ESAB U8 Aristo® User manual

GB

Valid for program version 1.41, 1.500459 310 274 080115

U8

Aristot

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 INTRODUCTION 6...................................................

1.1 Equipment 6................................................................

1.2 Do this first 6...............................................................

1.3 Display 8...................................................................

1.3.1 Symbols in the display 8.................................................

1.4 Keys 9.....................................................................

1.5 About settings 9.............................................................

1.5.1 Setting numverical values 9..............................................

1.5.2 Setting fixed options 10...................................................

1.5.3 ON/OFF or YES/ NO settings 10...........................................

1.6 ENTER and QUIT 10.........................................................

2 MENUS 11...........................................................

2.1 Main menu 11...............................................................

2.1.1 Auxiliary functions menu 11...............................................

2.1.2 Weld data setting menu 12................................................

2.1.3 Measure image 12.......................................................

2.1.4 Memory functions menu 13...............................................

2.1.5 Fast mode menu 13......................................................

2.2 Menu structure 14............................................................

3 MIG/MAG WELDING 15................................................

3.1 Settings in the weld data setting menu 15........................................

3.1.1 MIG/MAG welding with dip/spray 15........................................

3.1.2 MIG/MAG welding with pulsing 16.........................................

3.2 Function explanations for settings 17............................................

3.2.1 Voltage 17..............................................................

3.2.2 Wire feed speed 17......................................................

3.2.3 Inductance 17...........................................................

3.2.4 Regulator type 17........................................................

3.2.5 Pulse current 17.........................................................

3.2.6 Pulse time 17...........................................................

3.2.7 Pulse frequency 17......................................................

3.2.8 Background current 18...................................................

3.2.9 Slope 18...............................................................

3.2.10 Ka 18..................................................................

3.2.11 Ki 18...................................................................

3.2.12 Synergy 18.............................................................

3.2.13 Gas pre--flow 18.........................................................

3.2.14 Creep start 19...........................................................

3.2.15 Hot Start 19.............................................................

3.2.16 Crater filling 19..........................................................

3.2.17 Pinch--off pulse 20.......................................................

3.2.18 Burnback time 20........................................................

3.2.19 Gas post--flow 20........................................................

3.2.20 Limits 20...............................................................

3.2.21 Spot welding 20.........................................................

4 MMA WELDING 20....................................................

4.1 Settings in the weld data setting menu 21........................................

4.2 Function explanations for settings 21............................................

4.2.1 Current 21..............................................................

4.2.2 Arc force 21.............................................................

4.2.3 Min. current factor 21....................................................

4.2.4 Synergy 21.............................................................

4.2.5 Limits 21...............................................................

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5 TIG WELDING 21.....................................................

5.1 Settings in the weld data setting menu 22........................................

5.1.1 TIG welding without pulsing 22............................................

5.1.2 TIG welding with pulsing 22...............................................

5.2 Function explanations for settings 22............................................

5.2.1 HF 22..................................................................

5.2.2 LiftArc 23...............................................................

5.2.3 2--stroke 23.............................................................

5.2.4 4--stroke 23.............................................................

