INSTRUCTION MANUAL COMMANDER BDH MIG

Transcription

1 INSTRUCTION MANUAL COMMANDER BDH MIG Valid from A Version 1.0

2 CONTENTS INTRODUCTION PRIMARY OPERATIONAL FUNCTIONS Reading and setting Programmes Trigger function Sequences Welding voltage indicator Overheat indicator Remote interface SECONDARY OPERATIONAL FUNCTIONS Setting of secondary welding parameters Automated welding parameters Secondary parameters General function selection MMA Loading of MMA welding programmes Welding with an MMA programme MANUAL MIG/MAG WELDING Loading MIG/MAG welding programmes Welding with a MIG/MAG or MIG pulse programme SYNERGIC MIG/MAG WELDING Synergic welding Loading synergic curves Correcting synergic curves Appendix A. Programmes loaded by the factory...a-1 Appendix B. Error codes...b-1 Appendix C. Connection and disconnection of robot-interface...c-1

3 INTRODUCTION Control panel The control panel on the BDH MIG welding machine has the following appearance when the machine is switched off: Primary and secondary operational functions The functions of the control panel are divided into two halves. The right half can be concealed behind a flap which covers the advanced operational functions, which are unnecessary during normal operations. These advanced functions are known as the secondary functions. The remaining functions on the left half of the control panel are known as the primary functions. COMMANDER How to use this manual Chapters 1 and 2 are intended for new users of the machine. The primary operational functions on the left half of the panel are described in chapter 1, and the secondary operational functions on the right half of the panel are described in chapter 2. Chapters 3, 4 and 5 deal with MMA and MIG/MAG welding respectively. These three chapters explain all operating functions for each of these welding methods. Appendix A deals with welding settings (programmes) that have been loaded by the factory, and Appendix B explains the various error codes which the machine is capable of issuing during operations. Appendix C describes how the robotic control can be connected and disconnected. Introduction Page 0-1

4 1. PRIMARY OPERATIONAL FUNCTIONS This chapter will describe the primary operational functions on the left-hand side of the control panel. Reading and setting Displays and control keys The first thing that is obvious on inspection of the control panel is that there are no knobs or display instruments such as those found on conventional welding machines. Conventional display instruments have been replaced by two displays, and conventional knobs by control keys positioned above and below these displays. Each display shows three digits. Above and below each display there are two rows of arrow keys, with three keys in each row corresponding to each digit. Each digit can be increased by using the arrow key above, and decreased by using the arrow key below. The digit on the left is affected if counting goes past zero. If counting goes past zero on the way down, one is subtracted, and if counting goes past zero on the way up, one is added. It is not necessary to activate the same key more than once. Keys can simply be held in while the machine counts up or down. Release keys when the required value has been reached. 1. Primary operational functions Page 1-1

5 There are two indicators immediately to the right of each display. The symbol is illuminated when the left-hand display shows current level. The welding. symbol is illuminated when the left-hand display shows wire speed during MIG/MAG The symbol is illuminated when the right-hand display shows voltage. The symbol is illuminated when the right-hand display shows the trim value during synergic MIG/MAG welding. Primary parameters Switching on the machine Current, wire speed, voltage and trim value are the four primary parameters. The secondary parameters will be dealt with in the next chapter. When the machine is switched on, an automatic test is carried out, during which time information is shown in the displays. When the or symbol is illuminated in the left-hand display, the machine is ready for use. If the machine registers an error while starting, an error code will be shown in the two displays. Appendix B explains all these error codes, as well as the corresponding measures that should be taken by the operator. Programmes What is a programme? Selecting a programme When the machine is switched on, it will start at the setting which applied last time it was switched off. This setting is memorised in a particular location in the machine's computer, and this location is known as a programme. It is important that operators are aware of the meaning of the word "programme" in this context if they are to operate the machine in optimum fashion. A programme consists of a complete setting of the entire control panel, including not only the general setting (e.g. whether MMA or MIG/MAG welding has been selected) but also each small detail in each setting. There are ten different programmes in the machine in all. In other words, there are ten different settings stored in the machine. These programmes are numbered from 0 to 9. Each programme can be selected from among these ten settings by activating the key marked "PROG" on the control panel. The number in the display immediately to the right of the PROG key shows the programme number that has been selected. 1. Primary operational functions Page 1-2

