ESAB LTP 450 Programming Manual

Valid for program version 2.10B and 2.11A0456 638 104 981110

PROTIG 450

LTP 450

104

Programming manual

TOCe

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1 INTRODUCTION 4........................................................

1.1 Mode of operation -- Control box 4.......................................

1.2 Sectors 4............................................................

1.3 Display and keyset 6..................................................

2 WELDING PARAMETERS 12................................................

2.1 Welding current 12.....................................................

2.2 Gas 14...............................................................

2.3 Wire feed speed 15....................................................

2.4 Preheating time 15.....................................................

2.5 Rotation speed 16.....................................................

2.6 Arc voltage control (A VC) 16............................................

2.7 Weaving 18..........................................................

3 START AND STOP 19......................................................

3.1 Start 19...............................................................

3.2 Stop 19...............................................................

3.3 Restart 19............................................................

4 TO GET STARTED 20......................................................

4.1 General 20............................................................

4.2 How to indicate a tool code 20............................................

4.3 How to change languages 22.............................................

5 PROGRAM EDITING 23.....................................................

5.1 Entering a parameter value 23............................................

5.2 Increasing/decreasing a parameter value 23................................

5.3 Creating a new sector 24................................................

5.4 Changing the breakpoint of a sector 24....................................

5.5 Creating a transport sector 25............................................

5.6 Finding the home position 26.............................................

5.7 Entering a slope 26.....................................................

5.8 Moving within a program 27..............................................

5.9 Deleting in a program 28................................................

5.10Changing weld data during welding 29.....................................

5.11Zeroing the control box 30...............................................

6 PROGRAMMING EXAMPLES 31.............................................

6.1 Example 1a: 31........................................................

6.2 Example 1b: 35........................................................

6.3 Example 1c: 38........................................................

6.4 Example 1d: 42........................................................

6.5 Example 1e: 48........................................................

7 THE LIBRARY 53..........................................................

7.1 Storing a program 53...................................................

7.2 Recalling a program 53..................................................

7.3 Viewing the tool code 54.................................................

7.4 Deleting a program 55..................................................

8 MANUAL MODE 56........................................................

8.1 Field of application 56...................................................

8.2 Editing a parameter 56..................................................

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9 PC--CARD 59.............................................................

9.1 Field of application 59...................................................

9.2 How to install the card 59................................................

9.3 How to recall a program 59..............................................

9.4 How to store a program 60...............................................

9.5 How to delete a program 61..............................................

9.6 How to take out the PC--card 62..........................................

10 ERROR CODES 62.........................................................

10.1 Error handling 62.......................................................

10.2 Incorrect editing codes 71...............................................

11 SHOW CURRENT PARAMETER VALUES 72..................................

11.1 Field of application 72...................................................

11.2 How to view actual parameter values 73...................................

12 SOFTWARE UPGRADE 73..................................................

12.1 Application field 73.....................................................

12.2 Menu explanation 74....................................................

12.3 How to upgrade 75.....................................................

12.4 Measures to be taken when the upgrading of the power source units failed 78....

12.5 Measures to be taken when the upgrading of the control box failed 79...........

13 SOFWARE KEY 80.........................................................

13.1 General 80............................................................

13.2 Locking the control box 80...............................................

13.3 Unlocking the control box 81.............................................

13.4 Changing the code 82...................................................

14 NOTEBOOK 83............................................................

14.1 Field of application 83...................................................

14.2 How to enter data in the notebook 83......................................

14.3 Example 2a: 84........................................................

15 MANUAL WELDING 94.....................................................

15.1 Field of application 94...................................................

15.2 How to create a welding program 94.......................................

15.3 Example 3a: 94........................................................

15.4 How to weld 100........................................................

16 APPENDIX 100.............................................................

16.1 Tool codes 100..........................................................

16.2 Symbols 101...........................................................

16.3 Setting ranges -- welding parameters 102....................................

17 TECHNICAL TERMS 103.....................................................

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1 INTRODUCTION

1.1 Mode of operation -- Control box

The control box consists of four memory units, the working area, the

library, the notebook and the auxiliary function.

S In the working area the welding program is created.

S In the library the program can be stored.

During welding it is always the contents of the working area that control

the welding process. Thus it is also possible to call in a welding program

from the library to the working area.

S In the notebook you can make your own notes about special welding

parameters, for example.

S In the auxiliary function you can:

S change languages

S view all existing error messages

S show actual parameter values

S software upgrade

S sofware key

1.2 Sectors

A welding program for welding of tubes can be divided into different parts or

sectors. Each sector corresponds to a special part of the circumference of

the tube. Max. number of sectors for one program is one hundred (100).

