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

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.

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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.

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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

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