6 Press the PROG key ten times to see all the programmes, and notice how the setting on the front panel changes from programme to programme. Ten fixed programmes have been loaded by the factory, one for each programme number. The programmes loaded by the factory are always stored in the machine, but they can be replaced by the user's own programmes. The programme number display shows whether a programme set by the factory has been changed. A full-stop after the number in the programme number display indicates that the factory programme has been changed. Programme number 5 is shown here by way of example. Loading your own programmes Recall of factory programmes As mentioned above, factory programmes can be replaced by the user's own settings in order to meet requirements for specific welding tasks. Programmes can be changed by first selecting the number of the programme which is to be altered, and then entering the setting required. No special measures need to be taken in order to save the new setting. The new setting will be remembered by the machine, not only when programme changes are made but also when the machine is switched off. This means that each time the programme number in question is selected, the user's own setting will appear. In other words, an alteration of the programme that has been selected is carried out each time a setting is changed. The way in which programmes can be loaded for various welding methods will be explained in chapters 3, 4 and 5 below. Factory programmes can always be recalled, and this can be achieved as follows: First select the programme number in question by using the PROG key. Then press two keys simultaneously. One of these keys is situated beneath the flap, and is marked "RECALL". The other is the PROG key. Afterwards press the AUTO key. It is also possible to select another setting of the chosen programme by means of the process library. This is further described in Appendix A. 1. Primary operational functions Page 1-3

7 Trigger function TRIG-key The trigger function is used to select the way in which the welding torch switch is to function. Use the TRIG key to select the function required. The method chosen is shown by three indicators to the right of the TRIG key. When the indicator next to the top symbol is illuminated, welding can be started by activating the torch switch. Welding will continue until the switch is released again. We shall refer to this method as "two-stroke welding". If the middle indicator is illuminated, welding can be stopped or started by a quick press (activate the switch and release immediately). The torch switch must not be held in during welding. This method is known as "four-stroke welding". Finally, if the indicator next to the bottom symbol is illuminated, welding can be started by a quick press (as in four-stroke welding), and will continue for a pre-set period of time. The setting of this period of time will be explained in a later section. This method is known as "spot welding". Sequences In many welding tasks it is necessary to shift between two or more settings in order to cope with various thicknesses of material, penetration depth, etc. These shifts can be achieved extremely quickly and easily both during and after welding by using the sequence shift function on the BDH welding machine. What are sequences? SEQ key Sequences can be used for MIG/MAG and MIG pulse welding. A sequence contains the settings of the parameters that influence the welding process. For MIG/MAG welding these parameters are wire speed, voltage and Arc Adjust. For MIG pulse welding, the parameters are wire speed, voltage, Arc Adjust and the pulse parameters (pulse time, pulse frequency, and base amp). Arc Adjust and pulse parameters are secondary parameters, and will be explained in chapter 2 below. The way in which parameters can be loaded in a sequence will be explained in the descriptions of MIG/MAG welding in chapters 4. A maximum of four different sequences can be loaded, and each sequence can be selected by using the SEQ key. The number of sequences can be selected by entering the value 0 in the left display after the most recently selected sequence; i.e. if 2 sequences are requested, a 0 is entered after the third sequence. When a sequence has been selected, an indicator is illuminated next to the sequence number to the right of the SEQ key. If none of the sequence number indicators is illuminated, the sequence shift function is nonoperational. When there is no welding carried out, it is possible to change between the chosen sequences by quickly pressing the knob on the torch. 1. Primary operational functions Page 1-4

8 Welding with sequences When welding with sequence shift, one of the sequences that have been loaded (normally number 1) must have been selected before commencing welding. During welding, a shift to the next sequence can be achieved by quickly activating (less than 0.3 seconds) or releasing the torch switch, depending on the trigger function in question. A shift from the previous sequence to sequence number 1 will then be made. During welding, the current shown in the left-hand display can be adjusted by torch regulation around the nominal value, if there is a regulation knob on the welding torch. The new value will not be remembered until the next time the sequence in question is selected. As mentioned above, shifting sequence using the torch switch depends on the trigger function that has been selected by the TRIG key. If two-stroke welding ( ) has been selected, the torch switch should be released and then activated again quickly (within the space of 0.3 seconds). If four-stroke welding ( ) or spot welding ( ) has been selected, the switch should be activated briefly and then released again. Finally, it should be mentioned that it is also possible to shift sequence during welding by activating the SEQ key. Welding voltage indicator Welding Voltage The welding voltage indicator is illuminated for reasons of safety if there is any voltage on the electrode or the torch. Overheat Indicator Overheat The overheat indicator is illuminated if welding is interrupted as a result of overheating of the machine. Remote Interface Remote Interface A multiple plug for the connection of remote interface interface. In addition, please see description of AMP key in the next chapter. 1. Primary operational functions Page 1-5

