U8 ins

GB
U8
Aristot
Instruction manual
0459 310 274 080115 Valid for program version 1.41, 1.50
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Do this first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.1 Symbols in the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 About settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5.1 Setting numverical values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5.2 Setting fixed options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5.3 ON/OFF or YES/NO settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 ENTER and QUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.1 Auxiliary functions menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.2 Weld data setting menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.3 Measure image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.4 Memory functions menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.5 Fast mode menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 MIG/MAG WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Settings in the weld data setting menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1 MIG/MAG welding with dip/spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.2 MIG/MAG welding with pulsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Function explanations for settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.1 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.2 Wire feed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.3 Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.4 Regulator type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.5 Pulse current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.6 Pulse time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.7 Pulse frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.8 Background current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.9 Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.10 Ka . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.11 Ki . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.12 Synergy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.13 Gas pre--flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.14 Creep start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.15 Hot Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.16 Crater filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.17 Pinch--off pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.18 Burnback time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.19 Gas post--flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.20 Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.21 Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 MMA WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.1 Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.2 Arc force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.3 Min. current factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.4 Synergy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.5 Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rights reserved to alter specifications without notice.
TOCe -- 2 --
5 TIG WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.1 TIG welding without pulsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.2 TIG welding with pulsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2.1 HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2.2 LiftArc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.3 2--stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.4 4--stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.5 Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.6 Pulse current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.7 Background current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.8 Pulse time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.9 Background time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.10 Slope up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.11 Slope down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.12 Gas pre--flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.13 Gas post--flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.14 Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3 Other function explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3.1 Gas purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6 CARBON, ARC AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 Function explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.1 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.2 Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.3 Regulator type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 Aristo SuperPulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Wire and gas combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2 Different types of pulsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.4.1 Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.5 Wire feed unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8 MEMORY MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.1 How the controller works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.2 Store . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.3 Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.4 Recall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.5 Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9 AUXILIARY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10 FILEMANAGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.1 Inserting a compact flash card / PC--card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.2 Example: Saving welding data settings in the internal memory . . . . . . . . . . . . . . . . . . . 36
10.3 Example: Creating a new folder on a memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.4 Deleting a file or folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.5 Changing the name of a file/folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.6 Copying files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.7 Recalling welding data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.8 Quality data files content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.8.1 About the welding equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.8.2 About the welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TOCe -- 3 --
11 WELD DATA SETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.1 Example: Saving welding data on a memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.2 Recalling welding data from a memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.3 Deleting welding data from a memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
12 CONFIGURATION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
12.1 Code lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
12.1.1 Lock code mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
12.1.2 Set / change lock code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
12.2 Remote control configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
12.2.2 Configuring a digital remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
12.2.3 Configuring an analogue remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
12.3 MIG/MAG defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
12.3.1 Gun trigger mode (2--stroke / 4--stroke) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
12.3.2 Soft keys setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
12.3.3 Voltage measurement for dip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
12.3.4 4--stroke configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
12.4 MMA defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.4.1 Hot start amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.4.2 Hot start duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.4.3 Droplet welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.5 General defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.5.1 Fast mode soft keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.5.2 Double start sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.5.3 Panel remote enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.5.4 Auto save mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
12.5.5 Trigger weld data switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
12.5.6 Quality data logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
12.6 Multiple wire feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
12.6.1 Weld data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
12.7 Unit of length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
13 QUALITY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
13.1 Saving quality data on a compact flash card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
14 PRODUCTION STATISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
15 ERROR LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
15.1 Deleting error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
15.2 Reviewing error summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
15.3 Error code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
15.4 Error code descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
16 USER-- DEFINED SYNERGIC DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
16.1 Specify voltage/wire co--ordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
16.1.1 Dip/spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
16.1.2 Pulsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
16.2 Specifying the valid wire/gas combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
16.3 Creating user--defined wire/gas options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
16.4 Deleting a user--defined synergic line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
17 LIMIT EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
18 OTHER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
18.1 ESAB Logic Pump (Water lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
WIRE AND GAS COMBINATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
TOCe -- 4 --
ORDERING NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
TOCe -- 5 --
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1 INTRODUCTION
In order to get the maximum benefit from your welding equipment, we recommend
that you read this instruction manual.
For general information about operation, see the power source’s instruction manual.
The text shown in the display is available in the following languages:
English, Swedish, Finnish, Norwegian, Danish, German, French, Italian, Dutch,
Spanish, Portuguese, Hungarian, Polish, US English and Czech.
1.1 Equipment
U8 is supplied with a holder, 3 spacer screws and an English instruction manual.
The instruction manuals and the spare parts list are available in other languages on
the Internet at www.esab.com
Under ”Products” and ”Welding & cutting equipment”, you will find a link to the page
where you can both search for and download instructions and spare parts lists.
1.2 Do this first

This menu appears in the display when you start the machine for the first time.
When delivered, the controller is set to English. To select your language, do as

follows:
Press to bring up the main menu.
ESAB Mig
Using the arrow

keys, move the PROCESS: MIG/MAG
cursor to the line for METHOD: DIP / SPRAY
AUXILIARY
WIRE TYPE: Fe
FUNCTIONS
SHIELDING GAS: Ar+8%CO2
Press ENTER
WIRE DIMENSION: 1.2 mm
AUXILIARY FUNCTIONS "
FAST
SET MEASURE MEMORY MODE ENTER
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AUXILIARY FUNCTIONS
Move the cursor to the line

for CONFIGURATION FILEMANAGER
Press ENTER WELD DATA SETS
CONFIGURATION
QUALITY FUNCTIONS
PRODUCTION STATISTICS
ERROR LOG
USER DEFINED SYNERGIC DATA
LIMIT EDITOR
QUIT ENTER
AUXILIARY FUNCTIONS -- CONFIGURATION
Press ENTER to call up a

list of the languages LANGUAGE: ENGLISH
available in the controller. CODE LOCK
REMOTE CONTROLS
MIG/MAG DEFAULTS
MMA DEFAULTS
TIG DEFAULTS
GENERAL DEFAULTS
MULTIPLE WIRE FEEDERS
QUIT ENTER
Move the cursor to the line for your language and press ENTER. ENGLISH
SVENSKA
SUOMI
DANSK
DEUTSCH
FRANCAIS
ITALIANO ↓
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1.3 Display
ESAB Mig
PROCESS: MIG/MAG
METHOD: DIP / SPRAY
WIRE TYPE: Fe
SHIELDING GAS: CO2
WIRE DIMENSION: 1.2 MM
AUXILIARY FUNCTIONS
FAST
The cursor
The cursor in the controller appears as a shaded field around the text, which has the
effect of turning the selected text white. The cursor appears in bold text in the
instruction manual.
Text boxes
At the bottom of the display there are five boxes containing text that explains the
current functions of the five keys in the line directly below them.
Saver mode
To extend the life of the backlit display, it is switched off after three minutes if there is
no activity.
1.3.1 Symbols in the display
A The selected weld data set

B Recalled memory position number
C More information is available on the next
page
D Select the plus/minus buttons marked
with * to increase or decrease the
parameter value
E Select the plus/minus buttons marked
with # to increase or decrease the
parameter value
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1.4 Keys
You can use the arrow keys to move the cursor to different lines in the display.
The menu key will always return you to the main menu.
The plus/minus keys are used to increase (+) or decrease (--) the value of a
setting.
The two plus/minus keys are each marked with their own symbol. Most settings can
be defined using either the plus or minus key, but certain settings must be defined
using a key marked or (the symbols appear in the display).
Pressing a key briefly produces an increase/decrease in small steps. If you hold a
key down for longer, the size of the steps increases.
Soft keys
The five keys in a row under the display have a
variety of functions. These are the ”soft keys”, i.e.
they can have different functions depending on
which menu you are using. The current functions
of these keys are shown by the text in the bottom
line of the display.
When a function is active, this is indicated by a
white dot alongside the text .
1.5 About settings

There are three main types of settings:
S Settings with numerical values

S Settings with fixed options
S Settings of the type ON/OFF or YES/NO
1.5.1 Setting numverical values

When setting a numerical value, you use either the plus or minus keys to increase or
decrease a given value. Some values can also be modified by means of the remote
control.
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1.5.2 Setting fixed options

Certain settings are defined by selecting an option from a list.
The list might look like this:
MIG/MAG
MMA
TIG
CARBON, ArcAir
MIG SUPERPULSE
Here the cursor is on the line for MIG/MAG. If you press the ENTER key now, you
will select the MIG/MAG option.
However, if you want to select another option you move the cursor to the line in
question by moving up or down using the arrow keys.
You then press the ENTER key.

If you want to exit the list without making a selection, press the QUIT key.
Some settings have so many options that they cannot all be displayed in the list at
the same time. An arrow at the top or bottom of a list indicates that more options will
become visible if you scroll up or down using the arrow keys.
1.5.3 ON/OFF or YES/NO settings

For some functions you can set the values ON or OFF or YES or NO. The synergic
function for MIG/MAG welding and MMA welding is one example of such a function.
The ON/OFF or YES/NO settings can be defined in one of two ways:
You can select ON or OFF or YES or NO from a list of options as described above.
You can also use the plus/minus keys to define ON/OFF or YES/NO (applies to
certain functions).
S + (plus) = ON or YES
S -- (minus) = OFF or NO
1.6 ENTER and QUIT

The two ”soft” keys on the far right are primarily used for ENTER and QUIT but are
sometimes used for other functions.
S By pressing ENTER you confirm the selected option in a menu or list.
S By pressing QUIT you return to the previous menu or display.
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2 MENUS
The controller uses a number of different menus. These are the main menu, auxiliary
functions menu, weld data setting menu, measure image, memory functions menu
and fast mode menu. During start--up, a start--up screen also appears containing
information about which program version is being used.
2.1 Main menu
In the MAIN MENU you can ESAB Mig

change weld process,
process weld
method, wire type, etc.
From this menu you can PROCESS: MIG/MAG
then access all other METHOD: DIP / SPRAY
submenus. WIRE TYPE: Fe
SHIELDING GAS: Ar+8%CO2
WIRE DIAMETER: 1.2 mm
AUXILIARY FUNCTIONS
FAST
2.1.1 Auxiliary functions menu
In the AUXILIARY AUXILIARY FUNCTIONS

FUNCTIONS
MENU you can view the
memory card functions. You FILEMANAGER
can also switch to the WELD DATA SETS
configuration menu, view
quality functions, production CONFIGURATION
statistics, the error log, etc. QUALITY FUNCTIONS
ERROR LOG
LIMIT EDITOR
QUIT ENTER
2.1.1.1 Configuration menu
In the CONFIGURATION AUXILIARY FUNCTIONS -- CONFIGURATION

MENU you can switch
language, change other
basic settings, measure- LANGUAGE: ENGLISH
ment unit, etc. CODE LOCK
REMOTE CONTROLS
MIG/MAG DEFAULTS
MMA DEFAULTS
TIG DEFAULTS
GENERAL SETTINGS
QUIT ENTER
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2.1.2 Weld data setting menu
In the WELD DATA WELD DATA SETTING

SETTING MENU you can
change various weld
parameters. The menu’s VOLTAGE: # 26.8 (+0.0) V
appearance differs, WIRE SPEED: * 6.0 m/min
depending on which weld
process you have selected. INDUCTANCE: 80 %
In this example it is SYNERGIC MODE PÅ
MIG/MAG welding with START DATA...
dip/spray. STOP DATA...
LIMITS
CRATR HOT 4--

FILL START STROKE QUIT
2.1.3 Measure image
In the MEASURE IMAGE DIP/SPRAY. Fe, CO2, 1.2 mm

you can see the measured
# 0.0 Volt
values of various weld
parameters during welding.
The measured values
0 Amp
remain in the display even
after welding has been
completed.
You can move to other
menus without losing the
measured values. * 6.0 m/min
↓
CRATER HOT 4-- 2ND
FILL START STROKE REM FUNCT
The arrow in the bottom right--hand corner of the display indicates that there is more
information available.
In the measure image you can change the value of certain parameters. Which
parameters these are depends on which weld process has been set. The parameter
values that can be adjusted are always marked with # or *.
When values are changed while no welding is in progress, the measured values will
change to zero to avoid misunderstandings regarding which settings correspond to
the measure result.
TIP!
In pulsing you can select whether the voltage value is displayed as an average value
or peak value. This setting can be defined under MIG/MAG basic settings, see
chapter 12.3.
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2.1.4 Memory functions menu
In the MEMORY MEMORY FUNCTIONS -- STORED DATA SETS

