ESAB LTP 450 Programming manual

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PROTIG 450

LTP 450

104

Programming manual

Valid for program version 2.10B and 2.11A0456 638 104 981110

1 INTRODUCTION 4........................................................

1.1 Mode of operation -- Control box 4.......................................

1.2 Sectors 4............................................................

1.3 Display and keyset 6..................................................

2 WELDING PARAMETERS 12................................................

2.1 Welding current 12.....................................................

2.2 Gas 14...............................................................

2.3 Wire feed speed 15....................................................

2.4 Preheating time 15.....................................................

2.5 Rotation speed 16.....................................................

2.6 Arc voltage control (AVC) 16............................................

2.7 Weaving 18..........................................................

3 START AND STOP 19......................................................

3.1 Start 19...............................................................

3.2 Stop 19...............................................................

3.3 Restart 19............................................................

4 TO GET STARTED 20......................................................

4.1 General 20............................................................

4.2 How to indicate a tool code 20............................................

4.3 How to change languages 22.............................................

5 PROGRAM EDITING 23.....................................................

5.1 Entering a parameter value 23............................................

5.2 Increasing/decreasing a parameter value 23................................

5.3 Creating a new sector 24................................................

5.4 Changing the breakpoint of a sector 24....................................

5.5 Creating a transport sector 25............................................

5.6 Finding the home position 26.............................................

5.7 Entering a slope 26.....................................................

5.8 Moving within a program 27..............................................

5.9 Deleting in a program 28................................................

5.10Changing weld data during welding 29.....................................

5.11Zeroing the control box 30...............................................

6 PROGRAMMING EXAMPLES 31.............................................

6.1 Example 1a: 31........................................................

6.2 Example 1b: 35........................................................

6.3 Example 1c: 38........................................................

6.4 Example 1d: 42........................................................

6.5 Example 1e: 48........................................................

7 THE LIBRARY 53..........................................................

7.1 Storing a program 53...................................................

7.2 Recalling a program 53..................................................

7.3 Viewing the tool code 54.................................................

7.4 Deleting a program 55..................................................

8 MANUAL MODE 56........................................................

8.1 Field of application 56...................................................

8.2 Editing a parameter 56..................................................

TOCe

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9 PC--CARD 59.............................................................

9.1 Field of application 59...................................................

9.2 How to install the card 59................................................

9.3 How to recall a program 59..............................................

9.4 How to store a program 60...............................................

9.5 How to delete a program 61..............................................

9.6 How to take out the PC--card 62..........................................

10 ERROR CODES 62.........................................................

10.1 Error handling 62.......................................................

10.2 Incorrect editing codes 71...............................................

11 SHOW CURRENT PARAMETER VALUES 72..................................

11.1 Field of application 72...................................................

11.2 How to view actual parameter values 73...................................

12 SOFTWARE UPGRADE 73..................................................

12.1 Application field 73.....................................................

12.2 Menu explanation 74....................................................

12.3 How to upgrade 75.....................................................

12.4 Measures to be taken when the upgrading of the power source units failed 78....

12.5 Measures to be taken when the upgrading of the control box failed 79...........

13 SOFWARE KEY 80.........................................................

13.1 General 80............................................................

13.2 Locking the control box 80...............................................

13.3 Unlocking the control box 81.............................................

13.4 Changing the code 82...................................................

14 NOTEBOOK 83............................................................

14.1 Field of application 83...................................................

14.2 How to enter data in the notebook 83......................................

14.3 Example 2a: 84........................................................

15 MANUAL WELDING 94.....................................................

15.1 Field of application 94...................................................

15.2 How to create a welding program 94.......................................

15.3 Example 3a: 94........................................................

15.4 How to weld 100........................................................

16 APPENDIX 100.............................................................

16.1 Tool codes 100..........................................................

16.2 Symbols 101...........................................................

16.3 Setting ranges -- welding parameters 102....................................

17 TECHNICAL TERMS 103.....................................................

TOCe

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1 INTRODUCTION

1.1 Mode of operation -- Control box

The control box consists of four memory units, the working area, the library, the notebook and the auxiliary function.

S In the working area the welding program is created. S In the library the program can be stored.

During welding it is always the contents of the working area that control the welding process. Thus it is also possible to call in a welding program from the library to the working area.

S In the notebook you can make your own notes about special welding

parameters, for example.

S In the auxiliary function you can:

S change languages S view all existing error messages S show actual parameter values S software upgrade S sofware key

1.2 Sectors

A welding program for welding of tubes can be divided into different parts or sectors. Each sector corresponds to a special part of the circumference of the tube. Max. number of sectors for one program is one hundred (100).

Sector 4

Sector 3

A sector can be assigned its own set of values for different welding parameters, such as current, rotation speed, wire feed speed, etc. In this way the welding can be performed using different parameter settings for different parts of the joint of the tube.

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Sector 1

Sector 2

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The division into sectors is done by indicating different breakpoints along the circumference of the tube. Each such breakpoint constitutes the starting point of a new sector. In the figure below, the breakpoint 0.000 is the starting point of sector 1, breakpoint 0.250 the starting point of sector 2, etc.

Breakpoint 0,000

Sector 4

Breakpoint 0,750

Sector 1

Breakpoint 0,250

Sector 3

Sector 2

Breakpoint 0,500

L TP 450 allows welding of up to 10 turns in the same welding joint, i.e. the welding tool can be rotated 10 times round the tube.

The breakpoints in the previous figure all start with the integer 0 which means that they form the breakpoints of turn 1. The breakpoints of turn 2 (if there is one) always start with the integer 1,etc.

S Turn 1 = breakpoints 0.000 -- 0.999 S Turn 2 = breakpoints 1.000 -- 1.999 S Turn 3 = breakpoints 2.000 -- 2.999 S Turn 4 = breakpoints 3.000 -- 3.999 S Turn 5 = breakpoints 4.000 -- 4.999 S Turn 6 = breakpoints 5.000 -- 5.999 S Turn 7 = breakpoints 6.000 -- 6.999 S Turn 8 = breakpoints 7.000 -- 7.999 S Turn 9 = breakpoints 8.000 -- 8.999 S Turn 10 = breakpoints 9.000 -- 9.999

To terminate a welding program a so--called end sector is indicated. For a sector to be counted as an end sector the following two conditions

must be fulfilled:

S There is no sector following. S The welding current value of the sector = 0 ampere.

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1.3 Display and keyset

A Display B Soft keys

C Function keys

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Display

SECTOR 2(4)

WELD GAS

ROOT GAS

START GAS

0.500

s s s

WELD

GAS

ROOT

GAS

START GAS

The following information is shown in the display.

a The program sector at present involved. b The number of sectors in the current program. c The breakpoint of the sector (sector 2 in this example). d The digit box shows the numerical value entered and different

numerical characters. For further information, see page 101.

e Showing that the indicated value has been borrowed from a previous

sector (in this example from sector 1).

g 5 text boxes describing the function of the so--called soft keys (f). h Message line describing the actual state.

WELDING = a welding sequence is going on. END = a welding sequence is completed. TRANSPORT = transfer without welding. STOP = the welding sequence was interrupted due to activation

of the stop key.

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Soft keys

By way of the soft keys (a) the functions connected with the respective display (in this case the GAS parameter display), the significance of which is indicated in the text boxes (b). Depending on the display selected, up to five soft keys can be activated.

Function

keys

Parameter keys

The welding parameters are divided into seven different groups, each group represented by one ordinary key and a set of soft keys.

Welding current Gas

Rotation speed Wire feed speed

Arc voltage control (AVC) Weaving

Preheating time

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SHIFT key

This key is used for changing the significance of other keys on the keyboard.

PLUS/MINUS keys

These keys are used for increasing/decreasing set values.

Numerical keys

These keys are used for entering the digits 0--9 and decimal point.

Other keys

SLOPE

This key is used when you want to add a slope function to a parameter and

is indicated in the following way in the display

By slope is meant a gradual change of a set value.

Slope up = gradual increase Slope down = gradual decrease

The following parameters can be assigned a slope function:

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Current (both peak and background current) when pulsed current is used, rotation, arc length control, wire feed speed , weaving amplitude.

A slope can be time--controlled by indicating that it shall go on for a certain number of seconds. It can also be sector--controlled, making it a so--called sector slope, by indicating between which two breakpoints it shall be located.

SECTOR

This key indicates the breakpoint of a program and moving to indicated sector.

STEP

This key is used for stepping forward in the program.

DELETE

This key is used for deleting the whole program, part of a program in the working area, or just the figures in the digit box.

MANUAL MODE

This key is used for positioning the electrode before welding, and for making sure that the program in the working area functions as desired.

MEMORY (library)

This key is used for entering or leaving the library and for storing a program, or for recalling a program from the library to the working area.

CORRECT

This key is used for correcting the position of the electrode in connection with weaving (centre line adjustment).

MODE (auxiliary functions)

This key is used for getting to the different auxiliary functions, such as language, error log, show actual parameter values and software upgrading.

This key is not used.

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NOTEBOOK

These keys are used if you want to make notes on a welding sequence.

TOOL CODE

These keys are used if you want to view the code of the connected tool.

RESTART

These keys are used for restarting a welding sequence.

SECTOR SLOPE

These keys are used if you want to create a sector slope.

DIRECT STOP

Pressing this key will lead to direct stop of the welding. The gas postflow takes place according to settings in the end sector.

START

This key is used for starting a welding sequence.

STOP

This key is used for stopping a welding sequence. The welding sequence is terminated according to the settings in the end sector.

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2 WELDING PARAMETERS

Setting ranges for the welding parameters can be found in the APPENDIX on page 102.

2.1 Welding current

There are four different parameters for welding current:

S PEAK CURRENT S BACKGROUND CURRENT S PEAK TIME (1 s) S BACKGROUND TIME (1 s)

The values in brackets are preset values.

Peak time

Background time

current

Peak

Background current

The welding current can be either pulsed or continuous (not pulsed).

If you want to weld using pulse current a value must be entered for all four parameters. When welding with continuous current, however, you only need to enter the value for peak current. Entering a value also for background

current will result in pulsed current with preset pulse and background times. Of course, the pulse and background times can also be changed.

The weaving motion can be synchronised with the welding current (pulsed current) so that the peak current sets in at the same time as the electrode is in an end position. This is also called special pulsing.

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Special pulsing

By special pulsing is meant that the welding current is synchronised with the weaving motion, i.e. you get peak current when the electrode is in an end position of the weaving motion. Thus the peak current time is determined by the dwell time of the respective dwell position.

Special pulsing can be used in combination with both continuous and pulsed rotation. Special pulsing with pulsed rotation -- also called square--wave pulsing -- means that the gear ring rotates when the electrode is in an end position of the weaving motion.

Special pulsing with continuous rotation

Rotation direction

Special pulsing with pulsed rotation

Rotation direction

A = background current B = peak current

As to special pulsing, the wire feed can be either continuous or pulsed. As to pulsed wire feed, the synchronisation with the welding current takes place in the way described above, see the section “Wire Feed Speed“ on page 15.

