F-15-565
February, 1999
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BOMBARDIER, INC./ESAB WELDING SYSTEMS
Table of Content
Section I
1. Welding System Features
2. Operating Instructions
Section II
1. SVI 450i Power Supply
Assembly Dwg. D-34055 with Bill of Material
Schematic Diagram D-34308
Wiring Diagram D-34309
Wire Kit Bill of Material BM-31953
Control PCB D-31496
Power PCB D-674991
Section III
1. Digipulse Dual Control
Assembly Dwg. D-(8) 33387
Schematic Diagram D-33380
Wiring Diagram D-33381
Wire Kit Bill of Material BM-33397
Display PCB D-675236
J-Gov PCB D-994236
I/O PCB D-674994
MPU PCB C-18155 & E-Prom A-18090
2. Digipulse Dual Wire Feeder
Assembly Dwg. D-37843 with Bill of Material
(See Model No. 33299)
Section IV
1. The Welding System Revision History
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General
This dual pulse Mig welding system has been designed and manufactured to specifications provided by
Bombardier, Inc.. The software is modified to provide eight separate schedules for each torch. The first four
schedules (1-4) on each torch are dedicated to pulse welding of stainless steel in the synergic mode. The
second four schedules (5-8) are dedicated to short or spray arc welding and have no synergic relationships.
This means that IIPM and VOLTS are entered separately depending if a short arc or spray arc weld condition
is required. The following will detail the set-up and operation of this unique welding system.
Start Up
Assembly of the power source, feeder and interconnect cable is the same as specified in the general oper-
ating instruction manuals provided with the SVI-450i Power Source and Digipulse Dual wire feeder. After
power up of the SVI-450i (575 Vac) and the feeder, the windows on the feeder will display IPM=5 and
VOLTS=45 for a brief period. This indicates that the stainless steel program (same as a standard Digipulse)
is running and the synergic curve is for .045-inch (1.2 mm) diameter wire. These parameters CANNOT be
changed. The windows will then display the last welding parameters set by the operator. Place the Remote/
Panel switch on the SVI-450i power source in the Remote position and follow the instructions below.
Selecting System Presets
System parameters are those that affect BOTH torches and ALL schedules. These parameters are always
active and should be set first. They are:
Gas preflow preset
Gas postflow preset
Cold inch preset
Trigger selection (dual schedule operation)
Half speed run-in
Set the shield gas preflow parameters by holding down the Purge key and using the Inc/Dec key under
the IPM window to set a preflow time in 1/10 seconds. Repeat the above for postflow using the key below the
VOLTS window.
The cold inching feature is a two speed design. When placing the Inch key in the up position, the feed
motor will operate at 50 ipm for a period of 2-1/2 seconds. This is for bumping the wire to adjust the wire
stick-out from the contact tip. After 2-1/2 seconds the wire feed speed will transfer to the cold inching speed
shown in the IPM window. The wire feed speed can be further adjusted using the Inc/Dec key under the
IPM window. This function is designed for wire threading.
The Trigger Selection option allows dual schedule operation. This means that two welding schedules are
available to the operator on each torch. This option is disabled when Rocker Switch #4 on Dip Switch #2 is
in the closed position. Dip switch #2 is located on the MPU board inside the feeder control box. Place this
switch in the open position for Trigger selection (dual schedule operation). Welding will always begin
using the current weld schedule selected. Double clicking the torch trigger switch changes the welding
parameters to the next highest schedule number. See diagram below.
Operating Instructions
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Example:
If pulse arc welding is being used in schedule #4, double click the torch trigger to switch to the short/
spray arc parameters resident in schedule #5. Double click the torch trigger a second time causes
the weld parameters to switch back to the pulse weld parameters in schedule #4. Releasing the torch
trigger stops welding.
The Trigger Selection function (dual schedule operation) is automatically disabled when a spot weld time is
preset on that torch. See Torch Parameter Presets below.
Half speed run-in is always on when using the pulse arc schedules (1 to 4). Half speed run-in will also be
on in the short/spray arc schedules (5 to 8) when the arc voltage is 26 volts or higher. Below 26 volts will
result in full speed run-in of the welding wire. This option is enabled when Rocker Switch #1 on Dip Switch #2
is in the open position. Dip switch #2 is located on the MPU board inside the feeder control box . Place this
switch in the closed position for full speed run-in for all welding schedules 1 to 8. This function is triggered
off the high open circuit voltage (OCV) of the SVI-450i power source. Half speed run-in cannot be enabled
using power sources having a low OCV.