FUNCTIONS MENU you
can store, recall and delete
various items of preset weld 1 2 5 11 12
data. Weld data settings
can be stored in 255
different memory positions.
STORE QUIT
2.1.5 Fast mode menu
In the FAST MODE DIP/SPRAY. Fe, CO2, 1.2 mm

MENU you can link soft
# 0.0 Volt
buttons to weld data
memory positions. This
setting is defined under
general settings.
0 Amp
* 6.0 m/min
↓
WELD WELD WELD WELD 2ND
DATA 1 DATA 2 DATA 3 DATA 4 FUNCT
For more information about setting this menu, see chapter 12.5.1 ”Fast mode, soft
keys”.
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2.2 Menu structure
AUXILIARY FUNCTIONS SET MEASURE MEMORY FAST MODE
STOP DATA COPY

START DATA RECALL
DELETE
STORE
*) This is the start image (measure image) that is shown when you switch on the machine.
The sample image above is for MIG/MAG--welding with synergic mode.
AUXILIARY FUNC- auxiliary functions S see page 35
TIONS menu
SET weld data setting menu S for MIG/MAG welding, see page 15
S for MMA welding, see page 21
S for TIG welding, see page 22
S for carbon, arc air, see page 26
S for MIG Superpulse, see page 28
MEASURE measure image S see page 12
MEMORY Memory management S ses page 30
menu
FAST MODE Fast mode menu S see page 51
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3 MIG/MAG WELDING
Main menu - - > Process
The arc in MIG/MAG welding melts a filler wire (the electrode) that is continuously
fed into the weld, with the molten zone being protected by a shielding gas.
Pulsing is used to affect the transfer of the droplets from the arc so that it is stable
and does not produce spray, even with low weld data.
The table on page 68 shows the wire diameters that can be selected for MIG/MAG
welding with DIP/SPRAY.
The table on page 69 shows the wire diameters that can be selected for MIG/MAG
welding with PULSE.
3.1 Settings in the weld data setting menu

3.1.1 MIG/MAG welding with dip/spray
Settings Setting range In steps Values Synergic Adjust--
of: after reset depend- able in
ent synergic
Voltage 8 -- 60 0.25 (dis- synergic x x
played to deviation
one deci- ¦0
mal place)
Wire speed ** 0.8 -- 25.0 m/min 0.1 m/min 5 m/min x
Inductance 0 -- 100% 1 80% x x
Control type 1 -- 12 1 4 x
Synergic mode* OFF or ON -- ON * -- --
Gas pre--flow 0.1 -- 25 s 0.1 s 0.1 s x
Creep start NO or YES -- NO x
Hot start NO or YES -- NO x
Hot start time 0 -- 10 s 0.1 s 1.5 s x
Hot start wire speed Complete wire feed 0.1 m/min 2 m/min x
range
Hot start voltage Complete voltage 0.25 V 4.5 V x
range
Crater filling NO or YES -- NO x
Crater fill time 0 -- 10 s 0.1 s 1.5 s x
Final crater filling wire 1.5 m/min to current 0.1 m/min 3 m/min x
speed wire feed speed
Final crater filling 8 V to actual voltage 0.25 V 18 V x
voltage
Pinch off pulse 10 -- 120% 1 60% x
Burn back time 0 -- 1 s 0.01 s 0.12 s x
Gas post--flow 0.1 -- 25 s 0.1 s 0.1 s x
Limits 1 -- 50 -- -- -- --
Spot welding OFF or ON -- OFF x
Spot welding time 0 -- 25 s 0,1 s 0,5 s x
*) Default synergic line: solid wire (Fe), shielding gas CO2 with wire 1.2 mm.
**)The setting range is dependent on the wire feed unit used.
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3.1.2 MIG/MAG welding with pulsing

ent synergic
Voltage 10 -- 50 0.25 (dis- synergic x x
played to deviation
one deci- ¦0
mal place)
Wire speed ** 0.8 -- 25.0 m/min 0.1 m/min 5 m/min x
Pulse current *** 100 -- 600 A 4A 476 A x
Pulse time 1.7 – 25.5 ms 0.1 ms 2.2 ms x
Pulse frequency 16 -- 312 Hz 2 Hz 96 Hz x
Background current *** 4 -- 300 A 1A 52 A x
Slope 1 -- 9 1 9 x
Ka 0 -- 100% 1 13% x
Ki 0 -- 100% 1 0% x
Synergic mode* OFF or ON -- ON * -- --
Gas pre--flow 0.1 -- 25 s 0.1 s 0.1 s x
Creep start NO or YES -- NO x
Hot start NO or YES -- NO x
Hot start time 0 -- 10 s 0.1 s 1.5 s x
Hot start wire speed Complete wire feed 0.1 m/min 2 m/min x
range
Hot start voltage Complete voltage 0.25 V 4.5 V x
range
Crater filling NO, NON--PULSED or -- NO x
PULSED
Crater fill time 0 -- 10 s 0.1 s 1.5 s x
Final crater filling wire 1.5 m/min to current 0.1 m/min 3 m/min x
speed wire feed speed
Final crater filling 8 V to actual voltage 0.25 V 18 V x
voltage
Final crater filling pulse 100 A to actual pulse 4A 464 A x
current current
Final crater filling 12 A to actual 4A 36 A x
background current background current
Final crater filling 20 Hz to actual 2 Hz 62 Hz x
frequency freauency
Burn back time 0 -- 1 s 0.01 s 0.13 s x
Gas post--flow 0.1 -- 25 s 0.1 s 0.1 s x
Limits 1 -- 50 -- -- -- --
Spot welding OFF or ON -- OFF x
Spot welding time 0 -- 25 s 0,1 s 0,5 s x
*) Default synergic line: solid wire (Fe), shielding gas CO2 with wire 1.2 mm.
**)The setting range is dependent on the wire feed unit used.
***) Minimal background current and pulse current are depending on which type of machine is used.
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3.2 Function explanations for settings

3.2.1 Voltage
Higher voltage increases the arc length and produces a hotter, wider weld pool.
The voltage setting differs between synergy and non synergy modes. In synergy
mode the voltage is set as a positive or negative offset from the synergic line of the
voltage. In non synergy mode the voltage value is set as an absolute value.
The voltage is set in either the measure image--, the weld data setting menu, or the
fast mode menu. When the remote control unit is used the setting can be made from
this.
3.2.2 Wire feed speed

This sets the required feed speed of the filler wire in m/minute.
The wire feed speed is set in either the measure image, the weld data setting menu,
or the fast mode menu. When the remote control unit is used the setting can be
made from this.
3.2.3 Inductance
Higher inductance results in a wider weld pool and less spatter. Lower inductance
produces a harsher sound but a stable, concentrated arc.
Only applies for MIG/MAG welding with dip/spray.
3.2.4 Regulator type

Affects the short circuit process and heat in the weld.
This setting should not be changed.
3.2.5 Pulse current

The higher of the two current values in the event of pulsed current.
Only applies for MIG/MAG welding with pulse.
3.2.6 Pulse time

The time the pulse current is on during a pulse period.
3.2.7 Pulse frequency

Time for background current, which, along with the time for pulse current, gives the
pulse period.
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3.2.8 Background current

The lower of the two current values in the event of pulsed current.
Current
Pulse current
Background current Pulse Pulse period time

time Time
MIG/MAG welding with pulsing.
3.2.9 Slope
Slope means that the pulse current rises/falls slowly to the set value. The slope
parameter can be set in nine steps, with each step corresponding to 100 μs.
Slope is significant with respect to sound. A steep slope generates a higher, sharper
sound. A slope that is too gentle can in the worst case, affect the pulse’s capacity to
cut off the droplet.
3.2.10 Ka
Ka is the proportional element and corresponds to the regulator’s amplification. A
low value means that the voltage is not maintained at a constant level as precisely.
3.2.11 Ki
Ki is the integrating element that attempts in the longer term to eliminate an error.
Here too, a low value will produce a weaker regulatory effect.
3.2.12 Synergy
Each combination of wire type, wire diameter and gas mixture requires a unique
relationship between wire feed speed and voltage (arc length) to obtain a stable
functioning arc. The voltage (arc length) automatically conforms in accordance with
the pre--programmed synergic line you have selected, which makes it much easier to
find the correct welding parameters. The relationship between the wire feed speed
and the other parameters is called the synergic line.
It is also possible to order other packages of synergy lines, but these must be
installed by an authorised ESAB service engineer.
3.2.13 Gas pre--flow
Gas pre--flow controls the time during which shielding gas flows before the arc is
struck.
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3.2.14 Creep start

Creep starting feeds out the wire at 50% of the set speed until it makes electrical
contact with the workpiece. With a hot start it is 50% of the hot start time.
3.2.15 Hot Start

Hot start increases the wire feed speed and voltage for an adjustable time at the
start of welding, thus reducing the risk of poor fusion at the beginning of the joint.
Hot start wire speed

It is possible to increase the wire feed speed during a specific period compared to
the present wire feed speed to provide more energy during the weld start and ensure
penetration. The speed is set relative to the ordinary wire feed speed. The time
starts when the arc is ignited and the length is the set hot start time. Synergy gives
an increase in the wire speed by 2 m/min.
Hot start voltage

The voltage increases by 2 volts in addition to the contribution from the synergy line
slope and the extra 2 m/min in wire feed speed. In non synergy mode, the voltage in
question will be the one set and it is not synergy dependent.
Note!: It is possible to set negative values for the hot start wire feed and hot start
voltage. This can be used with high weld data to give a smooth weld start by initially
”stepping up” the weld data.
-- Hot start is enabled in the measure image and the settings are defined in the
settings menu.
3.2.16 Crater filling

Crater filling makes a controlled reduction in the heat and size of the weld pool
possible when completing the weld. This makes it easier to avoid pores, thermal
cracking and crater formation in the weld joint.
In pulse welding mode it is possible to choose between pulsed and non pulsed crater
filling. Non pulsed crater filling is faster to do. Pulsed crater filling takes a little longer,
yet gives spatter free crater filling when appropriate values are used.
Synergy
In synergy mode the crater filling time and the final wire feed speed are both set in
pulsed and non pulsed crater filling. The voltage and the pulse parameters drop to
the final values with the help of synergy.
Non synergy
In non synergy mode the settings can be changed to give another arc length at the
end of crater filling.
The final voltage can be set for non pulsed crater filling. The final voltage, final pulse
current, final background current and the final frequency can be set for pulsed crater
filling.
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The final parameter values must always be equal to or lower than the set values for
continuous welding. If the settings for continuous welding are lowered below the set
final values they will also lower the final values. The final parameter values will not
increase again if the setting for continuous welding is increased.
Example:
You have 4 m/min as the final wire feed speed and lower the wire feed speed to
3.5 m/min. The final wire feed speed will also be lowered to 3.5 m/min. The final wire
speed remains at 3.5 m/min even when the wire feed speed is increased again.
-- Crater filling is enabled in the measure image and the settings are defined in the
settings menu.
3.2.17 Pinch-- off pulse

Pinch--off pulse is a pulse that is added to ensure than no ball is formed on the wire
when welding stops.
Only applies for MIG/MAG welding with dip/spray. When pulsing completion is
synchronised with a pulse, finishing pulse.
3.2.18 Burnback time

Burnback time is a delay between the time when the wire starts to brake until the
time when the power source switches off the welding voltage. Too short a burnback
time results in a long wire stickout after completion of welding, with a risk of the wire
being caught in the solidifying weld pool. A long burnback time results in a shorter
stickout, with increased risk of the arc striking back to the contact tip.
3.2.19 Gas post--flow

Gas post--flow controls the time during which shielding gas flows after the arc is
extinguished.
3.2.20 Limits
In this function you can choose a limit number. For settings, see chapter 17
”Configuring limits”.
3.2.21 Spot welding

Select Spot welding when you want to ”spot--weld” thin metal sheets.
Note! You can not shorten the weld time by releasing the gun trigger.
4 MMA WELDING
MMA welding may also be referred to as welding with coated electrodes. Striking the
arc melts the electrode, and its coating forms a protective slag.
The table on page 69 shows the electrode diameters that can be selected for MMA
welding.
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ent synergic
Current* 16 -- 500 A 1A 128 A x
Synergic mode OFF or ON -- ON ** -- --
Arc force 0 -- 100% 1% 10% x
Min current factor 0 -- 100% 1% 25% x
*) Maximum current depending on which type of machine is used.
**) Default synergic line: electrode type basic 3.2 mm.