9 2. SECONDARY OPERATIONAL FUNCTIONS In this chapter we shall deal with the operational functions that are normally concealed behind the right-hand flap. These functions are not used in normal, routine welding tasks, but only in specific individual tasks or when loading new programmes. The secondary functions can be divided into three main groups as follows: 1. Setting of secondary welding parameters. 2. General function selection. 3. Loading synergic curves. The first two main groups will be described here, whereas synergic welding will be described in chapter Secondary operational functions Page 2-1

10 Setting Secondary Parameters In addition to the primary parameters described in the previous chapter, there are a number of secondary parameters which also influence the welding process. This chapter does not contain a description of the functions of each of these parameters. However, it does describe the way in which the values of these parameters can be read and set. Parameter column The secondary parameters are stated in the parameter column. Reading and setting The value of secondary parameters is shown in the righthand display, and can be set by using the appropriate arrow keys. When a secondary parameter is displayed in the righthand display, the arrow between the display and the parameter column will be illuminated, and both symbols for the two primary parameters will be extinguished. Parameter selection keys The parameter which is to be displayed or set is selected by using the two arrow keys above and below the parameter column. When the secondary parameters are inspected by the parameter selection keys, the machine omits some parameters. This is due to the fact that not all parameters are used by all three welding methods. The parameters used in each welding method will be described in the three following chapters. 2. Secondary operational functions Page 2-2

11 Automated welding parameters Instead of setting secondary parameters yourself, it is possible to allow the machine to set a suitable value for certain parameters. AUTO Parameters can be automated by activating the AUTO key once the parameter in question has been selected. "AUt" will now be shown in the right-hand display whenever the parameter in question is selected. If the AUTO key is activated again, the parameter will be de-automated. RECALL and AUTO If you wish to see which value the machine has calculated for the automated parameter. the RE- CALL and AUTO keys should be held down simultaneously, and the value will then be shown in the right-hand display. Carry out your own experiments to see which parameters can be automated, and which value the machine calculates in each case. The secondary welding parameters that can be automated are explained in greater detail in the description of each individual welding method contained in chapters 3 to Secondary operational functions Page 2-3

12 Secondary Parameters A brief list of all secondary parameters is given below. Each parameter will be described in greater detail in the three following chapters. Volt/Trim Arc power Hot start Spot time Pre-flow Arc adjust Pulse time Pulse freq. Base Amp Slope down Burn Back Post flow Volt/Trim indicates that the right-hand display shows one of the primary parameters (welding voltage or trim value). When the indicator is illuminated, the arrow ( ) will be extinguished, and one of the indicators in the right-hand display will be illuminated. When the flap is closed, it will always be this "parameter" that has been chosen. Arc power (MMA). Hot start (MMA). Spot time (MIG/MAG). Pre-flow (MIG/MAG). Arc adjust (MIG/MAG). Selection of pulse welding and setting of pulse time (MMA and MIG/MAG). Pulse frequency (MMA and MIG/MAG). Base amp (MMA and MIG/MAG). Slope down (MIG/MAG-synergy). Burn back (MIG/MAG). Post flow (MIG/MAG). General Function Selection MMA MIG/MAG Selection of welding method Normally, the welding method will be chosen by selecting a programme, as described in the previous section. However, when loading a new programme, the welding method required can be selected by this key. Anti freeze Anti-freeze of electrodes During MMA welding the electrode sometimes freezes onto the workpiece. If the anti-freeze function has been activated, the machine will register that the electrode has frozen onto the workpiece, and will then reduce welding current to 5 A so the area of the workpiece which has melted will harden, making it possible to break off the electrode. Welding can then continue in normal fashion. 2. Secondary operational functions Page 2-4

13 WIRE Wire feed unit If the machine has an internal as well as an external wire feed box, you can use this key to choose between internal and external wire feed. COOL Cooling of welding torch If the machine has a water module installed, it is possible for MIG/MAG welding to allow the torch to be water-cooled. When the Air indicator is illuminated, water cooling is non-operational. AMP Setting function The AMP key makes it possible to select the point at which the control parameter for the welding process should be set. The controlling parameters are current level for MMA, wire speed for manual MIG/MAG and for synergic MIG/MAG current densities. These parameters are always shown in the left-hand display, which means that it is also possible to regard the function of the AMP key as a way of choosing the points from which values shown in the left-hand display are set. The three options are as follows: Int. Internal: Arrow keys around left-hand display used for setting. Ext. External: Setting carried out by remote control connected to the plug marked "Remote Interface". 2. Secondary operational functions Page 2-5

