ESAB Digital Dual Schedule Pulse MMI (Man Machine Interface) Panel Kit User manual

Category
Welding System
Type
User manual

This manual is also suitable for

DuraDrive 4-30 and DuraDrive 4-48
WIRE FEEDERS
P/N - 0558002496
Digital Dual Schedule Pulse
MMI (Man Machine Interface) Panel Kit
Installation and Operation
INSTRUCTION MANUAL
F15-703-C 02 / 2009
2
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-
vice facility designated by the manufacturer.
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 arc welding and cutting 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 the Safety Precautions be-
fore installing or operating this equipment.
CAUTION
USER RESPONSIBILITY
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
3
TABLE OF CONTENTS
SECTION TITLE PAGE
SAFETY .......................................................................................................................................................................... 5
1 DESCRIPTION .....................................................................................................................................................................17
2 INSTALLATION ...................................................................................................................................................................21
3 OPERATION ........................................................................................................................................................................27
4
TABLE OF CONTENTS
5
SAFETY PRECAUTIONS
Safety Precautions
Safety - English
WARNING: These Safety Precautions are
for your protection. They summarize pre-
cautionary information from the references
listed in Additional Safety Information sec-
tion. Before performing any installation or operating
procedures, be sure to read and follow the safety precau-
tions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield tted with the correct lter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating
or observing operations. Warn bystanders not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
3. Wear ameproof gauntlet type gloves, heavy long-
sleeve shirt, cuess trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A ameproof apron may also be desirable as protec-
tion against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cus, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-ammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protec-
tive non-ammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in oors or wall openings and cause a hid-
den smoldering re or res on the oor below. Make
certain that such openings are protected from hot
sparks and metal.
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might
produce ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have re extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable re extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For ex-
ample, overloaded welding cable can overheat and
create a re hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later re. Use re watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA
02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is conned, or if there is
danger of falling.
6
SAFETY PRECAUTIONS
1. Be sure the power source frame (chassis) is con-
nected to the ground system of the input power.
2. Connect the workpiece to a good electrical
ground.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
9. Turn o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommenda-
tions. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric cur-
rent owing through any conduc-
tor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health eects which
are unknown.
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the workpiece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stain-
less steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat ir-
ritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discom-
fort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specic ventilation recommendations.
7
SAFETY PRECAUTIONS
5. WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
§25249.5 et seq.)
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and vio-
lently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and ttings in good
condition. Follow manufacturer's operating instruc-
tions for mounting regulator to a compressed gas
cylinder.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar-
riages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures where they may
become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and ames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualied personnel perform the instal-
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equip-
ment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
8
SAFETY PRECAUTIONS
5. AWS C5.5 - "Recommended Practices for Gas Tung-
sten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Hand-
book.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used
throughout this manual: Means Atten-
tion! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in im-
mediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
17
SECTION 1 DESCRIPTION
NOTE
Using the Dual Schedule Pulse MMI panel in
combination with a power source with pulse
built-in is NOT recommended.
NOTE
For ALL dual schedule MMI panels, a weld
schedule can be disabled by placing the wire
feed speed knob to the minimum position
or "0" (zero) position. This will eliminate the
accidental triggering of the Mig gun into the
alternate weld schedule.
NOTE
The DuraDrive feeder is not compatible and
cannot be used with the UltraPulse 450i
Pendant or the DigiPulse power source.
Use with the 350 MPi UltraPulse Pendant
limits the MMI operation to the STANDARD
mode ONLY.
NOTE
Dual schedule parameter switching from the
gun trigger is disabled when TRIGGER LOCK
is turned "ON".
SAFETY
Before this MMI Panel Kit put into opera-
tion, the safety section at the front of this
manual should be read completely. This will
help avoid possible injury due to misuse or
improper installation.
The denitions relating to the:
safety notations are described at the end of
the Safety Section in the front of this manual
read them and their specic text refer-
ences carefully.
1.0 . DESCRIPTION
A. Digital Dual Schedule Pulse MMI Kit
The Digital Dual Schedule Pulse MMI Kit is designed to provide simple to use,
high quality, synergic pulsed Mig welding. Synergic pulsed Mig welding means
that pulse parameters (pulse height, pulse width, background current and pulse
frequency) are automatically adjusted as you change wire feed speed.
The Digital Dual Schedule Pulse MMI panel provides a Pulse Arc VOLTS Trim that
allows the operator to ne tune the pulse arc length. The VOLTS knob becomes the
pulse arc length adjustment when in the pulse process mode. The operator can
change to standard CV Mig welding by simply moving the PULSE /STANDARD
switch to the STANDARD position.