4.2.1 Current
A higher current produces a wider weld pool, with better penetration into the
workpiece.
Current is set in either the measure image, the weld data setting menu, or the fast
mode menu.
4.2.2 Arc force
The arc force controls how the current changes when the arc length changes. A
lower value gives a calmer arc with less spatter.
4.2.3 Min. current factor
The min. current factor setting is used in conjunction with certain specific electrodes.
Note! This setting should not be changed.
4.2.4 Synergy
Synergy for MMA welding means that the welding power source automatically
optimises the properties of the electrode type and diameter selected.
4.2.5 Limits
In limits you can choose a limit number. For settings, see chapter 17 ”Configuring
limits”.
-- Limits are enabled in the weld data setting menu.
5 TIG WELDING
TIG welding melts the metal of the workpiece, using an arc struck from a tungsten
electrode, which does not itself melt. The weld pool and the electrode are protected
by shielding gas.
Pulsing is used for improved control of the weld pool and the solidification process. The
pulse frequency is set so slow that the weld pool has time to solidify at least partially be-
tween each pulse. In order to set pulsing, four parameters are required: pulse time,
background time, pulse current and background current.
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5.1.1 TIG welding without pulsing
Settings Setting range In steps of: Values after reset
HF / LiftArct HF or LiftArc -- LiftArc
2/4--stroke 2--stroke or 4--stroke -- 2--stroke
Current* 4 -- 500 A 1A 25 A
Slope up time 0 -- 25 s 0.1 s 1.0 s
Slope down time 0 -- 25 s 0.1 s 2.0 s
Gas pre--flow 0 -- 25 s 0.1 s 1.0 s
Gas post--flow 0 -- 25 s 0.1 s 3.0 s
Limits 1 -- 50 -- --

5.1.2 TIG welding with pulsing
Settings Setting range In steps of: Values after reset
HF/LiftArct HF or LiftArc -- LiftArc
2/4--stroke* 2--stroke or 4--stroke -- 2--stroke
Pulse current* 4 -- 500 A 1A 25 A
Pulse time 0.001 -- 5 s 0.001 s 0.010 s
Background time 0.001 -- 5 s 0.001 s 0.020 s
Background current* 4 -- 500 A 1A 25 A
Slope up time 0 -- 25 s 0.1 s 1.0 s
Slope down time 0 -- 25 s 0.1 s 2.0 s
Gas pre--flow 0 -- 25 s 0.1 s 1.0 s
Gas post--flow 0 -- 25 s 0.1 s 3.0 s
Limits 1 -- 50 -- --

5.2.1 HF
The HF function strikes the arc by means of a spark from the electrode to the
workpiece as the electrode is brought closer to the workpiece.
-- HF is enabled in the main menu.
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5.2.2 LiftArc
With LiftArct the arc is struck when the electrode is lifted from the workpiece.
Striking the arc using the LiftArct function. Step 1: the electrode is touched on to the workpiece. Step
2: the trigger switch is pressed, and a low current starts to flow. Step 3: the welder lifts the electrode
from the workpiece: the arc strikes, and the current rises automatically to the set value.
-- LiftArct is enabled in the main menu.
5.2.3 2--stroke
Gas pre--flow Slope Slope down Gas post--

up flow
Functions when using 2--stroke control of the welding torch.

In 2--stroke control mode, pressing the trigger switch starts gas pre--flow (if used)
and strikes the arc (1). The current rises to the set value (as controlled by the slope
up function, if in operation). Releasing the trigger switch (2) reduces the current (or
starts slope down if in operation) and extinguishes the arc. Gas post--flow follows if it
is in operation.
-- 2--stroke is enabled in the measure image or the main menu.
5.2.4 4--stroke
Gas pre--flow Slope Slope down Gas post--

up flow
Functions when using 4--stroke control of the welding torch.
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In 4--stroke control mode, pressing the trigger switch starts gas pre--flow (if used) (1).
At the end of the gas pre--flow time, the current rises to the pilot level (a few
amperes), and the arc is struck. Releasing the trigger switch (2) increases the
current to the set value (with slope up, if in use). At the end of welding, the welder
presses the trigger switch again (3), which reduces the current to pilot level again
(with slope down, if in use). Releasing the switch again (4) extinguishes the arc and
starts gas post--flow.
-- 4--stroke is enabled in the measure image or the main menu.
5.2.5 Current
A higher current produces a wider weld pool, with better penetration into the
workpiece.
Current is set in either the measure image, the weld data setting menu, or
the fast mode menu.
Only applies for TIG welding with constant current.
5.2.6 Pulse current

The higher of the two current values in the event of pulsed current. By pulsing the slope
up and slope down will also be pulsed.
-- Pulse current is set in the weld data setting menu.
Only applies for TIG welding with pulse.
5.2.7 Background current

The lower of the two current values in the event of pulsed current.
-- Background current is set in the weld data setting menu.
5.2.8 Pulse time

The time the pulse current is on during a pulse period.
-- Pulse time is set in the weld data setting menu.
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5.2.9 Background time

Time for background current, which, along with the time for pulse current, gives the
pulse period.
-- Background time is set in the weld data setting menu.
Current
Background time
Background current Pulse current

Pulse time
Time
TIG welding with pulsing.
5.2.10 Slope up
The slope up function means that, when the TIG arc strikes, the current rises slowly
to the set value. This provides ‘gentler’ heating of the electrode, and gives the welder
a chance to position the electrode properly before the current has reached the preset
value.
-- Slope up is set in the weld data setting menu.
5.2.11 Slope down

TIG welding uses slope down, by which the current falls ‘slowly’ over a controlled
time, to avoid craters and/or cracks when a weld is finished.
-- Slope down is set in the weld data setting menu.
5.2.12 Gas pre--flow

Gas pre--flow controls the time during which shielding gas flows before the arc is
struck.
-- Gas pre--flow is set in the weld data setting menu.
5.2.13 Gas post--flow

Gas post--flow controls the time during which shielding gas flows after the arc is
extinguished.
-- Gas post--flow is set in the weld data setting menu.
5.2.14 Limits
In limits you can choose a limit number. For settings, see chapter 17 ”Configuring
limits”.
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5.3 Other function explanations
5.3.1 Gas purge

The gas purge function is used when measuring the gas flow or to purge the gas
hoses of any air and moisture before welding commences. Gas purging proceeds as
long as the key is pressed down, and is conducted without current and wire feed
being switched on.
-- Gas purging is enabled in the measure image.
6 CARBON, ARC AIR

Mig 4000i, Mig 4500i, Mig 5000i
Carbon, Arc air involves the use of a special electrode consisting of a carbon bar
with a copper case.
An arc is formed between the carbon bar and the workpiece, air is supplied to blow
away the melted material, and a seam is formed.
The table on page 69 shows the electrode diameters that can be selected for
carbon, arc air.

ent synergic
Voltage 8 -- 60 V 1V 39 V x x
Inductance 0 -- 100% 70% x
Control type 1 -- 5 1 1 x
Synergic mode* ON or OFF -- ON -- --
*) Default synergic line: 5.0 mm electrode (carbon bar).
6.2 Function explanations
6.2.1 Voltage
Higher current produces wider and deeper penetration into the workpiece
Voltage is set in either the measure image, the weld data setting menu, or the fast
mode menu.
6.2.2 Inductance
6.2.3 Regulator type

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7 Aristo SuperPulse
Mig 4000i, Mig 4500i, Mig 5000i
MIG SUPERPULSE (Aristo SuperPulset) is used for improved control of the weld
pool and the solidification process. The weld pool has time to solidify partially
between each pulse.
Advantages of using MIG SUPERPULSE:
S Less sensitive to variations in the root gap
S Better control of the wel pool during position welding
S Better control of penetration and penetration profile
S Less sensitive to uneven heat evaporation
MIG SUPERPULSE can be seen as a programmed changeover between two

MIG/MAG settings. The time intervals are determined by the primary and secondary
phase time settings.
MIG SUPERPULSE takes up two positions in the weld data memory. The primary
data in an odd memory position and the secondary data in the following even
memory position. One effect of this is that a digital remote control unit cannot use the
even memory positions when MIG SUPERPULSE data is saved.
Welding always starts in the primary phase. When hot start is selected primary data
will be used during the hot start time in addition to the phase time for the primary
data. Crater filling is always based on secondary data. When a stop command has
been activated during the primary phase time the process immediately switches to
secondary data. The weld completion is based on secondary data.
7.1 Wire and gas combinations

For combinations of wire and gas, see tables on page 68.
7.2 Different types of pulsing

The figure below shows which pulsing methods can be used depending on the
thickness of the material to be welded.
Heat
C
Sprayarc in primary phase
and pulse in secondary
phase
B
Pulse in primary phase and
pulse in secondary phase
A
Pulse in primary phase and
diparc in secondary phase
Material dimension
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Settings for dip--/spray arc alternative pulsing see chapter 3.1.1 and 3.1.2.
Settings Setting range In steps of: Values after Synergic Adjust--

reset depend- able in
ent synergic
Phase Primary or -- Primary x
secondary
Phase weld time 0 -- 2.50 s 0,01 0.05 (secondary) x
0.22 (primary)

The function explanations for settings for Superpulse and other MIG/MAG--welding
see pages 17-- 20.
7.4.1 Phase
In this function you can choose between primary or secondary.
High data is set in primary and low data is set in secondary.
The settings are used to determine whether primary or secondary data should be
available for editing. It also determines which data is affected in measuring and
remote modes. The wire feed speed shown in the measure image shows the speed
in the selected phase. However, the voltage, current and weld output are based on
the measurement under both phases.
You can choose different synergy in the primary and secondary phases. Note that
you must make the same selection in both primary and secondary when the same
synergy is required.
-- Phase is set in the main menu.
7.5 Wire feed unit

Use only wire feed unit Feed 3004, Aristot with MIG SUPERPULSE.
Precautions!
When using MIG SUPERPULSE there is a high load on the wire feed unit. To ensure
that the reliability of the feed unit is not endangered follow the limits in the diagram
below.
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Difference in wire feed speed

n m/min
Cycle time (s)
The graphs for 15 m/min and 20 m/min respectively refer to the primary wire feed
speed. The cycle time is the sum of the primary and secondary phase weld time.
The difference between primary and secondary wire feed speed must not exceed the
speed that is indicated by the graphs of the primary wire feed speed.
Example: If the cycle time is 0.25 and the primary wire feed speed is 15 m/min the
difference between primary and secondary wire feed speed must not exceed
6 m/min.
Welding example A
In this exemple we will weld a 10 mm plate with 1.2 mm aluminium wire and argon
shielding gas .
Make the following settings with the controller:
Process MIG SUPERPULSE MIG SUPERPULSE

Phase Primary Secondary
Method Dip/spray Pulse
Wire type Al Mg Al Mg
Shielding gas Ar Ar
Wire dimension 1.2 mm 1.2 mm
Voltage (+ 1.0V) (+ 3.0V)
Wire feed speed 15.0 m/min 11.0 m/min
Phase weld time 0.1 s 0.1 s
The primary and secondary phase time is 0.1 s + 0.1 s = 0.2 s.
The difference in wire feed speed is 15.0 m/min -- 11.0 m/min = 4 m/min.
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Welding example B
In this exemple we will weld a 6 mm plate with 1.2 mm aluminium wire and argon
shielding gas.
Make the following settings with the controller:
Process MIG SUPERPULSE MIG SUPERPULSE

Phase Primary Secondary
Method Pulse Pulse
Wire type Al Mg Al Mg
Shielding gas Ar Ar
Wire dimension 1.2 mm 1.2 mm
Voltage (+ 1.0V) (+ 2.0V)
Wire feed speed 12.5 m/min 9.0 m/min
Phase weld time 0.15 s 0.15 s
The primary and secondary phase time is 0.15 s + 0.15 s = 0.3 s.

The difference in wire feed speed is 12.5 m/min -- 9.0 m/min = 3.5 m/min.
8 MEMORY MANAGEMENT
8.1 How the controller works

The controller consists in principle of two units: primary memory and weld data
memory.
Store
Primary memory Weld data memory
Recall
In the primary memory you create a complete set of weld data settings, which can be
saved in the weld data memory.
During welding it is always the content of the working memory that controls the
process. It is therefore also possible to recall a weld data setting from the weld data
memory to the working memory.
Note that the working memory always contains the last weld data settings that were
defined. They may have been recalled from the weld data memory, or they can be
individually modified settings. In other words, the working memory is never empty or
”reset to zero”.
Main menu - - >
In the controller you can store up to 255 sets of weld data. Each set is given a
number from 1 to 255.
You can also delete and copy data sets, and you can also recall a set of weld data
to the working memory.
Here are some examples to show how to store, recall, copy and delete.
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8.2 Store
If the weld data memory is empty, the following screen appears in the display.
MEMORY FUNCTIONS -- STORED DATA SETS
We will now store a set of

weld data. We will give it
memory position 5. Press
the STORE key.
* NO STORED DATA SETS *
STORE QUIT
The following screen appears in the display.
STORE IN DATA NO. 1
If you press ENTER here,

the data set is saved
as number 1, as indicated
in the top line of the display.
QUIT ENTER
By scrolling using the plus/minus keys, you can define which memory position the data set will have.
The figure shown in the top line of the display is the first empty position that was
located in the memory.
STORE IN DATA NO. 5
Scroll forwards to number 5

using the plus/minus
keys. Press ENTER.
QUIT ENTER
The data set has now been stored as number 5. At the bottom of the display you can
see parts of the content of data set number 5.
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STORE IN DATA NO. 5
" DIP/SPRAY, Fe, CO2, 1.2 mm
QUIT ENTER
Return to the memory menu by pressing the QUIT key.