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SECTOR 1(4)

PEAK CURRENT BACKGR. CURRENT PEAK TIME BACKGR. TIME

0.000 A

A s s

CONT/

PEAK

CURR

BACKGR

CURR

PEAK TIME

BACKGR TIME

SPEC. PULS

To activate the function special pulsing, press the marked soft key in the display for welding parameters.

2.2 Gas

In the Shielding Gas parameter group three parameters are represented:

S WELD GAS S ROOT GAS S START GAS

By weld gas is meant the shielding gas on the upper side of the joint. The weld gas parameter indicates the time the shielding gas is to flow on the upper side of the joint before and after welding. The values of the weld gas parameter are preset. The following values for preflow and postflow of the weld gas apply at the start if nothing else has been indicated:

S Weld gas preflow = 2 s S Weld gas postflow = 4 s

By root gas is meant the shielding gas on the underside of the joint. The root gas parameter indicates the time the shielding gas is to flow on the underside of the joint before and after welding.

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Some shielding gases, for example helium (He), can cause difficulty with regard to striking the arc. If such a shielding gas is to be used as weld gas, it could be advisable to use another gas mixture at the start moment -- a so--called start gas.

If one value is entered for weld gas in sector 1 and one for start gas, only the start gas is going to flow. The weld gas starts flowing when the arc is struck.

2.3 Wire feed speed

This parameter is used to indicate the desired feed speed of the filler wire in cm/min.

The wire feed speed can be pulsed or continuous (not pulsed).

In the Wire Feed Speed parameter group two parameters are represented:

S PEAK WIRE FEED SPEED S BACKGROUND WIRE FEED SPEED

For welding with continuous (not pulsed) wire feed speed, only the peak wire feed parameter shall be entered.

For welding with pulsed wire feed speed, both the peak wire feed speed and the background wire feed speed parameters shall be entered.

The pulsed wire feed speed is always automatically synchronised with the welding current. The wire feed speed is high using pulse current and low using background current.

2.4 Preheating t ime

Preheating is used for heating the workpiece at the starting point in order to obtain correct penetration of the molten pool. The preheating time is defined as the time elapsing between arc strike and start of the rotary motion. If no value has been entered for the preheating parameter, the arc will strike at the same time as rotation is started.

NOTE! In the Welding Current parameter group you cannot indicate a sector slope when preheating is involved.

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2.5 Rotation speed

This parameter indicates the rotation speed of the electrode round the workpiece. It is indicated in per mill (thousandths) of the max. rotation speed of the welding tool used.

Just like welding current and wire feed speed, the rotation speed can be pulsed or continuous (not pulsed).

In the Rotation Speed parameter group four parameters are represented:

S ROTATION FORWARDS S ROTATION BACKWARDS S PULSED ROTATION FORWARDS S PULSED ROTATION BACKWARDS

The pulse rotation is always automatically synchronised with the welding current. The welding tool rotates when peak current is used, and stands still when background current is used.

2.6 Arc voltage control (AVC)

This parameter is used for automatic control of the arc when welding with a tool fitted with an AVC unit.

Arc voltage control (AVC) means that the arc voltage, and by that the length of the arc (i.e. the distance between the tip of the electrode and the workpiece), is automatically controlled in the course of welding.

In the Arc Voltage Control (AVC) parameter group three parameters are represented:

S PEAK VOLTAGE (Arc voltage when using peak current) S BACKGROUND VOLTAGE (Arc voltage when using background

current)

S DELA Y TIME

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With the parameters peak voltage and background voltage you set the reference value for arc voltage control when using peak current and background current. When using continuous current only the peak voltage parameter shall be entered.

If no value is entered for peak voltage a value measured right after the welding start is used as reference value.

If no value is entered for background voltage and pulsed welding current has been selected, no arc voltage control takes place when background current is used.

NOTE! A time slope cannot be indicated in sector 1 for peak voltage and background voltage.

In order to stabilise the arc before starting the arc voltage control, a delay time can be entered. During the delay time the AVC unit is locked.

If no delay time is entered the following applies:

S The delay time will be equally long (at least 5 seconds) as the slope--up

time (if any) for the welding current. If the slope--up time is shorter than 5 seconds, the AVC unit can start controlling when the slope time has elapsed, but only by increasing the arc voltage (arc length).

S If no slope--up time has been entered for the welding current, a fixed

delay time of 5 seconds applies. The AVC unit is not completely locked -the arc voltage (arc length) can be increased.

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2.7 Weaving

Weaving is used if you want to oscillate the electrode laterally when welding with welding tools fitted with a weaving unit.

In the Weaving parameter group four parameters are represented:

S WEAVE AMPLITUDE (5 mm) S WEAVE SPEED (5 mm/s) S DWELL TIME RIGHT (1 s) S DWELL TIME LEFT (1 s)

amplitude (mm)

left dwell time (s)

right dwell time (s)

Weave speed (mm/s)

The values in brackets are preset values. If one of the parameter values is indicated in the display, the preset values will come up automatically.

The weaving motion can be synchronised with the welding current (pulse current) so that the pulse current sets in at the same time as the electrode is in dwell position. This is also called special pulsing and is described in the section Special Pulsing on page 13.

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3 START AND STOP

3.1 Start

To start the welding, use the START key . It is impossible to start a welding program if another tool code has been indicated than the one used in the program in question.

3.2 Stop

A requested welding stop over the STOP key means that the program jumps to the following end sector, no matter which sector you are in at the moment. The welding is terminated according to the settings of the end sector.

A requested welding stop over the DIRECT STOP key immediate stop of the welding. The gas postflow takes place according to the time set in the end sector.

leads to

3.3 Restart

If the welding was interrupted it is restarted with the SHIFT and START

keys

Irrespective of whether the welding was stopped over the STOP

or the DIRECT STOP key , the start parameters of the preceding start sector are used. The program then continues from the position in the welding program where it was interrupted.

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4 TO GET STARTED

4.1 General

Some of the factors controlling the welding process are specific to each one of the welding tools, for example the rotation speed. Therefore, every welding program must be connected to a tool code, associated with the tool that the program was made up for.

4.2 How to indicate a tool code

S Turn the mains switch on the welding power source to position 1. S The following display comes up:

CHOOSE CONNECTED TOOL

PRB , PRC " PRH PRD POC 12--60 mm TIG HAND TORCH A25

ENTER

Example: You have connected PRC 33--90

S Move the marking to the line for PRB, PRC using the soft key NEXT.

Choose the desired tool and press ENTER. A window comes up, showing available tool sizes.

S Move the marking to the size of the tool you have connected (in this

example 33--90 mm) using the soft key NEXT and press ENTER.

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CHOOSE CONNECTED TOOL

Pressthesof

existingpro

TOOLTYPEMISMATC

gra

PRB, PRC " 8--17 mm

PRH 17-- 49 mm PRD 33-- 90 mm POC 12--60 mm 60--170 mm TIG HAND TORCH A25

QUIT ENTER

Result: The new tool code is accepted and the following text is displayed: CONNECTED TOOL: PRB, PRC 33--90 mm.

NOTE! In the event a program with another tool code should already be stored in the working area this must first be deleted. (If you want to keep the old program that was stored in the working area, you must store it in the library.)

The following information is displayed in the display:

key delete existin

ram.

ro-

WARNING! TOOLTYPE MISMATCH

PROGRAM MADE FOR: PRB, PRC 17-- 49 mm

CONNECTED TOOL: PRB, PRC 33-- 90 mm

DELETE

PROG.

Result: The new tool code is accepted and the display displays: CONNECTED TOOL: PRB, PRC 33--90 mm.

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4.3 How to change languages

Pressthesof

The different texts displayed on the control box are available in the following four languages:

S English, German, Swedish, Norwegian.

On delivery and after resetting the box, all texts displayed are in English.

Language

S Press the MODE key

selection

to get to the auxiliary functions, and the

following display comes up:

key language.

LANGUAGE "

ERROR LOG " SHOW ACTUAL PARAMETER VALUES SOFTWARE UPGRADE " SOFTWARE KEY "

LAN-GUAGE

AUXILIARY FUNCTIONS

ERROR LOG

SHOW PARA- METER

SOFT--. WARE UPGR.

SOFT-WARE KEY

S Press the soft key next language and step to the desired language. S

key change

CHOSEN LANGUAGE: ENGLISH

anguage.

AVAILABLE LANGUAGES ENGLISH NORSK DEUTSCH

SVENSKA

NEXT LANG

CHANGE

LANG

QUIT

Result: All texts will from now on be in the new language (in this example Swedish).

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Terminate

byy

ftk

pressing the so

bryt.

ey av-

VALT SPRÅK: SVENSKA

TILLGÄNGLIGA SPRÅK ENGLISH NORSK DEUTSCH SVENSKA

NÄSTA SPRÅK

BYT

SPRÅK

AVBRYT

S Press the MODE key to return to the working area.

5 PROGRAM EDITING

5.1 Entering a parameter value

S Make sure the right group of parameters is displayed in the display by

pressing one of the seven parameter keys.

S Enter a value in the digit box. S Press the soft key of the desired parameter.

Note that the parameters always inherit the value from the previous sector if no new value is entered.

5.2 Increasing/decreasing a parameter value

The parameter value to be altered must be shown in the digit box.

S Mark the desired parameter using one of the soft keys. The set value

comes up in the box.

S Press the PLUS

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or the MINUS key .

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5.3 Creating a new sector

A new sector is created by entering a new breakpoint into an existing sector.

S Enter a new value for the breakpoint of the new sector.

S Press the SECTOR key

In doing this, a new sector is created which is a copy of the original sector, but with another breakpoint and another sector number. The new sector is automatically positioned in the right place in the program. This is determined by the value of the new breakpoint.

Creating a new sector during welding

Proceed as follows to create a new sector during the welding:

S Enter a value into one of the following parameter groups using the

numerical keys:

S Press the corresponding soft key. A new sector is now automatically created.

5.4 Changing the breakpoint of a sector

Make sure the existing breakpoint value of the sector is displayed in the digit box.

S Press the SECTOR key

The breakpoint value is now shown in the digit box.

S Enter the new breakpoint value.

S Press the SECTOR key

S Change the breakpoint value using the PLUS key

key

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or the MINUS

5.5 Creating a transport secto r

If you want to rotate the welding tool without welding within a sector, you can create a transport sector. Sector 1 cannot function as a transport sector -- it can only function as a delayed start.

Transport sector

S Enter a value for the breakpoint of the new sector using the numerical

keys.

S Press the SECTOR key

S Set the WELDING CURRENT

(the peak current) to 0.

NOTE! If the welding current value is inherited, the welding current value of the following sector will also be 0. Don’t forget to change them to the right value.

All the other parameter values can remain.

