ESAB Teaching Mode Operation for Digipulse Wire Feeder Troubleshooting instruction

Brand: ESAB

Model: Teaching Mode Operation for Digipulse Wire Feeder

Type: Troubleshooting instruction

INSTRUCTIONS FOR

F-15-013-A

November, 1996

Be sure this information reaches the operator.

You can get extra copies through your supplier.

These instructions are for experienced operators. If you are not fully familiar with the principles of operation and safe practices

for electric welding equipment, we urge you to read our booklet “Precautions and Safe Practices for Arc Welding, Cutting and

Gouging, “Form 52-529”. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to

install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand

these instructions, contact your supplier for further information. Be sure to read all Safety Precautions in wire feeder manual

before installing or operating this equipment.

F-15-013-A

TEACHING MODE OPERATION

FOR DIGIPULSE WIRE FEEDER

adjustment to the pulse frequency to maintain

stable metal transfer. Since the operator selects pulse

parameters at a given point, the control will not assume

values at other wire feed speeds. Also note that the

Trigger Lock/Crater Fill feature is not programmable

I. INTRODUCTION

The Digipulse with optional teach control is the most en-

hanced version of the Digipulse family. It features a “teach”

mode that allows an operator to develop and store his

own pulse welding conditions in addition to the standard

preprogrammed conditions (codes 1- 6) already available

in the standard control. The Synergic program logic of-

fers the Digipulse system fixed operating parameters that

follow preprogrammed relationships. The Adaptive logic

utilizes a closed loop feedback system that continuously

modifies the output to maintain a constant arc voltage.

II. PROGRAMMING YOUR OWN PULSE PA-

RAMETERS

The “teach” mode program is incorporated in Material

Codes #11 through #15. Each of these codes is designed

to allow the operator to develop and store one set of cus-

tomized Pulsed mig parameters* for wire types which have

not been preprogrammed in this control (for example; ti-

tanium, inconel, monel, etc.). In some instances the

preprogrammed carbon steel or stainless steel param-

eters may be inadequate, and the “teach” mode can then

be used to further refine those particular arc characteris-

tics.

*You may wish to permanently incorporate your “self de-

veloped” conditions in codes 7 thru 10 which are reserved

for custom applications. If so, you can special-order a

custom E-PROM, from ESAB, that will include your teach

conditions along with the other preprogrammed applica-

tions. In order to do this, you

will have to provide the necessary welding condition de-

velopment parameters outlined in Section IV of this supple-

ment.

The following instructions assume that the operator is fa-

miliar with “pulse-mig” welding and the effects of pulse

variables with respect to arc performance.

Pulse height, width, background and frequency can be

programmed for any wire feed speed set in the IPM win-

dow. The metal transfer and arc characteristics are de-

fined by pulse height (PH), width (PW), and background

current (PB). These parameters, shown in Figure 1, must

be developed for each wire type, diameter, shielding gas,

and stickout. To maintain the proper arc characteristics

once an appropriate pulse height, width and background

have been established, the pulse frequency should be

the only parameter requiring readjustment with changes

in wire feed speed to maintain a stable arc condition. The

“teach” mode operates in the synergic logic “only”

(not adaptive), and only one wire feed speed setting can

be programmed in each material code (11 thru 15).

Changes in wire feed speed will require a manual

Zero Current

Fig. 1 - Pulse Wave Description

to the teach mode (codes 11 - 15).

For the inexperienced operator, use the following

graphs to assist in pulse parameter set-up. These

graphs will provide you with pulse parameters used in

the preprogrammed codes (1-6). To obtain specific arc

characteristics these parameters can be set-up and

changed in the teach mode. The following procedure

Fig. 2

Should be high

enough to detach the

droplet.

Works with the pulse

peak current to allow

time for the droplet to

form.

Peak Current

Spray Transition

Current

Background

Current

Average Current

Used to establish

the necessary arc

length for good arc

stability.

Should be set high

enough to maintain

the arc between

pulses.

Pulse

Width

Pulse

Frequency

pulse parameter switch (Item 1, Fig. 2) in its “down”

position and for following.

