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Section 1
up. If helpful for setting up the unit, the numbers 1
-10 can be thought of as representing 10%-100% of
full output for either voltage or wire speed. For
each wire diameter, most users will find 3 to 5
settings that will fit their welding style and applica-
tions but often the ability to fine tune these settings
for specific applications will be needed. At first,
some experimentation will be necessary. The fol-
lowing method of setting up wires peed and voltage
is commonly used by professionals in the industry
to setup almost any type MIG. When setting up
welding parameters, set the wire speed halfway
then begin to lower the voltage until it begins to
cold feed into the metal (also referred to as stub-
bing). Note the point where it begins to do so.
Next, raise the voltage until the puddle becomes
hot and the arc seems violent and irregular. Note
that point as well. Lower the voltage to a point
midway between the two extremes where the arc
seems to even out. After the voltage is set, gradu-
ally adjust the wire feed/amps until the sound of
the arc is crisp. Listen to the arc. A steady sizzle, or
whine should be present. The weld puddle should
be wetting out neatly on the edges of the weld.
This sound has often been referred to as a "frying"
sound. The sound should be regular, and the arc
should be visually stable without significant pop-
ping and snapping. The wire should be disappear-
ing easily into the puddle without the arc stopping.
If the wire speed is too high, violent popping with
bits of flying wire may be noticed. If it is too low
the arc will appear to melt the wire before it reach-
es the puddle and may melt irregularly, even burn-
ing back into the tip. Volts are responsible for how
flat and wet the puddle appears. If too much volt-
age is used, the weld will appear wide and flat with
the edges of the weld possibly exhibiting undercut.
This will create weakness in the weld. If too little is
used, the weld will appear rope like and may even
sit on top of the metal with irregular fusion. Am-
perage/Wire speed is responsible for penetration.
If it is set too high for the thickness of metal being
used, burn through can occur, especially on thin
gauge material. If welding thin materials such as
used in exhaust systems or body work, make sure
the wire speed is adjusted to reduce penetration
before attempting a voltage change. General fig-
ures for both wire speed and amps can be easily
determined. To determine wire speed, simply
press the trigger (without welding) and hold it for
15 seconds. Measure the length of the wire that is
run from the torch in 15 seconds and multiply by 4.
Introduction and Specifications
This figure is your wire speed in inches per minute
(IPM). To roughly determine amps, which are
sometimes used by manufacturers for recommend-
ed settings, use the following formulas for the fol-
lowing wire thicknesses:
.023": IPM/3.5 = Amps
.030": IPM/2 = Amps
.035": IPM/1.6 = Amps
The actual constant given in this formula represents
"inches per amp". This formula is only a guide and is
only accurate in lower ranges as the function is not tru-
ly linear. But it usually will be within the overall range
specified by the manufacturer. For each manufacturer,
the filler wire diameter amp range may differ some-
what, though a general range can be established.
1.7 Spool Gun. The spool gun is an optional, but use-
ful tool to have for welding small and medium projects
aluminum projects that are 3/32" and over in thickness.
The spool gun connects directly in place of the regular
MIG gun. The Spool gun picks up the gas and power at
the Euro connection with a separate control connection
for the trigger on the spool gun. Once the spool gun
panel switch is flipped, the trigger will control on and
off operation of the gun. Wire speed and voltage are
still controlled at the panel however. NOTE: Some
guns Everlast sells may have a separate control
mounted on the spool gun handle for wire speed, but
is inoperative and is not used with this unit. When
welding aluminum, the unit should be welded in the
spray arc mode. Typically spool guns are good for
welding 3/32" and thicker aluminum. Spray arc mode
is a mode where the voltage is increased to near maxi-
mum voltage for this unit, and wire speed is adjusted so
that the wire melts in a steady stream of consistently
sized droplets before the wire contacts the metal. A
slight hiss will be present if done correctly. There is a
threshold for spray arc, and it requires higher voltage
and increased wire speed to force it into this mode.
This is a quieter mode than regular short circuit with
quick wet in and fast forward travel. It's recommended
that .030" wire be used to achieve the best results.
.023" wire may be used as well, but the unit may not
achieve true spray arc mode as it requires more wire
speed than the wire feeder can generate. In general,
the smaller the wire, the more wire speed is required
for spray arc. Larger diameter wire may cause overcur-
rents and may not feed well through the gun. More
information about spray arc welding with MIG can be
found in a variety of educational welding resources
online. Read over materials available and watch
demonstration videos for more information.
13
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