F-15-565
February, 1999
Section I
Section II
Section III
BOMBARDIER, INC./ESAB WELDING SYSTEMS
Table of Content
1. Welding System Features
2. Operating Instructions
1. SVI 450i Power Supply
Assembly Dwg. D-34055 with Bill of Material
Schematic Diagram D-34308
Wiring Diagram D-34309
Wire Kit Bill of Material BM-31953
Control PCB D-31496
Power PCB D-674991
1. Digipulse Dual Control
Assembly Dwg. D-(8) 33387
Schematic Diagram D-33380
Wiring Diagram D-33381
Wire Kit Bill of Material BM-33397
Display PCB D-675236
J-Gov PCB D-994236
I/O PCB D-674994
MPU PCB C-18155 & E-Prom A-18090
Section IV
2. Digipulse Dual Wire Feeder
Assembly Dwg. D-37843 with Bill of Material
(See Model No. 33299)
1. The Welding System Revision History
2
Operating Instructions
General
This dual pulse Mig welding system has been designed and manufactured to specifications provided by
Bombardier, Inc.. The software is modified to provide eight separate schedules for each torch. The first four
schedules (1-4) on each torch are dedicated to pulse welding of stainless steel in the synergic mode. The
second four schedules (5-8) are dedicated to short or spray arc welding and have no synergic relationships.
This means that IIPM and VOLTS are entered separately depending if a short arc or spray arc weld condition
is required. The following will detail the set-up and operation of this unique welding system.
Start Up
Assembly of the power source, feeder and interconnect cable is the same as specified in the general operating instruction manuals provided with the SVI-450i Power Source and Digipulse Dual wire feeder. After
power up of the SVI-450i (575 Vac) and the feeder, the windows on the feeder will display IPM=5 and
VOLTS=45 for a brief period. This indicates that the stainless steel program (same as a standard Digipulse)
is running and the synergic curve is for .045-inch (1.2 mm) diameter wire. These parameters CANNOT be
changed. The windows will then display the last welding parameters set by the operator. Place the Remote/
Panel switch on the SVI-450i power source in the Remote position and follow the instructions below.
Selecting System Presets
System parameters are those that affect BOTH torches and ALL schedules. These parameters are always
active and should be set first. They are:
Gas preflow preset
Gas postflow preset
Cold inch preset
Trigger selection (dual schedule operation)
Half speed run-in
Set the shield gas preflow parameters by holding down the Purge key and using the Inc/Dec key under
the IPM window to set a preflow time in 1/10 seconds. Repeat the above for postflow using the key below the
VOLTS window.
The cold inching feature is a two speed design. When placing the Inch key in the up position, the feed
motor will operate at 50 ipm for a period of 2-1/2 seconds. This is for bumping the wire to adjust the wire
stick-out from the contact tip. After 2-1/2 seconds the wire feed speed will transfer to the cold inching speed
shown in the IPM window. The wire feed speed can be further adjusted using the Inc/Dec key under the
IPM window. This function is designed for wire threading.
The Trigger Selection option allows dual schedule operation. This means that two welding schedules are
available to the operator on each torch. This option is disabled when Rocker Switch #4 on Dip Switch #2 is
in the closed position. Dip switch #2 is located on the MPU board inside the feeder control box. Place this
switch in the open position for Trigger selection (dual schedule operation). Welding will always begin
using the current weld schedule selected. Double clicking the torch trigger switch changes the welding
parameters to the next highest schedule number. See diagram below.
3
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