Lincoln Electric IM579 Overview of Welding Procedures, Pulse Procedures, STICK/TIG Procedures

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B-19

B-19

OPERATION

OVERVIEW OF WELDING

PROCEDURES

FLUX CORED ARC WELDING (FCAW) AND GMAW PROCEDURES

For each wire feed speed, a corresponding voltage has been preprogrammed into the machine by welding experts. This preprogrammed voltage is the best average voltage 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 volt- ages can be adjusted on the wire feeder’s Voltage dis- play. 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 auto- matically increases the preset voltages at all the other wire feed speeds by 10 percent. In the GMAW FCAW process, the display shows the Procedure Description, WFS and Preset Voltage. The preset voltage which was programmed 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 “V ” or “V” sign will be displayed after the preset value. When the gun trigger is pulled, note that the display changes to show WFS, Actual Arc Voltage and Actual Arc Current. See Table B.5 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 voltage. 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 procedure. 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 1.0 means that no adjustments will be made to the preset 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 preset arc lengths. The arc length adjustment is factored in at all wire feed speed settings. Refer to Table B.6 for summary of arc length trim.

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 GMAW Pulse process, the display shows the Procedure Description, WFS and Arc Length Trim. Arc length trim is programmed to a default at the factory and may be adjusted on the wire feeder. When the trigger is pulled, the WFS, Actual Arc Voltage and Actual Arc Current are displayed.

STICK/TIG

PROCEDURES

Stick welding can be performed with the Power Wave by attaching a remote control kit to the 6-pin amphe- nol on the front of the machine. The K941-1 remote control kit is recommended. Select the stick process from either the GMAW Pulse, GMAW FCAW, stick process selection overlay, or recall it from a previously stored memory location with a Weld From Memory overlay. When this process is selected, the Power Wave reads the current (amps) setting from the remote control kit. It also controls the output of the machine based on the position of the Output Terminals switch, which is also located on the remote control kit. When this switch is in the ON position, the output terminals of the Power Wave are electrically hot. When the switch is in the OFF position, the output terminals of the Power Wave are electrically cold and the machine cannot produce an output. In the stick process, the LCD display shows Procedure Description, and Preset Current (SET=). The Current Trim is always equal to 1 (T=1.00). When the trigger is pulled the Preset Current, Actual Arc Voltage and Actual Arc Current are dis- played.

See Tables B.3 through B.6 for a summary of the infor- mation discussed above.

WAVE CONTROL

The wave control settings of all procedures can be changed on the Power Wave GMAW Pulse, GMAW FCAW, Stick Process Selection Overlay. The wave control is a setup parameter that may be adjusted when the welding procedures are set. This feature provides an easy way to change the arc behavior with- out creating a new procedure. The wave control set- ting of a procedure limits the speed at which the cur- rent waveform of that procedure can change. Typically, each procedure is programmed to have average wave control (at the center of the scale).

POWER WAVE 450

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Contents Invertec Power Wavetm Safety Depends on YouARC Rays can burn SafetyElectric Shock can kill Fumes and Gases can be dangerousWelding Sparks can cause fire or explosion Cylinder may explode if damagedFor Electrically pow- ered equipment For Engine powered equipment Electric and Magnetic FieldsMay be dangerous Précautions DE Sûreté Thank You Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Installation Technical Specifications Power WavePulse Pulse and Background Current Range Voltage Range Input Connections Safety PrecautionsHigh Frequency Precautions Select Suitable LocationInput Fuse and Supply Wire Considerations Input Voltage Reconnect ProcedureInput Power Connections Ground ConnectionsWork and Electrode Cable Connections Wire Feeder ConnectionsOutput Connections Water Cooler ConnectionsOperating Instructions Safety InstructionsOperation Fumes and Gases can beSelect your process information Save process information if desiredSynergic Welding Design Features and AdvantagesOperational Features and Controls Recommended ProcessesControls and Settings Case Front ControlsInstalling AN Overlay Operating OverlaysOverview Overlay Types OverlayName PULSE, GMAW, FCAW, and STICK/TIG Process Selection Overlay Overlay ID Number =Operation Then Weld from Memory Overlay Memory Location # is EmptyWeld from MEMORY, Dual Procedure Overlay Figure B.6 Weld from MEMORY, Dual Procedure OverlayOperation Dual Wire FEEDERS, Dual Procedure Overlay Optional Position ProcedureLimits Overlay Optional Recall from Memory KEY Memory Location NumbersOperation Setup Overlay Figure B.9 Setup OverlayTable B.1 Positive Voltage Sensing Options Wire Feeder Setup DescriptionPositive Polarity Voltage Sensing Negative Polarity Voltage SensingPositive Voltage Sensing Polarity Pulse Procedures Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures STICK/TIG ProceduresExplanation of Table B.3 Pulse Welding Pulse processesOverload Protection Thermal ProtectionOver Current Protection Wire Feeder Setup AccessoriesOPTIONS/ACCESSORIES Guns and CablesWater Cooler Usage Maintenance Routine and Periodic MaintenanceInput Filter Capacitor DIS Charge Procedure Figure D.1 Resistor Locations Discharge labels, on each of the four Switch Locate the #9 and #12 terminals, identified byPreventive Maintenance Figure D.4 General Component Locations Troubleshooting HOW to USE Troubleshooting GuideTroubleshooting Guide Authorized Field Service FacilitySists, contact your local Lincoln 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 Wiring Diagrams Wiring DiagramHow To Read Shop Drawings New Lessons in Arc WeldingNeed Welding Training? Precaucion Aviso DE Limited Warranty
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