Delayed start

Change the breakpoint of sector 1 in the following way in order to delay the start:

S Press the STEP key

S Press the SECTOR key

and go to sector 1.

S Enter the breakpoint, for example 0.100 instead of 0.000, using the

numerical keys.

S Press the SECTOR key

again.

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5.6 Finding the home position

When the tube welding tools PRH and POC are used, it can sometimes be necessary to return to the home position (start position), for example in the event of a welding stop.

S Rotate the tool manually till it is within a tenth of a rotation to the left or

right of the home position. See also under the section “Manual Mode” on page 56.

S Press the START key

Once this is done, the welding tool automatically starts rotating to the home position, and a welding sequence starts.

5.7 Entering a slope

A time slope or a sector slope can be indicated for the following parameter groups:

Welding current Rotation speed

Arc voltage control (AVC) Weaving

Wire feed speed

Time slope

S Press the key for the parameter group in question. S Mark the desired parameter using one of the soft keys. S Enter the desired slope time value.

S Press the SLOPE key

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Sector slope

To create a sector slope no time value is to be entered. A sector slope always goes on from one breakpoint to the next one.

NOTE! In the Welding Current parameter group you cannot indicate a sector slope when preheating is involved.

S Press the key for the parameter group in question. S Mark the desired parameter using one of the soft keys.

S Press the SHIFT key

and the SLOPE key simultaneously,

and a sector slope is created.

Whatisaslope?

A slope is a linear change between two parameter values, based on time or position (breakpoint).

A time--based slope (time slope) is active during the time indicated.

A position--based slope (sector slope) is active between two adjacent breakpoints.

5.8 Moving within a program

Move to the next parameter group

Using the STEP key When using the STEP function, only the parameter groups that have been assigned a value are displayed.

When stepping through the end sector, you will automatically jump to the tool code.

Move between

sectors

By entering a sector number in the digit box in the display and then pressing

you can step through the whole welding program.

the SECTOR key

it is possible to jump between the different sectors of the program. When jumping to a new sector you always end up in the same group of parameters as the one you left.

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5.9 Deleting in a program

Delete a parameter value

You can delete a parameter value if it has not been borrowed from a previous sector. For the value to be deleted, it must be displayed in the digit box.

S Press the DELETE key

. The digit box asks DEL?

S Press the soft key of the parameter to confirm.

Delete a

sector

You can only delete the sector in which you are at the moment. It can be done in two different ways:

Alternative 1

S Press the DELETE key

and then the SECTOR key .

Alternative 2

S Press the SECTOR key

. The breakpoint of the sector comes up in

the digit box.

S Press the DELETE key

S Press the SECTOR key

. The digit box asks DEL?

to confirm.

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Delete the contents of the working area

The working area always contains the welding program last used. Maybe you want to clear the working area completely, for example to change the tool code.

Delete a program in the working area in the following way:

S Press the DELETE key

and then the MEMORY key .

5.10 Changing weld data during welding

To change welding data in the course of welding, a value must be displayed in the digit box.

S Mark the parameter in question using one of the soft keys. The set value

now comes up in the digit box.

S Enter the new value using the numerical keys, or increase/decrease the

value using the PLUS

NOTE! When a value is changed in the working area, the old value will be overwritten and the new one applies. If the value is inherited, the value in the following sector will also be changed.

/ MINUS keys.

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5.11 Zeroing the control box

In the event the control box should get blocked, i.e. it does not react when the keys are activated, it is necessary to reset the box. This is done in the following way:

S Set the mains voltage switch on the power source to 0. S Hold down the mid one of the five soft keys on the control box, and turn

the mains voltage switch to position 1.

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6 PROGRAMMING EXAMPLES

Pressthesof

ouspeak

6.1 Example 1a:

The first example is a simple welding program, consisting of two sectors, sector 2 being a stop sector. The program contains four parameters:

welding current, rotation, weld gas preflow and weld gas postflow.

Sector 1 Sector 2

Breakpoint 0.000 1.010 Welding current (continuous) (A) 200 0 Rotation (continuous) (‰) 250 250 Gas preflow (weld gas) (s) 5 Gas postflow (weld gas) (s) 7

Sector 1 Breakpoint

Sector 1 automatically is assigned the breakpoint 0.000, if nothing else is indicated.

Welding current Pulse current = 200 A

S Press the key for WELDING CURRENT

. The picture for welding

current settings comes up in the display.

S Enter the value 200 using the numerical keys. S

key continu-

pulse current.

SECTOR 1(1) 0.000

PEAK CURRENT A

BACKG. CURRENT A PEAK TIME s BACKGR.TIME s

CONT/ PEAK CURR.

BACKGR.

CURR.

PEAK TIME

200

BACKGR

TIME

SPEC. PULS

Result: PEAK CURRENT = 200 A in sector 1.

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-- 3 1 --

Rotation speed

Pressthesof

forward

Pressthesof

Continuous rotation forward = 250 ‰ of the max. rotation speed.

S Press the key for ROTATION SPEED

S Enter the value 250 using the numerical keys. S

key rotation

SECTOR 1(1) 0.000

ROTATION FORWARD

ROTATION BACKW. PULSE ROT. FORW. PULSE ROT. BACKW.

ROTA TION FORW

ROTA-TION BACKW

PULSE

ROT. FORW

250

PULSE ROT. BACKW.

Result: ROTATION FORWARD = 250 in sector 1.

Gas Preflow of weld gas = 5sin sector 1.

S Press the key for gas

S Enter the value 5 using the numerical keys.

The gas preflow has a preset value of 2 s, which applies if no other value is entered and displayed in the display at the start.

key weld gas.

SECTOR 1(1) 0.000

WELD GAS s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START-GAS

Result: WELD GAS = 5 s in sector 1.

dpa8d1eb

-- 3 2 --

Sector 2

Pressth

Pressthesof

ouspeak

Breakpoint

S Enter the value of the new breakpoint 1.010 using the numerical keys. S

SECTOR key.

SECTOR 1(1) 0.000

1 WELD GAS 5 s

ROOT GAS s START GAS s

1.010

WELD GAS

ROOT GAS

START GAS

Result: Sector 2 out of 2 sectors in all.

Welding current

Peak current = 0A

As sector 2 is to be a stop sector, the welding current must be assigned the value of 0 amperes. Note that the parameter (peak current) has been assigned the value 200 as the value was inherited from the preceding sector.

S Press the key for WELDING CURRENT

S Enter the value 0 using the numerical keys. S

key continu-

current.

SECTOR 2(2) 1.010

1 PEAK CURRENT 200 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: PEAK CURRENT = 0 A in sector 2 (end sector).

dpa8d1eb

-- 3 3 --

Rotation speed

Pressthesof

As this is the last sector of the program and the welding current is set to 0, the sector will be interpreted as a stop sector, irrespective of the rotation value. In other words, we can keep the rotation value that was borrowed from the previous sector.

S Press the key for ROTATION SPEED

SECTOR 2(2) 1.010

1 ROTATION FORWARD 250

ROTATION BACKW. PULSE ROT. FORW. PULSE ROT. BACKW.

ROTA TION FORW.

ROTA-TION BACKW.

to view the result.

PULSE

ROT. FORW.

PULSE ROT. BACKW.

Result: ROTATION FORWARD = 250 ‰ in sector 2 (borrowed value)

Gas The weld gas preflow of = 7s.

S Press the key for gas

S Enter the value 7 using the numerical keys. The gas postflow has a

preset value of 4 s, which applies if no other value is entered and displayed in the display at the start.

key weld gas.

SECTOR 2(2) 1.010

1WELDGAS s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START GAS

Result: WELD GAS = 7 s in sector 2.

dpa8d1eb

-- 3 4 --

6.2 Example 1b:

Pressth

We now want to extend the previous program by adding a slope up and slope down time to the welding current. We also add a new sector to the program, which is to be placed between the other two sectors.

Sector 1 Sector 2 Sector 3 Breakpoint 0.000 0.500 1.010 Welding current (continuous) (A) 200 150 0

Slope up (s) 2 -- -Slope down (s) -- -- 4

Rotation, continuous (‰) 250 250 250 Gas preflow (weld gas) (s) 5 -- -Gas postflow (weld gas) (s) -- -- 7

Sector 1

Go back to sector 1.

S Enter the value 1 using the numerical keys. S

SECTOR key.

SECTOR 2(2) 1.010

2 WELD GAS 7 s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START GAS

Result: Return to sector 1 with the breakpoint 0.000.

dpa8d1eb

-- 3 5 --

Slope

Enterth

eva

lue

Enterth

eva

lue

The slope--up time = 2sfor the peak current of sector 1. When a slope function is to be added, first make sure the corresponding

picture is displayed in the display.

S Press the key for WELDING CURRENT

S Press the soft key for continuous peak current. S

S Press the

SLOPE key.

SECTOR 1(2) 0.000

1 PEAK CURRENT 200 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: PEAK CURRENT = 200 A, 2.0 s in sector 1.

Sector

New breakpoint = 0.500 We are now going to add a sector to the program. The breakpoint of the

new sector is to be 0.500, and the sector will automatically be placed between the two sectors already existing.

0.5.

S Press the

SECTOR key.

SECTOR 1(2) 0.000

1 PEAK CURRENT 200 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

0.5

2.0 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: Breakpoint 0.500 is placed as sector no. 2 (borrowed value).

dpa8d1eb

-- 3 6 --

Welding current

Pressthesof

ouspeak

Enterth

eva

lue

numericalkeys

Peak current = 150 A

S Press the key for WELDING CURRENT S Enter the value 150 using the numerical keys.

key continu-

current.

SECTOR 2(3) 0.500

1 PEAK CURRENT 200 A

BACKGR CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

Result: PEAK CURRENT = 150 A in sector 2.

Sector

Go to sector 3.

3 using the

SECTOR 2(3) 0.500

S Press the

SECTOR key.

2 PEAK CURRENT 150 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

150

2.0 s

BACKGR

TIME

SPEC. PULS

CONT/ PEAK CURR

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: You have moved to sector 3 with the breakpoint 1.010.

dpa8d1eb

-- 3 7 --

Slope

Enterth

eva

lue

Slope down = 4sfor the peak current of sector 3.

S Press the soft key for continuous peak current. S

S Press the

SLOPE key.

SECTOR 3(3) 1.010

3 PEAK CURRENT 0 A

BACKGR CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: PEAK CURRENT = 0 A, 4.0 s in sector 3 (stop sector).

6.3 Example 1c:

We now extend the previous program by changing the welding current of sector 1 from 200 A to 180 A. We also add a new sector to the program, which will automatically be placed between sector 1 and sector 2.

Sector 1 Sector 2 Sector 3 Sector 4 Breakpoint 0.000 0.250 0.500 1.010 Welding current (continuous)

(A) Slope up (s) 2 -- -- -Slope down (s) -- 4 -- 4 Rotation, continuous (‰) 250 250 250 250 Gas preflow (weld gas) (s) 5 -- -- -Gas postflow (weld gas) (s) -- -- -- 7

180 170 150 0

dpa8d1eb

-- 3 8 --

Sector 1

Enterth

eva

lue

numericalkeys

Pressthesof

ouspeak

Go back to sector 1.