5.2.5 Current 24..............................................................

5.2.6 Pulse current 24.........................................................

5.2.7 Background current 24...................................................

5.2.8 Pulse time 24...........................................................

5.2.9 Background time 25......................................................

5.2.10 Slope up 25.............................................................

5.2.11 Slope down 25..........................................................

5.2.12 Gas pre--flow 25.........................................................

5.2.13 Gas post--flow 25........................................................

5.2.14 Limits 25...............................................................

5.3 Other function explanations 26.................................................

5.3.1 Gas purge 26...........................................................

6 CARBON, ARC AIR 26................................................

6.1 Settings in the weld data setting menu 26........................................

6.2 Function explanations 26......................................................

6.2.1 Voltage 26..............................................................

6.2.2 Inductance 26...........................................................

6.2.3 Regulator type 26........................................................

7 Aristo SuperPulse 27.................................................

7.1 Wire and gas combinations 27.................................................

7.2 Different types of pulsing 27...................................................

7.3 Settings in the weld data setting menu 28........................................

7.4 Function explanations for settings 28............................................

7.4.1 Phase 28...............................................................

7.5 Wire feed unit 28.............................................................

8 MEMORY MANAGEMENT 30...........................................

8.1 How the controller works 30...................................................

8.2 Store 31....................................................................

8.3 Delete 32...................................................................

8.4 Recall 33....................................................................

8.5 Copy 34.....................................................................

9 AUXILIARY FUNCTIONS 35............................................

10 FILEMANAGER 35....................................................

10.1 Inserting a compact flash card / PC--card 36.....................................

10.2 Example: Saving welding data settings in the internal memory 36...................

10.3 Example: Creating a new folder on a memory card 37.............................

10.4 Deleting a file or folder 37.....................................................

10.5 Changing the name of a file/folder 38...........................................

10.6 Copying files 38..............................................................

10.7 Recalling welding data 38.....................................................

10.8 Quality data files content 39...................................................

10.8.1 About the welding equipment 39...........................................

10.8.2 About the welds 40......................................................

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11 WELD DATA SETS 41.................................................

11.1 Example: Saving welding data on a memory card 41..............................

11.2 Recalling welding data from a memory card 42...................................

11.3 Deleting welding data from a memory card 42....................................

12 CONFIGURATION MENU 42...........................................

12.1 Code lock 42................................................................

12.1.1 Lock code mode 43......................................................

12.1.2 Set / change lock code 44................................................

12.2 Remote control configuration 44................................................

12.2.2 Configuring a digital remote control 45......................................

12.2.3 Configuring an analogue remote control 45..................................

12.3 MIG/MAG defaults 46.........................................................

12.3.1 Gun trigger mode (2--stroke / 4--stroke) 46..................................

12.3.2 Soft keys setup 47.......................................................

12.3.3 Voltage measurement for dip 49...........................................

12.3.4 4--stroke configuration 49.................................................

12.4 MMA defaults 50.............................................................

12.4.1 Hot start amplitude 50....................................................

12.4.2 Hot start duration 50.....................................................

12.4.3 Droplet welding 50.......................................................

12.5 General defaults 51...........................................................

12.5.1 Fast mode soft keys 51...................................................

12.5.2 Double start sources 51..................................................

12.5.3 Panel remote enable 51..................................................

12.5.4 Auto save mode 52......................................................

12.5.5 T rigger weld data switch 52...............................................

12.5.6 Quality data logging 53...................................................

12.6 Multiple wire feeders 54.......................................................

12.6.1 Weld data 55............................................................

12.7 Unit of length 55.............................................................

13 QUALITY FUNCTIONS 55..............................................

13.1 Saving quality data on a compact flash card 56...................................

14 PRODUCTION STATISTICS 57.........................................

15 ERROR L OG 58.......................................................

15.1 Deleting error messages 58....................................................

15.2 Reviewing error summary 58...................................................

15.3 Error code list 59.............................................................

15.4 Error code descriptions 60.....................................................

16 USER--DEFINED SYNERGIC DATA 63...................................

16.1 Specify voltage/wire co--ordinates 63............................................

16.1.1 Dip/spray 63............................................................

16.1.2 Pulsing 64..............................................................

16.2 Specifying the valid wire/gas combination 64.....................................

16.3 Creating user--defined wire/gas options 65.......................................

16.4 Deleting a user--defined synergic line 66.........................................

17 L IMIT EDITOR 66.....................................................

18 OTHER INFORMATION 67.............................................

18.1 ESAB Logic Pump (Water lock) 67..............................................

WIRE AND GAS COMBINATIONS 68......................................

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Rights reserved to alter specifications without notice.

ORDERING NUMBER 70.................................................

ACCESSORIES 71.......................................................

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1 INTRODUCTION

In order to get the maximum benefit from your welding equipment, we recommend

that you r ead this instruction m anual.

For general information about operation, see the power source’s instruction manual.

The text shown in the display is available in the following languages:

English, Swedish, Finnish, Norwegian, Danish, German, French, Italian, Dutch,

Spanish, Portuguese, Hungarian, Polish, US English and Czech.

1.1 Equipment

U8 is supplied with a holder, 3 spacer screws and an English instruction manual.

The instruction manuals and the spare parts list are available in other languages on

the Internet at www.esab.com

Under ”Products” and ”Welding & cutting equipment”, you will find a link to the page

where you can both search for and download instructions and spare parts lists.

1.2 Do this first

This menu appears in the display when you start the machine for the first time.

When delivered, the controller is set to English. To select your language, do as

follows:

Press to bring up the main menu.