Sector 1

Sector 2

Sector 4

Sector 3

A sector can be assigned its own set of values for different welding

parameters, such as current, rotation speed, wire feed speed, etc. In this

way the welding can be performed using different parameter settings for

different parts of the joint of the tube.

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The division into sectors is done by indicating different breakpoints along

the circumference of the tube. Each such breakpoint constitutes the

starting point of a new sector. In the figure below, the breakpoint 0.000 is

the starting point of sector 1, breakpoint 0.250 the starting point of sector 2,

etc.

Sector 1

Sector 2

Sector 4

Sector 3

Breakpoint 0,000

Breakpoint 0,250

Breakpoint 0,500

Breakpoint 0,750

LTP 450 allows welding of up to 10 turns in the same welding joint, i.e. the

welding tool can be rotated 10 times round the tube.

The breakpoints in the previous figure all start with the integer 0 which

means that they form the breakpoints of turn 1. The breakpoints of turn 2

(if there is one) always start with the integer 1,etc.

S T urn 1 = breakpoints 0.000 -- 0.999

S T urn 2 = breakpoints 1.000 -- 1.999

S T urn 3 = breakpoints 2.000 -- 2.999

S T urn 4 = breakpoints 3.000 -- 3.999

S T urn 5 = breakpoints 4.000 -- 4.999

S T urn 6 = breakpoints 5.000 -- 5.999

S T urn 7 = breakpoints 6.000 -- 6.999

S T urn 8 = breakpoints 7.000 -- 7.999

S T urn 9 = breakpoints 8.000 -- 8.999

S T urn 10 = breakpoints 9.000 -- 9.999

To terminate a welding program a so--called end sector is indicated.

For a sector to be counted as an end sector the following two conditions

must be fulfilled:

S There is no sector following.

S The welding current value of the sector = 0 ampere.

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1.3 Display and keyset

A Display

B Soft keys

C Function keys

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Display

SECTOR 2(4)

5

WELD GAS

ROOT GAS

START GAS

WELD

GAS

ROOT

GAS

START

GAS

s

a

b

c

d

e

15

0.500

f

g

h

The following information is shown in the display.

a The program sector at present involved.

b The number of sectors in the current program.

c The breakpoint of the sector (sector 2 in this example).

d The digit box shows the numerical value entered and different

numerical characters. For further information, see page 101.

e Showing that the indicated value has been borrowed from a previous

sector (in this example from sector 1).

g 5 text boxes describing the function of the so--called soft keys (f).

h Message line describing the actual state.

WELDING = a welding sequence is going on.

END = a welding sequence is completed.

TRANSPORT = transfer without welding.

STOP = the welding sequence was interrupted due to activation

of the stop key.

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Soft keys

By way of the soft keys ( a) the functions connected with the respective

display (in this case the GAS parameter display), the significance of which is

indicated in the text boxes (b). Depending on the display selected, up to five

soft keys can be activated.

Function

keys

Parameter keys

The welding parameters are divided into seven different groups, each group

represented by one ordinary key and a set of soft keys.

Welding current Gas

Rotation speed Wire feed speed

Arc voltage control (AVC) Weaving

Preheating time

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SHIFT key

This key is used for changing the significance of other keys on the

keyboard.

PLUS/MINUS keys

These keys are used for increasing/decreasing set values.

Numerical keys

These keys are used for entering the digits 0--9 and decimal point.

Other keys

SLOPE

This key is used when you want to add a slope function to a parameter and

is indicated in the following way in the display

.

By slope is meant a gradual change of a set value.

Slope up = gradual increase

Slope down = gradual decrease

The following parameters can be assigned a slope function:

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Current (both peak and background current) when pulsed current is used,

rotation, arc length control, wire feed speed , weaving amplitude.

A slope can be time--controlled by indicating that it shall go on for a certain

number of seconds. It can also be sector--controlled, making it a so--called

sector slope, by indicating between which two breakpoints it shall be

located.

SECTOR

This key indicates the breakpoint of a program and moving to indicated

sector.

STEP

This key is used for stepping forward in the program.

DELETE

This key is used for deleting the whole program, part of a program in the

working area, or just the figures in the digit box.

MANUAL MODE

This key is used for positioning the electrode before welding, and for making

sure that the program in the working area functions as desired.

MEMORY (library)

This key is used for entering or leaving the library and for storing a program,

or for recalling a program from the library to the working area.

CORRECT

This key is used for correcting the position of the electrode in connection

with weaving (centre line adjustment).

MODE (auxiliary functions)

This key is used for getting to the different auxiliary functions, such as

language, error log, show actual parameter values and software upgrading.