Figure 1-1. Digital Dual Schedule Pulse MMI Panel
Two welding parameters can be preset on the panel in either the Standard (CV)
or Pulse process mode. The arc starting schedule is selected with the SCHEDULE
select switch (A or B). The toggle switch position determines the welding schedule
to be used when the gun trigger is depressed. The welding schedules (parameters)
can be switched while welding by using the "Click Click" trigger technique where
the gun trigger is released and depressed quickly (within .2 sec). This method of
welding is used for providing a hot start, crater ll or gap lling welding param-
eter in addition to the standard welding parameters typically used for the given
weld application. This MMI panel MUST be used with a PULSE SELECTION module
installed on the wire feeder control cabinet rear panel.
18
B. Pulse Selection Panel
The PULSE SELECTION panel is mounted on the rear panel of the DuraDrive control cabinet
and is used to select the electrode WIRE TYPE and DIAMETER. See the chart below for
alloys and diameters supported on each power source.
The PULSE SELECTION panel has an option of using a trigger latch on, o or trigger latch
with crater ll selection. The crater ll parameter is selectable on either schedule A or B.
3.0. ADJUSTMENTS AND OPERATION
SECTION 1 DESCRIPTION
Table 1-1. Pulse Wire Type and Diameter
Figure 1-2. Pulse Selection Panel
DuraDrive PULSE SELECTION
Wire Type & Diameters for each Power Source
350MPi*/MTS-3500i MultiPower 460 SVI-450i
Carbon Steel 030, 035, 040, 045 035, 040, 045, 052, 062 030, 035, 045, 062
Stainless Steel (solid) 030, 035, 040, 045 035, 040, 045, 062 030, 035, 045, 062
4000 Aluminum 030, 035, 040, 3/64 035, 040, 3/64, 062 030, 035, 3/64, 062
5000 Aluminum 030, 035, 040, 3/64 035, 040, 3/64, 062 030, 035, 3/64, 062
Metal Core Steel 035, 040, 045, 052 035, 040, 045, 052, 062 N/A
Metal Core SS 045 045, 062 N/A
* - Pulsing with 062" diameter wire is not recommeded on the 350 MPi
19
SECTION 1 DESCRIPTION
C. ESAB Power Sources
The Digital Dual Schedule Pulse MMI Kit consists of the Digital Dual Schedule
Pulse MMI panel (PN-0558003005) and the Pulse Selection panel (PN-0558003007).
The kit is designed for welding applications where the pulse welding parameters
are supplied and controlled from the DuraDrive 4-30 or DuraDrive 4-48 wire feeder.
The following ESAB power sources MUST be used:
ESAB 350MPi / MTS-3500i
ESAB MultiPower 460 (non-pulse version)
ESAB SVI-450i
Table 1-2. MMI PANELS and POWER SOURCES
The DuraDrive feeder is shipped congured for pulsing the ESAB 350MPi / MTS-
3500i and MultiPower 460 (non-pulse model) power source. Other ESAB power
sources and competitors power sources are limited to the CV STANDARD weld-
ing mode ONLY and will not operate in the pulse process mode using this MMI
panel.
Pulsing with the SVI-450i power source is done by reconguring the DuraDrive
and SVI-450i for pulse welding compatibility. See setup instructions for SVI-450i
power source conguration for details.
21
SECTION 2 INSTALLATION
ELECTRIC SHOCK CAN KILL! Make sure
that all primary input power to the power
source and wire feeder has been discon-
nected at the wall (line) disconnect switch
or circuit breaker before making the fol-
lowing connections.
Tilt Adjustment Knob
Sixth Screw
Figure 2-1. Tilt Adjustment Figure 2-2. Sixth Screw
2.0. MMI PANEL INSTALLATION
A. MMI panel installation
The MMI panel installation is dierent between the DuraDrive 4-30 and DuraDrive
4-48.
1. Switch the POWER toggle switch on the DuraDrive front panel to the
"OFF" position. Turn "OFF" ALL power to the power source and DuraDrive
wire feeder using the main power disconnect switch and by unplugging
the power source.
DuraDrive 4-30
a. Remove the six screws holding the right side control cabinet
panel and lift up the hinged left door access to the drive stand
compartment.
b. Unplug the wire harness exiting the back of the MMI panel cover
from the DuraDrive main control PCB.
c. Remove the four plastic panel nuts that secure the MMI panel
corners.
d. Pull the MMI panel forward until the wire harness and plug(s)
clear the front panel of the DuraDrive control cabinet.
