INSTRUCTIONS FOR
TEACHING MODE OPERATION
FOR DIGIPULSE WIRE FEEDER
F-15-013-A
November, 1996
F-15-013-A
These instructions are for experienced operators. If you are not fully familiar with the principles of operation and safe practices
for electric welding equipment, we urge you to read our booklet “Precautions and Safe Practices for Arc Welding, Cutting and
Gouging, “Form 52-529”. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to
install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand
these instructions, contact your supplier for further information. Be sure to read all Safety Precautions in wire feeder manual
before installing or operating this equipment.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
I. INTRODUCTION
The Digipulse with optional teach control is the most enhanced version of the Digipulse family. It features a “teach”
mode that allows an operator to develop and store his
own pulse welding conditions in addition to the standard
preprogrammed conditions (codes 1- 6) already available
in the standard control. The Synergic program logic offers the Digipulse system fixed operating parameters that
follow preprogrammed relationships. The Adaptive logic
utilizes a closed loop feedback system that continuously
modifies the output to maintain a constant arc voltage.
II. PROGRAMMING YOUR OWN PULSE PA-
RAMETERS
The “teach” mode program is incorporated in Material
Codes #11 through #15. Each of these codes is designed
to allow the operator to develop and store one set of customized Pulsed mig parameters* for wire types which have
not been preprogrammed in this control (for example; titanium, inconel, monel, etc.). In some instances the
preprogrammed carbon steel or stainless steel parameters may be inadequate, and the “teach” mode can then
be used to further refine those particular arc characteristics.
*You may wish to permanently incorporate your “self developed” conditions in codes 7 thru 10 which are reserved
for custom applications. If so, you can special-order a
custom E-PROM, from ESAB, that will include your teach
conditions along with the other preprogrammed applications. In order to do this, you
will have to provide the necessary welding condition development parameters outlined in Section IV of this supplement.
adjustment to the pulse frequency to maintain
stable metal transfer. Since the operator selects pulse
parameters at a given point, the control will not assume
values at other wire feed speeds. Also note that the
Trigger Lock/Crater Fill feature is not programmable
P
W
Pulse
Width
P
F
Pulse
Frequency
Peak Current
P
H
Spray Transition
Current
Average Current
Background
P
B
Current
Zero Current
Fig. 1 - Pulse Wave Description
Should be high
P
H
enough to detach the
droplet.
Works with the pulse
P
W
peak current to allow
time for the droplet to
form.
Should be set high
P
B
enough to maintain
the arc between
pulses.
Used to establish
P
F
the necessary arc
length for good arc
stability.
to the teach mode (codes 11 - 15).
For the inexperienced operator, use the following
graphs to assist in pulse parameter set-up. These
graphs will provide you with pulse parameters used in
the preprogrammed codes (1-6). To obtain specific arc
characteristics these parameters can be set-up and
changed in the teach mode. The following procedure
The following instructions assume that the operator is familiar with “pulse-mig” welding and the effects of pulse
variables with respect to arc performance.
Pulse height, width, background and frequency can be
programmed for any wire feed speed set in the IPM window. The metal transfer and arc characteristics are defined by pulse height (PH), width (PW), and background
current (PB). These parameters, shown in Figure 1, must
be developed for each wire type, diameter, shielding gas,
and stickout. To maintain the proper arc characteristics
once an appropriate pulse height, width and background
have been established, the pulse frequency should be
the only parameter requiring readjustment with changes
in wire feed speed to maintain a stable arc condition. The
“teach” mode operates in the synergic logic “only”
(not adaptive), and only one wire feed speed setting can
be programmed in each material code (11 thru 15).
Changes in wire feed speed will require a manual
2
4
5
3
6
2
1
Fig. 2
will achieve a reasonable starting point for pulse welding.
pulse parameter switch (Item 1, Fig. 2) in its “down”
position and for following.
A. Make sure the Synergic/Adaptive logic switch (Item
2, Fig. 2) is set in SYN position.