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Torch Parameter Presets
Each torch can have the following parameters or variables preset:
Schedule number preset
Wire burnback preset
Shielding gas type
Spot weld time
The software will automatically switch to the torch being used when the torch trigger is depressed. Each torch
may have two welding schedules assigned at a time when using the Trigger Selection mode (described
above). The right side torch (viewed from the front of the feeder) is the default torch setting. This means that
when the feeder is first powered up this torch and its parameters will be displayed. If a red light between the
IPM and VOLTS display windows is illuminated, the left side torch parameters are being displayed.
Choose the schedule number (1- 8) for each torch by depressing the Schedule Selection key and setting the
desired schedule number in IPM window for the left torch and the VOLTS window for the right torch.
Preset the desired bumback by depressing the torch trigger switch to be preset. This action displays the
current welding parameters for that torch. Hold Burnback/Spot key in the up position and set a burnback
number in VOLTS window. Repeat this procedure for the other torch.
Attach the desired gas mixture to the appropriate torch for the type of welding to be completed.
Caution - Some shielding gases will not pulse arc and short arc equally well. Therefore, the
optimization of both pulse arc and short/spray arc parameters will be dependent on the shielding
gas and its ability to support both processes.
If spot welding is desired, depress the torch trigger switch to be preset. This action displays the current
welding parameters for that torch. Hold the Burnback/Spot key in the up position and set a spot time in
seconds in the IPM window. Repeat this procedure for the other torch if desired. Entering a spot weld time
automatically disables the Trigger Selection mode and dual schedule operation is not possible.
Weld Schedule Parameter Presets
Pulse Arc Welding
Schedules 1 through 4 are dedicated pulse arc welding schedules for stainless steel using .045" (1.2 mm)
diameter wire. The synergic relationship is the same on each torch and for each schedule. When entering a
schedule number 1 to 4, the feeder control and power source is automatically set for pulse welding with .045"
stainless steel wire.
Note - The SVI-450i power source slope switch should be set to the STEEP slope position. The
INUCTANCE & VOLTAGE knob on the SVI-450i is deactivated.
The !PM window will display the wire feed speed in inches per minute and the VOLTS window will show a
number between 0 and 200 with 100 being the default value. These numbers relate to the synergic relation-
ship programmed into the software and correspond to a pulse frequency. The number 100 is the nominal
pulse frequency required for the wire feed speed selected in the IPM window. This number will also affect the
arc length. If the welding arc length is too long the number can be decreased which shortens the arc length.
If the welding arc is too short, increase the number in the VOLTS window. Each count in the window changes
the pulse frequency by one pulse per second.
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Short/Spray Arc Welding
When setting a schedule number 5 to 8, the feeder control and power source is automatically set for short/
spray welding. The operator has full control over the slope and inductance of the power source. The IPM
window will display the preset wire feed speed in inches per minute. The VOLTS window will display arc
voltage and can be adjusted to any arc voltage needed for a good welding condition by using the Inc/Dec
key under the VOLTS window. The feeder control will automatically adjust the power source to maintain the
arc voltage set in the VOLTS window. There is no synergic relationship present in the short/spray arc sched-
ules.
Arc Start (Servo) Settings
Each schedule on each torch can have its own starting characteristic for any given weld parameter. The arc
start level must be set during welding. Choose desired schedule number and set a good welding condition.
If the arc starting is less than desirable it can be adjusted as follows:
Depress the Purge and Schedule Select key simultaneously while making a weld (two man operation).
The VOLTS window will display a number between 0 and 200 (95 is the typical setting). Using the Inc/Dec
key below the VOLTS window, reduce the number shown to give a hotter arc start or increase the number
for a colder arc start. Your setting will be saved to that schedule and will be recalled when you select that
schedule again. Changes in wire feed speed and/or voltage might necessitate readjusting the voltage servo
to optimize starting characteristics. Repeat this procedure for other welding schedules being used.
Motor Servo Setting
You can adjust the feed motor response by presetting the motor speed servo. Release the pressure roll and
pull the torch switch while depressing the Purge and Schedule Select key simultaneously. Change the
number (110 is standard) in the IPM window using the Inc/Dec key to a lower value if a faster motor
acceleration is needed or a higher number for a slower motor acceleration.
