INSTRUCTIONS FOR F-15-013-ANovember, 1996

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 practicesfor electric welding equipment, we urge you to read our booklet “Precautions and Safe Practices for Arc Welding, Cutting andGouging, “Form 52-529”. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt toinstall or operate this equipment until you have read and fully understand these instructions. If you do not fully understandthese instructions, contact your supplier for further information. Be sure to read all Safety Precautions in wire feeder manualbefore installing or operating this equipment.

F-15

-013

-A

TEACHING MODE OPERATIONFOR DIGIPULSE WIRE FEEDER

2

adjustment to the pulse frequency to maintainstable metal transfer. Since the operator selects pulseparameters at a given point, the control will not assumevalues at other wire feed speeds. Also note that theTrigger Lock/Crater Fill feature is not programmable

I. INTRODUCTION

The Digipulse with optional teach control is the most en-hanced version of the Digipulse family. It features a “teach”mode that allows an operator to develop and store hisown pulse welding conditions in addition to the standardpreprogrammed conditions (codes 1- 6) already availablein the standard control. The Synergic program logic of-fers the Digipulse system fixed operating parameters thatfollow preprogrammed relationships. The Adaptive logicutilizes a closed loop feedback system that continuouslymodifies the output to maintain a constant arc voltage.

II. PROGRAMMING YOUR OWN PULSE PA-RAMETERS

The “teach” mode program is incorporated in MaterialCodes #11 through #15. Each of these codes is designedto allow the operator to develop and store one set of cus-tomized Pulsed mig parameters* for wire types which havenot been preprogrammed in this control (for example; ti-tanium, inconel, monel, etc.). In some instances thepreprogrammed carbon steel or stainless steel param-eters may be inadequate, and the “teach” mode can thenbe used to further refine those particular arc characteris-tics.

*You may wish to permanently incorporate your “self de-veloped” conditions in codes 7 thru 10 which are reservedfor custom applications. If so, you can special-order acustom E-PROM, from ESAB, that will include your teachconditions along with the other preprogrammed applica-tions. In order to do this, youwill have to provide the necessary welding condition de-velopment parameters outlined in Section IV of this supple-ment.

The following instructions assume that the operator is fa-miliar with “pulse-mig” welding and the effects of pulsevariables with respect to arc performance.

Pulse height, width, background and frequency can beprogrammed for any wire feed speed set in the IPM win-dow. The metal transfer and arc characteristics are de-fined by pulse height (PH), width (PW), and backgroundcurrent (PB). These parameters, shown in Figure 1, mustbe developed for each wire type, diameter, shielding gas,and stickout. To maintain the proper arc characteristicsonce an appropriate pulse height, width and backgroundhave been established, the pulse frequency should bethe only parameter requiring readjustment with changesin wire feed speed to maintain a stable arc condition. The“teach” mode operates in the synergic logic “only”(not adaptive), and only one wire feed speed setting canbe programmed in each material code (11 thru 15).Changes in wire feed speed will require a manual

Zero Current

PW F

P

Fig. 1 - Pulse Wave Description

to the teach mode (codes 11 - 15).

For the inexperienced operator, use the followinggraphs to assist in pulse parameter set-up. Thesegraphs will provide you with pulse parameters used inthe preprogrammed codes (1-6). To obtain specific arccharacteristics these parameters can be set-up andchanged in the teach mode. The following procedure

6

3

54

2

Fig. 2

HP Should be high

enough to detach thedroplet.

Works with the pulsepeak current to allowtime for the droplet toform.

PW

PHPeak CurrentSpray TransitionCurrent

PB BackgroundCurrent

Average Current

Used to establishthe necessary arclength for good arcstability.

FP

BP Should be set high

enough to maintainthe arc betweenpulses.

PulseWidth

PulseFrequency

1

3

pulse parameter switch (Item 1, Fig. 2) in its “down”position and for following.

1. Set the selected Pulse Background (PB) param-eter in the IPM window using its Inc/Dec switch(Item 4). The number in this window representspulse background current from 15 to 100 amperes(in 1 amp increments).

