Lincoln Electric IM542-D manual Overview of Welding Procedures, Pulse Procedures, Wave Control

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B-16

B-16

OPERATION

OVERVIEW OF WELDING

PROCEDURES

FLUX CORED ARC WELDING (FCAW) AND GMAW PROCEDURES

For each wire feed speed, a corresponding voltage is preprogrammed into the machine by welding experts. This preprogrammed voltage is the best average volt- age for the procedure at the given wire feed speed. If the wire feed speed is changed on the wire feeder, the voltage automatically changes with it.

In some cases, the operator may want to change the preprogrammed voltages; for example, to compensate for cable and fixture voltage drops. The preset voltages can be adjusted on the wire feeder’s Voltage display. When a change is made to the voltage at one wire feed speed, this change is applied to all other wire feed speed settings. For example, if the operator turns up the voltage by 10 percent, the machine automatically increases the preset voltages at all the other wire feed speeds by 10 percent. In the GMAW and FCAW process, the display shows The Procedure Description, WFS and Preset Voltage. The preset voltage which was pro-grammed at the factory, may be changed on the wire feeder voltage display. Note that if you change the

default preset voltage up or down a respective “ ” or “ ” V sign will be dis-played after the preset value. When the

gun trigger is pulled note that the display changes to show WFS, Actual Arc Volt-age and Actual Arc Current. See Table B.4 for display summary.

PULSE PROCEDURES

In these procedures, the actual voltage greatly depends on the waveform used. The peak currents, background currents, rise times, fall times, and pulse times all affect the actual volt-age. The actual voltage for a given wire feed speed is not directly predictable unless the waveform is known. In this case, it is not practical to preset an actual voltage for the pro-cedure. Instead, an arc length adjustment is provided. The machine “knows” what the best arc length is at the given wire feed speed but allows the operator to change it.

The arc length can be adjusted between 0.5 and 1.5 on the wire feeder’s Voltage display. An arc length trim of

1.0means that no adjustments will be made to the pre- set arc lengths. An arc length trim greater than 1.0 increases the preset arc lengths. An arc length trim less than 1.0 decreases the pre-set arc lengths. The arc length adjustment is factored in at all wire feed

speed settings.

Increasing the arc length by 10 percent at a given wire feed speed also increases all the other arc length set- tings of the procedure by 10 percent. In the Pulse process, the display shows the Procedure Description, WFS and Arc Length Trim. Arc length trim is pro- grammed to a default at the factory and may be adjust- ed on the wire feeder. When the trigger is pulled, the WFS, Actual Arc Voltage and Actual Arc Current are dis-played.

WAVE CONTROL

The wave control settings of all procedures can be changed on the Power Wave 450 GMAW Pulse, GMAW and FCAW, Stick Process Selection Overlay. The wave control is a setup parameter that may be adjusted when the welding procedures are set. This feature pro-vides an easy way to change the arc behavior without creating a new procedure. The wave control setting of a procedure limits the speed at which the current waveform of that procedure can change. Typically, each procedure is programmed to have aver- age wave con-trol (at the center of the scale).

In Pulse processes:

The wave control adjustment allows the frequency set- ting to vary. Increasing the wave control allows the fre- quency setting to increase, and decreasing the wave control allows the frequency setting to decrease. Varying the wave control setting affects the droplet trans-fer and allows fine-tuning for different welding positions.

In GMAW and FCAW processes:

The wave control adjusts the inductance. (Inductance is inversely proportional to pinch.) Increasing the wave control setting decreases the inductance, which results in the arc getting colder and pinched tighter. Decreasing the wave control setting increases the induc-tance, which results in the arc getting wider.

POWER WAVE 450

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Contents Safety Depends on You For use with machines having Code NumbersSafety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcThank You Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Vii Section CViii Section DSection E Section FSection G SeriesInstallation Technical Specifications Power WavePower Wave AwgiecSafety Precautions High Frequency PrecautionsSelect Suitable Location Input ConnectionsInput Power Connections Input Fuse and Supply Wire ConsiderationsInput Voltage Reconnect Procedure Ground ConnectionsWire Feeder Connections Output ConnectionsWork and Electrode Cable Connections Water Cooler ConnectionsPower Wave 450 Robotic Dimensions Power Wave 450 Robotic Operating Instructions Safety InstructionsOperation Select your process information Save process information if desiredGeneral Description Controls and Settings Case Front ControlsOverview Installing AN OverlayOperating Overlays Name Overlay TypesOverlay PULSE, GMAW, FCAW, and STICK/TIG Process Selection Overlay Overlay ID Number =Operation Then Robotic Interface Weld from MEMORY, Dual Procedure Overlay Select a Memory LocationOperation SET Limit KEY Limit UP / Down Keys Limits Overlay OptionalRecall from Memory KEY Memory Location Numbers Operation Setup Overlay Figure B.7 Setup OverlayWire Feeder Setup Description +/- Polarity KEYPositive Polarity Voltage Sensing Table B.1 Positive Voltage Sensing OptionsOverview of Welding Procedures Flux Cored ARC Welding Fcaw and Gmaw ProceduresPulse Procedures Wave ControlFcaw Table B.3 Adjustble ParametersGmaw Pulse Welding Overload ProtectionThermal Protection Current ProtectionInterface Description Robot Signal DescriptionsRobotic Interface Touch Sense Signal GAS FaultWire Fault Water FaultPower Wave Circuits Dual Procedure Switch COM- MandWire Stick Detect Robot Controller Electrical CharacteristicsTouch Sense Command ARC Detect GAS FaultWater Fault Power Fault Dual Procedure Switch CommandRobot Controller Setup Weld System SetupWeld Equipment Setup Touch Sensing SetupPower Wave Interface Board ConnectionsArctool Welding Inputs and Outputs Miscellaneous ConnectionsAccessories Water Cooler UsageRecommended Coolants Priming the CoolerType L9777 Wire Feed Unit Dimension PrintFor the Latest Mounting the Wire Feed Unit Electrode Routing Connecting Wire Feed Unit to Power SourceProcedure to Install Drive Roll and Guide Tubes Steel Wire Sizes RollAluminum Wire Sizes Drive Roll and Guide Tube KitsIdle Roll Pressure Setting Feeding Electrode and Brake Adjustment Requires Installation of 2 51MM K162H Spindle KITFeeding Electrode Wire Loading of 13-14lb 6kg Innershield CoilsTo Mount a 50-60lb 22.7-27.2kg Coil Wire Reel Mounting 50 22.7kg and 60lb 27.2kg Coils Avoiding Wire Feeding ProblemsPeriodic Maintenance of Wire Drive Unit Wire Drive Motor and GearboxSwitch Requirements Connector for 1/16 5/64 1.6 2.0 mm WireInput Filter Capacitor DIS Charge Procedure MaintenanceRoutine and Periodic Maintenance Figure D.1 Resistor Locations Connected Discharge labels, on each of the four SwitchLocate the #9 and #12 terminals, identified by Preventive Maintenance G3503- Installation or SER Vice Tool Usage Removing and Installing the G3503 CoolerG3503- Cooler Periodic Maintenance G3503- Cooler ServiceFigure D.4 General Component Locations ED Tests TroubleshootingHOW to USE Troubleshooting Guide Sists, contact your local Lincoln Troubleshooting GuideAuthorized Field Service Facility Play fans run Check circuit breaker 5-amp Observe Safety Guidelines Controls and Settings Power-up Inspect the overlay bar code Saved in memory are different Check for proper shielding gas How To Read Shop Drawings New Lessons in Arc WeldingNeed Welding Training? Basic CoursePrecaucion Aviso DE
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