Key components for

Synchro-Feed welding
Ultra-Low-Spatter Technology
3
Pull Feeding Unit

Synchro-Feed Welding System

1 (Model AFPS-2503 for steel with
RT3500H Torch shown)
2 4

5
1

Maximum current
2 3
increased to

Wire Buffer
(Model L-11610 for steel shown)
Push Feeder
(Model AFS-2301 for steel with
Wire Reel Stand shown)
ʄ Range of applications for the Synchro-Feed welding system
Item

Material

Shielding gas
Applicable wire diameter ø0.9
Mild steel

CO2/MAG
ø1.0 ø1.2
Specification

Galvanized
steel plate

CO2/MAG
ø1.2
Stainless steel
(Ferrite, Austenite)

MIG (98%Ar+2%O2)
ø1.2
Aluminum

MIG (100%Ar)
ø1.2
330A with MAG
4 5
Wire stock method Wire reel/pack wire Voltage adjustment range double
CO2: 50–200A CO2: 50–250A CO2: 50–300A CO2: 50–300A MIG (98%Ar+2%O2): MIG (100%Ar):
Welding current

Rated duty cycle*1

MAG: 50–180A MAG: 50–250A
100%*2, *4
MAG: 50–330A
100%*3, *4
MAG: 50–250A
100%*2, *4
50–300A

100%*2, *4
40–150A

100%*2, *4
that of previous product
Welding current: Tip for
Applicable tips
50–200A: FA tip, 200–400A: E tip aluminum
Wire Feed Control Device
AFCA-S1W04
Welding Power Supply
WB-P500L Max. cable length in conduit
*1 Ambient temperature 45°C (113°F)
*2 When used at 100% rated duty cycle, cooling air supplied at 0.30MPa is required.
5m
Expand your range
*3 When CO2 welding at 300A or higher, the RT5000H torch and cooling air supplied at 0.35MPa are required.
When MAG welding at 250A or higher, the RT5000H torch and cooling air supplied at 0.45MPa are required.
*4 When no cooling air is supplied, the rated duty cycle is limited to 30%.
of applications
with low-spatter, high-quality welding

OTC DAIHEN Website DAIHEN ROBOT Website

www.DAIHEN-USA.com www.DAIHEN-robot.com/en

NORTH AMERICA CORPORATE HEADQUARTERS ATLANTA TECHNICAL CENTER DETROIT TECHNICAL CENTER

1400 Blauser Dr, Tipp City OH 45371 3135 Medlock Bridge Road 750 Welch Road
Phone: (937) 667-0800 Norcross, GA 30071 Commerce Township, MI 48390
Phone: 888-OTC-ROBO Phone: 888-OTC-ROBO
Fax: (937) 667-0885
Fax: (937) 667-0885 Fax: (937) 667-0885

Member of DAIHEN Group

April 2020 OTC-14 REV /2

 Synchro-Feed welding has evolved considerably with our newly developed current waveform control.

Ultra-low spatter performance at a maximum current of 330A (14% improvement)

Voltage adjustment range doubled from previous version
Next generation Synchro-Feed High-quality welding and no burn-through on very thin plates,
Sheet metal even with ø1.2mm wire (helps reduce cost).
Wire feeding with our new Current Waveform Control is more accurate. New Synchro-Feed New Synchro-Feed Plate thickness
Shielding gas : 100% CO2

0.6
Current : 50A
This ensures a more stable arc. Voltage : 18.0V
mm Welding : 70cm/min
Feature More applicable plate thicknesses Feature speed : 0.6mm

1 and increased welding speed 2 Wide, flat beads possible Plate thickness
Welding wire
: ø1.2mm

Welding current has been increased to 400A. Deeper The new control method doubles the voltage adjustment No burn through even on extremely thin plate High gap tolerance
penetration can be obtained compared to similar range. Wide, flat beads can be easily obtained by increasing
products. This allows the system to be adapted to welding the welding voltage. These high- quality welds are resistant to
thick sheets one size larger and allows high-speed welding. gaps and deviations. Low-spatter welding that ensures sufficient penetration
Shielding gas :
Current :
100% CO2
330A
New Synchro-Feed
High current
&
High speed
Similar conventional product New Synchro-Feed
Wide
&
Flat
Thick steel plate even at high current. Torch weaving also achieves
Voltage
Welding speed :
: 27.0V
59 in/min
a beautiful bead with low spatter.
Plate thickness : 3.2mmt
Improved! Shielding gas : 100% CO2
Joint : Overlap Conventional New Synchro-Feed Plate thickness

12.0
Current : 300A
Shielding gas: 100%CO2 Shielding gas: 100%CO2 Duty cycle Voltage : 23.0V
mm
330A
Current: 200A Voltage: 20V Current: 200A Voltage: 26V
Current
Welding speed : 40cm/min
Plate thickness : 12.0mm

100% Welding wire

Weaving frequency
: ø1.2mm
: 1.5Hz
Low spatter and sufficient penetration
Synchro-Feed solves the problem of spatter
Low spatter at 200A and higher, where spatter is most likely to occur.

1.6
Conventional
CO2 welding
8
Conventional
1.6
MAG welding
Conventional
Stainless steel Galvanized steel plate
Spatter generated (g/min)

Spatter generated (g/min)

Spatter generated (g/min)

1.2
Synchro-Feed
6
Synchro-Feed
1.2
Synchro-Feed High-quality welding with low spatter even on stainless and galvanized steel plates.
Adaptable to various manufacturing processes.
0.8 4 0.8
Shielding gas : 98%Ar + 2%O2 Welding speed : 39.4 in/min
Conventional New Synchro-Feed
Current : 180A Plate thickness : 1.0mm
0.4 2 0.4
Voltage : 15.0V Welding wire : ø1.2mm
Stainless steel
0 0 0
100 150 200 250 300 300 350 400 100 150 200 250 High-quality welding, free from spatter marks
Current Current Current
Shielding gas : 100% CO2 Welding speed : 31.5in /min
Conventional New Synchro-Feed
Current : 240A Plate thickness : 2.0mm
Galvanized Voltage : 21.5V Welding wire : ø1.2mm
Principle of Synchro-Feed steel plate

High-quality welding, free from spatter marks

Conventional welding Synchro-Feed welding Short-circuit period Arc period Feeds the wire at
Short-circuit Short-circuit high speed and
Forward feed Reverse feed Forward feed Reverse feed High-quality welding with low spatter
Aluminum
period Arc period period Arc period forcibly short-
Ensures deep penetration Welbee high- circuits while
Switches at
a maximum at high current. speed current
waveform keeping the achieves low smut with low heat input.
speed of control droplets small.
100Hz Conventional Improved! New Synchro-Feed
Plate thickness Shielding gas : 100% Ar
Forward Forward Forward
feed Spatter feed Reverse
feed feed Hard aluminum 2.0 Current : 130A

150A mm
Repeats Voltage : 12.3V
Current

Welding speed : 31.5in/min

When short-circuited, Ensures penetration
Plate thickness : 2.0mm (A5052)
Wire is always the wire reverses and with pulsed high Plate thickness Welding wire : ø1.2mm
arcing occurs. current. 2.0 mm
fed forward. Weaving : Yes
High-quality welding low in spatter and smut