire may be fed through a 10’ torch cable (providing the liner is in good condition and the cable is held as
straight as possible), 4043 wire needs to be fed through an 8’ torch cable. Teflon, or better, Graphite liners are
available and should be used for aluminum welding.
Flush tips or slightly recessed tips (tip holders) can be used for aluminum welding or stainless steel welding. To
improve shielding gas coverage, we suggest the use of a cylindrical nozzle for better gas distribution.
Please see the instructions that came with your aluminum wire for shielding gas flow rates and CTWD. A good gas
flow rate starting point for welding aluminum is about 35-50 CFH, but depends on wire diameter, nozzle shape,
nozzle size, etc., and a good CTWD starting point for welding aluminum is about 3/4” to 1”. The pinch function
needs to be set lower than 75 (when using .035” aluminum wire) to prevent burn backs (our suggestion is to start at