1 using the

S Press the

SECTOR key.

SECTOR 3(3) 1.010

3 PEAK CURRENT 0 A

BACKGR CURRENT A PEAK TIME s BACKGR. TIME s

4.0 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: Return to sector 1 with the breakpoint 0.000.

Welding current Peak current = changed from 200 A to 180 A.

S Enter the value 180 using the numerical keys. S

key continu-

current.

SECTOR 1(3) 0.000

1 PEAK CURRENT 200 A

BACKGR CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 180 A, 2.0 s in sector 1.

180

2.0 s

SPEC. PULS

dpa8d1eb

-- 3 9 --

Sector 2

Enterth

eva

lue

Pressthesof

ouspeak

New breakpoint = 0.250

We are now going to add a sector to the program. The new sector is to have the breakpoint 0.250 and will automatically be placed in the right position between sector 1 and sector 2.

0.25.

S Press the

SECTOR key.

SECTOR 1(3) 0.000

1 PEAK CURRENT 180 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

0.25

2.0 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: SECTOR 0.250 is placed as sector 2 in the program (values borrowed from sector 1).

Welding current Peak current = 170 A.

S Enter the value 170 using the numerical keys. S

key continu-

current.

SECTOR 2(4) 0.250

1 PEAK CURRENT 180 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

170

BACKGR

TIME

2.0 s

SPEC. PULS

Result: PEAK CURRENT = 170 A in sector 2.

dpa8d1eb

-- 4 0 --

Slope

Enterth

eva

lue

numericalkeys

Slope down = 4sfor the peak current in sector 2.

S Press the soft key for continuous peak current . S

4 using the

SECTOR 2(4) 0.250

2 PEAK CURRENT 170 A

S Press the

SLOPE key.

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 170 A, 4.0 s in sector 2.

SPEC PULS

dpa8d1eb

-- 4 1 --

6.4 Example 1d:

We now extend the program further by adding some new welding parameters.

Sector 1 Sector 2 Sector 3 Sector 4 Breakpoint 0.000 0.250 0.500 1.010 Welding current (continuous)

(A)

Welding current (background current) (A)

Welding current (pulse time) (s)

Welding current (Background time) (s)

Slope up (s) 2 -- -- -Slope down (s) -- 3 -- 4 Preheating (s) 2 2 2 2 Rotation, (cont. forward) (‰) 250 250 250 250 Gas preflow (weld gas) (s) 5 -- -- -Gas postflow (weld gas) (s) -- -- -- 7

Wire feed (continuous) (cm/min)

A VC, (pulse voltage) (V) 11.2 11.2 11.2 11.2 AVC,

(background voltage) (V) Weaving, (weaving ampl.)

(mm) Weaving, (weaving speed)

(mm/s) Weaving, (dwell time right)

(s) Weaving, (dwell time left) (s) 1.0 1.0 1.0 1.0

180 170 150 0

100 100 100 100

0.5 0.5 0.5 0.5

1.0 1.0 1.0 1.0

110 110 110 110

10.9 10.9 10.9 10.9

5.0 5.0 5.0 5.0

8.0 8.0 8.0 8.0

1.0 1.0 1.0 1.0

dpa8d1eb

-- 4 2 --

Sector 1

Enterth

eva

lue

numericalkeys

Pressthesof

groundcur

Go back to sector 1.

1 using the

S Press the

SECTOR key.

SECTOR 2(4) 0.250

2 PEAK CURRENT 170 A

BACKGR CURRENT A PEAK TIME s BACKGR TIME s

4.0 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: Return to sector 1 with the breakpoint 0.000.

Welding current Background current = 100 A.

S Press the key for WELDING CURRENT

S Enter the value 100 using the numerical keys. S

key back--

rent.

SECTOR 1(4) 0.000

1 PEAK CURRENT 180 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR

BACKGR

CURR.

PEAK TIME

100

BACKGR

TIME

2.0 s

SPEC. PULS

Result: BACKGR. CURRENT = 100 A. 2.0 s in sector 1 and PULSE TIME = 1.00 s and BACKGR. TIME = 1.00 s (preset values)

dpa8d1eb

-- 4 3 --

Pulse time = 0.5 s instead of 1.0.

Pressthesof

S Enter the value 0.5 using the numerical keys. S

key peak time.

SECTOR 1(4) 0.000

0.5

1 PEAK CURRENT 180 A

BACKGR. CURRENT 100 A PEAK TIME 1.00 s BACKGR.TIME 1.00 s

CONT/ PULSE CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK TIME = 0.50 s instead of 1.00 s in sector 1.

Preheating time The preheating time = 2s

S Press the key for PREHEATING TIME

S Enter the value 2.0 using the numerical keys. S

key preheat.

SECTOR 1(4) 0.000

PREHEAT s

2,0

2.0 s

SPEC. PULS

PRE-HEAT.

Result: PREHEAT = 2.0 in sector 1.

dpa8d1eb

-- 4 4 --

Wire feed speed

Pressthesof

ouspeakwire

Pressthesof

ous/pea

We are now going to use filler wire. As we intend to weld using continuous wire feed (not pulsed) only the pulsed wire parameter need to be entered.

Pulsed wire = 110 cm/min

S Press the key for WIRE FEED SPEED

S Enter the value 110 using the numerical keys S

key continu-

feed.

SECTOR 1(4) 0.000

PEAK WIRE. cm/m in BACKGR WIRE. cm/min

CONT/ PEAK WIRE

BACKGR

WIRE

Result: PEAK WIRE FEED = 110 cm/min in sector 1.

Arc voltage control (AVC) The peak voltage = 11.2 V

S Press the key for ARC VOLTAGE CONTROL, (AVC) S Enter the value 11.2 using the numerical keys. S

key continu-

voltage.

SECTOR 1(4 ) 0.000

PEAK VOLTAGE V BACKGR. VOLTAGE V DELAY TIME s

110

11.2

CONT/ PULSE VOLT.

BACKGR

VOLT.

DELAY

TIME

Result: PEAK VOLTAGE = 11.2 V in sector 1.

dpa8d1eb

-- 4 5 --

Background voltage = 10.9 V

Pressthesof

groundvol

Pressthesof

speed

S Enter the value 10.9 using the numerical keys. S

key back-

age.

SECTOR 1(4 ) 0.000

1 PEAK VOLTAGE 11,2 V

BACKGR. VOLTAGE V DELAY TIME s

10.9

CONT/ PULSE VOLT.

BACKGR

VOLT.

DELAY. TIME

Result: BACKGR VOLTAGE = 10.9 V in sector 1.

Weaving

We are now going to add values for weaving. Some of the values are preset. See preset values, page 18 .

Weaving speed = 8.0 mm

S Press the key for WEAVING

S Enter the value 8.0 using the numerical keys. S

key weaving

SECTOR 1 (4 ) 0.000

WEAVE AMPL. mm WEAVE. SPEED. mm/s DWELL RIGHT s DWELL LEFT s

WEAVE. AMPL

WEAVE

SPEED

DWELL RIGHT

8.0

DWELL LEFT

Result: WEAVING SPEED = 8.0 mm/s. The preset values are also shown (sector 1).

dpa8d1eb

-- 4 6 --

Sector 2

Enterth

eva

lue

numericalkeys

Enterth

eva

lue

numericalkeys

Go to sector 2.

2 using the

S Press the

SECTOR key.

SECTOR 1(4) 1.010

1 WEAVE. AMPL 5.0 mm 1 WEAVE SPEED 8.0 mm/s 1DWELLRIGHT 1.0s 1 DWELL LEFT 1.0 s

WEAVE AMPL

WEAVE

SPEED

DWELL RIGHT

DWELL LEFT

Result: You have moved to sector 2(4) with the breakpoint 0.250.

Slope

We are now going to change the slope--down time in sector 2. Make sure the corresponding parameter picture is shown in the display.

S Slope down = 3sinstead of 4 s.

Press the key for WELDING CURRENT

Press the soft key for continuous peak current .

3 using the

S Press the

SLOPE key.

SECTOR 2(4) 0.250

2 PEAK CURRENT 170 A 1 BACKGR. CURRENT 100 A 1 PEAK TIME 0,50 s 1 BACKGR. TIME 1,00 s

CONT/ PULSE CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

4.0 s

2.0 s

SPEC. PULS

Result: PEAK CURRENT = 170 A 3.0 s SLOPE in sector 2.

dpa8d1eb

-- 4 7 --

6.5 Example 1e:

We now want to make changes in the program by moving the breakpoint in sector 3 from 0.500 to 0.750 and adding special pulsingand a sector slope in sector 2 and sector 3.

Sector 1 Sector 2 Sector 3 Sector 4 Breakpoint 0.000 0.250 0.750 1.010 Welding current (continuous)

(A) Welding current (background

current) (A) Welding current (pulse time)

(s) Welding current (background

time) (s)

Special pulsing -- -- --

Slope up (s) 2 -- -- -Slope down (s) -- Sector

Preheating (s) 2 2 2 2 Rotation, (cont. forward) (‰) 250 250 250 250 Gas preflow (weld gas) (s) 5 -- -- -Gas postflow (weld gas) (s) -- -- -- 7 Wire feed (continuous)

(cm/min) AVC, (pulse voltage) (V) 11.2 11. 2 11.2 11.2 AVC, (background voltage) (V) 10.9 10.9 10.9 10.9 Weav. (weaving ampl) (mm) 5.0 5.0 5.0 5.0 Weav. (weaving speed) (mm/s) 8.0 8.0 8.0 8.0 Weaving (dwell time right) (s) 1.0 1.0 1.0 1.0 Weaving (dwell time left) (s) 1.0 1.0 1.0 1.0

180 170 150 0

100 100 100 100

0.5 0.5 0.5 0.5

1.0 1.0 1.0 1.0

slope

Sector slope

110 110 110 110

dpa8d1eb

-- 4 8 --

Sector 1

Enterth

eva

lue

numericalkeys

Pressthesoftk

eyy

pulsing

Go back to sector 1.

1 using the

S Press the

SECTOR key.

SECTOR 2(4) 0.250

2 PEAK CURRENT 170 A 1 BACKGR. CURRENT 100 A 1 PEAK TIME 0,50 s 1 BACKGR. TIME 1,00 s

3.0 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: Return to sector 1 with the breakpoint 0.000.

Special pulsing (welding current)

We are now going to add special pulsing. Make sure the corresponding picture is shown in the display.

PEAK TIME

2.0 s

BACKGR

TIME

SPEC. PULS

S Press the key for WELDING CURRENT

or special

SECTOR 1(4) 0.000

1 PEAK CURRENT 180 A 1 BACKGR CURRENT 100 A 1 PEAK TIME 0,50 s 1 BACKGR. TIME 1,00 s

CONT/ PEAK CURR.

