Top Gun SYN 2500 PULSE User Manual
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Top Gun SYN 2500 PULSE User Manual

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USER MANUAL
SYN 2500 PULSE

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  • Page 1 USER MANUAL SYN 2500 PULSE...

  • Page 2: Table Of Contents

    SYN 2500 PULSE USER MANUAL Please read carefully this user manual before using this machine Keep it for the future use. MANU SAFETY APPLICATION DESCRIPTION OF THE MACHINE TECHNICAL DATA OF THE DEVICE DEVICE CONNECTION - WELDING POLARITY SETTING PANEL OPERATION-GENERAL...

  • Page 3: Safety

    SYN 2500 PULSE USER MANUAL 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.
  • Page 4 SYN 2500 PULSE USER MANUAL 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.
  • Page 5 SYN 2500 PULSE USER MANUAL 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.

  • Page 6: Application

    SYN 2500 PULSE USER MANUAL 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.

  • Page 7: Device Connection - Welding Polarity Setting

    SYN 2500 PULSE USER MANUAL 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)
  • Page 8 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.
  • Page 9 SYN 2500 PULSE USER MANUAL ◼ 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.
  • Page 10 SYN 2500 PULSE USER MANUAL 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.

  • Page 11: Panel Operation-General

    SYN 2500 PULSE USER MANUAL 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.
  • Page 12 SYN 2500 PULSE USER MANUAL Function Function Return Execute 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)).
  • Page 13 SYN 2500 PULSE USER MANUAL 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...
  • Page 14 SYN 2500 PULSE USER MANUAL 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.

  • Page 15: Synergy Mode For Mag/Mig

    SYN 2500 PULSE USER MANUAL 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).
  • Page 16 SYN 2500 PULSE USER MANUAL 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.

  • Page 17: Mig Operation

    SYN 2500 PULSE USER MANUAL 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.
  • Page 18 SYN 2500 PULSE USER MANUAL 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.
  • Page 19 SYN 2500 PULSE USER MANUAL Page 19...
  • Page 20 SYN 2500 PULSE USER MANUAL 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.
  • Page 21 SYN 2500 PULSE USER MANUAL F. MIG / MAG WELDING WITH PULSE In order to start welding in MIG / MAG PULS mode, the settings should be made as in the previous chapter. Additional welding parameters in pulse welding mode are presented in the...
  • Page 22 SYN 2500 PULSE USER MANUAL G. MIG / MAG WELDING WITH DOUBLE PULSE To start welding in MIG / MAG mode, double PULSES should be pre-set as in the BASIC MIG / MAG SETTINGS chapter. Additional welding parameters in mode double pulse current welding is...
  • Page 23 SYN 2500 PULSE USER MANUAL Setting the minimum wire feeder speed ATTENTION! When adjusting this parameter, you can refer to the dynamic thickness data that shown on the left, until the data match with the real thickness of the workpiece. or change a little bit as you need.

  • Page 24: Tig Operation

    SYN 2500 PULSE USER MANUAL I. MIG Setting Chart MIG Welding Current-Wire Diameter And Plate Thickness Chart Wire diameter Plate thickness 10.0 Wire speed（M/min） AL-Si1.0/(4043) Welding current (A) (DCEP) Arc voltage 16.0 18.3 19.2 21.0 22.5 23.6 Wire speed（M/min） AL-Si1.2/(4043) Welding current (A) 27.0...
  • Page 25 SYN 2500 PULSE USER MANUAL TIG Welding In the TIG (Tungsten Inert Gas) method, the electric arc strikes under an inert gas (argon) shield, between the welded element and the non-fusible electrode made of pure tungsten or tungsten with additives.

  • Page 26: Mma Operation

    SYN 2500 PULSE USER MANUAL WELDING POLARITY IN THE TIG METHOD Negative polarity is used for most TIG welding operations. The welding gun is connected to the negative pole, while the earth gun is connected to the positive pole. In this way, the electrode consumption is reduced, the amount of heat accumulated in the welded material increases.
  • Page 27 SYN 2500 PULSE USER MANUAL MMA WELDING Arc welding is also called the MMA (Manual Arc Welding) method and is the oldest and most versatile arc welding method. The MMA method uses a coated electrode, consisting of a metal core covered with a lagging. An electric arc is created between the end of the electrode and the material being welded.

  • Page 28: Error Code

    SYN 2500 PULSE USER MANUAL Welding current setting Adjust the welding current by spin the knob. 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...

  • Page 29: Eletricity Safety Guidlines

    SYN 2500 PULSE USER MANUAL 8. ERROR CODE In special cases, the following messages may appear on the display indicating a problem with the operation of the device. Errors on the display will appear until the defect is removed. Error 001 Over current The device is operated beyond its rated efficiency.

  • Page 30: Electricity Diagram

    SYN 2500 PULSE USER MANUAL 9. ELECTRICITY SAFETY GUIDELINES WORKING CONDITIONS Optimal ambient temperature between -10 ° C and 40 ° C. Avoid welding in sunny conditions and when it is raining, do not allow water to get inside the device.
  • Page 31 SYN 2500 PULSE USER MANUAL 10 . ELECTRICAL DIAGRAM Page 31...

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