I had been struggling with the pulse MIG settings on my machine for 1/8 inch material. Anything less than quarter inch really. Using the autoset feature, I couldn't seem to stop the occasional to frequent short circuit crackling regardless of how I set the arc length. But I finally cracked the code. I find that if I turn off the autoset feature, the same wire speed and arc length recommendations work much better if I increase the arc control setting. I am guessing there is something in the autoset logic that either needs to be corrected, or most likely just doesn't work with the way I use the machine. The default setting for arc control (this used to be called arc sharp I believe, in the millermatic 350P) is 25. If I increase it to 35-40 I get a perfect sound pulse MIG buzz (hum?) without any short circuiting or any spatter whatsoever. I also find that turning up the arc control makes the arc much more tolerant to manipulation. I can now do small lower case 'e' loops without inducing any spatter. I find that doing some manipulation helps me to better gauge my travel speed and produce a more uniform bead, despite the fact that some experts say you shouldn't manipulate the gun when pulse welding. I will have to do some cut and etch samples soon to see if it matters.

I thought I would put this up here for other new multimatic/millermatic 255 owners.