BACKGR

CURR.

Result: SPECIAL PULSING = takes place throughout the program.

dpa8d1eb

-- 4 9 --

Sector 2

Enterth

eva

lue

numericalkeys

Go to sector 2.

2 using the

S Press the

SECTOR key.

SECTOR 1(4) 0.000

1 PEAK CURRENT 180 A 1 BACKGR. CURRENT 100 A

1 SPECIAL PULSING

2.0 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

Result: You have moved to sector 2.

Sector slope

We want to add a sector slope in sector 2.

S Press the soft key for continuous peak current .

S Press the keys SHIFT

2 PEAK CURRENT 170 A 1 BACKGR. CURRENT 100 A

2 SPECIAL PULSING

CONT/ PEAK CURR.

SECTOR 2(4) 0.250

and SLOPE .

BACKGR

CURR.

PEAK TIME

Result: PEAK CURRENT = 170 A in sector 2.

BACKGR

TIME

BACKGR

TIME

2.0 s

SPEC. PULS

dpa8d1eb

-- 5 0 --

Sector 3

Enterth

eva

lue

numericalkeys

Pressth

again

Go to sector 3.

3 using the

S Press the

SECTOR key.

SECTOR 2(4) 0.250

2 PEAK CURRENT 170 A 1 BACKGR CURRENT 100 A

2 SPECIAL PULSING

2.0 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

Result: You have moved to sector 3.

Breakpoint

The breakpoint = 0.750 instead of 0.500.

To change the breakpoint, proceed as follows:

S Press the SECTOR key

. The digit box now shows 0.500.

S Enter the value 0.75 using the numerical keys. S

SECTOR key

SECTOR 3(4) 0.500

3 PEAK CURRENT 150 A 1 BACKGR. CURRENT 100 A

3 SPECIAL PULSING

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

Result: The new breakpoint = 0.750 in sector 3.

BACKGR

TIME

0.75

BACKGR

TIME

3.0 s

SPEC. PULS

dpa8d1eb

-- 5 1 --

Sector slope

We now want to add a sector slope to sector 3.

S Press the soft key continuous peak current.

S Press the keys SHIFT

3 PEAK CURRENT 150 A 1 BACKGR. CURRENT 100 A

3 SPECIAL PULSING

CONT/ PEAK CURR.

SECTOR 3(4) 0.750

and SLOPE .

BACKGR

CURR.

Result: PEAK CURRENT = 150 A .

PEAK TIME

BACKGR

TIME

2.0 s

SPEC. PULS

dpa8d1eb

-- 5 2 --

7 THE LIBRARY

Pressthesof

Welding programs created in the working area are stored in the library. Up to 250 different programs can be stored here, depending on the size of the programs. (See the section PC--CARDS, page 59.)

7.1 Storing a program

S Make up a program in the working area.

S Press the MEMORY key

S Enter the position no. of the program (for example 3) using the numerical

keys.

key store.

LIBRARY Page 1 (1)

(NEXT) PAGE

STORE RECALL PC--

CARD

DELETE

PROG.

STO flashes in the digit box. Result: The program is to be found under program position 3 in the library.

S Leave the library and use the MEMORY key

to return to the

working area.

7.2 Recalling a program

Note! When recalling a program from the library, the working area must be

empty.

S Press the MEMORY key

dpa8d1ec

-- 5 3 --

S Select a program position (for example 3) using the numerical keys.

Pressthesof

Pressth

MEMkeysat

key recall.

LIBRARY Page 1 (1)

(NEXT) PAGE

STORE

RECALL

PC-CARD

DELETE

PROG.

RCL flashes in the digit box.

S Press the MEMORY key

to get back to the working area.

Result: You have recalled a copy of program no. 3 from the library to the working area.

7.3 Viewing the tool code

In the library you can also view the tool code that is connected with a particular program position.

S Press the MEMORY key S Select a program position (for example 3) using the numerical keys.

SHIFT and

thesametime.

LIBRARY Page 1 (1)

(NEXT) PAGE

STORE

RECALL

PC-CARD

DELETE

PROG.

Result: The display shows the tool code (PRB , PRC 33--90 mm) connected with program position no. 3.

dpa8d1ec

-- 5 4 --

S Press the MEMORY key to get back to the working area.

Pressthesof

program

Pressthesof

7.4 Deleting a program

S Press the MEMORY key . S Select a program position (for example 3) using the numerical keys

key delete

LIBRARY Page 1 (1)

(NEXT) PAGE

STORE RECALL PC--

CARD

The following display comes up:

key yes.

Library Page 1 (1)

DEL?

NO YES

Result: You have deleted program position no. 3 in the library.

S Press the MEMORY key

to get back to the working area.

DELETE

PROG.

dpa8d1ec

-- 5 5 --

8 MANUAL MODE

8.1 Field of application

Manual mode is used for correct positioning of the tungsten electrode

before the welding, and for making sure that the program in the working area functions as desired.

The following welding parameters can be modified:

NOTE! When pressing START in any of the manual menus (except the gas menu), the program will be run in the working area without arc.

Gas

Wire feed speed

Rotation speed

Arc voltage control (AVC)

Weaving

8.2 Editing a parameter

S Press the MANUAL MODE key .

Change rotation speed forward

S Press the ROTATION SPEED key

dpa8d1ec

-- 5 6 --

MANUAL

ROTATION FORWARD ROTATION BACKW:

ROTA-TION FORW.

ROTA-TION BACKW.

S Press the soft key rotation forward and run the motor by pressing the

PLUS key

or the MINUS key .

NOTE! If the soft key for rotation backward and the PLUS key are pressed, the result will be rotation forwards,

S Enter a value using the numerical keys and press the soft key rotation

forward (the rotation stops after 1 turn).

When you return to the working area, the program will start from the adjusted position.

MANUAL

ROTATION FORW ROTATION BACKW.

ROTA-TION FORW.

ROTA-TION BACKW.

Result: The program will start without the arc (i.e. the value of the welding current parameter = 0).

The same procedure is used for changing the value of the parameters for wire feed speed, arc voltage and weaving.

dpa8d1ec

-- 5 7 --

The following applies with regard to the gas parameter:

Themessagelineg

S Press the soft key weld gas to open the gas valve, S Press the soft key weld gas once again to close the gas valve.

From this position the welding (with arc) is started in the following way:

S Press the START key

displays welding.

WELDING

WELD GAS

MANUAL

ROOT GAS

START GAS

S Press the MANUAL MODE key to return to the working area.

dpa8d1ec

-- 5 8 --

9 PC--CARD

Pressthesof

9.1 Field of application

The PC--card is used for storing all the welding programs in the library. It also makes it possible to copy welding programs between different control boxes.

9.2 How to install the card

S Open the door on the left side panel of the

control box.

S Insert the PC--card into the card reader so

that the lock catches.

S Close the door.

9.3 How to recall a program

S Press the MEM key .

Note! When a program is recalled from the PC--card, all the

programs in the library are automatically deleted. If you want to keep the library programs, you must first store them on another PC--card.

S Press the soft key PC--card. S

key recall.

PC-- CARD

STORE

RECALL

QUIT

DELETE

CARD

After a couple of seconds a pop --up menu confirms the action.

dpa8d1ec

-- 5 9 --

PC-- CARD

Pressthesof

RECALLED WELD DATA

SET FROM PC--CARD

STORE RECALL QUIT

DELETE

CARD

Result: All the programs previously stored on the PC--card have now been copied and stored in the library.

S Press the soft key quit to return to the library.

9.4 How to store a program

S Press the MEMORY key

S Press the soft key PC--card.

Note! When a program is stored on the PC- card, all other

programs on the card will automatically be deleted.

key store.

PC-- CARD

STORE RECALL QUIT

DELETE

CARD

After a couple of seconds a pop --up menu confirms the action.

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-- 6 0 --

PC-- CARD

Pressthesof

STORED WELD DATA

SET IN PC--CARD

STORE RECALL QUIT

DELETE

CARD

Result: All programs stored in the library have now been copied and stored on the PC--card.

S Press the soft key quit to return to the library.

9.5 How to delete a program

S Press the MEM key . S Press the soft key PC--card.

key delete card.

After a couple of seconds a pop --up menu confirms the action.

PC-- CARD

STORE RECALL QUIT

DELETE

CARD

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-- 6 1 --

PC-- CARD

DELETEDWELDDATA

SET IN PC--CARD

STORE RECALL QUIT

DELETE

PROG

Result: You have deleted all the programs on the PC--card.

S Press the soft key quit to return to the library,

9.6 How to take out the PC --card

S Open the door on the left side panel of the control box. S Press the small black button to the right of the PC--card. S Draw the PC--card out of the card reader. S Close the door.

10 ERROR CODES

10.1 Error h andling

Error codes are used to indicate that an error has occurred in the welding process. The code is shown in the display by way of a pop--up menu,

displayed for 2,5 seconds. After that an exclamation mark the top left corner of the display.

All error codes are stored in an error list and can be studied later on.

is shown in

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-- 6 2 --

SECTOR 3(4) 0.500

Pressthesof

keyerrorlog

ERROR 12

IN WELD DATA UNIT

3 SPECIALPULSN

CONT/ PEAK CURR.

BACKGR

CURR

PEAK TIME

BACKGR

TIME

Result: An error has occurred in the weld data unit (control box).

Howtoviewtheerror

S Press the MODE key

log:

keyerror log.

AUXILIARY FUNCTIONS

LANGUAGE "

ERROR LOG " SHOW ACTUAL PARAMETER VALUES SOFTWARE UPGRADE " SOFTWARE KEY "

LAN-GUAGE

ERROR LOG

SHOW PARA- METER

SOFT--. WARE UPGR.

Result: You get into the error log codes.

This can be viewed on the display:

1. The queue number of the error.

2. When the error occurred (Date and time).

3. Where the error occurred.

4. The error code number. For further information about what is wrong, proceed as follows:

SPEC. PULS

SOFT--. WARE KEY

NOTE!

dpa8d1ec

disappears from the display as soon as you enter this menu.

-- 6 3 --

S Enter for example error no. 2, using the numerical keys.

Pressthesof

key view error

ERROR LOG Page 1(2 ) 2

number.

Error No" Date Tim Unit Error

1 " 971007 13:07.03 PSOURCE 1 2 " 971007 13:07.50 CBOX 18 3 " 971007 14:56.07 ROT/WIRE 2

(NEXT) PAGE

PAG E

VIEW ERROR NO.

QUIT DELETE

ALL

Result: Information about error code 18 is shown, CBOX (the weld data unit in the control box) has lost contact with the welding power source.

A more detailed description of the error and measures to be taken are shown in the table over Error Codes Resulting from Incorrect Editing on page 66.

How to delete an error

log

key delete

ERROR LOG -- VIEW MESSAGE 1

error.