ESAB Mig

Using the arrow

keys, move the

cursor to the line for

AUXILIARY

FUNCTIONS

Press ENTER

PROCESS: MIG/MAG

METHOD: DIP / SPRAY

WIRE TYPE: Fe

SHIELDING GAS: Ar+8%CO2

WIRE DIMENSION: 1.2 mm

AUXILIARY FUNCTIONS

"

SET MEASURE MEMORY

FAST

MODE

ENTER

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AUXILIARY FUNCTIONS

Move the cursor to the line

for CONFIGURATION

Press ENTER

FILEMANAGER

WELD DATA SETS

CONFIGURATION

QUALITY FUNCTIONS

PRODUCTION STATISTICS

ERROR LOG

USER DEFINED SYNERGIC DATA

LIMIT EDITOR

QUIT ENTER

AUXILIARY FUNCTIONS -- CONFIGURATION

Press ENTER t o call up a

list of the languages

available in the controller .

LANGUAGE: ENGLISH

CODE LOCK

REMOTE CONTROLS

MIG/MAG DEFAULTS

MMA DEFAULTS

TIG DEFAULTS

GENERAL DEFAULTS

MULTIPLE WIRE FEEDERS

QUIT ENTER

Move the cursor to the line for your language and press ENTER. ENGLISH

SVENSKA

SUOMI

DANSK

DEUTSCH

FRANCAIS

ITALIANO ↓

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1.3 Display

ESAB Mig

PROCESS: MIG/MAG

METHOD: DIP / SPRAY

WIRE TYPE: Fe

SHIELDING GAS: CO2

WIRE DIMENSION: 1.2 MM

AUXILIARY FUNCTIONS

SET MEASURE MEMORY

FAST

MODE

ENTER

The cursor

The cursor in the controller appears a s a shaded field around the text, which has the

effect of turning the selected text white. T he cursor appears in bold text in the

instruction m anual.

Text boxes

At the bottom of the display there are five boxes containing text that explains the

current functions of the five keys in the line directly below them.

Saver mode

To extend the life of the backlit display, it is switched off after three minutes if there is

no activity.

1.3.1 Symbo ls in th e disp lay

A The selected weld data set

B Recalled memory position number

C More information is available on the next

page

D Select the plus/minus buttons marked

with * to increase or decrease the

parameter value

E Select the plus/minus buttons marked

with # to increase or decrease the

parameter value

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1.4 Keys

You can use the arrow keys to move the cursor to different lines in the display.

The menu key will always r eturn you to the main menu.

The plus/minus keys are used to increase (+) or decrease (--) the value of a

setting.

The two plus/minus keys are each m arked with their own symbol. Most settings can

be defined using either the plus or minus key, but certain settings must be defined

using a key marked or (the symbols appear in the display).

Pressing a key briefly produces an increase/decrease in small steps. If you hold a

key down for longer, the size of the steps increases.

Soft keys

The five keys in a row under the display have a

variety of functions. These are the ”soft keys”, i.e.

they can have different functions depending on

which menu you are using. T he current functions

of these keys are shown by the text in the bottom

line of the display.

When a function is active, this is indicated by a

white dot alongside the text .

1.5 About settings

There are three main types of settings:

S Settings with numerical values

S Settings with fixed options

S Settings of the type ON/OFF or YES/NO

1.5.1 Setting numverical values

When setting a numerical value, you use either the plus or minus keys to increase or

decrease a given value. Some values can also be modified by means of the remote

control.

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1.5.2 Setting fixed options

Certain settings are defined by selecting an option from a list.

The list might look like this:

MIG/MAG

MMA

TIG

CARBON, ArcAir

MIG SUPERPULSE

Here the cursor is on the line for MIG/MAG. If you press the ENTER key now, you

will select the M IG/MAG option.

However, if you want to select another option you move the cursor to the line in

question by moving up or down using the arrow keys.

You then press the ENTER key.

If you want to exit the list without making a selection, press the QUIT key.

Some settings have so m any options that they cannot all be displayed in the list at

the same time. An arrow at the top or bottom of a list indicates that more options will

become visible if you scroll up or down using the arrow keys.

1.5.3 ON/OFF or YES/NO settings

For some functions you can set the values ON or OFF or YES or NO. T he synergic

function for MIG/MAG welding and MMA welding is one example of such a function.

The ON/OFF or YES/NO settings can be defined in one of two ways:

You can select ON or OFF or YES or NO from a list of options as described above.

