Plain answers on the add-on modules, feeders, cables, remote controls and torches that go with a multi-process inverter power source.
What kinds of options go with a multi-process inverter power source?
Options are the extra items that let a power source do more or work in a different set-up, rather than parts that replace something worn out. Typical examples are a wire feeder, an interconnecting cable between the power source and the feeder, a hand remote control, a plug-in process module for a specialist transfer mode, and a MIG torch.
Not every power source accepts every option. Some items depend on the connectors, software and control system of the particular unit, so start from the data plate and the instruction manual rather than from the look of the item.
How do I check an option will work with my power source and wire feeder?
Begin with the rating plate and the manual for both the power source and the feeder. The plate gives the supply requirements, performance and suitability for use, and the manual lists the compatible accessories. Check the control connector type, the control voltage, whether the feeder is designed for air-cooled or water-cooled working, and the torch connection.
If an item is described as being for a particular feeder family or control system, it may not suit another, even when the plug seems to fit. A wrong match can cause poor feeding or damage to the electronics. If you are unsure, our team can help you check the details before you order.
What does a controlled short-circuit transfer module add?
It is a plug-in option that lets a suitable power source run a controlled short-circuit MIG process. Instead of the usual voltage control, the current is shaped during each short circuit so that the droplet is released gently. The aim is low spatter, low heat input and good control of the weld pool.
It is mainly used for open root passes on pipe, for thin material and for gap bridging, where a conventional dip transfer can spatter or burn through. Which shielding gases it works with, and which wires, depends on the maker's instructions, so check the manual before choosing gas and wire.
When is pulsed MIG worth choosing over conventional MIG?
Pulsed MIG switches the current between a high peak and a lower background level. It can give clean, low-spatter welding at lower mean currents where ordinary MIG would be limited to irregular dip transfer, and its heat input sits between dip and spray transfer, which suits thicker sections that dip transfer would leave cold and spray transfer would overheat.
It is also used on aluminium and thin material to keep heat down. It does not replace a good joint fit-up or correct settings. Whether pulse programmes are built in or need an added module depends on the power source, so check the manual.
Why choose a separate wire feeder, and is a four-roll feeder better than a two-roll one?
A separate feeder lets you work some distance from the power source and keeps the heavy wire spool close to the work. A four-roll drive grips the wire at four points instead of two, so it can feed with less pressure at each point and less deformation. That is most useful with flux-cored wire, because tubular wire can be squashed by heavy roll pressure. A two-roll design is simpler and perfectly adequate for much general work, including aluminium.
For soft aluminium wire, the groove shape, the pressure setting and the liner usually matter more than the number of rolls. Choose according to the wire you use most and the duty of the job.
What does an interconnecting cable do, and why are there air-cooled and water-cooled versions?
The interconnecting cable carries the welding current, the control signals and, usually, the shielding gas from the power source to a separate wire feeder. Control cables have a particular connector and pin arrangement, so it must match both ends.
With a water-cooled torch, the feeder also needs coolant hoses, so the cable set includes the coolant lines. With an air-cooled set-up it does not. Heavier-duty work generally needs a cable built for the current involved. Maximum length and the exact cable type are set by the maker, so check the manual before extending or changing a cable.