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User Guide - Ultra 220MP Pulse MIG Welder
Date: 27-08-2021
The Inside Tack
The complete operators guide for the Weldclass Ultra 220MP Pulse MIG welder.
VIEW ONLINE / WEB VERSION OF THIS MANUAL
1. An introduction to Pulse MIG
What is Pulse? A highly-controlled spray-transfer MIG process. Unlike the traditional 'short-circuit' MIG
process (where the wire contacts the weld pool), with pulse welding the ller metal is transferred from
the wire to the weld pool, without the wire contacting the weld pool. The current alternates, or pulses,
between a high peak current and a low background current at a frequency of up to several hundred
times per second. With each pulse, the peak current pinches off a droplet of wire and propels it to the
weld joint, while the background current maintains the arc at a low enough power level so that short-
circuit can't occur.
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Summary of Contents for Weldclass Ultra 220MP Pulse
- Page 1 User Guide - Ultra 220MP Pulse MIG Welder Date: 27-08-2021 The Inside Tack The complete operators guide for the Weldclass Ultra 220MP Pulse MIG welder. VIEW ONLINE / WEB VERSION OF THIS MANUAL 1. An introduction to Pulse MIG ...
- Page 2 Why Pulse? Among other bene ts, Pulse MIG is best known (or desired) because it offers; Spatter is signi cantly reduced, or even eliminated = minimal cleanup Lower heat = minimal distortion, reduced burn-through on thin materials Visually appealing welds = added value to the nished product Higher deposition rates = increased e ciency &...
- Page 3 How to t te on (aluminium) liners If you are welding with steel or stainless-steel wire 0.9mm or above, you will need to buy and t a steel 0.9-1.2mm 'red' liner (Weldclass part no. P3-BRSL3). How to t steel liners ...
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Page 4: Material Thickness
Why is the MIG torch 3m? The remote-control MIG torch supplied with the 220MP is 3m long. This is the optimum length for successful & consistant wire feeding of aluminium, which is critical in pulse applications. If you need a torch longer than 3m, we recommend the Weldclass 8m push- pull torch. - Page 5 The 220MP does not currently offer a ø0.9mm aluminium wire program, for the above reasons. If there is some reason why you cannot avoid using ø0.9mm wire, we suggest using the ø1.0mm program. Weldclass Aluminium MIG Wire...
- Page 6 Stainless Steel Wire [Ss] The 220MP has programs for running 0.8mm, 0.9mm & 1.0mm stainless wires. All these wire sizes will weld down to approx 0.5-0.8mm material thickness, depending on the program. 0.8mm & 0.9mm are the most popular / common wire sizes. Steel Wire [Fe] While 3-phase pulse machines are used for welding heavy steel, pulse is not a recommended process for welding of mild steel in the thickness range that is achievable with single-phase power.
- Page 7 It is important to select the right drive roller type to match the wire you are using. Aluminium wires: Use U-groove roller (a v-groove roller will squash softer Aluminium wire out of shape). The 220MP is supplied with a 1.0/1.2mm U-groove roller. Solid Steel &...
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Page 8: Contact Tips
7. Wire Feed Tension Arm Tension should be enough to maintain consistent wire feed with no drive roller slippage, but no more. Avoid the temptation to wind up / increase the tension as "instant x" for wire feed issues. Excessive feed tension will not only cause premature wear of the drive roller, bearings and motor/gearbox - but it can also 'squash' the wire out of shape and make the problem worse. ... -
Page 9: Loading Wire
The optional Platinum PP365 Push-Pull MIG torch has been con gured speci cally for use with the 220MP and is ready to 'plug & play'. View details of this torch here and contact your Weldclass distributor for pricing & supply. - Page 10 carefully feed the wire into the handpiece without birds-nesting. A second person holding and twisting the handpiece, whilst manually feeding, may also help. Calibrate Wire Feed Speed The inline drive capsule mounted on the multi-pin push-pull torch lead synchronises the wire speed of the torch motor to the wire feed of the 220MP machine, so that both are 'relative'. ...
- Page 11 12. Controls, Modes & Settings [Popular] Control Panel MIG Functions & Settings: MIG Manual Non-pulse conventional MIG mode, where Voltage & Wire Speed (amps) are set independently. Synergic Machines with Synergic controls are pre-programmed with intelligent data that allows the operator to rst select the wire type/size, material type and gas type, and the machine will then automatically adjust voltage and amps/wire speed together based on the material thickness selected. Except for 'Manual', all other MIG modes on the 220MP are Synergic, including: MIG Synergic (non-pulse...
- Page 12 AB PoP Stands for Pulse-on-Pulse, or Double-Pulse mode. Adds an additional pulse wave, where the current alternates (or cycles) between the main current level [I2] and a secondary current level [I1]. In addition to the bene ts of single pulse, this allows for aesthetic welds and cooler weld pool, especially useful when welding out-of-position (such as vertical and overhead).
- Page 13 Secondary Current [I1] Also known as Background Current. Used in PoP (double pulse) or AB (single) Pulse with Bi-level trigger mode. Set as a % of main current [I2]. Typically this will be lower than the main current (<100%) for a cooler weld pool. Adjustable from 0% to 200% (or maximum machine output). End Current [IE] ...
- Page 14 increase 'heat'. Ajustable from 1-100%. Arc Length Also known as arc control or trim. Adjusts the distance from the end of the wire to the weld pool*. If arc length is too short (longer wire stick out) the arc will be very 'crackly' and produce a lot of spatter. Typically, a longer arc (shorter wire stick out) will result in a more uid weld pool, atter weld pro le &...
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Page 15: Trigger Modes
weld. Adjustable from 0-1.0sec, in 0.01s increments. Soft-Start / Hot-Start Available in Manual MIG mode only*. When a weld is started, the workpiece and the wire will be cold compared to welding temperature, and if full wire speed is applied immediately this can cause an uneven and poor start to the weld. - Page 16 Clean materials thoroughly before welding: Always clean the base material thoroughly before welding. Any oxide on the aluminum surface should be removed with a stainless-steel wire brush Weldclass Wire Brush Range Push Technique: Use push (rather than drag) torch technique Earth and Cables: For successful pulse welding, it is absolutely critical that there is no disruption or "leakage"...
- Page 17 The screen will display 3 lines of code as below. Do the numbers shown below in blue match your machine? Yes: you already have the latest version No: you have an older version, please update as per instructions below CODE: XXXXXXXX CRC: 296E CODE: XXXXXXXX CRC: C6E7 CODE: XXXXXXXX CRC: 9277 How to update to latest program version: ...
- Page 18 In MMA (stick welding) mode, the 220MP is suitable for running most types of common electrodes up to 4.0mm. A stick welding lead (Weldclass part number WC-06233) will be required to set up the 220MP for stick welding. MMA adjustments: Main current [I2]: Adjustable from 20 to 160 Amps.
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Page 19: Errors & Troubleshooting
Note that the 220MP is NOT suitable for TIG welding of aluminium, as this requires machines with AC/DC TIG function - such as the Weldclass 202T AC/DC TIG welder. TIG Welding Guide 19. Errors & Troubleshooting Error or Fault... - Page 20 Aluminium, which is especially critical in pulse applications. If you need a torch longer than 3m, we recommend the Weldclass Platinum PP365 8m Push-Pull torch. If welding with steel or stainless-steel wires, a standard 4m torch can be used if required. For this we recommend the Promax BZL 25 torch.
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