You can also use the plus/minus keys to define ON/OFF or YES/NO (applies to

certain functions).

S + (plus) = ON or YES

S --(minus)=OFForNO

1.6 ENTER and QUIT

The two ”soft” keys on the far right are primarily used for ENTER and QUIT but are

sometimes used for other functions.

S By pressing ENTER you confirm the selected option in a menu or list.

S By pressing QUIT you return to the previous menu or display.

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2MENUS

The controller uses a number of different menus. These are the main menu, auxiliary

functions menu, weld data setting menu, measure image, memory functions m enu

and fast mode menu. During start--up, a start --up screen also appears containing

information about which program version is being used.

2.1 Main menu

In the MAIN MENU you can

c

h

a

n

g

e

w

e

l

d

p

r

o

c

e

s

w

e

l

d

ESAB Mig

c

h

ange we

l

d

process, we

l

d

method, wire type, etc.

From this menu you can

then access all other

submenus.

PROCESS: MIG/MAG

METHOD: DIP / SPRAY

WIRE TYPE: Fe

SHIELDING GAS: Ar+8%CO2

WIRE DIAMETER: 1.2 mm

AUXILIARY FUNCTIONS

SET MEASURE MEMORY

FAST

MODE

ENTER

2.1.1 Auxiliary fun c tio n s menu

In the AUXILIARY

F

U

N

C

T

I

O

N

S

AUXILIARY FUNCTIONS

F

U

N

C

T

I

O

N

S

MENU you can view the

memory card functions. You

can also switch to the

configuration menu, view

quality functions, production

statistics, the error log, etc.

FILEMANAGER

WELD DATA SETS

CONFIGURATION

QUALITY FUNCTIONS

PRODUCTION STATISTICS

ERROR LOG

USER DEFINED SYNERGIC DATA

LIMIT EDITOR

QUIT ENTER

2.1.1.1 Configuration menu

In the CONFIGURATION

M

E

N

U

y

o

u

c

a

n

s

w

i

t

c

h

AUXILIARY FUNCTIONS -- CONFIGURATION

M

E

N

U

you can sw

i

t

c

h

language, change other

basic settings, measure-

ment unit, etc.

LANGUAGE: ENGLISH

CODE LOCK

REMOTE CONTROLS

MIG/MAG DEFAULTS

MMA DEFAULTS

TIG DEFAULTS

GENERAL SETTINGS

MULTIPLE WIRE FEEDERS

QUIT ENTER

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2.1.2 Weld data setting menu

In the WELD DATA

S

E

T

I

N

G

M

E

N

U

y

o

u

c

a

n

WELD DATA SETTING

S

E

T

I

N

G

M

E

N

U

you can

change various weld

parameters. The menu’ s

appearance differs,

depending on which weld

process you have selected.

In this example it is

MIG/MAG welding with

dip/spray.

VOLTAGE: # 26.8 (+0.0) V

WIRE SPEED: * 6.0 m/min

INDUCTANCE: 80 %

SYNERGIC MODE PÅ

START DATA...

STOP DATA...

LIMITS

CRATR

FILL

HOT

START

4--

STROKE

QUIT

2.1.3 Measure image

In the MEASURE IMAGE

y

o

u

c

a

n

s

e

t

h

e

m

e

a

s

u

r

e

d

DIP/SPRAY. Fe, CO2, 1.2 mm

you can see

t

h

e measure

d

values of various weld

parameters during welding.

The measured values

remain in the display even

after welding has been

completed.

You can move to other

menus without losing the

measured values.

# 0.0 Volt

0Amp

* 6.0 m/min

↓

CRATER

FILL

HOT

START

4--

STROKE

REM

2ND

FUNCT

The arrow in the bottom right--hand corner of the display indicates that there is more

information available.

In the measure image you can change the value of certain parameters. Which

parameters these are depends on which weld process has been set. The parameter

values that can be adjusted are always marked with # or *.

When values are changed while no welding is in progress, the measured values will

change to zero to avoid misunderstandings regarding which settings correspond to

the measure result.

TIP!

In pulsing you can select whether the voltage value is displayed as an average value

or peak value. This setting can be defined under MIG/MAG basic settings, see

chapter 12.3.