DuraDrive 4-48
a. Remove the six screws of the right side control cabinet cover.
b. Remove ve of the six screws on the left side cover of the feeder
that are easily accessible.
c. For access to the panel screw behind the drive stand, remove the
"Tilt Adjustment" knob above the drive stand and tilt the drive
stand to the top position (see Figure 2-1). Remove the sixth screw
(see Figure 2-2).
d. Lift up the hinged drive stand door to the top position with the
motor and gearbox attached (see Figure 2-3).
e. Unplug the wire harness exiting the back of the MMI panel cover
from the DuraDrive main control PCB (see Table 2-1).
f. Remove the four plastic panel nuts that secure the MMI panel
corners.
g. Pull the MMI panel forward until the wire harness and plug(s)
clear the front panel of the DuraDrive control cabinet.
22
Panel Nuts (Not Shown)
SECTION 2 INSTALLATION
Figure 2-3. Motor Side
2. Install the new MMI panel into the DuraDrive front panel and secure
with the nger nuts from the old MMI panel.
3. Route the wire harness and plug so they enter the control PCB compart-
ment (right side).
4. Connect the MMI harness plugs to the DuraDrive motor Control PC
board as shown in Figure 2-4 and Table 2-1.
5. Replace the DuraDrive Control cabinet motor side panel.
B. INSTALLATION OF PULSE SELECTION PANEL
1. Remove the four screws holding the BLANK option cover plate on the
rear panel of the DuraDrive control cabinet.
2. Replace the Blank Plate with the PULSE SELECTION panel and secure
with the BLANK plate screws.
3 Connect the P-9 to the J-9 receptacle and the P-10 plug to the J-10
receptacle on the main motor control PC board. See Figure 2-4.
4. Replace the right side panel.
C. POWER SOURCE CONFIGURATION
The DuraDrive 4-30 and 4-48 wire feeders ship from the factory congured pulse
welding with the 350MPi / MTS-3500i and MultiPower 460 power sources. In this
conguration there is a gray wire connected to both sides of terminal #5 on the
lower right bae plate inside the control PCB compartment. If a SVI-450i power
source is to be used, one of the gray wires must be moved to Terminal #6. The
power source conguration dip switches must be reset.
23
Table 2-1 - MMI Panel Plug Connection Table
Pulse Selection Panel
Pulse Dual MMI Panel
Figure 2-4 - MMI Panel Plug Connection
DuraDrive Motor Control PC Board
SECTION 2 INSTALLATION
24
SECTION 2 INSTALLATION
Figure 2-5. Terminal Strip
Gray Wire
Black Wire
Gray Wire
Figure 2-6.
S1 of SW 2 "Open"
SVI-450i Pulse
Conguration
Figure 2-7.
S1 of SW-2 "Closed"
350MPi / MTS-3500i
Pulse Conguration
ELECTRIC SHOCK CAN KILL! Make sure
that all primary input power to the power
source and wire feeder has been discon-
nected at the wall (line) disconnect switch
or circuit breaker before making the fol-
lowing connections.
DuraDrive Wire Feeder
1. Switch the POWER toggle switch on the DuraDrive front panel to the
"OFF" position. Turn "OFF" ALL power to the power source and DuraDrive
wire feeder using the main power disconnect switch and unplugging
the power source.
2. Remove the six screws holding the right side control cabinet panel.
3. Remove the GRAY wire at position #5 from the LEFT side of the terminal
strip and connect it to position #6 on the LEFT side. This is opposite a
BLACK wire on the Right side at position #6. See Figure 2-5.
4. Find dip switches SW-2 on the main control PC board. See Figure
2-4.
5. Place S1 to the "OPEN" (OFF) position for the SVI-450i or in the CLOSED
(ON) position for the 350MPi / MTS-3500i and MultiPower 460. See
Figures 2-6 and 2-7.
6. Replace the right side panel.
25
SECTION 2 INSTALLATION
SVI-450i Power Source
1. Turn "OFF" ALL power to the power source and DuraDrive wire feeder
using the main power disconnect switch and unplugging the power
source.
2. Remove the Top Panel cover of the SVI-450i power source by removing
the four screws in the chrome handles.
3. Check to conrm the jumper wire between P5-2 and P5-4. This is the
inductor bypass jumper.
4. Change the jumper pins on the main PC board as shown in the Table
2-2.
5. Remove and tape one end of ORANGE wire between P3-2 and P2-9. This
is the Pulse/Standard select that bypasses the inductor circuit when in the
Pulse mode. This function is provided by the DuraDrive feeders.
6. Place the SVI-450i SLOPE switch on the power source front panel to the
STEEP slope position.