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NOTEBOOK

These keys are used if you want to make notes on a welding sequence.

TOOL CODE

These keys are used if you want to view the code of the connected tool.

RESTART

These keys are used for restarting a welding sequence.

SECTOR SLOPE

These keys are used if you want to create a sector slope.

DIRECT STOP

Pressing this key will lead to direct stop of the welding. The gas postflow

takes place according to settings in the end sector.

START

This key is used for starting a welding sequence.

STOP

This key is used for stopping a welding sequence. The welding sequence is

terminated according to the settings in the end sector .

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2 WELDING PARAMETERS

Setting ranges for the welding parameters can be found in the APPENDIX

on page 102.

2.1 Weldin g current

There are four different parameters for welding current:

S PEAK CURRENT

S BACKGROUND CURRENT

S PEAK TIME (1 s)

S BACKGROUND TIME (1 s)

The values in brackets are preset values.

Peak time

Background time

Background current

Peak

current

The welding current can be either pulsed or continuous (not pulsed).

If you want to weld using pulse current a value must be entered for all four

parameters. When welding with continuous current, however, you only need

to enter the value for peak current. Entering a value also for background

current will result in pulsed current with preset pulse and background

times. Of course, the pulse and background times can also be changed.

The weaving motion can be synchronised with the welding current (pulsed

current) so that the peak current sets in at the same time as the electrode is

in an end position. This is also called special pulsing.

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Special pulsing

By special pulsing is meant that the welding current is synchronised with the

weaving motion, i.e. you get peak current when the electrode is in an end

position of the weaving motion. Thus the peak current time is determined by

the dwell time of the respective dwell position.

Special pulsing can be used in combination with both continuous and pulsed

rotation. Special pulsing with pulsed rotation -- also called square--wave

pulsing -- means that the gear ring rotates when the electrode is in an end

position of the weaving motion.

Special pulsing with

continuous rotation

Rotation direction

Special pulsing with

pulsed rotation

Rotation direction

A = background current B = peak current

As to special pulsing, the wire feed can be either continuous or pulsed. As

to pulsed wire feed, the synchronisation with the welding current takes place

in the way described above, see the section “Wire Feed Speed“ on page 15.

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SECTOR 1(4)

PEAK CURRENT

BACKGR. CURRENT

PEAK TIME

BACKGR

CURR

PEAK

TIME

A

s

0.000

BACKGR. TIME

s

BACKGR

TIME

SPEC.

PULS

PEAK

CURR

CONT/

To activate the function special pulsing, press the marked soft key in the

display for welding parameters.

2.2 Gas

In the Shielding Gas parameter group three parameters are represented:

S WELD GAS

S ROOT GAS

S START GAS

By weld gas is meant the shielding gas on the upper side of the joint. The

weld gas parameter indicates the time the shielding gas is to flow on the

upper side of the joint before and after welding.

The values of the weld gas parameter are preset. The following values for

preflow and postflow of the weld gas apply at the start if nothing else has

been indicated:

S Weld gas preflow = 2 s

S Weld gas postflow = 4 s

By root gas is meant the shielding gas on the underside of the joint. The

root gas parameter indicates the time the shielding gas is to flow on the

underside of the joint before and after welding.

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Some shielding gases, for example helium (He), can cause difficulty with

regard to striking the arc. If such a shielding gas is to be used as weld gas,

it could be advisable to use another gas mixture at the start moment -- a

so--called start gas.

If one value is entered for weld gas in sector 1 and one for start gas, only

the start gas is going to flow. The weld gas starts flowing when the arc is

struck.

2.3 Wire feed speed

This parameter is used to indicate the desired feed speed of the filler wire in

cm/min.

The wire feed speed can be pulsed or continuous (not pulsed).

In the Wire Feed Speed parameter group two parameters are represented:

S PEAK WIRE FEED SPEED

S BACKGROUND WIRE FEED SPEED

For welding with continuous (not pulsed) wire feed speed, only the peak

wire feed parameter shall be entered.

For welding with pulsed wire feed speed, both the peak wire feed speed

and the background wire feed speed parameters shall be entered.

The pulsed wire feed speed is always automatically synchronised with the

welding current. The wire feed speed is high using pulse current and low

using background current.

2.4 Preheatin g time

Preheating is used for heating the workpiece at the starting point in order to

obtain correct penetration of the molten pool. The preheating time is defined

as the time elapsing between arc strike and start of the rotary motion. If no

value has been entered for the preheating parameter , the arc will strike at

the same time as rotation is started.

NOTE! In the Welding Current parameter group you cannot indicate a

sector slope when preheating is involved.