1. Set the selected Pulse Background (PB) param-

eter in the IPM window using its Inc/Dec switch

(Item 4). The number in this window represents

pulse background current from 15 to 100 amperes

(in 1 amp increments).

2. Now, set the selected Pulse Frequency (PF) pa-

rameter in the VOLTS window using its Inc/Dec

switch (Item 5). The number in this window repre-

sents the approximated pulse frequency derived

from the graph for wire feed speed selected (step

D) and is displayed in Hertz from 25 to 909 pulse

cycles/second.

H. Assuming that any other desired parameters (e.g.,

preflow, inch, spot, postflow, burnback, etc.) have

been programmed, as described previously in F-15-

012, you can energize the torch switch and begin

welding. The torch switch must be held closed

throughout the teach mode operation.

I. Once an acceptable arc condition has been obtained

by further modifying pulse height, pulse width, and

pulse background, changes in wire feed speed will

necessitate a manual adjustment to the pulse fre-

quency to maintain a stable metal transfer.

Operating Note: The 5 programmable codes (11 thru

15) provide the operator with an opportunity to develop

a complete welding procedure by having different weld-

ing parameters preprogrammed into separate schedules.

Once programmed, the operator only needs to change

to the appropriate program number for the weld

parameters required. For example, when welding pipe,

root pass, fill pass and capping pass pulse parameters

can be programmed into separate schedules and ac-

cessed when needed (see II-C). Each set of parameters

can have a different pulse height, width, background,

frequency, and wire feed speed.

III. USEFUL DATA FOR SYNERGIC-ADAPTIVE

OPERATION

The operating characteristics of synergic vs adaptive

logic in the welding operation is covered in booklet F-

15-012 and following. The selectability of either of these

features is made from the front panel (see Item 2, Fig.

2) in the feeder. Please note that either type of logic can

be used in the “preprogrammed” material codes 1 thru

10; however, only the synergic position can be used in

the “teach” mode material codes 11 thru 15.

1. Synergic Operation

a. Pulse Arc Welding:

Synergic welding is a relationship of pulse fre-

quency and wire feed speed (see graph) pro-

grammed into the weld control. As the wire feed

will achieve a reasonable starting point for pulse weld-

ing.

A. Make sure the Synergic/Adaptive logic switch (Item

2, Fig. 2) is set in SYN position.

B. Set the Process selector switch (Item 6, Fig. 2) to its

PULSE position.

C. Select a programmable Material code from 11 thru

15 by “holding down” the Material selector key (Item

3, Fig. 2) and holding the Inc/Dec key (Item 4, Fig. 2)

under the IPM window in the up position. Release

both keys once a Material code is selected.

NOTE: You may notice that a Wire Dia. code number

will appear in the VOLTS window when the Wire

Dia/Material key is depressed. This code # must

match the wire installed when you’re using

“preprogrammed” data in codes 1 thru 6, how-

ever, this is not required in the teach mode codes

11 thru 15. Please remember that all other pa-

rameters that are programmed will be retained

in memory (for teach codes 11-15) except for

the wire size—therefore, it is suggested that you

document the wire size dia. used and all other

parameters relating to a particular teach code

for future reference.

D. Set a wire feed speed in the IPM window by using the

Inc/Dec key (Item 4) below the window.

E. Using the pulse parameter graph(s)), shown on the

following pages, approximate the pulse height, width

(for step F), and pulse background and frequency (for

step G) settings for the material type and diameter

you plan to use. Select the appropriate pulse param-

eter graph which corresponds to the material type

being used. For wire types other than those shown,

choose the graph that comes closest to your wire type.

For example, for coppers use the silicon bronze graph

parameters as a starting point.

F. Program the Pulse Height (PH) and Pulse Width (PW)

parameters, from the material graph legend for the

diameter wire installed, by “holding” the pulse param-

eter switch (Item 1, Fig. 2) to its “up” position and the

following:

1. Set the selected Pulse Height (PH) parameter in

the IPM window using its Inc/Dec switch (Item 4).

The number in this window represents pulse height

from .1 to 10 volts (in 1/10 volt increments).