2. Now, set the selected Pulse Frequency (PF) pa-rameter in the VOLTS window using its Inc/Decswitch (Item 5). The number in this window repre-sents the approximated pulse frequency derivedfrom the graph for wire feed speed selected (stepD) and is displayed in Hertz from 25 to 909 pulsecycles/second.

H. Assuming that any other desired parameters (e.g.,preflow, inch, spot, postflow, burnback, etc.) havebeen programmed, as described previously in F-15-012, you can energize the torch switch and beginwelding. The torch switch must be held closedthroughout the teach mode operation.

I. Once an acceptable arc condition has been obtainedby further modifying pulse height, pulse width, andpulse background, changes in wire feed speed willnecessitate a manual adjustment to the pulse fre-quency to maintain a stable metal transfer.

Operating Note: The 5 programmable codes (11 thru15) provide the operator with an opportunity to developa complete welding procedure by having different weld-ing parameters preprogrammed into separate schedules.Once programmed, the operator only needs to changeto the appropriate program number for the weldparameters required. For example, when welding pipe,root pass, fill pass and capping pass pulse parameterscan be programmed into separate schedules and ac-cessed when needed (see II-C). Each set of parameterscan have a different pulse height, width, background,frequency, and wire feed speed.

III. USEFUL DATA FOR SYNERGIC-ADAPTIVEOPERATION

The operating characteristics of synergic vs adaptivelogic in the welding operation is covered in booklet F-15-012 and following. The selectability of either of thesefeatures is made from the front panel (see Item 2, Fig.2) in the feeder. Please note that either type of logic canbe used in the “preprogrammed” material codes 1 thru10; however, only the synergic position can be used inthe “teach” mode material codes 11 thru 15.

1. Synergic Operation a. Pulse Arc Welding:

Synergic welding is a relationship of pulse fre-quency and wire feed speed (see graph) pro-grammed into the weld control. As the wire feed

will achieve a reasonable starting point for pulse weld-ing.

A. Make sure the Synergic/Adaptive logic switch (Item2, Fig. 2) is set in SYN position.

B. Set the Process selector switch (Item 6, Fig. 2) to itsPULSE position.

C. Select a programmable Material code from 11 thru15 by “holding down” the Material selector key (Item3, Fig. 2) and holding the Inc/Dec key (Item 4, Fig. 2)under the IPM window in the up position. Releaseboth keys once a Material code is selected.

NOTE: You may notice that a Wire Dia. code numberwill appear in the VOLTS window when the WireDia/Material key is depressed. This code # mustmatch the wire installed when you’re using“preprogrammed” data in codes 1 thru 6, how-ever, this is not required in the teach mode codes11 thru 15. Please remember that all other pa-rameters that are programmed will be retainedin memory (for teach codes 11-15) except forthe wire size—therefore, it is suggested that youdocument the wire size dia. used and all otherparameters relating to a particular teach codefor future reference.

D. Set a wire feed speed in the IPM window by using theInc/Dec key (Item 4) below the window.

E. Using the pulse parameter graph(s)), shown on thefollowing pages, approximate the pulse height, width(for step F), and pulse background and frequency (forstep G) settings for the material type and diameteryou plan to use. Select the appropriate pulse param-eter graph which corresponds to the material typebeing used. For wire types other than those shown,choose the graph that comes closest to your wire type.For example, for coppers use the silicon bronze graphparameters as a starting point.

F. Program the Pulse Height (PH) and Pulse Width (PW)parameters, from the material graph legend for thediameter wire installed, by “holding” the pulse param-eter switch (Item 1, Fig. 2) to its “up” position and thefollowing:

1. Set the selected Pulse Height (PH) parameter inthe IPM window using its Inc/Dec switch (Item 4).The number in this window represents pulse heightfrom .1 to 10 volts (in 1/10 volt increments).