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2.1.4 Memory functions menu

In the MEMORY

F

U

N

C

T

I

O

N

S

M

E

N

U

y

o

u

MEMORY FUNCTIONS -- STORED DATA SETS

F

U

N

C

T

I

O

N

S

M

E

N

U

you

can store, recall and delete

various items of preset weld

data. Weld data settings

canbestoredin255

different memory positions.

1251112

STORE QUIT

2.1.5 Fast mode menu

In the FAST MODE

M

E

N

U

y

o

u

c

a

n

l

i

n

k

s

o

f

t

DIP/SPRAY. Fe, CO2, 1.2 mm

M

E

N

U

you can

l

i

n

k

so

f

t

buttons to weld data

memory positions. This

setting is defined under

general settings.

# 0.0 Volt

0Amp

* 6.0 m/min

↓

WELD

DATA 1

WELD

DATA 2

WELD

DATA 3

WELD

DATA 4

2ND

FUNCT

For more information about setting this menu, see chapter 12.5.1 ”Fast mode, soft

keys”.

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2.2 Menu structure

AUXILIAR Y FUNCTIONS SET MEASURE MEMORY FAST MODE

STOP DATA COPY

START DATA RECALL

DELETE

STORE

*) This is the start image (measure image) that is shown when you switch on the machine.

The sample image above is for MIG/MAG --welding with synergic mode.

AUXILIAR Y FUNC-

TIONS

auxiliary functions

menu

S see page 35

SET weld data setting menu S for MIG/MAG welding, see page 15

S for MMA welding, see page 21

S for TIG welding, see page 22

S for carbon, arc air, see page 26

S for MIG Superpulse, see page 28

MEASURE measure image S see page 12

MEMORY Memory management

menu

S ses page 30

FAST MODE Fast mode menu S see page 51

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3 MIG/MAG WELDING

Main menu ----> Process

The arc in MIG/MAG welding m elts a filler wire (the electrode) that is continuously

fed into the weld, with the molten zone being protected by a shielding gas.

Pulsing is used to affect the transfer of the droplets from the arc so that it is stable

and does not produce spray, even with low weld data.

The table on page 68 shows the wire diameters that can be selected for MIG/MAG

welding with DIP/SPRAY.

The table on page 69 shows the wire diameters that can be selected for MIG/MAG

welding with PULSE.

3.1 Settings in the weld data setting menu

3.1.1 MIG/MAG welding with dip/spray

Settings Setting range In steps

of:

Values

after reset

Synergic

depend -

ent

Adjust--

able in

synergic

Voltage 8--60 0.25 (dis-

played to

one deci-

mal place)

synergic

deviation

¦ 0

x x

Wire speed ** 0.8 -- 25.0 m/min 0.1 m/min 5m/min x

Inductance 0 -- 100% 1 80% x x

Control type 1--12 1 4 x

Synergic mode* OFF or ON -- ON * -- --

Gas pre-- flow 0.1 -- 25 s 0.1 s 0.1 s x

Creep start NO or YES -- NO x

Hot start NO or YES -- NO x

Hot start time 0--10s 0.1 s 1.5 s x

Hot start wire speed Complete wire feed

range

0.1 m/min 2m/min x

Hot start voltage Complete voltage

range

0.25 V 4.5 V x

Crater filling NO or YES -- NO x

Crater fill time 0--10s 0.1 s 1.5 s x

Final crater filling wire

speed

1.5 m/min to current

wire feed speed

0.1 m/min 3m/min x

Final crater filling

voltage

8 V to actual voltage 0.25 V 18 V x

Pinch off pulse 10 -- 120% 1 60% x

Burn back time 0--1s 0.01 s 0.12 s x

Gas post--flow 0.1 -- 25 s 0.1 s 0.1 s x

Limits 1--50 -- -- -- --

Spot welding OFF or ON -- OFF x

Spot welding time 0--25s 0,1 s 0,5 s x

*) Default synergic line: solid wire (Fe), shielding gas CO

2

with wire 1.2 mm.