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2.5 Rotation speed

This parameter indicates the rotation speed of the electrode round the

workpiece. It is indicated in per mill (thousandths) of the max. rotation speed

of the welding tool used.

Just like welding current and wire feed speed, the rotation speed can be

pulsed or continuous (not pulsed).

In the Rotation Speed parameter group four parameters are represented:

S ROTATION FORWARDS

S ROTATION BACKWARDS

S PULSED ROTATION FORWARDS

S PULSED ROTATION BACKWARDS

The pulse rotation is always automatically synchronised with the welding

current. The welding tool rotates when peak current is used, and stands still

when background current is used.

2.6 Arc voltage control (AVC)

This parameter is used for automatic control of the arc when welding with a

tool fitted with an AVC unit.

Arc voltage control (AVC) means that the arc voltage, and by that the length

of the arc (i.e. the distance between the tip of the electrode and the

workpiece), is automatically controlled in the course of welding.

In the Arc Voltage Control (AVC) parameter group three parameters are

represented:

S PEAK VOLTAGE (Arc voltage when using peak current)

S BACKGROUND VOLTAGE (Arc voltage when using background

current)

S DELAY TIME

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With the parameters peak voltage and background voltage you set the

reference value for arc voltage control when using peak current and

background current. When using continuous current only the peak voltage

parameter shall be entered.

If no value is entered for peak voltage a value measured right after the

welding start is used as reference value.

If no value is entered for background voltage and pulsed welding current

has been selected, no arc voltage control takes place when background

current is used.

NOTE! A time slope cannot be indicated in sector 1 for peak voltage and

background voltage.

In order to stabilise the arc before starting the arc voltage control, a delay

time can be entered. During the delay time the AVC unit is locked.

If no delay time is entered the following applies:

S The delay time will be equally long (at least 5 seconds) as the slope--up

time (if any) for the welding current.

If the slope--up time is shorter than 5 seconds, the AVC unit can start

controlling when the slope time has elapsed, but only by increasing the

arc voltage (arc length).

S If no slope--up time has been entered for the welding current, a fixed

delay time of 5 seconds applies. The AVC unit is not completely locked --

the arc voltage (arc length) can be increased.

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2.7 Weaving

Weaving is used if you want to oscillate the electrode laterally when welding

with welding tools fitted with a weaving unit.

In the Weaving parameter group four parameters are represented:

S WEAVE AMPLITUDE (5 mm)

S WEAVE SPEED (5 mm/s)

S DWELL TIME RIGHT (1 s)

S DWELL TIM E LEFT (1 s)

amplitude (mm)

dwell time (s)

right

left

dwell time (s)

Weave speed (mm/s)

The values in brackets are preset values. If one of the parameter values is

indicated in the display, the preset values will come up automatically.

The weaving motion can be synchronised with the welding current (pulse

current) so that the pulse current sets in at the same time as the electrode is

in dwell position. This is also called special pulsing and is described in the

section Special Pulsing on page 13.

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3 START AND STOP

3.1 Start

To start the welding, use the START key .

It is impossible to start a welding program if another tool code has been

indicated than the one used in the program in question.

3.2 Stop

A requested welding stop over the STOP key means that the program

jumps to the following end sector, no matter which sector you are in at the

moment. The welding is terminated according to the settings of the end

sector.

A requested welding stop over the DIRECT STOP key

leads to

immediate stop of the welding. The gas postflow takes place according to

the time set in the end sector.

3.3 Restart

If the welding was interrupted it is restarted with the SHIFT and START

keys

.

Irrespective of whether the welding was stopped over the STOP

or the DIRECT STOP key , the start parameters of the preceding

start sector are used. The program then continues from the position in the

welding program where it was interrupted.

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4 TO GET STARTED

4.1 Gen eral

Some of the factors controlling the welding process are specific to each one

of the welding tools, for example the rotation speed. Therefore, every

welding program must be connected to a tool code, associated with the

tool that the program was made up for.

4.2 How to indicate a tool code

S T urn the mains switch on the welding power source to position 1.

S The following display comes up:

CHOOSE CONNECTED TOOL

PRB , PRC "

PRH

PRD

POC 12--60 mm

TIG HAND TORCH

A25

Example: You have connected PRC 33--90

S Move the marking to the line for PRB, PRC using the soft key NEXT.

Choose the desired tool and press ENTER.

A window comes up, showing available tool sizes.

S Move the marking to the size of the tool you have connected (in this

example 33--90 mm) using the soft key NEXT and press ENTER.

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ESAB LTP 450 Programming Manual

ESAB LTP 450 Programming Manual

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