2. Now, set the selected Pulse Width (PW) param-eter in the VOLTS window using its Inc/Dec switch(Item 5). The number in this window representspulse width from 1 to 10 milliseconds (in 1/10 mil-lisecond increments)

G. Program the Pulse Background (PB) and Pulse Fre-quency (PF) parameters, from the material graph leg-end for the diameter wire installed, by “ holding” the

4

Wire Feed Speed (ipm)

Puls

e Fr

eque

ncy

Puls

e Fr

eque

ncy

Wire Feed Speed (ipm)

Carbon Steel Pulse Parameters

Carbon Steel Pulse Parameters

5

Puls

e Fr

eque

ncy

Puls

e Fr

eque

ncy

Wire Feed Speed (ipm)

5356 Aluminum Pulse Parameters

Stainless Steel Pulse Parameters

Wire Feed Speed (ipm)

6

speed increases the control will automatically in-crease the pulse frequency to maintain stable weldperformance. Changes in welding current (heat)can be completed by increasing or decreasing theIPM switch without readjusting voltage. Changesin tip to work will affect arc length. The synergicrelationship is only available if a program is resi-dent in the control.

b. Spray Arc and Short Arc:In this mode the machine will operate like a con-ventional welder where an arc voltage is set-up bythe weld control program and changes in tip to workwill effect arc length. The voltage can be read dur-ing welding and increased accordingly to obtaina stable welding condition based on the wire feedspeed used. If the wire feed speed is changed,

the program will calculate the new voltage neces-sary to maintain a stable arc.

2. Adaptive Operation a. Pulse Arc Welding:

Adaptive welding is a synergic relationship pro-grammed into the weld control which will calculateand display the proper arc voltage for a given wirefeed speed and material setting (see graph). Asthe wire feed speed increases the control will au-tomatically increase the pulse frequency to main-tain the arc voltage set in the control VOLTS win-dow. Changes in tip to work will not affect arclength. The Adaptive function is only available if aprogram is resident in the control.

b. Spray Arc and Short Are:In this mode the machine will control the powersupply to maintain the arc voltage set-up in the voltswindow of the control. Changes in tip to work willnot change arc length. The voltage can be presetbefore welding and changed during welding to ob-tain a stable welding condition based on the wirefeed speed used. If the wire feed speed is changedthen the program will calculate the new voltagenecessary to maintain a stable arc.

5356 Aluminum Pulse ParametersPu

lse

Freq

uenc

y

Wire Feed Speed (ipm)

Arc Length Will Not ChangeWith Tip To Work Distance

Puls

e Fr

eque

ncy

Or

Arc

Volts

(Spr

ay/S

hort)

Frequency ChangesWith Tip To Work Distance

Arc Length Will ChangeWith Tip To Work Distance

Puls

e Fr

eque

ncy

Or

Arc

Volts

(Spr

ay/S

hort)

Frequency Does Not ChangeWith Tip To Work Distance

7

IV. CUSTOM PROGRAM DEVELOPMENT PROCEDURES

ESAB can supply custom Synergic and Adaptive programs to be placed in Material Codes 7 thru 10 if the proper datais supplied (see below). Once acceptable arc stability and weld performance has been established using the pulseparameter keys on the “teach” control, record the pulse height,, width and background settings you have programmed.Then take 5 samples at different wire feed speeds and record the data in the chart below at each wire feed speedtested. You will have to increase the pulse frequency as the wire feed speed increases in order to establish a GOODwelding condition which will also change the arc voltage. From this information we can program the synergic andadaptive relationships for your custom program. Contact your ESAB Sales Representative for further details andpricing information on this custom service.

V. NOTES

The remaining space in this supplement can be used to provide a written record (similar to the chart shown in SectionIV) of the various programs you have developed.

DO NOT Change Once Established

Wire Average Average Pulse Pulse Pulse Pulse Additional InformationFeed Current Arc Frequency Height Width Bkgrd.(ipm) (Amps) Volts (Hz.) (Ref. Volts) (m sec) (Amps) Wire Type Base Metal Type

1 Wire Diameter Weld Joint type

2 Shielding Gas Mig Gun Type

3 Tip to Work Weld Position

4 Travel Speed

5

F-15-013-A 11/96 5C Printed in U.S.A.