7. Replace and secure the TOP panel of the SVI-450i power source.
OPTIONAL SVI-450i Conguration
Remove and tape GRAY wire going to P2-5. This wire, when disconnected, places the
power source in the steep slope operating mode permanently. Steep slope is required
for optimum synergic pulse welding operation and is needed for the pulse parameters
to operate correctly. It eliminates the Slope Selection switch.
26
SECTION 2 INSTALLATION
* When connected, this wire bypasses the inductor circuit (previously Pulse/
Standard select switch) in the Pulse mode. The Pulse starts are handled by the
DuraDrive feeder in the CV mode.
** Place SVI-450i Slope Switch to "STEEP" Slope for best Pulse Operation.
Figure 2-8. SVI-450i Control PC Board
J1 Jumper
SVI-450i Control Board
Jumper Conguration for
DuraDrive Wire Feeders
27
The following instructions are intended to supplement the manuals supplied with
the wire feeder and power source. Be sure to follow all installation, operation and
safety information provided by these manuals.
A. MMI Dual Set-Up and Operation
Two welding parameters can be preset on the panel in either the STANDARD
(CV) or PULSE process mode. The arc starting schedule is selected with the
SCHEDULE switch. The SCHEDULE toggle switch position determines the
welding schedule to be used when the gun trigger is depressed. The weld-
ing schedules (parameters) can be switched between schedule A & B while
welding by using the "Click Click" trigger technique. If the gun trigger is
released and depressed quickly (within .2 sec) the weld schedule will switch
to the alternate schedule. This method of welding is used for providing a hot
start, crater ll or gap lling welding parameter in addition to the standard
welding parameters typically used for the given weld application.
B. Power Source and DuraDrive STANDARD (CV) Set-Up
1. Turn the power source and DuraDrive wire feeder "ON".
2. Place the power source PROCESS SELECTOR on the Power Source switch
(if present) in the Mig position and the MIG SELECTOR switch (if present)
to the type of Mig wire to be used. (Example - 350MPi / MTS-3500i)
3. Position the REMOTE/PANEL switch on the power source to the REMOTE
position.
4. Choose SCHEDULE A using the SCHEDULE SELECT toggle switch on the
Dual Schedule MMI panel and set a wire feed speed.
5. Make a weld and adjust the arc voltage and wire feed as needed for good
welding characteristics.
6. Choose SCHEDULE B using the SCHEDULE SELECT toggle switch on the
Dual Schedule MMI panel and set a wire feed speed.
7. Make a weld and adjust the arc voltage and wire feed as needed for good
welding characteristics.
8. Position the SCHEDULE SELECT toggle switch to the preferred schedule
for starting the weld.
9. While welding, the weld schedule can be changed from the Mig gun trigger
by using the "Click Click" method.
a. After starting the weld, double click the gun trigger (within .2 seconds)
and the MMI will switch to the second weld schedule.
b. Switch back to the rst weld schedule by double clicking the trigger
again.
C. Pulse Selection Module and MMI Panel Set-Up
1. Set the WIRE TYPE and WIRE DIAMETER knobs on the PULSE SELECTION
module to the electrode wire type and diameter installed on the DuraDrive
wire feeder.
a. A "STEADY" - "NO PROGRAM" light indicates there is no program for
the material and wire diameter selected.
b. A "BLINKING" - "NO PROGRAM" light means the wire feed speed
chosen is outside of the recommended range. A weld can still be made
but good welding arc stability cannot be guaranteed and additional
arc trimming might be needed.
2. Place the PULSE/STANDARD toggle switch to the PULSE position.
3. Choose SCHEDULE A using the SCHEDULE SELECT toggle switch on the
SECTION 3 OPERATION
NOTE
For ALL dual schedule MMI panels, a weld
schedule can be disabled by placing the wire
feed speed knob to the minimum position
or "0" (zero) position. This will eliminate the
accidental triggering of the Mig gun into the
alternate weld schedule.
NOTE
Arc voltage CANNOT be preset on the digital
meter. Actual arc voltage will be displayed
once welding begins.
NOTE
Dual schedule parameter switching from
the gum trigger is disabled when TRIGGER
LOCK is turned "ON".
28
NOTE
The RED light on the MMI panel will "Blink"
when the wire feed speed is out of range.
NOTE
The digital VOLT METER will read "0" in the
center or #5 position. ARC TRIM is used to
ne tune the arc length performance. Turn
the knob clockwise to increase the arc length
or counterclockwise to decrease the arc. The
number shown on the digital display will go
plus (clockwise) and minus (counterclock-
wise). This number indicates the number of
pulses per second (pulse frequency) above
or below the programmed parameters in the
DuraDrive control circuitry.
SECTION 3 OPERATION
Dual Schedule MMI panel and set a wire feed speed.