NOTE! Every MIG SUPERPULS data take two memory positions.
8.3 Delete
In the memory menu you can delete one or more data sets.
We are going to delete the data set that we stored in the previous example.
Press the DELETE key.

5
STORE DELETE RECALL COPY QUIT
The most recently saved data set is automatically selected. If more than one data set
is stored, you can move the cursor between them using the arrow left and arrow right
keys.
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DELETE WELD DATA NO. 5
Press ENTER to confirm

the deletion of data set 5
number 5.
QUIT ENTER

NOTE! If MIG SUPERPULSE is deleted, both of the memory positions 5 and 6 will
be deleted.
8.4 Recall
We are now going to recall a stored data set:
Press the RECALL key.

5

keys.
RECALL WELD DATA NO. 10
Press ENTER to confirm

that you want to recall data 5
set number 5.
QUIT ENTER
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The following text box appears briefly:
RECALLED DATA SET NO. 5

This icon in the measure image shows which
memory position has been recalled.
8.5 Copy
This is how you copy the content of a weld data setting to a new memory position:
Press the COPY key.

5

keys. We are now going to copy the content of memory position 5 to position 50.
By scrolling using the plus/minus keys, you can define the memory position to which
you want to copy.
COPY WELD DATA NO. 5 TO NO. 50
Scroll to number 50 using

the plus key and press 5
ENTER.
QUIT ENTER
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Weld data setting number 5 has now been copied to memory position 50.
If memory position 50 is already taken, you are informed of this on the display.
COPY WELD DATA NO. 5 TO NO. 50
5 50
QUIT ENTER
9 AUXILIARY FUNCTIONS
Main menu - - > Auxiliary functions menu
This menu contains the following submenus:
S File manager, see chapter 10.

S Weld data set, see chapter 11
S Configuration, see chapter 12.
S Quality functions, see chapter 13.
S Production statistics, see chapter 14.
S Error log, see chapter 15.
S User--defined synergic data, see chapter 16.
S Limit editor, see chapter 17.
10 FILEMANAGER
Main menu - - > Auxiliary functions menu - - > Filemanager
The file manager allows you to manage information partly in the controller’s internal
memory (R:\) and partly in a compact flash memory or PC--card (PCMCIA) (C:\).
The file manager enables manual saving, deleting and copying of welding data and
quality data, and recall of welding data.
The file manager remembers where you were when you last used the file manager
so that you return to the same location in the file structure when you resume.
To obtain information on the amount of storage space remaining for each memory,
use the INFO function.
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10.1 Inserting a compact flash card / PC--card

To enable you to use this function fully, you must first insert a compact flash card /
PC--card (PCMCIA) into the controller. A card adapter is also required to enable the
compact flash card and welding machine to work together.
S Switch off the power source’s main power switch.

S Open the left--hand end of the controller.
S Insert the card into the adapter.
S Push the adapter into the
controller so that the locking
bracket snaps shut.
S Close the door.
S Switch on the power
source’s main power
switch.
Note! The compact flash card must use the FAT 16 file system. Most new cards are
FAT 32 why card needs to be formatted before use.
Format your card:
S Put in the card / adapter in the PC.
S Go to file handling.
S Marke the catalogue and click right button of mouse, format and choose file
system FAT or FAT 16 (not 32).
S Click on start.
10.2 Example: Saving welding data settings in the internal memory
FILE MANAGER
Use the Down arrow to

highlight R:\. Press ALT. C:\
R:\
INFO ALT QUIT ENTER
Use the Down arrow to highlight WeldData.awd and press NEW FOLDER
ENTER. WeldData.awd
Qdata050622_01.aqd
The entire welding data settings configuration saved in the welding data memory
(utilised memory positions 1--255) is now saved in the WeldData.awd file. Save on
the compact flash card in the same way.
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To save the quality data stored on the controller, do the same as for WeldData.awd,
but highlight the file with the extension .aqd instead and press ENTER. You have
then saved information on the last 100 welding cases.
For a description of quality data, see the 13 ”Quality functions” chapter, and for
information on what the quality data files contain, see the 10.8 ”Quality data files
content” chapter.
NB: If you have already saved welding data once and save again in the same folder,
the previous file will be overwritten without any warning. If you want to keep the file
saved previously, it must be renamed or the new file saved in a different folder.
10.3 Example: Creating a new folder on a memory card
FILE MANAGER
Highlight C:\ and press ALT.

C:\
R:\
INFO ALT QUIT ENTER
Highlight NEW FOLDER and press ENTER. NEW FOLDER

WeldData.awd
Qdata050622_01.aqd
A keyboard will then appear in the display. Use the arrow keys to highlight the
character/function you want to use and then press the PRESS KEY soft key. Once
the folder name is complete, confirm using enter .
10.4 Deleting a file or folder
.\QData\
Highlight the file or folder to

be deleted and press ALT. ..
Qdata050622_01.aqd
Qdata050621_02.aqd
Qdata050621_03.aqd
INFO ALT QUIT ENTER
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Highlight DELETE and press ENTER. COPY

DELETE
RENAME
The file/folder has now been deleted.

A folder can only be deleted if it is empty, i.e. the files inside the folder must be
deleted first.
10.5 Changing the name of a file/folder

Highlight the file or folder to have its name changed and press ALT. Highlight
RENAME and press ENTER.
A keyboard will then appear in the display. Use the arrow keys to highlight the
character/function you want to use and then press the PRESS KEY soft key. Once
the file/folder name is complete, confirm using enter .
10.6 Copying files

Highlight the file to be copied and press ALT. Highlight COPY and press ENTER.
Highlight the name of the folder into which the file is to be copied, or a file name in
the folder, and press ALT. Highlight PASTE and press ENTER.
The copy is saved as Copy of plus the original name, e.g. Copy of WeldData.awd.
10.7 Recalling welding data

When a file with the extension .awd is highlighted, the ALT function also offers a
RECALL option. RECALL recalls welding data from the file to the welding data
memory so that you can use the settings when welding.
RECALL does not overwrite the entire welding data memory, just the memory
positions that have a value in the file. This means that if there were welding data
settings stored at position 1 and 3 when the file was created, the file only overwrites
position 1 and 3 when it is recalled. The remaining memory positions retain the
values they had prior to the recall.
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10.8 Quality data files content

The quality data files look like this:
The first block contains information on the welding equipment and the second block,
the welds. Differing data on a single row is separated by a semicolon. Quotation
marks are used to mark text, i.e. anything that is not to be translated (and
processed), as numbers. Different welds are separated by line breaks.
The files are structured in this way to allow you to open .aqd files in a spreadsheet
application (e.g. Excel) and obtain distinct formatting of the values.
The file format is FAT, which allows the files to be handled by the standard PC
operating systems. The compact flash card must use the FAT file system in order to
function.
10.8.1 About the welding equipment
Review of the first block, row by row.
Sernr Serial number of the power source

Powersource The power source used, an Mig U5000i, Aristot in the example above.
WD version The software version used in the controller, 1.30 in the example above.
PS version The software version used in the power source. 1.20 in the example above.
WF version The software version used in the wire feed unit. 3.02 in the example above.
Synergy date When synergy data is changed, the new version is given a date as its version
number. In the example above the date/version number is 050915.
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10.8.2 About the welds

Review of the second block based on the column headings.
Weld no. In the example above, data has been stored for four welds, which can be read
out from the far left column, Weld no. A new row is created with a new Weld no.
for each new weld. A weld must be longer than one second to be registered.
Note that this means that a start procedure that has been interrupted, but is
longer than one second, is logged with a new Weld no. A change to a parameter
during a weld in progress does not give cause for a new weld no. but is counted
as the same weld. Neither does requesting a new welding schedule give cause
for a new weld no., this produces a new row with the same weld no. in the qdata
file. This makes it easier to track changes made while welding is in progress.
SchedNo. The last requested welding schedule.
ChangeStatus Cause of any changes in the welding data parameters, see description below
Date The date on which the weld was performed, in YY/MM/DD format.
Start time The time when the weld was started in hours, minutes and seconds.
Weld time Welding time, i.e. duration of actual weld, in seconds.
Iave The average value of the current intensity during the welding time, in amperes.
Imax The maximum value of the current intensity during the welding time (A).
Imin The minimum value of the current intensity during the welding time (A).
Uave The average value of the voltage during the welding time, in volts.
Umax The maximum voltage value during the welding time (V).
Umin The minimum voltage value during the welding time (V).
Pave The average value of the power during the welding time, in watts.
Pmax The maximum value of the power during the welding time (W).
Pmin The minimum value of the power during the welding time (W).
10.8.3 Explanation of ChangeStatus:

ChangeStatus is based on a combination of three values:
Bit 0 Neither the wire speed nor voltage have been changed after the last requested
welding schedule
Bit 1 Wire speed and/or voltage have been changed during last weld
Bit 2 Registration is a part weld as it starts in a weld data switch (not new welding
start)
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10.8.4 Explanation of digits in the ChangeStatus column:

0 Neither the welding schedule, wire speed nor voltage have been changed since
the end of the previous weld.
1 Wire speed and/or voltage changed before welding started.
2 Wire speed and/or voltage changed during welding.
3 Wire speed and/or voltage changed before and during welding (1+2)
4 New welding schedule requested during weld in progress.
5 Does not occur
6 New welding schedule requested and wire speed and/or voltage changed during
weld in progress (4+2)
7 Does not occur
10.8.5 Description of welding data schedule

Each welding data schedule can have a short description. Under the ”Setting” and ”Edit description”
menus, the last requested welding data schedule can be given a description of 40 characters via the
built--in keyboard. The current description can also be modified or deleted.
If the requested schedule has a description, this is shown in the ”Memory”, ”Measure” and ”Remote”
windows instead of the welding data parameters which are otherwise displayed.
11 WELD DATA SETS

Main menu - - > Auxiliary functions menu
To enable you to use this function fully, insert a compact flash card into the controller
(see the 10 ”File manager”. chapter).
Please note that PC cards used in previous U8s can also be used for storage and
recall of welding data. Consequently, welding data saved on PC cards need not be
lost with this modification of the U8. The one requirement is that the U8 used for
storage must not have such an old software version that it causes compatibility
problems. Data stored using a PUA cannot be recalled on this controller.
11.1 Example: Saving welding data on a memory card
AUXILIARY FUNCTIONS
Highlight welding data

configurations. Press FILE MANAGER
STORE. WELD DATA SETS
CONFIGURATION
QUALITY FUNCTIONS
ERROR LOG
LIMIT EDITOR
STORE DELETE RECALL QUIT
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The entire welding data settings configuration saved in the welding data memory
(utilised memory positions 1--255) is now saved on the compact flash card in the
WeldData.awd file. The file is located in a folder called WData. WData is generated
automatically when you insert a memory card.
NB: If you have already saved welding data once and save again, the old file will be
overwritten without any warning. If you want to keep the old file, it must be renamed.
11.2 Recalling welding data from a memory card

The RECALL function recalls welding data from the WeldData.awd file, which is
located in the WData folder, to the welding data memory.
If you want to recall welding data with a different file name, or located in a folder
other than WData, use the recall function in the file manager (see the 10 ”File
manager” section)
11.3 Deleting welding data from a memory card

The DELETE function clears welding data from the WeldData.awd file.
12 CONFIGURATION MENU
Main menu -- --> Auxiliary function meny - - > Configuration menu
This menu contains the following submenus:
S Language, see chapter ”Do this first” 1.2.
S Code lock, see chapter 12.1.
S Remote controls, see chapter 12.2.
S MIG/MAG defaults, see chapter 12.3.
S MMA defaults, see chapter 12.4.
S General defaults, see chapter 12.5.
S Multiple wire feeders, see chapter 12.6.
S Unit of length, see chapter 12.7.
12.1 Code lock
Main menu - - > Auxiliary function menu -- --> Configuration menu -- --> Code
lock
When the code lock is enabled and you are in the measure image, remote control or
the fast mode menu, a password (lock code) is required to leave these menus.
CODE LOCK
LOCK STATUS: OFF

