Pulse Mig Operation - Everlast POWER i-MIG 253DP Operator's Manual

Section 2
The Power i-MIG 253DPi pulse design features
both Single and Double Pulse wave forms that
feature synergic control of the pulse parame-
ters. Simply put, this means that the compli-
cated parameters required to perfect the pulse
action of the welder are controlled largely by
an algorithm designed and tested by qualified
welding engineers to provide smooth and well-
regulated welding performance. To under-
stand the Everlast Pulse MIG design and setup,
it is important to recognize and discuss basic
types of Pulse MIG welding and how each is
performed and managed.
The Types of Pulse MIG Welders. There are
many different types of pulse MIG welders.
Every brand has their own type or types of
pulse MIG welders. Over the years, pulse MIG
welders have changed in design and function
and multiple types of Pulse MIG may be repre-
sented under one brand. Many times it is diffi-
cult to pinpoint the differences in the pulse
function from generation to generation or
model to model as many companies prefer to
explain the effects rather than the functions.
There are nomenclature differences as well
from brand to brand and model to model. One
function may be called by one name by one
company, while the same function is called by
another name by another company. Some
offer more fine tuning control over the param-
eters than others. Over the years pulse MIG
welders have steadily evolved. This has creat-
ed a lot of confusion and misunderstanding in
the industry by users about what pulse MIG
welding is and what it is capable of. Training
seminars provided to dealers of one type of
brand may indeed teach that a Pulse MIG prod-
uct feature is unique or special by trademark-
ing a name of a type of Pulse or Pulse function,
while another brand has the same exact fea-
Setup Guide and component Identification

PULSE MIG OPERATION

ture but is called by another name. It has lead
to a lot of confusion in the industry. However,
to be clear, there are two major categories of
pulse MIG welders: single (or simple) pulse,
and double (or pulse-on-pulse) pulse. With
most single-pulse MIGs, the power is pulsed
between two preset values, creating a simple,
modified square wave output of DC. With a
double-pulse MIG, the unit simply pulses be-
tween a higher layer and a lower layer of sin-
gle pulse MIG. In the most simple terms, this
creates a more complex wave form which
looks and sounds different than a single pulse
square (up and down) wave form. The main
advantage of using the double pulse MIG, is
potential for aesthetically pleasing welds that
closely approximates the "stack-of-dimes"
look desired in high-quality finished welds.
When it is properly set-up, a Double Pulse MIG
creates a pattern of defined separation in the
cooled weld similar to what you'd expect to
find in a well-crafted TIG weld. Though the
completed look of a double-pule MIG weld
may be similar and appealing to TIG, a trained
eye can still spot the difference. However,
whether or not it is 100% identical looking to
TIG, double-pulse MIG provides a visually ap-
pealing weld that stands up to the scrutiny and
expectations of most customers. Depending
upon how the unit is fine-tuned and how well
practiced the operator is, an additional meas-
ure of heat control can also be gained through
the double pulse MIG process.
The Basic Theory and Purpose Behind Single
Pulse-MIG. Regardless of the type of pulse
MIG we are referring to, most single-pulse
MIG welders are cycling several times a sec-
ond between high and low values of voltage.
Many single pulse-MIG welders cycle between
20-500 Hz. This allows good control over the
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