Warning - The motor response adjustment will be in effect for ALL schedules and BOTH
torches. The servo number set in the IPM window can be set exactly for the schedule
being used and wire feed speed preset but switching to a different schedule having a
different wire feed speed setting will cause the servo number in the IPM window to vary
slightly. This is normal and should have little affect on welding performance.
Power Source Changes
The standard SVI-450i power source has been modified to achieve the performance requested by Bombar-
dier, Inc. Pulse arc capability has been added and the V/A slope has been adjusted to Flat Slope = 3 V/100
Amps, Medium Slope = 4.5 V/100 Amps and Steep Slope = 6 V/100 Amps. A separate part number and
special drawings have been established for this machine which include a unique calibration procedure. Do
not attempt to use a standard SVI-450i power source as a substitute.
Additional Features
Displaying Welding Parameters
The feeder will display the actual welding conditions (IPM and Volts) during welding and will retain these
values for 2-1/2 seconds after welding. After 2-1/2 seconds the display will revert to the preset parameters.
To view the last welding condition used, bump the torch trigger. The welding conditions will be displayed.
Displaying Schedule Numbers
The schedules selected for each torch can be viewed by depressing the Schedule Select key on the feeder
control or depress and hold the torch trigger (without welding).
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SVI-450i Power Supply Revision History
Rev. B
Changed the digital meter from P/N 951042 to P/N 951795 (Ref. Schematic Diagram Rev.A and Wiring
Diagram Rev. B)
Rev. C
Changed the color from L-TEC green to ESAB yellow.
Rev. D
Added paint color suffix to Bill of Material for sheet metal P/Ns.
Rev. E
Changed the knobs from P/N 950814 (Alum) to P/N 13730611 (blk. w/ skirt).
Rev. F
Changed the 110V receptacle P/N 951033 (round) to P/N 952219 (square type snap-in).
Rev. G
Added a note to clarify assembly of isotrate insulators.
Rev. H
Changed C5 and C6 capacitors from P/N 950516 (.05 uf, 600 VDC) to P/N 951313 (.01 uf, 1000V),
moved cable assembly P/N 37096 from wire kit to top assembly, added resistors R11 and R12 P/N
17120110 (100 OHM, ½ W) (Ref. Schematic Diagram Rev. C and Wiring Diagram Rev. D)
Rev. J
Removed R11 and R12 Resistors P/N 17120110 (100 OHM, ½ W)
Changed R9 and R10 Resistors from P/N 17120110 (100 OHM, ½ W) to P/N 17130110 (100 OHM, 1W)
(Ref. Schematic Diagram Rev. B and Wiring Diagram Rev. C)
Schematic Diagram D-34308 Rev D
Updated schematic layout
Wiring Diagram D-34309 Rev E
Removed reference to: ICB P2-9 from ICB-P3-2 and ICB P3-2 from ICB-P2-9
Note:The most current revision of the drawing is always on top
Digipulse Dual Control Revision History
Rev. A
Added label P/N 954232 (Schedule Select) to front panel.
Rev. B
Removed the 6 pin (P/N 634772) and 8 pin (P/N 2062106) box receptacles and added a 19 pin (P/N
950762) box receptacle P/N 950762. (Ref. Schematic Diagram Rev.A and Wiring Diagram Rev. A)
Rev. C
Modified note 7 of the assembly drawing and added the accessory support leads 1&2 to T1-20 of the
wiring diagram. (Ref. Schematic Diagram Rev.A and Wiring Diagram Rev. B)
Rev. D
Changed from a green/light green cabinet with L-Tec decals to a gray/yellow cabinet with ESAB decals,
changed CTR1 and CTR2 from a welded assembly ,added mounting bracket P/N 35477, and changed
the signal lead assembly from P/N 30685 to P/N 36644. Title Digmig Dual was changed to Digipulse
Dual. (Ref. Schematic Diagram Rev.B and Wiring Diagram Rev. C)
Digipulse Dual Wire Feeder Revision History
Rev. A
Re-designed the base and reel support , changed the color from L-Tec green to ESAB gray/yellow
Note:The most current revision of the drawing is always on top
F-15-565 2/99
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