SET/CHANGE LOCK CODE
QUIT ENTER
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-- Code lock is enabled in the configuration menu.
12.1.1 Lock code mode

In lock code mode you can enable/disable the lock function without deleting the
existing lock code in case you disable the function. If no lock code is stored and you
attempt to enable the code lock, the following screen appears, in which you can
enter a new lock code.
When you have enabled the code, a small icon with a key appears to indicate that
the lock code function is enabled. You can then move freely between all menus
without any restriction, until you come to the measure image, remote control or the
fast mode menu, when the code lock is triggered this prevents the user from exiting
these menus without first entering the lock code.
CODE LOCK
LOCK STATUS: OFF

SET / CHANGE LOCK CODE
QUIT ENTER
Exiting lock code mode
When you are in the measure image or the fast mode menu and the code lock is
disabled, you are free to exit these menus by pressing the QUIT or MENU key to
return to the main menu.
If it is enabled and you try to exit, the following message appears to warn the user
about the lock code protection.
PRESS ENTER TO
LOCK CODE...
Here you can select QUIT to change your mind and return to the previous menu, or
proceed by pressing ENTER and keying in the lock code.
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This brings you to the keyboard display, where you can type in the lock code. After
each character press the PRESS KEY and confirm the lock code using the ENTER
key.
The following text box appears:
UNIT UNLOCKED!
If the lock code is incorrect, you will see an error message that gives the user the
option of trying again or returning to the original menu, i.e. the measure image or the
fast mode menu.
If the lock code is correct, all restrictions on moving to other menus are removed,
although the code lock remains enabled, which means that the user can leave the
measure image and fast mode menu temporarily, but when you return to them the
lock will be enabled once more.
12.1.2 Set / change lock code
In set/change lock code you can edit an existing lock code or enter a new one. A
lock code can consist of max. 10 letters or digits.
12.2 Remote control configuration

Main menu -- --> Auxiliary function menu - - > Configuration menu - - > Remote
control
A non CAN--bus connected remote control must be connected via a remote control
adapter. When connected, enable the remote control in the measure image under
the REMOTE soft key.
12.2.1 Forget override
Move the cursor to the line MIG/MAG -- REMOTE CONTROLS

for FORGET OVERRIDE
OVERRIDE.
Press ENTER to call up a FORGET OVERRIDE: DISABLE
list of options. DIGITAL OP: 5--PROG
ANALOG 1: VOLTAGE
ANALOG 2: WIRE SPEED
RANGE OF INPUTS:
ANALOG 1, DIG +/-- MIN --10.0 V
MAX 10.0 V
ANALOG 2 MIN 1.5 m/min
MAX 25.0 m/min
QUIT ENTER
When the ”Forget override” function is ”enable”, an automatic recall of last recalled
memory will be performed before each new weld starts. This is to eliminate the result
of all weld data tuning that has been done during the last weld procedure.
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12.2.2 Configuring a digital remote control

Without remote control adapter
When a CAN--bus remote control is connected, the configuration for DIGITAL OP is
made automatic.
With remote control adapter
When using a digital remote control, specify which type of remote control is being
used:
If you move the cursor to the line for DIGITAL OPERATED and press ENTER, you
will call up a list from which you can select an option.
BINARY CODED
5--PROG
S 32--program device BINARY CODED

S 5--program device or a welding gun with a 3--program choice 5--PROG
12.2.3 Configuring an analogue remote control
Without remote control adapter
When a CAN--bus remote control is connected, the configuration for ANALOG 1 and
ANALOG 2 is made automatic. You can not change the configuration.
With remote control adapter
When using an analogue remote control, you can use the controller to specify which
potentiometer(s) you want to use (maximum 2).
The potentiometers are designated ANALOG 1 and ANALOG 2 in the controller, and
these refer to the parameters defined for the welding process in each case, e.g.
voltage (ANALOG 1) and wire feed (ANALOG 2) for MIG/MAG.
If you move the cursor to the line for ANALOG 1 and NONE
press ENTER, a list appears. VOLTAGE
You can now select whether potentiometer ANALOG 1 is to be used (VOLTAGE) or

not (NONE).
Select the line for VOLTAGE and press ENTER
If you move the cursor to the line for ANALOG 2 and NONE
press ENTER, a list appears. WIRE SPEED
You can now select whether potentiometer ANALOG 2 is to be used (WIRE SPEED)
or not (NONE).
Select the line for WIRE SPEED and press ENTER
All remote control configurations apply to any wire feeders that are connected.
If you deselect ANALOG 1, this will apply for both wire feeders if you are using
double wire feeders.
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12.2.4 Range of inputs

You can set the control range for the potentiometer(s) to be used. You do this by
using the plus/minus keys on the controller to define a minimum value and a
maximum value.
Note you can set different voltage limits in synergy and non synergy modes. The
voltage setting in synergy is a deviation (plus or minus) of the synergy value. In non
synergy mode the voltage setting is an absolute value. The value set applies to
synergy when you are in synergy mode. When you are not in synergy mode it is an
absolute value. There are also different voltage control limits for dip/spray welding
and pulsing in non synergy mode.
Value after resetting
Synergy dip/spray and pulsing min --10 V max 10 V
Non synergy dip/spray min 8 V max 60 V
Non synergy pulsing min 8 V max 50 V
12.3 MIG/MAG defaults

Main menu -- --> Auxiliary function menu - - > Configuration menu - - >
MIG/MAG defaults
In this menu you can define the following:
S Gun trigger mode (2--stroke / 4--stroke)

S Soft keys setup
S Voltage measure in pulsed
S 4--stroke configuration
12.3.1 Gun trigger mode (2-- stroke / 4-- stroke)
2--stroke
Gas pre--flow Hot Welding Crater Gas post--flow

start fill
Functions when using 2--stroke control of the trigger.

In 2--stroke operation gas pre--flow (if used) starts when the trigger is pressed (1).
The welding process then starts. When the trigger is released (2), crater filling starts
(if selected) and the welding current is stopped. Gas post--flow starts (if selected).
TIP: Pressing the trigger again while crater filling is in progress continues crater
filling as long as the trigger is held depressed (the dotted line). Crater filling can also
be interrupted by quickly pressing and releasing the trigger while it is in progress.
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-- Activation of 2--stroke performed in the measure image, configuration menu or with

a soft key in the measure image.
4--stroke
There are 3 start and 2 stop positions for 4--stroke. This is start and stop position 1.
When resetting position 1 is selected. See the chapter 12.3.4 ”4--stroke
configuration”.
Gas pre--flow Hot Welding Crater fill Gas post--flow

start
Functions when using 4--stroke control of the trigger.

In 4--stroke operation gas pre--flow starts when the trigger is pressed (1). When the
trigger is released (2) the welding process starts. Pressing the trigger again (3) starts
crater filling (if selected) and reduces the weld data to a lower value. Releasing the
trigger (4) stops welding entirely and starts gas post--flow (if selected).
TIP: Crater filling stops when the trigger is released. Keeping it held in instead
continues crater filling (the dotted line).
For a different start and stop function for 4--stroke, see chapter 12.3.4 ”4--stroke”.
-- Activation of 4--stroke performed in the measure image, configuration menu or with
a soft key in the measure image.
12.3.2 Soft keys setup

We have already explained the ”soft” keys on the controller. When MIG/MAG welding
the user has the possibility of setting the function of these controls by selecting from
a list of set options. There are seven soft keys that can be assigned a function.
You can choose from the following options:
S None
S Gas purge
S Wire inching
S Trigger mode (2--stroke/4--stroke)
S Crater filling ON/OFF
S Creep start ON/OFF
S Hot start ON/OFF
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S Trigg weld data switch ON/OFF

The selection you set for weld data switch before the soft key is activated applies
with weld data switch ON. AT ARC OFF or ON.
Weld data switch is off when weld data switch OFF is selected.
The display image contains two columns: one for function and one for key number
ASSOCIATE FUNCTIONS TO SOFT KEYS
Function Soft key
NONE 7
GAS PURGE 6
WIRE INCHING 5
TRIGGER MODE (2/4) 3
CRATER FILL ON/OFF 1
CREEP START ON/OFF 4
CRATER HOT 4-- 2ND

FILL START STROKE QUIT FUNCT
The controller has five soft keys. Pressing the far right key
”2ND FUNCT” accesses an additional five soft keys.
When you assign functions to the keys, these are numbered from the left as follows
2ND
1 2 3 QUIT FUNCT
2ND •
4 5 6 7 FUNCT
How to assign a new function to a soft key:
S Position the cursor on the function row with the function ”NONE” and press the
soft key with the function that is to switch key number,
S Repeat the above for the key with the key number to be used.
S Position the cursor on the function row to which you want to give a new key
number and press the soft key to which you want to assign the function.
The other two keys can each have a new function assigned in the same way, by
pairing one of the functions in the left--hand column with a key number in the
right--hand column.
Gas purge
The gas purge function is used when measuring the gas flow or to purge the gas
hoses of any air and moisture before welding commences. Gas purging proceeds as
long as the key is pressed down, and is conducted without voltage and wire feed
being switched on.
Cold wire feed (wire inching)

Cold wire feed is used when you want to feed the wire without switching on the
welding voltage. The wire is fed at the set wire feed speed as long as the button is
pressed down.
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12.3.3 Voltage measurement for dip

The voltage measurement options for dip welding are as follows:
S Peak value for pulse voltage (PULSE)

The voltage is only measured during pulses and is filtered before the voltage
value is displayed.
S Average voltage value (AVERAGE)
The voltage is measured continuously and is filtered before the voltage value is
displayed.
The measured values displayed are used as input data for internal and external
quality functions.
12.3.4 4--stroke configuration

In 4--stroke configuration you can have different functions for 4--stroke start and stop.
4--stroke start mode

1 Trigger--controlled gas supply, see chapter 12.3.1 ”4--stroke”
2 Timer--controlled gas supply
Gas flow
Wire feed
Gas pre flow Welding
Press in the trigger (1), the gas supply starts, and after a preset gas supply period
the welding process starts. Release the trigger (2).
3 Trigger--controlled ”hot start”
Gas flow
Wire feed
Gas pre flow Hot start Welding
Press in the trigger (1), the gas supply starts, and ”hot start” is enabled until the
trigger is released (2).
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4--stroke stop mode

1 Time controlled crater filling with the possibility of extending this, see the chapter
12.3.1 ”4--stroke”
2 Trigger--controlled crater fill time
Gas flow
Wire feed
Welding ----------Crater filling--------
Press in the trigger (3), crater filling starts and expires. If the trigger is released (4)
during crater fill time (crater fill time reduced) the welding stops.
12.4 MMA defaults

Main menu -- --> Auxiliary function menu - - > Configuration menu - - > MMA
defaults
12.4.1 Hot start amplitude
Setting that defines how much current there is for ”hot start”. Stronger workpieces or
certain electrodes require a higher ”hot start” amplitude.
12.4.2 Hot start duration

Hot start increases the weld current for an adjustable time at the start of welding,
thus reducing the risk of poor fusion at the beginning of the joint.
12.4.3 Droplet welding

In droplet welding, the arc is struck and extinguished in order to achieve better
control over the heat supply. The electrode only needs to be raised slightly to
extinguish the arc. The start process is optimised for starting on hot material.
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12.5 General defaults

Main menu - - > Auxiliary function menu - - > Configuration menu - - > General
defaults
12.5.1 Fast mode soft keys
The soft keys ”WELD DATA 1” – ”WELD DATA 4” are visible in the fast mode menu.
These are configured as follows:
FAST MODE SOFT KEYS

with soft key numbers. SOFT KEY NUMBER : 1
The keys are numbered
1--4, from left to right.
Select the desired key by
entering its number using
the plus/minus keys.
ASSOCIATED WELD DATA: 1

QUIT
Then scroll down using the arrow down key to the line for ”ASSOCIATED WELD
DATA”. Here you can browse among the weld data settings that are stored in the
welding data memory. Select the desired weld data number using the plus/minus
keys.
12.5.2 Double start sources

When this option is activated (ON) you can start MIG/MAG welding both from the
wire feed unit’s start input and from the power source’s TIG--start input and vice
versa. When welding is started from a start signal input it must be stopped from the
same input.
12.5.3 Panel remote enable