Error 18: " Lost contact with power source Unit: CBOX Date: 971007 Time: 13:07.50

QUIT DELETE

ERROR

Result: The error code disappears from the display. If you want full control over errors occurring over a period you need not

delete the errors. Up to 100 error numbers can be stored in the control box.

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-- 6 4 --

Overview of error handling codes

Code Description CBOX ROOT/WIRE

WEAVE/AVC

1 EPROM x x x 2 RAM x x x 3 External RAM (write, read) x x 4 Supply voltage 5V x 5 High + DC voltage x 6 High temperature x 7 High primary current x 8 Supply voltage 1* x x x

9 Supply voltage 2* x x 10 Supply voltage 3* x 11 Current servo/Wire speed servo x 12 Communication error (warning) x x x 13 Servo 1 x 14 Communications error (bus off) x 15 Lost messages x x x 16 Servo 2 x 17 Contact lost with the motor unit x 18 Contact lost with weld. power source x 19 Memory error in battery-- fed computer

memory 20 Prohibited setting values x 21 Current limit 1 x 22 Spill in buffer transmitter x 23 Spill in buffer receiver x 25 Incompatible weld data format x 26 Watch dog x x 27 Current limit 2 x 28 Spill in stack x x x 29 No water flow x 30 Contact lost with TIG card x 31 No response from display unit x 32 No gas flow x

PSOURCE

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-- 6 5 --

Unit

CBOX +3V ROOT/WIRE

WEAVE/AVC PSOURCE +15VC --15V +15VB

Supply voltage

+ 15V + 60V

Supply voltage

CBOX = Weld Data card, control box

ROOT/WIRE = Motor card for controlling the rotation and wire feed motors.

WEAVE/AVC = Motor card for controlling the weaving and AVC motors.

PSOURCE = Circuit card for controlling the welding power source.

Error handling codes

Code Description

1 Program memory error (EPROM)

Cause: The program memory has lost a value. I.e the value in a

particular memory position no longer agrees with the original value. No functions are blocked through this error. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

2 Error in the microprocessor RAM

Cause: The microprocessor cannot write/read a certain memory

position in its own internal memory. No functions are blocked through this error. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

3 Error in external RAM

Cause: The microprocessor cannot write/read a certain memory

position in its own external memory. No functions are blocked through this error. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

4 Voltage drop in the 5 V supply voltage

Cause: Supply voltage too high.

All normal microprocessor activities cease, waiting for switch--off. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

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-- 6 6 --

5 High + DC voltage outside limit value

Cause: Voltage too high or too low. Too high a voltage can be due

to powerful transients on the mains supply or to a weak supply system (high inductance on the mains) The welding power source is automatically switched off. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

6 High temperature

Cause: The thermal cut--out has tripped.

The welding power source is automatically switched off and cannot be switched on again until the temperature has gone down and the cut--out is reset. Measure: Check that the cooling air intake/outlet are not blocked or dirty. Check that the work cycle does not exceed the ratings.

7 High primary current

Cause: Current too high in the welding power source.

The welding power source is automatically switched off and permanently blocked. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

8 Low battery voltage, weld data card (control box)

Cause: Battery voltage too low.

No functions are blocked through this error. Measure: Make a backup on a PC--card. Call in a service technician.

8 Supply voltage +15 VC, PC--card (welding power source)

Cause: Voltage too high or too low. Measure: Call in a service technician.

8 Supply voltage +15 V, motor card (rotation/wire) (weaving/

AVC) Cause: Voltage too low. Measure: Call in a service technician.

9 Supply voltage --15V, PC--card (welding power source)

Cause: The voltage is either too high or too low. Measure: Call in a service technician.

9 Supply voltage +60 V, motor card (rotation/wire)(weaving/

AVC) Cause: Current too low. Measure: Call in a service technician.

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-- 6 7 --

10 Supply voltage +15 VB, PC--card (welding power source)

Cause: Voltage too high or too low. Measure: Call in a service technician.

11 Incorrect current, PC--card (welding power source)

Cause: The welding power source failed in supplying the current

determined by the processor. No functions are blocked through this error.

Measure: Call in a service technician.

12 Communication error (warning)

Cause: The CAN circuit error counter shows too high value.

The contact with the control box can be broken. This can result from occasional overload.

Measure: Check the handling of the program during welding.

13 Incorrect rotation speed

Cause: Cannot keep up the speed determined by the processor.

The welding is interrupted Measure: Check the cabling. If the error remains, call in a service technician.

14 Communication error

Cause: The CAN circuit error counter shows too high value.

The welding process is stopped. This can result from occasional overload. Measure: Check the handling of the program during welding. Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

15 Lost messages

Cause: A message has been overwritten by another message. A

too frequent use of the pushbuttons on the control box, during welding, may cause this fault. The welding process is stopped. Measure: Check the handling of the program during welding. Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

16 Incorrect wire feed / weaving speed

Cause: Cannot keep up the speed determined by the processor. Measure: Check the cabling.

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-- 6 8 --

17 Contact lost

Cause: The control box has lost contact with one or both the mo-

tor units. Activities in progress are disabled. Measure: Check the cabling. If the error remains, call in a service technician.

18 Contact lost

Cause: The control box has lost contact with the power source.

Activities in progress are disabled. Measure: Check the cabling. If the error remains, call in a service technician.

19 Error in computer memory (RAM)

Cause: Can result from program upgrading. Measure: Switch on the mains voltage, and automatic resetting is

effected.

20 Unpermitted setting values stored (RAM)

Cause: Unpermitted values found at the start. The error may re-

sult from software upgrading. All data in the control box are deleted. Measure: Switch on the mains voltage, and automatic resetting is effected.

21 Current limit 1

Cause: Motor overload for rotation or weaving. Measure: Check the welding tool and its cabeling.

22 Spill in buffer transmitter

Cause: The buffer transmitter is full. Activities in progress are dis-

abled.

Measure: Check the handling of the program during welding.

23 Spill in buffer receiver

Cause: CAN messages are received faster than the weld data

card can cope with. Activities in progress are disabled. Measure: Check the handling of the welding program during welding.

25 Incompatible weld data format

Cause: TriedtostorewelddataonaPC--card.ThePC--cardcon-

tained other data format than the weld data memory. Measure: Use another PC--card.

dpa8d1ec

-- 6 9 --

26 Watchdog

Cause: Something prevented the processor executing its normal

tasks in the program. No functions are blocked through this error. Measure: Check the handling of the welding program during welding.

27 Current limit 2

Cause: Motor overload for WEAVE/AVC, ROT/WIRE Measure: Check the welding tool.

28 Spill in the stack

Cause: The internal memory is full. The error may be caused by

abnormal load on the processor. Measure: Check the handling of the welding program during welding.

29 No water flow

Cause: The cooling water flow has gone down below 0.7 l/min.

Activities in progress are disabled.

Measure: Check the cooling water.

30 Contact lost with the TIG--card

Cause: The control box has lost contact with the TIG--card.

Activities in progress are disabled. Measure: Check the cabling. If the error remains, call in a service technician.

31 No response from the display unit

Cause: The microprocessor gets no acknowledgement from the

display unit.

Measure: Call in a service technician.

32 No gas flow

Cause: The gas flow has gone down below 6 l/min. Measure: Check the gas valve, gas hoses and connections.

dpa8d1ec

-- 7 0 --

10.2 Incorrect editing codes

Codes depending on incorrect editing come up in the digit box when the wrong key is activated. The error code number always starts with

Code

13 Error in running the program.

110 Working area not empty when a program is recalled from the libra-

ry.

111 The program number does not exist in the library.

131 Key activation prohibited during welding. 132 Key activation prohibited during welding with special pulsing. 133 Permitted only during welding. 134 PC--card missing. 135 PC--card model for the welding power source (LTP 450) not accep-

ted.

136 Wrong program version of PC--card. 160 Working area is full. 163 The value in the digit box cannot be interpreted by the control box. 176 Welding program not accepted for welding. 177 Welding start prohibited in this program position in the control box. 178 The reset function does not work; must be preceded by a stop. 198 Welding start prohibited in manual program when the motors are

activated.

199 Welding start prohibited when activities are going on in the library. 204 A sector value cannot be changed so as to be placed before the

previous sector or after the following one.

205 A key is activated on the control box when the tool is started. 206 Tool code for the connected tool is missing. 207 Tool code not accepted. 212 Soft key not activated. 213 Delete state: Key prohibited.

Cause

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-- 7 1 --

221 Key not defined in this state. 222 When starting: Only tool code permitted. 223 Delete state: Key not defined. 229 Corr. state: Key activation prohibited. 233 Desired slope function: Parameter empty or not defined. 252 The tool code of the connected tool does not correspond to the

one of the welding program in the working area.

11 SHOW CURRENT PARAMETER VALUES

11.1 Field of applicatio n

Using this function it is possible to view the measured values of different welding parameters in the course of welding. The values are updated every

0.5 seconds.

The following parameter groups can show actual parameter values:

Welding current Wire feed speed

Rotation speed Gas

Arc voltage control (AVC) Weaving

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-- 7 2 --

11.2 How to view actual parameter values

Pressthesof

keyshow

S Press the MODE key and you get to the Auxiliary Functions. S

key show parameter.

LANGUAGE " ERROR LOG " SHOW ACTUAL PARAMETER VALUES SOFTWARE UPGRADE " SOFTWARE KEY "

AUXILIARY FUNCTIONS

LAN-GUAGE

ERROR LOG

SHOW PARA-METER

SOFT-WARE UPGR.

SOFT-WARE KEY

Result: SHOW ACTUAL PARAMETER VALUES is marked and you have activated show actual parameter values.

S Press the START key

to start welding.

S Press the desired parameter key.

The actual parameter values can now be viewed in the display.

12 SOFTWARE UPGRADE

12.1 Application field

Using the upgradE function you can replace (upgrade) programs in the different units (PC--cards) of the welding equipment by new software from a PC--card.

By unit is here meant a PC--card, containing software that can be upgraded.

dpa8d1ec

-- 7 3 --

12.2 Menu explanation

SYSTEM VERSION. 1.00B BOOT SOFTWARE 1.12

j POWER SOURCE 1.00 2.00 j ROT/WIRE UNIT ? --

j WEAVE/AVCUNIT 0.00 -- j WELD DATA UNIT 0.00 --

SOFTWARE UPGRADE

Unit Curr.ver PC--card

j j

QUIT UP--

GRADE

Curr--ver Describes which program version that is active in

this unit.

PC--card Describes the program version stored on the

PC--card.

? A unit exists but the computer does not know

which version it is.

-- There is no program for this unit on the PC--card. SYSTEM VERSION Indicates the program version stored on the PC--

card. A program version can consist of 1--4 programs (1 for each unit).

BOOT SOFTWARE Program for upgrade handling. POWER SOURCE PC--card for controlling the welding power sour-

ce.

ROT/WIRE UNIT PC--card for controlling the rotation and wire feed

motors.

WEAVE/AVC UNIT PC--card for controlling the weaving and AVC

motors.