B. Set the Process selector switch (Item 6, Fig. 2) to its
PULSE position.
C. Select a programmable Material code from 11 thru
15 by “holding down” the Material selector key (Item
3, Fig. 2) and holding the Inc/Dec key (Item 4, Fig. 2)
under the IPM window in the up position. Release
both keys once a Material code is selected.
NOTE: You may notice that a Wire Dia. code number
will appear in the VOLTS window when the Wire
Dia/Material key is depressed. This code # must
match the wire installed when you’re using
“preprogrammed” data in codes 1 thru 6, however, this is not required in the teach mode codes
11 thru 15. Please remember that all other parameters that are programmed will be retained
in memory (for teach codes 11-15) except for
the wire size—therefore, it is suggested that you
document the wire size dia. used and all other
parameters relating to a particular teach code
for future reference.
D. Set a wire feed speed in the IPM window by using the
Inc/Dec key (Item 4) below the window.
E. Using the pulse parameter graph(s)), shown on the
following pages, approximate the pulse height, width
(for step F), and pulse background and frequency (for
step G) settings for the material type and diameter
you plan to use. Select the appropriate pulse parameter graph which corresponds to the material type
being used. For wire types other than those shown,
choose the graph that comes closest to your wire type.
For example, for coppers use the silicon bronze graph
parameters as a starting point.
F. Program the Pulse Height (PH) and Pulse Width (PW)
parameters, from the material graph legend for the
diameter wire installed, by “holding” the pulse parameter switch (Item 1, Fig. 2) to its “up” position and the
following:
1. Set the selected Pulse Height (PH) parameter in
the IPM window using its Inc/Dec switch (Item 4).
The number in this window represents pulse height
from .1 to 10 volts (in 1/10 volt increments).
2. Now, set the selected Pulse Width (PW) parameter in the VOLTS window using its Inc/Dec switch
(Item 5). The number in this window represents
pulse width from 1 to 10 milliseconds (in 1/10 millisecond increments)
G. Program the Pulse Background (PB) and Pulse Fre-
quency (PF) parameters, from the material graph legend for the diameter wire installed, by “ holding” the
1. Set the selected Pulse Background (PB) parameter in the IPM window using its Inc/Dec switch
(Item 4). The number in this window represents
pulse background current from 15 to 100 amperes
(in 1 amp increments).
2. Now, set the selected Pulse Frequency (PF) parameter in the VOLTS window using its Inc/Dec
switch (Item 5). The number in this window represents the approximated pulse frequency derived
from the graph for wire feed speed selected (step
D) and is displayed in Hertz from 25 to 909 pulse
cycles/second.
H. Assuming that any other desired parameters (e.g.,
preflow, inch, spot, postflow, burnback, etc.) have
been programmed, as described previously in F-15012, you can energize the torch switch and begin
welding. The torch switch must be held closed
throughout the teach mode operation.
I. Once an acceptable arc condition has been obtained
by further modifying pulse height, pulse width, and
pulse background, changes in wire feed speed will
necessitate a manual adjustment to the pulse frequency to maintain a stable metal transfer.
Operating Note: The 5 programmable codes (11 thru
15) provide the operator with an opportunity to develop
a complete welding procedure by having different welding parameters preprogrammed into separate schedules.
Once programmed, the operator only needs to change
to the appropriate program number for the weld
parameters required. For example, when welding pipe,
root pass, fill pass and capping pass pulse parameters
can be programmed into separate schedules and accessed when needed (see II-C). Each set of parameters
can have a different pulse height, width, background,
frequency, and wire feed speed.
III. USEFUL DATA FOR SYNERGIC-ADAPTIVE
OPERATION
The operating characteristics of synergic vs adaptive
logic in the welding operation is covered in booklet F15-012 and following. The selectability of either of these
features is made from the front panel (see Item 2, Fig.
2) in the feeder. Please note that either type of logic can
be used in the “preprogrammed” material codes 1 thru
10; however, only the synergic position can be used in
the “teach” mode material codes 11 thru 15.