Ordinarily you cannot make settings using the pushbuttons when the panel is in
remote control mode. When “panel remote enable.” is ON the current/wire feed or
voltage can be set using the control panel and remote control.
When “panel remote enable.” is used in combination with limits, machine usage can
be limited to a specific setting range. This applies to the following settings: wire feed
and voltage for MIG/MAG welding, current setting for MMA and TIG welding, pulse
current with pulsed TIG.
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12.5.4 Auto save mode

When a weld data set has been recalled from a memory position in the weld data
memory and you change the settings, the changes will be automatically saved in the
memory position when you recall a new weld data set from memory.
Saving weld data manually in a memory position blocks the next automatic save.
The memory number in which the data is stored is displayed in the upper right corner
in the measure image.
12.5.5 Trigger weld data switch
This function enables the user to switch to various preset weld data options by
double--clicking the welding torch’s trigger.
Switching take place between choosen memory positions (maximum 5 memory
positions) (see chapter 8 ”Memory management”).
OFF -- No weld data switching.
AT ARC OFF -- The user can not switch between memory positions during welding.
ON -- The user can switch between memory positions always.
Enabling weld data switch
TRIGGER WELD DATA SWITCH

for TRIGGER WELD DATA TRIGGER WELD DATA SWITCH OFF
SWITCH and press ADD/DELETE WELD DATA 1
ENTER. Select OFF, AT
ARC OFF or ON. Press
ENTER. SELECTED WELD DATA:
STORE DELETE QUIT ENTER

Selecting weld data from the memory
TRIGGER WELD DATA SWITCH

for ADD/DELETE WELD TRIGGER WELD DATA SWITCH AT ARC OFF
DATA. ADD/DELETE WELD DATA 10
Select the numbers of the
memories where the SELECTED WELD DATA: 52 4 10
relevant weld data is stored
using the plus/minus keys,
and then press STORE.
STORE DELETE QUIT ENTER

The line for SELECTED WELD DATA shows which weld data has been selected and
in which order it comes, from left to right.
To remove weld data, repeat the above process but press the DELETE key.
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12.5.6 Quality data logging

To enable you to use this function, insert a compact flash card into the controller, see
the 10 ”File manager”. chapter.
Activating/deactivating logging of quality data
CONFIGURATION -- GENERAL DEFAULTS
Use the arrow keys to

highlight QUALITY DATA FAST MODE SOFT BUTTONS
LOG TO FILE and press DOUBLE START SOURCES: OFF
ENTER.
PANEL REMOTE ENABLE OFF
AUTO SAVE MODE: OFF
TRIGGER WELDDATA SWITCH
QUALITY DATA LOG TO FILE ON
QUIT ENTER
Highlight ON and press ENTER to activate. Highlight OFF and ON

press ENTER to deactivate. OFF
Once logging has been activated, quality data is saved continuously on the compact
flash card, i.e. after each weld, data about it is automatically saved in a file on the
card. With the first weld after logging has been started, a file is generated into which
data on all subsequent welds is also saved.
content” chapter.
Naming quality data files with continuous incorporation

The files are named using the format CQdata050621_01.aqd. The file name always
starts with CQdata (specific to continuously saved quality data) and ends with .aqd
(common to all quality data files). The figures in the example denote that it is a file
generated on 21 June 2005 and that was the first file generated on that day.
If logging is suspended and resumed on the same day, the later file will have a
higher serial number. In this example, the name of the new file would be
CQdata050621_02.aqd.
If logging continues into the next day, a new file will be initiated with the day’s date in
the name. In this example, the name of the new file would be CQda-
ta050622_01.aqd.
The file is placed in a folder called QData. QData is generated automatically when
you insert a compact flash card.
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12.6 Multiple wire feeders

Main menu -- --> Auxiliary fuction menu - - > Configuration menu-- - > Multiple
wire feeders
When connecting multiple wire feed units (maximum 4), use wire feed units without
weld data unit, control panel M0.
All wire feeders are delivered with the ID number 0.
The first thing to do when connecting multiple wire feeders is to switch the ID number
(node address) of one wire feeder.
To switch ID number, do as follows:
S Connect the first wire feeder, then go to the ”MULTIPLE WIRE FEEDERS” menu.
S Press and release the trigger to enable the wire feeder.
S Then read the wire feeder’s ID number from the first line (should be 0 the first
time), and select a new ID number between 1--3.

for SELECT A NEW ID CURRENT ID NUMBER
NUMBER. Set the desired SELECT A NEW ID NUMBER: 0
number between 0--3 by
scrolling using the
plus/minus keys. CONNECTED WIRE FEEDERS ID
Press ENTER.
QUIT ENTER
In the top line the figure for the ID number will change to the desired number.
S Connect the next wire feeder.

S Press and release the trigger to enable this wire feeder, and now you will see
that the wire feeder’s ID number is 0.
Configuration is now complete, and you can start to use the equipment in the usual
way. You can use the same procedure to configure and run four wire feeders. The
important issue when using multiple wire feeders is not which ID numbers you
assign, but that you assign different numbers so that you can differentiate between
them.
If you accidentally assign the same ID number to two wire feeders, error message 15
will appear on the display continuously. Disconnect one wire feeder and restart the
above procedure. You can always call up the ”MULTIPLE WIRE FEEDERS” menu
and check the ID numbers of the connected wire feeders by pressing the trigger.
In the line for CONNECTED WIRE FEEDERS ID you can see the ID numbers of all
connected wire feeders.
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12.6.1 Weld data

Weld data is connected individually to each wire feeder. To connect weld data to a
wire feeder, it must be active; when it is, you can recall data in the usual way, see
chapter 8 ”Memory management”, and make any necessary modifications. All of this
will then be connected to the active wire feeder.
To enable the next wire feeder, press and release the trigger. Then recall the weld
data that you want to connect to this wire feeder.
12.7 Unit of length

Main menu -- --> Auxiliary function menu - - > Configuration menu - - > Unit of
length
Here you can choose whether you want:
METRIC
INCH
13 QUALITY FUNCTIONS
Main menu - - > Auxiliary function menu - - > Quality functions
Quality functions keep track of a range of useful weld data for individual welds.
These functions are:
S Time of weld start
S How long the weld took
S Average, maximum and minimum current during welding
S Average, maximum and minimum voltage during welding
S Average, maximum and minimum power during welding
You can also key in the length of the joint manually, and the weld data unit will
calculate the heat input.
The number of welds since the last reset is also displayed. Information on up to 100
welds can be stored. With more than 100 welds the first is ignored. A weld must last
longer than 1 second to be registered.
The last recorded weld is shown on the display, but you can also scroll through all
other recorded welds. When you press RESET, all variables are reset to zero.
QUALITY FUNCTIONS
WELD 1 START: 26--MAY--03 16.55.13

WELD TIME:
W LENGTH.0cm HEAT INPUT 0.00 kJ/mm
AVE. MAX MIN
I (Amp) 0.00 0.00 0.00
U (V) 0.00 0.00 0.00
P (kW) 0.00 0.00 0.00
NUMBER OF WELDS SINCE RESET: 0
RESET QUIT
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You can select a particular weld by pressing the plus/minus keys when the cursor is
on the line that shows the relevant weld number.
In the same way, you can enter the length of the weld to obtain the heat input.
13.1 Saving quality data on a compact flash card

To enable you to use this function, insert a compact flash card into the controller (see
the 10 ”File manager” chapter).
AUXILIARY FUNCTIONS
Highlight quality functions.

Press STORE. FILE MANAGER
WELD DATA SETS
CONFIGURATION
QUALITY FUNCTION
ERROR LOG
LIMIT EDITOR
STORE QUIT ENTER

The entire quality data configuration (information on the last 100 welders) stored on
the controller is now saved on the compact flash card.
content” chapter.
The files are named as in this example: Qdata050620_1.aqd. The name always
starts with Qdata, and the extension is always .aqd. The figures in between are date
and serial number. In the example you can see that the file was generated on 20
June 2005 and that it was the first quality data file generated on that day.
The file is located in a folder called QData. QData is generated automatically when
you insert a compact flash card.
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14 PRODUCTION STATISTICS
Main menu -- --> Auxiliary function menu -- --> Production statistics
Production statistics are used to keep track of the total arc time, the total volume of
material used and the number of welds since the last reset. They also keep track of
the arc time and the amount of material used for the last weld. For further reference,
the display also shows the wire material consumed per unit of length, and when the
last reset took place.
The number of welds is not increased if the arc time was less than 1 second. The
display therefore does not show how much material was consumed for such a short
weld. However, material consumption and the time are included when calculating the
total material consumption and arc time.
LAST WELD TOTALT
ARC TIME 0s 0s
CONSUMED WIRE 0g 0g
BASED ON 8.9 g/m
NUMBER OF WELDS 0
LAST RESET 26--MAY--03 16.55.13
RESET QUIT
When you press RESET all counters are reset to zero, and the date and time show
the last reset.
If you do not reset the counters, these are all automatically reset when one of then
has reached its maximum value.
Maximum counter values

Time 999 hours, 59 minutes, 59 seconds
Weight 13350000 grams
Quantity 65535
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15 ERROR LOG
Main menu - - > Auxiliary function menu - - > Error log
Error monitoring codes are used to indicate that an error has occurred in the welding
process. This is shown in the display with the aid of a pop--up menu, which appears
for 2.5 seconds. After this, an exclamation mark is displayed in the top right--hand
corner of the display.
Note! disappears from the display as soon as you call up the error log menu.
All errors that occur when the welding equipment is in use are documented as error
messages in the error log. Up to 99 error messages can be saved. If the error log is
full, i.e. if 99 error messages have been saved, the oldest message is automatically
deleted when the next error occurs.
The following information can be seen in the error log menu:
S The error’s error number

S When the error occurred (date, time)
S Where the error occurred
S The error code
67 " Date Time Unit Error
030528 11:24,13 U8 19
Error in battery--driven memory
030528 11:24,18 U8 18
Lost contact with power source
030528 11:24,18 U8 17
Lost contact with wire feeder
DELETE VIEW
DELETE ALL TOTAL QUIT
15.1 Deleting error messages

If you want to delete error messages there are two options, each with its own soft
key.
S Delete selected messages

S Delete all messages
15.2 Reviewing error summary

By pressing the ”VIEW TOTAL” key you can call up a presentation of the number of
registered error messages in the error log. Here you can also see the date and time
of the oldest and most recently registered error messages.
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15.3 Error code list
Error Description Controller Power Wire

code source feeder
1 Memory error EPROM x x x
2 Memory error RAM x x x
3 Memory error external RAM x
4 5V power supply x x x
5 High DC intermediate voltage x
6 High temperature x
7 High primary current x
8 Mains power supply 1* x x x
9 Mains power supply 2* x x
10 Mains power supply 3* x
11 Wire feed servo x x
12 Communication error (warning) x x x
14 Communication error (bus off) x
15 Messages lost x x x
17 Lost contact with wire feeder x
18 Lost contact with power source x
19 Incorrect setting values in external RAM x
20 Unacceptable settings stored in RAM x
21 Incompatible settings stored in RAM x
22 Transmitter buffer overflow x
23 Receiver buffer overflow x
25 Incompatible weld data format x
26 Program error x x x
27 Out of wire x
28 Program data lost x x x
29 No cooling water flow x
30 Lost contact with TIG card x
31 No reply from display unit x
32 No gas flow x x
40 Incompatible units x
Unit Mains power Mains power Mains power supply 3*

supply 1* supply 2*
Controller +3 V
Mig 4500i +15 VC --15 V +15 VB
Mig 4000i/Mig 5000i/L 3000i +15 V --15 V +24 V
Wire feeder 15 V 20 V
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15.4 Error code descriptions