WELD DATA UNIT The PC--card in the control box.

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-- 7 4 --

12.3 How to upgrade

Pressthesoftkeysoftware

upgrade

When upgrading the control box, all existing weld data will be deleted. Do not forget to store the data on a PC--card before the upgrade procedure is started.

To upgrade the ROT/WIRE , WEAVE/AVC WELD DATA (control box) unit, proceed in the same way as for the POWER SOURCE.

Upgrading the power source unit

Make sure the mains voltage for the welding power source will not be disconnected in the course of upgrading.

S Insert the PC--card containing the upgrading program.

S Press the MODE key

to get to the auxiliary functions.

upgrade.

LANGUAGE " ERROR LOG " SHOW ACTUAL PARAMETER VALUES SOFTWARE UPGRADE " SOFTWARE KEY "

LAN-GUAGE

AUXILIARY FUNCTIONS

ERROR LOG

SHOW PARA- METER

Result: You have come to the software upgrade menu.

dpa8d1ec

-- 7 5 --

SOFT WARE

UPGR.

SOFT-WARE KEY

In this example the program version of the PC--card only consists of one

Pressthesof

ttill

gettopowe

Pressthesof

upgrade program for the power source unit. The following display comes up.

ey nex et to “power

source”.

you

Unit Curr.ver PC--card

SYSTEM VERSION. 1.00B BOOT SOFTWARE 1.12

j POWER SOURCE 1.00 2.00 j ROT/WIRE UNIT ? -- j WEAVE/AVC UNIT 0.00 -- j WELD DATA UNIT 0.00 --

SOFTWARE UPGRADE

j j

QUIT UP

GRADE

S Press the second soft key to mark the power source unit (gets ticked

off). If further units are to be upgraded, they shall be marked in the same

way. By pressing the second soft key once again, the selection marked is

cancelled (the marking disappears).

ey upgrade.

Unit Curr.ver PC--card

SYSTEM VERSION. 1,00B BOOT SOFTWARE. 1,12

j POWER SOURCE 1.00 2.00 j ROT/WIRE UNIT ? -- j WEAVE/AVD UNIT 0.00 -- j WELD DATA UNIT 0,00 --

SOFTWARE UPGRADE

dpa8d1ec

j j

-- 7 6 --

QUIT UP--

GRADE

A dialogue box comes up in the display.

Pressthesof

upgrading

ey yesfor

rading.

SOFTWARE UPGRADE

THE SOFTWARE UPGRADING CAN

TAKE UP TO 5 MIN/UNIT AND.

CANNOT BE INTERRUPTED!

DO YOU STILL WANT TO DO IT ?

YES NO

The following dialogue box comes up in the display while upgrading:

SOFTWARE UPGRADE

DO NOT SWITCH OF THE EQUIPMENT

DURING THIS PROCESS!!

UPGRADING POWER SOURCE .....

23% completed

kkkkkkkkkkkkkkkkk

After completed upgrading the following comes up in the display:

SOFTWARE UPGRADE

SUCCESSFUL UPGRADE!

YOU MAY NOW RESTART THE EQUIPMENT !

Result: The power source unit has been upgraded to program version 2.00.

dpa8d1ec

-- 7 7 --

To make it possible to use the welding equipment, restart the welding power source by

S Turning the mains voltage switch to position 0. S Turning the mains voltage switch to position 1.

12.4 Measures to be taken when the upgrading of the

power source units failed

The software upgrade can for example fail if the supply voltage for the welding power source is interrupted while upgrading is going on.

Failure in upgrading the power source, rot/wire and weave/A VC units

The following dialogue box comes up in the display when the software upgrade has failed:

SOFTWARE UPGRADE

UPGRADING PROCESS FAILED!: 6

UNIT: 2!

Try once more to upgrade:

S Turn the mains voltage switch on the power source to position 0. S Hold down the fourth one of the five soft keys on the control box and turn

the mains voltage switch to position 1. Hold down the soft key until a double--squeak is heard. The welding power source starts again, the power source, rot/wire ,

pendl/AVC units in an upgrade position, permitting a new program upgrade.

The control box shows the upgrade menu display.

Repeat the program procedure “how to upgrade”, see page 75.

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-- 7 8 --

12.5 Measures to be taken when the upgrading of the

control box failed

The software upgrade can for example fail if the supply voltage for the welding power source is interrupted while upgrading is going on.

Should this happen the first fifteen seconds during the upgrade

procedure, an ESAB service technician must be called in.

Try once more to upgrade:

S Turn the mains voltage switch on the welding power source to position 0. S Insert the PC--card containing the upgrade program for the control box. S Hold down the fifth one of the five soft keys at the same time as you turn

the mains voltage switch to position 1.

Hold down the soft key until a double--squeak is heard. While the control box is being upgraded the display is empty. When the

procedure is finished, the control box will start up in the normal way . The upgrade procedure takes about 5 minutes. N.B. Do not switch off the welding power source while upgrading is going

on.

If it still does not work, call in a service technician.

dpa8d1ec

-- 7 9 --

13 SOFWARE KEY

Pressthesoftwarekey

Pressthesof

13.1 General

The software key is intended for locking certain functions, such as the modification of setting data in a welding program and the access to the auxiliary functions.

13.2 Locking the control box

S Press the MODE key to get to the auxiliary functions. S

LANGUAGE " ERROR LOG " SHOW ACTUAL PARAMETER VALUES SOFTWARE UPGRADE " SOFTWARE KEY "

AUXILIARY FUNCTIONS

LAN-GUAGE

ERROR LOG

SHOW PARA- METER

SOFT--. WARE UPGR.

SOFT-WARE KEY

Result: You have come to the software key menu.

S Enter 4 code numbers using the numerical keys. S

key enter.

dpa8d1ec

SOFTWARE KEY 1234

KEY CODE (4 NUMBERS):

THE CONTROLBOX IS UNLOCKED!

LOCK UN--

LOCK

LIMITS QUIT ENTER

-- 8 0 --

The following display comes up:

Pressthesof

Enterth

key lock.

SOFTWARE KEY

KEY CODE (4 NUMBERS): 1234

THE CONTROLBOX IS UNLOCKED!

LOCK UN

LOCK

Result: The control box is locked.

S Press the key

to return to the working area.

13.3 Unlocking the control box

S Press the MODE key . The following display comes up:

correct code (4 numbers, e.g.1234) using the numerical keys.

THECONTROLBOXISLOCKED!

PLEASE, GIVE LIMITSKEY CODE (4 NUMBERS):

LIMITS. QUIT ENTER

. ENTER

Each code number entered is acknowledged by :

S Press the soft key enter.

Result: The control box is unlocked and you have come to the auxiliary function menu.

dpa8d1ec

-- 8 1 --

13.4 Changing the code

Pressthesof

S Enter 4 new code numbers using the numerical keys. S

key enter.

SOFTWARE KEY 1111

KEY CODE (4 NUMBERS): 1234

THE CONTROLBOX IS UNLOCKED!

LOCK UN--

LOCK

LIMITS QUIT ENTER

The following display comes up:

key lock.

SOFTWARE KEY

KEY CODE (4 NUMBERS): 1234

THE CONTROLBOX IS UNLOCKED!

LOCK UN--

LOCK

LIMITS QUIT ENTER

Result: The control box has got a new code and is locked.

S Press the key

to return to the working area.

dpa8d1ec

-- 8 2 --

14 NOTEBOOK

14.1 Field of ap p licatio n

The notebook is used for making notes on for example:

S MATERIAL, TUBE DIAMETER, WALL THICKNESS, RUN NUMBER S START POINT, WELD TIME S ELECTRODE DIAMETER, ELECTRODE STICKOUT, ELECTRODE

ANGLE

S DISTANCE: ELECTRODE--WIRE, ELECTRODE--WORKPIECE S WIRE TYPE, WIRE DIMENSION, ELECTRODE TYPE S WELD GAS S ROOT GAS S START GAS

All notes are stored together with the welding program in the library.

14.2 How to enter data in the notebook

S Press the SHIFT key and the STEP key to get to the

notebook.

dpa8d1ec

NOTEBOOK Page 1(8)

MATERIAL TUBE DIAMETER. WALL THICKNESS RUN NUMBER

(NEXT) PAGE

MATER.

TUBE DIAM.

-- 8 3 --

WALL THICKN

RUN NO

14.3 Example 2a:

Here a few examples of notes that can be made in the notebook.

Welding para-

Explanation Value

meter

Material SIS designation for stainless steel. 2333 Tube diameter The external diameter of the tube. 60 mm Wall thickness The thickness of the tube wall. 3mm Run number Which joint number. 2 Start point Where on the tube the start point is. 3 o’clock Weld time The time required for running a wel-

1h20min30s

ding a program.

Electrode diameter

Electrode stick--out

Electrode angle The angle of the tungsten electrode

The diameter of the tungsten electrode.

The stick--out of the tungsten electrode from the electrode holder.

1.6 mm

5mm

30˚

in relation to the tube.

Distance: Electrode--wire

Distance: Elec-trode--workpiece

The distance between the tungsten electrode and the filler wire.

The distance between the tungsten electrode and the workpiece (the tube).

5mm

Wire type Type of filler wire used. OK 12.51 Wire dimension Dimension of the filler wire used. 0.8 mm Electrode type Quality of tungsten electrode (thori-

2% Th, 2% La

um, lanthan).

Weld gas Weld gas components (argon, heli-

100 % Ar

um, hydrogen, nitrogen).

Root gas Root gas components (argon, heli-

100 % Ar

um, hydrogen, nitrogen).

Start gas Start gas components (argon, heli-

100 % He

um, hydrogen, nitrogen).

dpa8d1ec

-- 8 4 --

Material = 2333

Pressthesof

ete

S Enter the value 2333 using the numerical keys. S

key material.

NOTEBOOK Page 1(8)

MATERIAL TUBE DIAMETER. WALL THICKNESS RUN NUMBER

2333

(NEXT) PAGE

MATER.

TUBE DIAM.

External tube diameter = 60 mm

S Enter the value 60 using the numerical keys. S

key tube diam-

NOTEBOOK Page 1(8)

MATERIAL 2333 TUBE DIAMETER. WALL THICKNESS RUN NUMBER

(NEXT) PAGE

MATER.

TUBE DIAM.

TUBE THICKN

RUN NO

dpa8d1ec

-- 8 5 --

Wall thickness = 3 mm

Pressthesof

nes

Pressthesof

numbe

S Enter the value 3 using the numerical keys. S

key wall thick-

NOTEBOOK Page 1(8)

MATERIAL 2333 TUBE DIAMETER. 60. mm WALL THICKNESS RUN NUMBER

(NEXT) PAGE

MATER.

TUBE DIAM.

Run number = No 2

S Enter the value 2 using the numerical keys. S

key run

S Press the soft

key next page.