4. Set the VOLTS (Arc Trim) knob to the "5" or center position.
5. Make a weld and adjust the arc voltage (TRIM) and wire feed as needed
for good welding characteristics.
6. Choose SCHEDULE B using the SCHEDULE SELECT toggle switch on the
Dual Schedule MMI panel and set a wire feed speed.
7. Set the VOLTS (Arc Trim) knob to the "5" or center position.
8. Make a weld and adjust the arc voltage (TRIM) and wire feed as needed
for good welding characteristics.
9. Position the SCHEDULE SELECT toggle switch to the preferred schedule
for starting the weld.
10. While welding, the weld schedule can be changed from the Mig gun
trigger by using the "Click Click" method.
a. After starting the weld, double click the gun trigger (within .2 seconds)
and the MMI will switch to the second weld schedule.
b. Switch back to the rst weld schedule by double clicking the trigger
again.
D. Pulse Process control
1. Use a tip-to-work distance of 3/8" to 5/8". This refers to the distance between
the end of the Mig gun contact tip and the plate or weld puddle.
2. For the best arc stability, keep the arc on the front edge of the molten
puddle and use a 5 to 10 degree gun angle from the vertical.
3. The VOLTS knob on the Pulse MMI panel is used to trim the arc length
by turning the dial clockwise to lengthen the arc or counterclockwise to
shorten the arc. If the arc is "crackling" or if spatter is excessive, lengthen
the arc. If the arc is "uttering" or dicult to control, then shorten the
arc length.
E. Pulse MIG Arc Stability
Many variables can aect the arc stability of pulse MIG welding. Some examples
are:
High resistance cables and connections
Long welding cables (greater than 60 ft.)
Dierences in shielding gas compositions
Dierences in weld wire chemistry
Water vs. air cooled guns
Base metal surface condition
29
SECTION 3 OPERATION
TABLE 3-1. Material and Shielding Gases
When adverse conditions are present, the pulse arc stability is sometimes less than
desirable. The arc will "crackle" and produce higher than normal spatter levels.
This occurs due to higher resistances in the welding circuit causing changes,
pulse waveform and average current levels. The VOLTS knob on the DuraDrive
MMI Panel adjusts the pulse frequency to accommodate small changes in the
welding equipment set-up and base material variations to achieve a stable pulse
welding condition.
F. Shielding Gases
Table 3-1 lists the range of shielding gases that can be used with the Pulse MMI
Panel. The wire burn-o rate and synergic operation will vary with changes in
shielding gas. The Pulse MMI VOLTS knob is used to compensate for changes in
shield gas composition.
G. Pulse Parameters
Tables 3-2 through 3-12 list the approximate pulse welding parameters for each
material and diameter. These are provided for general reference only. Actual pulse
parameters can vary with the equipment set-up, welding application and shield-
ing gas being used. The wire feed speed ranges shown in the tables are the same
as programmed into the DuraDrive software. Attempting to weld outside of the
suggested speed ranges will result in a "blinking" indicator light on the MMI panel.
A "steady" light on the panel indicates the wire material and diameter combination
selected does not have any pulse data programmed.
Material
Type
Shielding Gas
(AWS Designation)
Carbon
Steel
A
r - 5% CO2 (SG-AC-5)
A
r - 8% CO2 (SG-AC-8)
A
r - 10% CO2 (SG-AC-10)
A
r - 2% O2 (SG-AO-2)
Ar - 8% CO2 - 2% O2 (SG-ACO-8/2)
Stainless
Steel
A
r -2% CO2 (SG-AC-2)
A
r - 8% CO2 (SG-AC-8)
A
r - 2% O2 (SG-AO-2)
A
r - 8% CO2 - 2% O2 (SG-ACO-8/2)
Ar - He
4000 &
5000
Aluminum
A
r ( SG-A) Ar -
He 25% (SG-AHe-25) Ar -
He 50% (SG-Ahe-50)
Metal Core
Carbon
Steel
A
r - 5% CO2 (SG-AC-5)
A
r - 8% CO2 (SG-AC-8)
A
r - 10% CO2 (SG-AC-10)
A
r - 2% O2 (SG-AO-2)
Ar - 8% CO2 - 2% O2 (SG-ACO-8/2)
Metal Core
Stainless
Steel
A
r - 2% CO2 (SG-AC-2)
A
r - 8% CO2 (SG-AC-8)
A
r - 1% O2 (SG-AO-1)
A
r - He 50% - 2% CO2 (SG-AHeC-50/2)
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ESAB Digital Dual Schedule Pulse MMI (Man Machine Interface) Panel Kit User manual

Category
Welding System
Type
User manual
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