Error Description
code
1 Program memory error (EPROM)
The program memory is damaged.
This fault does not disable any functions.
Action: Restart the machine. If the error persists, call a service engineer.
2 Microprocessor RAM error
The microprocessor cannot write/read to the internal memory.
3 External RAM error
The microprocessor cannot write/read to the external memory.
4 5 V power supply low
The power supply voltage is too low.
The current welding process is stopped and cannot be restarted.
Action: Turn off the mains power supply to reset the system. If the error persists, call a
service engineer.
5 Intermediate DC voltage outside limits
The voltage is too low or too high. Too high a voltage can be due to severe transients on
the mains power supply or to a weak power supply (high inductance in the mains or a
phase lost).
The power source stops and cannot be restarted.
service engineer.
6 High temperature
The thermal overload cutout has been triggered.
The current welding process is stopped, and cannot be restarted until the cutout has reset.
Action: Check that the cooling air inlets or outlets are not blocked or clogged with dirt.
Check the duty cycle being used, to make sure that the equipment is not being overloaded.
7 High primary current
The power source is drawing too much voltage from the DC that is supplying it.
The power source stops and cannot be restarted.
service engineer.
8 Low battery voltage +3V, (controller)
Battery voltage too low. If the battery is not replaced, all data stored will be lost.
Action: Call a service engineer to replace the battery.
8 +15VC power supply, (Mig 4500i)
The supply voltage is too high or too low.
Action: Call a service engineer.
8 +15V power supply, (Mig 4000i/Mig 5000i)
8 +15V power supply, (wire feeder)
The supply voltage on the PCB is too high or too low.
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Error Description
code
9 --15V power supply, (power unit)
9 +20V power supply, (wire feeder)
10 +15VB power supply, (Mig 4500i)
10 +24VB power supply, (Mig 4000i/Mig 5000i)
11 Wire speed
The wire speed is deviating from the preset value.
When this error occurs, the wire feed process stops.
12 Communication error (warning)
The load on the system’s CAN bus is too high at the moment.
The power source/wire feeder might have lost contact with the controller.
Action: Check the equipment to make sure that everything is properly connected.
If the error persists, call a service engineer.
14 Communication error
The system’s CAN bus has temporarily stopped working due to the load being too high.
The current welding process stops.
Action: Check the equipment to make sure that everything is properly connected. It will
be necessary to turn off the power supply to reset the system. If the error persists, call a
service engineer.
15 Messages lost
The microprocessor cannot process incoming messages at the required speed, and
information has been lost.
Action: It will be necessary to turn off the power supply to reset the system. If the error
persists, call a service engineer.
17 Lost contact
The controller has lost contact with the wire feeder.
Action: Check the cables. If the error persists, call a service engineer.
18 Lost contact
The controller has lost contact with the power unit.
19 Memory error in battery--powered data memory RAM
The battery has no power.
Action: Turn off the mains power supply to reset the system. Reset the controller. The
settings will be in English with MIG/MAG, DIP/SPRAY, Fe, CO2, 1.2 mm.
-- 61 --
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Error Description
code
20 Non--permitted settings stored in RAM.
Non--permitted values have been found during start--up. Deletes all data in the controller.
Action: Turn off the mains power supply to reset the system. Reset the controller. The
settings will be in English with MIG/MAG, DIP/SPRAY, Fe, CO2, 1.2 mm.
21 Incompatible settings stored in RAM.
Non--permitted weld data combinations have been entered.
Action: It will be necessary to turn off the power supply to reset the system. If the error
persists, call a service engineer.
22 Transmitter buffer overflow
The controller cannot transmit information to the other units at a sufficiently high speed.
Action: Turn off the mains power supply to reset the system.
23 Receiver buffer overflow
The controller cannot process information from the other units at a sufficiently high speed.
Action: Turn off the mains power supply to reset the system.
25 Incompatible weld data format
Tried to store weld data on a PC card. The PC card has a different data format than the
weld data memory.
Action: Use a different PC card.
26 Program error
Something has prevented the processor from performing its normal duties in the program.
The program is restarted automatically. The current welding process will be stopped. This
fault does not disable any functions.
Action: Review the handling of welding programs during welding. If the error is repeated,
call a service engineer.
27 Out of wire (wire feeder)
The wire feeder is not feeding out any wire. The current welding process will be stopped,
and prevent welding from restarting.
Action: Load new wire.
28 Program data lost
Program execution does not work.
service engineer.
29 No cooling water flow
The flow monitor switch has been triggered.
The current welding process is stopped and cannot be restarted.
Action: Check the cooling water circuit and the pump.
30 Lost contact with TIG card
The controller has lost contact with the TIG card. The current activity stops.
31 No reply from display unit
The microprocessor has no contact with the display card.
-- 62 --
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Error Description
code
32 No gas flow
Gas flow is less than 6 l/min. Unable to start.
Action: Check the gas valve, hoses and connectors.
40 Incompatible units
Incorrect wire feed unit is connected. Start is prevented
Action: Connect the correct wire feed unit.
16 USER--DEFINED SYNERGIC DATA

Main menu -- --> Auxiliary function menu - - > User-- defined synergic data
It is possible to create user--defined synergic lines that relate to the wire feed speed
and voltage. A maximum of ten such synergic lines can be saved.
Creation of a new synergic line is performed in two stages:
1. Define the new synergic line by specifying a number of voltage/wire speed

co--ordinates, see steps A--D in the following diagram:
Voltage
Wire feed
2. Specify which wire/gas combination the new synergic line is to apply to.
16.1 Specify voltage/wire co--ordinates

You need four co--ordinates to create a synergic line for dip/spray welding, and two
co--ordinates for pulse welding. These co--ordinates must then be saved under
special weld data numbers in the weld data memory.
16.1.1 Dip/spray
S Call up the main menu and select the MIG/MAG method DIP/SPRAY.
S Key in the desired values for voltage and wire feed speed for the first
co--ordinate.
S Call up the memory menu and store the first co--ordinate as weld data number
96.
S The four co--ordinates for a dip/spray line must be saved as numbers 96, 97,
98 and 99.
-- 63 --
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The following also applies:

S A higher weld data number must contain higher values for voltage and
wire feed speed than the weld data number that precedes it.
S The weld parameters inductance, regulator type and hot start--voltage
must have the same values in all four weld data numbers.
S Define the number of co--ordinates that are needed, and then proceed to chapter
16.2 ”Specifying the valid wire/gas combination”.
16.1.2 Pulsing
S Call up the main menu and select the MIG/MAG method PULSE.
S Key in the desired values for voltage and wire feed speed for the first
co--ordinate.
S Call up the memory menu and store the first co--ordinate as weld data number
96.
S The two co--ordinates for a pulse line must be saved as numbers 96 and 97.
The following also applies:
S A higher weld data number must contain higher values for voltage, wire
feed speed, pulse frequency, pulse amplitude and background current
than the weld data number that precedes it.
S The weld parameters pulse time, hot start--voltage, Ka, Ki and ”slope”
must have the same value in both weld data numbers.
S Define the number of co--ordinates that are needed, and then proceed to chapter
16.2 ”Specifying the valid wire/gas combination”.
16.2 Specifying the valid wire/gas combination
MAKE CUSTOMISED SYNERGIC LINES
Move the cursor to the line WIRE TYPE Fe

for WIRE TYPE and press SHIELDING GAS: CO2
ENTER. WIRE DIAMETER : 1.2 mm
STORED NEW LINE FROM

WELD DATA MEMORY 96, 97
DELETE SYNERGIC LINE
QUIT ENTER
-- 64 --
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S Select one of the options from the list and press Fe

ENTER. Ss (Stainless)
Ss duplex
Al Mg
Al Si
Metal cored Fe
Rutile FCW Fe ↓
S Make a selection for shielding gas in the same way, CO2

and press ENTER. Ar+20%CO2
Ar+2%O2
Ar
He
Ar+30%He+1%O2
Ar+2%CO2 ↓
S Make a selection for wire diameter in the same way, 0.6 mm

and press ENTER. 0,8 mm
1.0 mm
1.2 mm
1.4 mm
1.6 mm
2.0 mm ↓
S Select the line for STORE NEW LINE ..... and press ENTER.
The operation is now complete – a synergic line has been defined.
Note! A corresponding dip/spray synergy is needed for each pulsing instance.
When you create a new synergic line for the pulse welding method, you will therefore
always receive a warning message if a corresponding line has not been created for
the dip/spray welding method.
WARNING!
No corresponding synergic line
for dip/spray welding
16.3 Creating user--defined wire/gas options
The lists of wire/gas options can be extended to include Ar+15%CO2+5%O2 ↑

up to ten user--defined options. At the bottom of each list Ar+50%He
is an empty line (------). If you place the cursor on this line SELF SHIELDED
and press ENTER, you gain access to a ”keyboard” that Ar+16%CO2
allows you to type in your own options. Ar+25%CO2
Ar+1%O2
------
-- 65 --
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The controller’s ”keyboard” is used as follows:

S Position the cursor over the desired
keyboard character using the arrow keys.
Press the soft key ”PRESS KEY”. Type in a
full text string with a maximum 13 characters
in this way.
S Position the cursor over and press the
soft key ”PRESS KEY”, after which the
user--defined, named option will appear in
the list.
How to delete a user--defined option:
S Select the user--defined wire/gas option in the current list.
S Press the soft key ”DELETE”.
Note! A user--defined wire/gas option cannot be deleted if it is part of the weld data
setting that is currently in the working memory.
16.4 Deleting a user--defined synergic line

A user--defined synergic line can be deleted if it is not enabled, i.e. if it is not part of
the weld data setting that is currently in the working memory.
S Move the cursor to the line for DELETE SYNERGIC LINE.

S Press the soft key ENTER.
A new screen appears in the display. Here you can use the NEXT soft key to scroll
through the user--defined synergic lines that have been saved.
MAKE CUSTOMISED SYNERGIC LINES
Scroll to the line to be

deleted and press the
DELETE key. CHOOSE SYNERGIC LINE TO BE DELETED
" PULSE, Ss duplex, Ar, 1.4 mm
NEXT DELETE QUIT
17 LIMIT EDITOR
Main menu -- --> Auxiliary function menu - - > Limit editor
Values for wire feed/current or voltage. You can enter 50 different limits.
This function does not apply for arc air gouging.
-- 66 --
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This is how to enter various limits:
GENERAL DEFAULTS -- LIMIT EDITOR
Select the number for which LIMIT NUMBER: 1

you want to enter limits (2) PROCESS: --
and press ENTER.
Select the process to which
it applies (MIG/MAG) and
press ENTER
DELETE QUIT ENTER

The following menu appears:
GENERAL DEFAULTS -- LIMIT EDITOR
Move the cursor to the line LIMIT NUMBER: 1

for VOLTAGE. Use the PROCESS: MIG/MAG
#plus/minus key for max.
voltage setting and the
VOLTAGE: MAX 60.0 V
*plus/minus key for min.
voltage setting. MIN 8.0 V
WIRE SPEED: . MAX 25.0 m/min
MIN 1.5 m/min
AUTO DELETE QUIT

Follow the same procedure for WIRE SPEED.
TIP: If you want to set limits at +/--10% from actual data, press AUTO.
When you have selected a limit number, the limits for the operator are not locked
until you set the wire feed speed/current and voltage within the limit values.
18 OTHER INFORMATION
18.1 ESAB Logic Pump (Water lock)

U8 works together with the ELP function on the wire feed unit/power source, see the
Instruction Manual for the wire feed unit/power source for further information.
-- 67 --
bi09d1e2
Wire and gas combinations
MIG/MAG welding with DIP/SPRAY

Wire type Shielding gas Wire diameter (mm)
Low alloy or unalloyed wire CO2 0.8 0.9 1.0 1.2 1.6*
(Fe) Ar + 20% CO2 0.8 0.9 1.0 1.2 1.6*
Ar + 2% O2 0.8 0.9 1.0 1.2 1.6*
Ar + 5%O2 + 5% CO2 0.8 1.0 1.2 1.6*
Ar + 8% CO2 0.8 0.9 1.0 1.2 1.6*
Ar + 23% CO2 0.8 1.0 1.2 1.6*
Ar + 15% CO2 + 5%O2 0.8 0.9 1.0 1.2 1.6*
Ar +16% CO2 0.8 1.0 1.2 1.6*
Ar + 25% CO2 0.8 0.9 1.0 1.2 1.6*
Ar + 2% CO2 0.8 1.0 1.2 1.6*
SELF--SHIELDING 1.2 1.6*
Stainless solid wire (Ss) Ar + 2%O2 0.8 0.9 1.0 1.2 1.6*
Ar + 30%He + 1%O2 0.8 1.0 1.2 1.6*
Ar + 2% CO2 0.8 0.9 1.0 1.2 1.6*
Ar + 3%CO2 + 1%H2 0.8 0.9 1.0 1.2 1.6*
Ar + 32%He + 3%CO2 + 1% H2 0.8 0.9 1.0 1.2 1.6*
Stainless duplex wire Ar + 2% O2 1.0
(Ss Duplex) Ar + 30%He +1%O2 1.0
Magnesium--alloyed Ar 0.9 1.0 1.2 1.6*
aluminium wire (AlMg)
Silicon--alloyed aluminium Ar 0.9 1.0 1.2 1.6*
wire (AlSi) Ar + 50% He 0.9 1.0 1.2 1.6*
Metal powder cored wire (Fe) Ar + 20% CO2 1.0 1.2 1.4* 1.6*
Ar+ 8% CO2 1.0 1.2 1.4* 1.6*
Rutile flux cored wire CO2 1.2 1.4* 1.6*
(Fe) Ar + 20% CO2 1.2 1.4* 1.6*
Basic flux cored wire CO2 1.0 1.2 1.4* 1.6*
(Fe) Ar + 20% CO2 1.0 1.2 1.4* 1.6*
Stainless flux cored wire Ar + 20% CO2 1.2
(Ss) Ar+ 8% CO2 1.2
SELF--SHIELDING 1.6* 2.4*
Duplex rutile flux Ar + 20% CO2 1.2
cored wire (Ss)
Metal powder cored stainless Ar + 8% CO2 1.2
wire (Ss) Ar + 2% O2 1.2
Ar + 20% CO2 1.2
Ar + 2% CO2 1.2
Nickel base Ar + 50% He 0.9
Silicon bronze (CuSi3) Ar + 1%O2 1.0 1.2
Ar 1.0 1.2
Copper and aluminum wire Ar 1.0 1.2
(CuAl8) Ar + 1%O2 1.0 1.2
*) Only for Mig 4000i, Mig 4500i, Mig 5000i
-- 68 --
bi09syn
MIG/MAG welding with PULSE
Wire type Shielding gas Wire diameter (mm)