NOTEBOOK Page 1(8)

MATERIAL 2333 TUBE DIAMETER 60.0 mm WALL THICKNESS 3.00 mm RUN NUMBER

(NEXT) PAGE

MATER.

TUBE DIAM.

WALL THICKN

TUBE THICKN

RUN NO

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-- 8 6 --

Start point = 3 o’clock

Pressthesof

S Enter the value 3 using the numerical keys. S

key start point.

NOTEBOOK Page 2(8)

START POINT WELD TIME

(NEXT) PAGE

START POINT

HOUR

Welding time = 1 h 20 min 30 s

S Enter the value 1 using the numerical keys. S Press the soft key hour. S Enter the value 20 using the numerical keys. S Press the soft key minute. S Enter the value 30 using the numerical keys. S Press the soft key second.

key next page.

NOTEBOOK Page 2(8)

START POINT 3 o’clock WELD TIME 1 h

(NEXT) PAGE

START POINT

HOUR

20 min 30 s

MIN

SECOND

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-- 8 7 --

Electrode diameter = 1.6

Pressthesof

S Enter the value 1.6 using the numerical keys. S

key diameter.

NOTEBOOK Page 3(8)

ELECTRODE DIAMETER ELECTRODE STICKOUT ELECTRODE ANGLE

1.6

(NEXT) PAGE

DIAM.

STICK- -

OUT

Electrode stick--out = 5 mm

S Enter the value 5 using the numerical keys. S

key stick--out.

NOTEBOOK Page 3(8)

ELECTRODE DIAMETER 1.6 mm ELECTRODE STICKOUT ELECTRODE ANGLE

(NEXT) PAGE

DIAM.

STICK--

OUT

ANGLE

dpa8d1ec

-- 8 8 --

Electrode angle = 30˚

Pressthesof

wir

S Enter the value 30 using the numerical keys. S

key angle.

S Press the soft

key next page.

NOTEBOOK Page 3(8)

ELECTRODE DIAMETER 1.6 mm ELECTRODE STICKOUT 5.0 mm ELECTRODE ANGLE

(NEXT) PAGE

DIAM.

STICK- -

OUT

Distance: Electrode--Wire = 5 mm

S Enter the value 5 using the numerical keys. S

key electrode--

NOTEBOOK Page 4(8)

DISTANCE: ELECTRODE -- WIRE ELECT. -- WORKPIECE

(NEXT) PAGE

ELECT.

-WIRE

ELECT.

WORKP.

ANGLE

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-- 8 9 --

Distance: Electrode--workpiece = 5 mm

Pressthesof

workpiece

Pressthesof

S Enter the value 5 using the numerical keys. S

key electrode--

NOTEBOOK Page 4(8)

S Press the soft

key next page.

DISTANCE: ELECTRODE -- WIRE 5.0 mm ELECT. -- WORKPIECE

(NEXT) PAGE

ELECT.

-WIRE

ELECT.

WORKP.

Wire quality = OK 12.51

S Enter the value 12.51 using the numerical keys. S

key wire type.

NOTEBOOK Page 5(8)

WIRE TYPE WIRE DIAMETER ELECTRODE TYPE

(NEXT) PAGE

WIRE TYPE

WIRE.

DIAM.

12.51

ELECT. %Th

ELECT. %La

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Wire dimension = 0.8 mm

Pressthesof

ete

Pressthesof

S Enter the value 0.8 using the numerical keys. S

key wire diam-

NOTEBOOK Page 5(8)

WIRE TYPE 12.51 WIRE DIAMETER ELECTRODE TYPE

0.8

(NEXT) PAGE

WIRE TYPE

WIRE.

DIAM.

Electrode quality = 2% Th, 2 % La

S Enter the value 2 using the numerical keys. S Press the soft key electrode % Th. S Enter the value 2 using the numerical keys. S Press the soft key electrode % La.

key next page.

NOTEBOOK Page 5(8)

WIRE TYPE 12.51 WIRE DIAMETER 0.8 mm ELECTRODE TYPE

(NEXT) PAGE

WIRE TYP

WIRE.

DIAM.

ELECT. %Th

ELECT. %La

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Weld gas = 100 % Ar

Pressthesof

S Enter the value 100 using the numerical keys. S

key % Argon.

S Press the soft

key next page.

NOTEBOOK Page 6(8)

WELD GAS

100

(NEXT) PAGE

%Ar

%He

Root gas = 100 % Ar

S Enter the value 100 using the numerical keys. S

key % Argon.

S Press the soft

key next page.

NOTEBOOK Page 7(8)

ROOT GAS

(NEXT) PAGE

%Ar

%He

%H %N

100

%H %N

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Start gas = 100 % He

Pressthesof

S Enter the value 100 using the numerical keys. S

key % Helium.

NOTEBOOK Page 8(8)

START GAS

100

(NEXT) PAGE

%Ar

%He

%H %N

S Press the keys SHIFT and STEP to return to the working

area.

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15 MANUAL WELDING

15.1 Field of ap p licatio n

Used for normal manual TIG welding with a hand torch (see the respective instruction manual).

15.2 How to create a welding program

To enable hand--welding it is necessary to create a welding program, consisting of two sectors with the welding current and gas parameters indicated. Note! Rotation must not be indicated.

15.3 Example 3a:

Start by entering the correct tool code TIG HAND TORCH.

This is a simple welding program, consisting of 2 sectors, sector 2 being a stop sector.

Sector 1 Sector 2

Breakpoint 0.000 1.000 Welding current (continuous) (A) 80 0 Welding current (background cur-

rent) (A) Welding current (pulse time) (s) 0.5 0.5 Welding current (background time)

(s) Slope up (s) 2 -Slope down (s) -- 5 Gas preflow (weld gas) (s) 5 -Gas postflow (weld gas) (s) -- 10

40 40

0.5 0.5

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Sector 1

Pressthesof

ouspeak

Pressthesof

ousback

Breakpoint

Sector 1 automatically is assigned the breakpoint 0.000, if nothing else is indicated. Start by indicating the welding current parameter.

Welding current Peak current = 80 A

S Press the key for WELDING CURRENT

The picture for setting the welding current comes up in the display.

S Enter the value 80 using the numerical keys. S

key continu-

current.

SECTOR 1(1) 0.000

PEAK CURRENT A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEQAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 80 A in Sector 1. Background current = 40 A

S Enter the value 40 using the numerical keys. S

key continu-

ground current.

SECTOR 1(1) 0.000

PEAK CURRENT 80 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

SPEC. PULS

CONT/ PEAK CURR.

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BACKGR

CURR.

-- 9 5 --

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: BACKGROUND CURRENT = 40 A in sector 1.

Pressthesof

groundtim

Pulse time = 0.5 s instead of 1.0

S Enter the value 0.5 using the numerical keys. S

key peak time.

SECTOR 1(1) 0.000

1 PEAK CURRENT 80 A

BACKGR. CURRENT 40 A PEAK TIME 1.00 s BACKGR. TIME 1.00 s

0.5

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: PULSE TIME = 0.50 s instead of 1.00 s in sector 1.

Background time = 0.5 s instead of 1.0

S Enter the value 0.5 using the numerical keys. S

key back-

SECTOR 1(1) 0.000

1 PEAK CURRENT 80 A

BACKGR. CURRENT 40 A PEAK TIME 0. 50 s BACKGR. TIME 1.00 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

0.5

BACKGR

TIME

SPEC. PULS

Result: BACKGROUND TIME = 0.50 s instead of 1.00 s in sector 1.

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Slope

Enterth

eva

lue

numericalkeys

Pressthesof

Slope up = 2sfor peak current.

S Press the soft key continuous peak current. S

2 using the

SECTOR 1(1) 0.000

S Press the

SLOPE key.

2 PEAK CURRENT 80 A

BACKGR. CURRENT 40 A PEAK TIME 0.50 s BACKGR. TIME 0.50 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: PEAK CURRENT = 80 A, 2.0 s in sector 1, and BACKGROUND CURRENT = 40 A,

2.0 s in sector 1.

Gas Gas preflow, weld gas = 5s.

S Press the gas key

S Enter the value 5 using the numerical keys.

The gas preflow is preset to 2 seconds, which applies if nothing else is entered and indicated in the display at the start.

key weld gas.

SECTOR 1(1) 0.000

WELD GAS s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START GAS

Result: WELD GAS = 5 s in sector 1.

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Sector 2

Pressth

Pressthesof

ouspeak

Breakpoint

S Enter the value of the new breakpoint 1.010 using the numerical keys. S

SECTOR key.

SECTOR 1(1) 0.000 1.010

1 WELD GAS 5 s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START GAS

Result: Sector 2 out of 2 sectors in all.

Welding current

Pulse current = 0A

As sector 2 is to be a stop sector, the welding current must be set to 0 amperes.

S Press the key for WELDING CURRENT

S Enter the value 0 using the numerical keys. S

key continu-

current.

SECTOR 2(2) 1.000

1 PEAK CURRENT 80 A

BACKGR CURRENT 40 A PEAK TIME 0.50 s BACKGR. TIME 0.50 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

2,0 S

2.0 S

SPEC. PULS

Result: PEAK CURRENT = 0 A in sector 2 (stop sector)

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Slope

Enterth

eva

lue

numericalkeys

Pressthesof

Slope down = 5sfor peak current.

S Press the soft key continuous peak current. S

5 using the

SECTOR 2(2) 1.000

S Press the

SLOPE key.

2 PEAK CURRENT 0 A

BACKGR CURRENT 40 A PEAK TIME 0.50 s BACKGR. TIME 0.50 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

SPEC. PULS

Result: PEAK CURRENT = 0 A, 5.0 s in sector 12, and BACKGROUND CURRENT = 40 A,

5.0 s in sector 1.

Gas Gas postflow, weld gas = 10 s in sector 2.

S Press the GAS key

S Enter the value 10 using the numerical keys.

The gas postflow is preset to 4 seconds, which applies if nothing else is entered and indicated in the display at the start.

key weld gas.

SECTOR 2(2) 1.000

1WELDGAS s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START GAS

Result: WELD GAS = 10 s in sector 2.

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15.4 How to weld

Starting a welding sequence (arc strike)

S Press the torch contact and then release it again.

The parameter values for sector 1 (the start sector) apply throughout the welding sequence.

Stopping a welding sequence

S Press the torch contact and then release it again.

The parameter values for sector 2 (the end sector) are used.

16 APPENDIX

16.1 Tool codes

Welding tool Size

PRB, PRC 8--17*

17--49*

33--90

60--170

PRH 6--40

25--90

40--115

PRD Indicate the number of cogs on the

gear ring, for ex. 1120.

POC 12--60

Manual TIG torch --

A25 automatic welding machine With rotation

Without rotation

When the conversion kit PRB , PRC 8--17 is used, the tool code 17--49 applies. When a drive unit with the gear ratio 134:1 is used, the tool code 8--17 applies.

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ESAB LTP 450 Programming manual

Specifications and Main Features

Frequently Asked Questions

User Manual