**)The setting range is dependent on the wire feed unit used.

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3.1.2 MIG/MAG welding with pulsing

Settings Setting range In steps

of:

Values

after reset

Synergic

depend -

ent

Adjust--

able in

synergic

Voltage 10 -- 50 0.25 (dis-

played to

one deci-

mal place)

synergic

deviation

¦ 0

x x

Wire speed ** 0.8 -- 25.0 m/min 0.1 m/min 5m/min x

Pulse current *** 100 -- 600 A 4A 476 A x

Pulse time 1.7 – 25.5 ms 0.1 ms 2.2 ms x

Pulse frequency 16 -- 312 Hz 2Hz 96 Hz x

Background current *** 4 -- 300 A 1A 52 A x

Slope 1--9 1 9 x

Ka 0 -- 100% 1 13% x

Ki 0 -- 100% 1 0% x

Synergic mode* OFF or ON -- ON * -- --

Gas pre-- flow 0.1 -- 25 s 0.1 s 0.1 s x

Creep start NO or YES -- NO x

Hot start NO or YES -- NO x

Hot start time 0--10s 0.1 s 1.5 s x

Hot start wire speed Complete wire feed

range

0.1 m/min 2m/min x

Hot start voltage Complete voltage

range

0.25 V 4.5 V x

Crater filling NO, NON--PULSED or

PULSED

-- NO x

Crater fill time 0--10s 0.1 s 1.5 s x

Final crater filling wire

speed

1.5 m/min to current

wire feed speed

0.1 m/min 3m/min x

Final crater filling

voltage

8 V to actual voltage 0.25 V 18 V x

Final crater filling pulse

current

100 A to actual pulse

current

4A 464 A x

Final crater filling

background current

12 A to actual

background current

4A 36 A x

Final crater filling

frequency

20 Hz to actual

freauency

2Hz 62 Hz x

Burn back time 0--1s 0.01 s 0.13 s x

Gas post--flow 0.1 -- 25 s 0.1 s 0.1 s x

Limits 1--50 -- -- -- --

Spot welding OFF or ON -- OFF x

Spot welding time 0--25s 0,1 s 0,5 s x

*) Default synergic line: solid wire (Fe), shielding gas CO

2

with wire 1.2 mm.

**)The setting range is dependent on the wire feed unit used.

***) Minimal background current and pulse current are depending on which type of machine is used.

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3.2 Function explanations for settings

3.2.1 Voltage

Higher voltage increases the arc length and produces a hotter, wider weld pool.

The voltage setting differs between synergy and non synergy modes. In synergy

mode the voltage is set as a positive or negative offset from the synergic line of the

voltage. In non synergy mode the voltage value is set as an absolute value.

The voltage is set in e ither the measure image-- , the weld data setting menu, or the

fast mode menu . When the remote control unit is used the setting can be m ade from

this.

3.2.2 Wire feed speed

This sets the required feed speed of the filler wire in m/minute.

The wire feed speed is set in either the measure image, the weld data setting menu,

or the fast mode menu. When the remote control unit is used the setting can be

made from this.

3.2.3 Inductance

Higher inductance results in a wider weld pool and less spatter. Lower inductance

produces a harsher sound but a stable, concentrated arc.

Only applies for MIG/MAG welding with dip/spray.

3.2.4 Regulator typ e

Affects the short circuit process and heat in the weld.

This setting should not be changed.

3.2.5 Pulse current

The higher of the two current values in the event of pulsed current.

Only applies for MIG/MAG welding with pulse.

3.2.6 Pulse time

The time the pulse current is on during a pulse period.

Only applies for MIG/MAG welding with pulse.

3.2.7 Pulse frequency

Time for background current, which, along with the time for pulse current, gives the

pulse period.

Only applies for MIG/MAG welding with pulse.

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3.2.8 Background current

The lower of the two current values in the event of pulsed current.

Only applies for MIG/MAG welding with pulse.

Current

Pulse current

Background current Pulse

time

Pulse period time

Time

MIG/MAG welding with pulsing.

3.2.9 Slope

Slope means that the pulse current rises/falls slowly to the set value. The slope

parameter can be set in nine steps, with each step corresponding to 100 μs.

Slope is significant with r espect to sound. A steep slope generates a higher, sharper

sound. A slope that is too gentle can in the worst case, affect the pulse’s capacity to

cut off the droplet.

Only applies for MIG/MAG welding with pulse.

3.2.10 Ka

Ka is the proportional element and corresponds to the regulator’s amplification. A

low value means that the voltage is not maintained at a constant level as precisely.

Only applies for MIG/MAG welding with pulse.

3.2.11 Ki

Ki is the integrating element that attempts in the longer term to eliminate an error.

Here too, a low value will produce a weaker regulatory effect.

Only applies for MIG/MAG welding with pulse.

