Lincoln Electric SVM185-A 7OPERATIONB-7, Making a Weld with Waveform, Technology Power Sources

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B-7OPERATIONB-7

MAKING A WELD WITH WAVEFORM

FIGURE B.2 - SMAW (STICK) WELDING

TECHNOLOGY POWER SOURCES

 

WARNING

The serviceability of a product or structure utilizing the welding programs is and must be the sole respon- sibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding pro- cedure, plate chemistry and temperature, weldment design, fabrication methods and service require- ments. The available range of a welding program may not be suitable for all applications, and the builder/user is and must be solely responsible for welding program selection.

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The steps for operating the Power Wave® will vary depending upon the user interface of the welding sys- tem. The flexibility of the POWER FEED® lets the user customize operation for the best performance.

First, consider the desired welding process and the part to be welded. Choose an electrode material, diam- eter, shielding gas and process (GMAW, GMAW-P, GMAW-STT™, etc.)

Second, find the program in the welding software that best matches the desired welding process. The stan- dard software shipped with the POWER FEED®s encompasses a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales repre- sentative.

All adjustments are made on the user interface. Because of the different configuration options your sys- tem may not have all of the following adjustments. Regardless of availability, all controls are described below.

SMAW (STICK) WELDING

SMAW is most often used for outdoor construction, pipe welding and general repairs. The wire feeder con- trols Amperage, Output Control and Arc Force during SMAW welding.

During SMAW welding, the wire feeder sets the weld parameters and the wire drive remains idle.

The “Volts”-”Trim” control is used to turn the power Source Output ON or OFF. (See Figure B.3)

 

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K2368-1

Power Wave® 355M

1

K2202-1

Power Wave® 455M

 

K2203-1

Power Wave® 455M/STT™

 

K2230-1

POWER FEED® 10M, Bench

 

 

Model

2

K2234-1

POWER FEED® 10M Dual, Bench

 

 

Model

 

K2536-1

POWER FEED® 25M

3

K1543-xx

Digital Control Cable

4

K1842-xx

Weld Power Cable, Lug to Lug

 

K910-xx

Ground Clamp

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K909-xx

Electrode Holder

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K2176-1

Twist-Mate™ to Lug Cable

 

 

Adapter

Return

Return

SMAW Welding (See Figure B.2)

POWER FEED® 25M

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Contents Power Feed 25M Power Feed 25M SafetyFumes and Gases Electric Shock can killIii For ElectricallySûreté Pour Soudage a L’Arc Précautions DE SûretéElectromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Power Feed 25M K2536-1 InstallationLocation Safety Precautions High Frequency ProtectionElectric Shock can Kill Wiring Power Source Wire FeederDigital Control CABLE, K1543-XX FunctionCoaxial Weld Cable Weld Cable SizeTable A.1 Gmaw Electrode Polarity Shielding GAS ConnectionGtaw Build UP of Shielding GAS MAYOFF Changing the Drive Motor Gear RatioProcedure to Install Drive Rolls and Wire Guides Wire Drive ConfigurationLoading Spools of Wire Remote Sense Lead SpecificationsTypical System Configurations Table of Contents Operation Section Operation Safety PrecautionsDefinition of Welding Terms General DescriptionDuty Cycle Recommended Processes Recommended Power SourcesEquipment Limitations 11. ON/OFF switch Connector for a remote controlPin connector Left Display windowStatus LED ON-OFF SwitchTable B.1 Definition7OPERATIONB-7 Technology Power SourcesMaking a Weld with Waveform Smaw Stick Welding8OPERATIONB-8 Process ModeSmaw Stick Welding Display MSP4 OperationWelding NON-SYNERGIC Gmaw and FcawThree non-synergic welding modes are available Non-Synergic Gmaw and Fcaw Welding Display Modes 5 MSP4 OperationFigure B.5 Gmaw MIG Synergic Welding220 26.4 ARC Control Steel and Stainless Synergic GMAW-P Pulsed MIG WeldingStainless Steel Gmaw Migwelding 220 Aluminum Synergic GMAW-P Pulsed 16OPERATIONB-16Migand GMAW-PP Pulse on Pulse Pulse-on-Pulse WeldingAluminum Pulse Welding Aluminum GMAW-P and GMAW-PPFigure B.14 Aluminum GMAW-P and GMAW-PP WeldingAluminum Pulse and Pulse-On-Pulse Synergic Weld Display Figure B.15 GMAW-STT WeldingGMAW-STT 109Figure B.16 TailoutTouch Start Gtaw TIG WeldingTIG OFF Power Feed SET-UP Features Menu10M All Models Feed 10AQuick Preflow time will not be accessible from the MSP4 Operation PROCEDURE/MEMORY Panel Opera User Memories Tion Parameter Range Units LimitsMSP4 Display Limits may be set forLow Limit High LimitParameter Name Item D Escription Internal ControlsLight Switch Cold FEED/GAS Purge SwitchHeater Switch Step Trigger OperationPreflow 34OPERATIONStrike WeldFigure B.20 Figure B.21 UpslopePostflow 37OPERATIONB-37Figure B.23 StartRear Controls DescriptionFlow Meter Operation on Lincnet Power SourcesScfh Liter/MinTable of Contents Accessories Section Factory Installed Equipment AccessoriesWire Type Electrode Size KP KIT Drive Roll Kits UsedK2593-xx #1 Co-Axial Power Cable Accessories K1500-5 Gun Receiver Bushing compatible Cooling KIT InstallationUse a 5/16 nut driver to remove the screws holding Water cooling cover on the case front of the innerFigure C.1 Python Water Cooled GunsPower Feed 25M Table of Contents Maintenance Section Routine Maintenance MaintenancePeriodic Maintenance Calibration Specification1TABLE of CONTENTS-THEORY of Operation Section E-1 Figure E.2 General Physical Description Theory of OperationFigure E.3 GAS Solenoid Controls Power Feed 25MControl BOX User Interface Component is causing the problem. By using the status TroubleshootingComponent Status Lights Status Light StatesStatus Light States CON’T 1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Troubleshooting and RepairSee Setting DIP Switches Wire Drive Troubleshooting and Repair Output Problems Power Power source is functioning Make certain the Power WaveSetting Dip Switches in the Wire Troubleshooting and Repair Fault Code Description Possible Adjustments ArcLink System Error CodesPower Feed 25M Test Description Voltage Sense PC Board TestMaterials Needed Figure F.1 Plug J1 and J2 Locations ProcedureTach Feedback Test Blue RED Drive Motor Test #550 #551 Gear BOX and Drive Motor Removal and Replacement Procedure Gear BOX Removal and Drive Motor Figure F.4 Gear BOX and Drive Motor Removal and ReplacementReplacement Procedures To Remove the Wire Drive Assembly from the Gear BOXTo Remove the Drive Motor from the Gear BOX Retest After Repair SET UPTable of Contents Diagram Section Wiring Diagram Complete Machine Code 11313 G5585 Electrical DiagramsG5638 Schematic Complete Machine Code 11313 G5638Schematic 42 VAC & Arclink Feeder PC Board #1 G3883-2 Schematic 42 VAC & Arclink Feeder PC Board #2 G3883-2 Schematic MSP4 Optional Display PC Board G4456 Schematic SPI Display PC Board L11756 PC Board Assembly SPI Display L11757-1 Schematic Voltage Sense Select PC Board S24779 PC Board Assembly Voltage Sense Select M19540 Schematic Spool GUN PC Board L12008 PC Board Assembly Spool GUN M20159