1. Synergic Operation
a. Pulse Arc Welding:
Synergic welding is a relationship of pulse frequency and wire feed speed (see graph) programmed into the weld control. As the wire feed
3
Pulse Frequency
Carbon Steel Pulse Parameters
Wire Feed Speed (ipm)
Pulse Frequency
Carbon Steel Pulse Parameters
Wire Feed Speed (ipm)
4
Pulse FrequencyPulse Frequency
5356 Aluminum Pulse Parameters
Wire Feed Speed (ipm)
Stainless Steel Pulse Parameters
Wire Feed Speed (ipm)
5
Pulse Frequency
5356 Aluminum Pulse Parameters
Wire Feed Speed (ipm)
speed increases the control will automatically increase the pulse frequency to maintain stable weld
performance. Changes in welding current (heat)
can be completed by increasing or decreasing the
IPM switch without readjusting voltage. Changes
in tip to work will affect arc length. The synergic
relationship is only available if a program is resident in the control.
b. Spray Arc and Short Arc:
In this mode the machine will operate like a conventional welder where an arc voltage is set-up by
the weld control program and changes in tip to work
will effect arc length. The voltage can be read dur-
ing welding and increased accordingly to obtain
a stable welding condition based on the wire feed
speed used. If the wire feed speed is changed,
the program will calculate the new voltage necessary to maintain a stable arc.
2. Adaptive Operation
a. Pulse Arc Welding:
Adaptive welding is a synergic relationship programmed into the weld control which will calculate
and display the proper arc voltage for a given wire
feed speed and material setting (see graph). As
the wire feed speed increases the control will automatically increase the pulse frequency to maintain the arc voltage set in the control VOLTS window. Changes in tip to work will not affect arc
length. The Adaptive function is only available if a
program is resident in the control.
b. Spray Arc and Short Are:
In this mode the machine will control the power
supply to maintain the arc voltage set-up in the volts
window of the control. Changes in tip to work will
not change arc length. The voltage can be preset
before welding and changed during welding to obtain a stable welding condition based on the wire
feed speed used. If the wire feed speed is changed
then the program will calculate the new voltage
necessary to maintain a stable arc.
Arc Length Will Change
With Tip To Work Distance
Frequency Does Not Change
With Tip To Work Distance
6
Or
Arc Volts
(Spray/Short)
Pulse Frequency
Arc Length Will Not Change
With Tip To Work Distance
Frequency Changes
With Tip To Work Distance
Or
Arc Volts
(Spray/Short)
Pulse Frequency
IV. CUSTOM PROGRAM DEVELOPMENT PROCEDURES
ESAB can supply custom Synergic and Adaptive programs to be placed in Material Codes 7 thru 10 if the proper data
is supplied (see below). Once acceptable arc stability and weld performance has been established using the pulse
parameter keys on the “teach” control, record the pulse height,, width and background settings you have programmed.
Then take 5 samples at different wire feed speeds and record the data in the chart below at each wire feed speed
tested. You will have to increase the pulse frequency as the wire feed speed increases in order to establish a GOOD
welding condition which will also change the arc voltage. From this information we can program the synergic and
adaptive relationships for your custom program. Contact your ESAB Sales Representative for further details and
pricing information on this custom service.
DO NOT Change Once Established
Wire Average Average Pulse Pulse Pulse Pulse Additional Information
Feed Current Arc Frequency Height Width Bkgrd.
(ipm) (Amps) Volts (Hz.) (Ref. Volts) (m sec) (Amps) Wire Type Base Metal Type
1 Wire Diameter Weld Joint type
2 Shielding Gas Mig Gun Type
3 Tip to Work Weld Position
4 Travel Speed
5
V. NOTES
The remaining space in this supplement can be used to provide a written record (similar to the chart shown in Section
IV) of the various programs you have developed.
7
F-15-013-A 11/96 5C Printed in U.S.A.
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