Low alloy or unalloyed wire Ar + 20% CO2 0.8 0.9 1.0 1.2 1.6*
(Fe) Ar + 2% O2 0.8 0.9 1.0 1.2 1.6*
Ar + 2% CO2 0.8 1.0 1.2 1. 6*
Ar + 5%O2 + 5% CO2 0.8 0.9 1.0 1.2 1.6*
Ar + 8% CO2 0.8 0.9 1.0 1.2 1. 6*
Ar + 23% CO2 0.8 1.0 1.2 1.6*
Ar +16% CO2 0.8 1.0 1.2 1.6*
Ar + 25% CO2 0.9
Ar + 5%O2 1.0 1.2
Stainless wire (Ss) Ar + 2%O2 0,8 1.0LOW 1.0HIGH 1.2 1.6*
Ar + 30%He + 1%O2 0.8 1.0 1.2 1.6*
Ar + 2% CO2 0,8 0,9 1.0LOW 1.0HIGH 1.2 1.6*
Ar + 3% CO2 + 1%H2 0.8 0.9 1.0 1.2 1.6
Ar + 32%He + 3%CO2 + 1% H2 0.8 0.9 1.0 1.2 1.6
Stainless duplex wire Ar + 30%He + 1%O2 1.0
(Ss Duplex) Ar + 2%O2 1.0
Magnesium--alloyed Ar 0.8 0.9 1.0 1.2 1.6*
aluminium wire (AlMg) Ar + 50%He 1.2
Silicon--alloyed aluminium Ar 0,9 1,0 1.2 1.6*
wire (AlSi) Ar + 50% He 0.9 1.0 1.2 1.6*
Metal powder cored wire Ar + 20% CO2 1.0 1.2 1.4* 1.6*
(Fe) Ar + 8% CO2 1.0 1.2 1.4* 1.6*
Metal powder cored Ar + 2% O2 1.2
stainless wire (Ss) Ar + 2% CO2 1.2
Ar + 8% CO2 1.2
Nickel base Ar 1.0 1.2
Ar + 50% He 0.9 1.0 1.2
Ar + 30% He + 2%H2 1.0
Ar + 30% He + 0.5%CO2 1.0
Silicon bronze (CuSi3) Ar + 1% O2 1.0 1.2
Ar 1.0 1.2
Stainless wire (13964) Ar + 8%O2 1.0LOW 1.0HIGH
Copper and aluminum wire Ar 1.0 1.2
(CuAl8) Ar + 1%O2 1.0 1.2
*) Only for Mig 4000i, Mig 4500i, Mig 5000i

MMA welding
Electrode type Electrode diameter (mm)

Basic 1.6 2.0 2.5 3.2 4.0 4.5 5.0 5.6* 6.0*
Rutile 1.6 2.0 2.5 3.2 4.0 4.5 5.0 5.6* 6.0* 7.0*
Cellulose 2.5 3.2 4.0 5.0
*) Only for Mig 4000i / Mig 5000i

Carbon, arc air
Electrode diameters (mm) 4.0 5.0 6.0 8.0
-- 69 --
bi09syn
U8
Ordering number
Ordering no. Denomination
0456 290 981 Aristot U8

0459 310 270 Instruction manual SE
0459 310 271 Instruction manual DK
0459 310 272 Instruction manual NO
0459 310 273 Instruction manual FI
0459 310 274 Instruction manual GB
0459 310 275 Instruction manual DE
0459 310 276 Instruction manual FR
0459 310 277 Instruction manual NL
0459 310 278 Instruction manual ES
0459 310 279 Instruction manual IT
0459 310 280 Instruction manual PT
0459 310 282 Instruction manual PL
0459 310 283 Instruction manual HU
0459 310 284 Instruction manual CZ
0459 310 990 Spare parts list
Instruction manuals and the spare parts list are available on the Internet at www.esab.com
-- 70 -- Edition 080115
bi09o11a
U8
Accessories
Control cable (connectors included)

5 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0456 280 881
10 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0456 280 882
Adapter set 230 V AC / 12 V DC, for control 0457 043 880

box . . .
(for training with the control box disconnected
from the machine).
Compact Flash Memory 1Gb . . . . . . . . . . . . 0194 255 001
PCMCIA--Compact Flash adapter . . . . . . . 0194 256 001
-- 71 -- R0459 310/E080115/P72
bi09a11a
ESAB subsidiaries and representative offices
Europe NORWAY Asia/Pacific Representative offices

AUSTRIA AS ESAB BULGARIA
CHINA
ESAB Ges.m.b.H Larvik ESAB Representative Office
Tel: +47 33 12 10 00 Shanghai ESAB A/P
Vienna--Liesing Shanghai Sofia
Tel: +43 1 888 25 11 Fax: +47 33 11 52 03 Tel/Fax: +359 2 974 42 88
Tel: +86 21 5308 9922
Fax: +43 1 888 25 11 85 Fax: +86 21 6566 6622
POLAND EGYPT
BELGIUM ESAB Sp.zo.o. INDIA ESAB Egypt
S.A. ESAB N.V. Katowice ESAB India Ltd Dokki--Cairo
Brussels Tel: +48 32 351 11 00 Calcutta Tel: +20 2 390 96 69
Tel: +32 2 745 11 00 Fax: +48 32 351 11 20 Tel: +91 33 478 45 17 Fax: +20 2 393 32 13
Fax: +32 2 745 11 28 Fax: +91 33 468 18 80
PORTUGAL ROMANIA
THE CZECH REPUBLIC ESAB Lda INDONESIA ESAB Representative Office
ESAB VAMBERK s.r.o. Lisbon P.T. ESABindo Pratama Bucharest
Vamberk Tel: +351 8 310 960 Jakarta Tel/Fax: +40 1 322 36 74
Tel: +420 2 819 40 885 Fax: +351 1 859 1277 Tel: +62 21 460 0188
Fax: +420 2 819 40 120 Fax: +62 21 461 2929 RUSSIA
SLOVAKIA LLC ESAB
DENMARK ESAB Slovakia s.r.o. JAPAN Moscow
Aktieselskabet ESAB Bratislava ESAB Japan Tel: +7 095 543 9281
Herlev Tel: +421 7 44 88 24 26 Tokyo Fax: +7 095 543 9280
Tel: +45 36 30 01 11 Fax: +421 7 44 88 87 41 Tel: +81 3 5296 7371
Fax: +45 36 30 40 03 Fax: +81 3 5296 8080 LLC ESAB
SPAIN St Petersburg
FINLAND ESAB Ibérica S.A. MALAYSIA Tel: +7 812 336 7080
ESAB Oy Alcalá de Henares (MADRID) ESAB (Malaysia) Snd Bhd Fax: +7 812 336 7060
Helsinki Tel: +34 91 878 3600 Selangor
Tel: +358 9 547 761 Fax: +34 91 802 3461 Tel: +60 3 8027 9869
Fax: +358 9 547 77 71 Fax: +60 3 8027 4754 Distributors
SWEDEN For addresses and phone
FRANCE ESAB Sverige AB SINGAPORE numbers to our distributors in
ESAB France S.A. Gothenburg ESAB Asia/Pacific Pte Ltd other countries, please visit our
Cergy Pontoise Tel: +46 31 50 95 00 Singapore home page
Tel: +33 1 30 75 55 00 Fax: +46 31 50 92 22 Tel: +65 6861 43 22
www.esab.com
Fax: +33 1 30 75 55 24 ESAB international AB Fax: +65 6861 31 95
Gothenburg
GERMANY Tel: +46 31 50 90 00 SOUTH KOREA
ESAB GmbH Fax: +46 31 50 93 60 ESAB SeAH Corporation
Solingen Kyungnam
Tel: +49 212 298 0 SWITZERLAND Tel: +82 55 269 8170
Fax: +49 212 298 218 ESAB AG Fax: +82 55 289 8864
Dietikon
GREAT BRITAIN Tel: +41 1 741 25 25 UNITED ARAB EMIRATES
ESAB Group (UK) Ltd Fax: +41 1 740 30 55 ESAB Middle East FZE
Waltham Cross Dubai
Tel: +44 1992 76 85 15 North and South America Tel: +971 4 887 21 11
Fax: +44 1992 71 58 03 Fax: +971 4 887 22 63
ARGENTINA
ESAB Automation Ltd CONARCO
Andover Buenos Aires
Tel: +44 1264 33 22 33 Tel: +54 11 4 753 4039
Fax: +44 1264 33 20 74 Fax: +54 11 4 753 6313
BRAZIL
HUNGARY
ESAB S.A.
ESAB Kft
Contagem--MG
Budapest
Tel: +55 31 2191 4333
Tel: +36 1 20 44 182
Fax: +55 31 2191 4440
Fax: +36 1 20 44 186
CANADA
ITALY ESAB Group Canada Inc.
ESAB Saldatura S.p.A. Missisauga, Ontario
Mesero (Mi) Tel: +1 905 670 02 20
Tel: +39 02 97 96 81 Fax: +1 905 670 48 79
Fax: +39 02 97 28 91 81
MEXICO
THE NETHERLANDS ESAB Mexico S.A.
ESAB Nederland B.V. Monterrey
Amersfoort Tel: +52 8 350 5959
Tel: +31 33 422 35 55 Fax: +52 8 350 7554
Fax: +31 33 422 35 44
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.com
070514

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Rights reserved to alter specifications without notice.

Rights reserved to alter specifications without notice.

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Rights reserved to alter specifications without notice.

1.2 Do this first

When delivered, the controller is set to English. To select your language, do as

Press to bring up the main menu.

Using the arrow

Move the cursor to the line

AUXILIARY FUNCTIONS -- CONFIGURATION

Press ENTER to call up a

1.3.1 Symbols in the display

A The selected weld data set

1.5 About settings

S Settings with numerical values

1.5.1 Setting numverical values

1.5.2 Setting fixed options

question by moving up or down using the arrow keys.

You then press the ENTER key.

1.5.3 ON/OFF or YES/NO settings

1.6 ENTER and QUIT

2.1 Main menu

In the MAIN MENU you can ESAB Mig

In the AUXILIARY AUXILIARY FUNCTIONS

In the CONFIGURATION AUXILIARY FUNCTIONS -- CONFIGURATION

2.1.2 Weld data setting menu

In the WELD DATA WELD DATA SETTING

CRATR HOT 4--

In the MEASURE IMAGE DIP/SPRAY. Fe, CO2, 1.2 mm

2.1.4 Memory functions menu

In the MEMORY MEMORY FUNCTIONS -- STORED DATA SETS

In the FAST MODE DIP/SPRAY. Fe, CO2, 1.2 mm

2.2 Menu structure

AUXILIARY FUNCTIONS SET MEASURE MEMORY FAST MODE

STOP DATA COPY

3.1 Settings in the weld data setting menu

3.1.2 MIG/MAG welding with pulsing

Settings Setting range In steps Values Synergic Adjust--

3.2 Function explanations for settings

3.2.2 Wire feed speed

3.2.4 Regulator type

3.2.5 Pulse current

3.2.6 Pulse time

3.2.7 Pulse frequency

3.2.8 Background current

Background current Pulse Pulse period time

MIG/MAG welding with pulsing.

3.2.14 Creep start

3.2.15 Hot Start

Hot start wire speed

Hot start voltage

3.2.16 Crater filling

3.2.17 Pinch-- off pulse

3.2.18 Burnback time

3.2.19 Gas post--flow

3.2.21 Spot welding

4.1 Settings in the weld data setting menu

4.2 Function explanations for settings

5.1 Settings in the weld data setting menu