3.2.12 Synergy

Each combination of wire type, wire diameter and gas mixture requires a unique

relationship between wire feed speed and voltage (arc length) to obtain a stable

functioning arc. The voltage (arc length) automatically conforms in accordance with

the pre--programmed synergic line you have selected, which m akes it much easier to

find the correct welding parameters. The relationship between the wire feed speed

and the other parameters is called the synergic line.

It is also possible to order other packages of synergy lines, but these must be

installed by an authorised ESAB service engineer.

3.2.13 Gas pre--flow

Gas pre--flow controls the time during which shielding gas flows before the arc is

struck.

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3.2.14 Creep start

Creep starting feeds out the wire at 50% of the set speed until it makes electrical

contact with the workpiece. With a hot start it is 50% of the hot start time.

3.2.15 Hot Start

Hot start increases the wire feed speed and voltage for an adjustable time at the

start of welding, thus reducing the risk of poor fusion at the beginning of the joint.

Hot start wire speed

It is possible to increase the wire feed speed during a specific period compared to

the present wire feed speed to provide more energy during the weld start and ensure

penetration. T he speed is set relative to the ordinary wire feed speed. The time

starts when the arc is ignited and the length is the set hot start time. Synergy gives

an increase in the wire speed by 2 m/min.

Hot start voltage

The voltage increases by 2 volts in addition to the contribution from the synergy line

slope and the extra 2 m/min in wire feed speed. In non synergy mode, the voltage in

question will be the one set and it is not synergy dependent.

Note!: It is possible to set negative values for the hot start wire feed and hot start

voltage. T his can be used with high weld data to give a smooth weld start by initially

”stepping up” the weld data.

-- Hot start is enabled in the measure image and the settings are defined in the

settings menu.

3.2.16 Crater filling

Crater filling makes a controlled reduction in the heat and size of the weld pool

possible when completing the weld. This makes it easier to avoid pores, thermal

cracking and crater formation in the weld joint.

In pulse welding mode it is possible to choose between pulsed and non pulsed crater

filling. Non pulsed crater filling is faster to do. Pulsed crater filling takes a little longer,

yet gives spatter free crater filling when appropriate values are used.

Synergy

In synergy mode the cra ter filling time and the final wire feed speed are both set in

pulsed and no n pulsed crater filling. The voltage and the pulse parameters drop t o

the final values with the help of synergy.

Non synergy

In non synergy mode the settings can be changed to give another arc length at the

end of crater filling.

The final voltage can be set for non pulsed crater filling. The final voltage, final pulse

current, final background current and the final frequency can be set for pulsed crater

filling.

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The final parameter values must always be equal to or lower than the set values for

continuous welding. If the settings for continuous welding are lowered below the set

final values they will also lower the final values. The final parameter values will not

increase again if the setting for continuous welding is increased.

Example:

You have 4 m/min as the final wire feed speed and lower the wire feed speed to

3.5 m/min. The final wire feed speed will also be lower e d to 3.5 m /min. The final wire

speed remains at 3.5 m/min even when the wire feed speed is increased again.

-- Crater filling is enabled in the measure image and the settings are defined in the

settings menu.

3.2.17 Pinch--off pulse

Pinch --off pulse is a pulse that is added to ensure than no ball is formed on the wire

when welding stops.

Only applies for MIG/MAG welding with dip/spray. When pulsing completion is

synchronised with a pulse, finishing pulse.

3.2.18 Burnback time

Burnback time is a delay between the time when the wire starts to brake until the

time when the power source switches off the welding voltage. Too short a burnback

time results in a long wire stickout after completion of welding, with a risk of the wire

being caught in the solidifying weld pool. A long burnback time results in a shorter

stickout, with increased risk of the arc striking back to the contact tip.

3.2.19 Gas post--flow

Gas post--flow controls the time during which shielding gas flows after the arc is

extinguished.

3.2.20 Limits

In this function you can choose a limit number. For settings, see chapter 17

”Configuring limits”.

3.2.21 Spot welding

Select Spot welding when you want to ”spot--weld” thin metal sheets.

Note! You can not shorten the weld time by releasing the gun trigger.

4 MMA WELDING

Main menu ----> Process

MMA welding may also be referred to as welding with coated electrodes. Striking the

arc melts the electrode, and its coating forms a protective slag.

The table on page 69 shows the electrode diameters that can be selected for MMA

welding.

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