2. Now, set the selected Pulse Width (PW) param-

eter in the VOLTS window using its Inc/Dec switch

(Item 5). The number in this window represents

pulse width from 1 to 10 milliseconds (in 1/10 mil-

lisecond increments)

G. Program the Pulse Background (PB) and Pulse Fre-

quency (PF) parameters, from the material graph leg-

end for the diameter wire installed, by “ holding” the

Wire Feed Speed (ipm)

Pulse Frequency

Wire Feed Speed (ipm)

Carbon Steel Pulse Parameters

Pulse FrequencyPulse Frequency

Wire Feed Speed (ipm)

5356 Aluminum Pulse Parameters

Stainless Steel Pulse Parameters

Wire Feed Speed (ipm)

speed increases the control will automatically in-

crease the pulse frequency to maintain stable weld

performance. Changes in welding current (heat)

can be completed by increasing or decreasing the

IPM switch without readjusting voltage. Changes

in tip to work will affect arc length. The synergic

relationship is only available if a program is resi-

dent in the control.

b. Spray Arc and Short Arc:

In this mode the machine will operate like a con-

ventional welder where an arc voltage is set-up by

the weld control program and changes in tip to work

will effect arc length. The voltage can be read dur-

ing welding and increased accordingly to obtain

a stable welding condition based on the wire feed

speed used. If the wire feed speed is changed,

the program will calculate the new voltage neces-

sary to maintain a stable arc.

2. Adaptive Operation

a. Pulse Arc Welding:

Adaptive welding is a synergic relationship pro-

grammed into the weld control which will calculate

and display the proper arc voltage for a given wire

feed speed and material setting (see graph). As

the wire feed speed increases the control will au-

tomatically increase the pulse frequency to main-

tain the arc voltage set in the control VOLTS win-

dow. Changes in tip to work will not affect arc

length. The Adaptive function is only available if a

program is resident in the control.

b. Spray Arc and Short Are:

In this mode the machine will control the power

supply to maintain the arc voltage set-up in the volts

window of the control. Changes in tip to work will

not change arc length. The voltage can be preset

before welding and changed during welding to ob-

tain a stable welding condition based on the wire

feed speed used. If the wire feed speed is changed

then the program will calculate the new voltage

necessary to maintain a stable arc.

5356 Aluminum Pulse Parameters

Pulse Frequency

Wire Feed Speed (ipm)

Arc Length Will Not Change

With Tip To Work Distance

Pulse Frequency

Arc Volts

(Spray/Short)

Frequency Changes

With Tip To Work Distance

Arc Length Will Change

With Tip To Work Distance

Pulse Frequency

Arc Volts

(Spray/Short)

Frequency Does Not Change

With Tip To Work Distance

IV. CUSTOM PROGRAM DEVELOPMENT PROCEDURES

ESAB can supply custom Synergic and Adaptive programs to be placed in Material Codes 7 thru 10 if the proper data

is supplied (see below). Once acceptable arc stability and weld performance has been established using the pulse

parameter keys on the “teach” control, record the pulse height,, width and background settings you have programmed.

Then take 5 samples at different wire feed speeds and record the data in the chart below at each wire feed speed

tested. You will have to increase the pulse frequency as the wire feed speed increases in order to establish a GOOD

welding condition which will also change the arc voltage. From this information we can program the synergic and

adaptive relationships for your custom program. Contact your ESAB Sales Representative for further details and

pricing information on this custom service.

V. NOTES

The remaining space in this supplement can be used to provide a written record (similar to the chart shown in Section

IV) of the various programs you have developed.

DO NOT Change Once Established

Wire Average Average Pulse Pulse Pulse Pulse Additional Information

Feed Current Arc Frequency Height Width Bkgrd.

(ipm) (Amps) Volts (Hz.) (Ref. Volts) (m sec) (Amps) Wire Type Base Metal Type

1 Wire Diameter Weld Joint type

2 Shielding Gas Mig Gun Type

3 Tip to Work Weld Position

4 Travel Speed

F-15-013-A 11/96 5C Printed in U.S.A.

ESAB Teaching Mode Operation for Digipulse Wire Feeder Troubleshooting instruction

ESAB Teaching Mode Operation for Digipulse Wire Feeder Troubleshooting instruction

ESAB Teaching Mode Operation for Digipulse Wire Feeder Troubleshooting instruction

Related papers

Other documents