14 Torch Torch adjustment: Setting carried out by using the adjustment knob on the welding torch, if there is such a knob. With regard to torch adjustment, it should be added that the control keys on the left-hand display are used to set the mean value with a view to allowing torch adjustment of +/- 50%. For example, if the control keys are used to set wire speed at 12 m/s by manual MIG/MAG welding, the torch setting can be altered by +/- 6 m/s, or between 6 m/s and 18 m/s. If the midpoint of the interval is set so high that it will be possible for torch regulation to exceed 24 m/s, the lower limit is extended to ensure that the area of regulation is still as wide as the value of the mid-point. This also means that if you wish to regulate within the entire setting area, the mid-point of the wire speed should be set at 24 m/s. 2. Secondary operational functions Page 2-6

15 3. MMA As explained in chapter 1 above, the principle involved in operating the BDH welding machine is that no single welding method is chosen, but rather a particular programme which is set for the method required. Consequently, the descriptions of the welding methods contained in this chapter and following chapters are divided into two main sections. The first section contains an explanation of the way a programme can be set for the method in question, and the second section describes how to weld using the programme set for the method in question. Loading MMA Welding Programmes Select programme number Welding methode The programme in which the new MMA programme is to be loaded should be selected using the PROG key. The control box must be reset for MMA welding by using the welding method key. When MMA welding has been selected, the control panel will have the following setting: The current, which is shown in the left-hand display, is minimum value MMA welding. The righthand display shows no-load voltage (80 V). The secondary parameters have not altered their values. Anti-freeze is non-operational, and current is set internally (AMP=Int). 3. MMA Page 3-1

16 General Function Selection Anti freeze The only general function selection that is necessary is to choose whether the anti-freeze function should be operational or non-operational. Method of regulation Use the AMP key to select where the current strength shown in the left-hand display should be set from. Internal or external setting can be selected. Once MMA welding has been selected, the left-hand display switches to show the welding current that has been set, and the right-hand display shows no-load voltage, which is 80 V. Welding current can be set by using the arrow keys around the left-hand display. No-load voltage cannot be set. Primary parameters Secondary parameters The following secondary parameters can be selected from the list in the parameter column by using the parameter selection keys for MMA welding: Arc power, Hot start, Pulse time, Pulse freq., and Base Amp. A description of the function of these secondary welding parameters is given below. 3. MMA Page 3-2

17 Arc power The arc power function is used to stabilise the arc.. This can be achieved by momentarily increasing welding current by a percentage value while wire drops are short circuited The arc power value is this percentage value, and can be set between 0 and 100% of the welding current setting. The parameter can be automated, and the automated value is 0%. Hot start Hot start is a function that helps to establish the arc. This can be achieved by increasing start amp (when the electrode is applied to the workpiece) by a certain percentage value in relation to the set value. This increased start amp is maintained for half a second, after which it decreases exponentially towards the set value for welding current with a time constant of one second. The hot start value reflects the percentage value by which initial current is increased, and can be set between 0% and 100%. The parameter can be automated, and the automated value is 25% constant. 3. MMA Page 3-3

18 Pulse time Pulse freq. Base Amp Pulse time, pulse frequency and base amp are used for pulse welding, and will be dealt with jointly. If pulse time is set at 0 ms, pulse welding is disconnected and pulse frequency and base amp cannot be selected by using the parameter selection keys. The figure below illustrates the three pulse parameters: Pulse time reflects the time in a pulse period during which welding uses the peak current level that has been set. For the rest of the pulse period, welding is carried out using the current level stated in the base amp figure. Pulse frequency reflects the number of pulses per second. The zones in which pulse frequency and pulse time can be set are connected, in that it is not possible to set pulse frequency so high that there is no room for pulse time during the pulse period. The pulse period can be calculated as 1/pulse frequency. For MMA welding the pulse time can be set between 0.1 and 99.9 ms, depending on the setting of the pulse frequency. And the pulse frequency can be set between 1 and 999 Hz, depending on the setting of the pulse time. If the pulse time is less than 1 ms, the pulse frequency can be set up to its maximum value (1000 Hz = 1/1 ms). And when the pulse time is set at its maximum value (99.9 ms), the pulse frequency can be set at 10 Hz (10 Hz = 1/0.1 s). The figure illustrates the setting zones for pulse time and pulse frequency. Base amp is set as a value between 15 A and the current level set on the left display. The pulse parameters cannot be automated. 3. MMA Page 3-4

19 Welding with an MMA Programme Before welding Select an MMA programme using the PROG key. Set the required welding current by using the keys around the left-hand display. During welding The values measured for welding current and welding voltage are shown on the two displays. If necessary, the current can be adjusted by using the arrow keys around the left-hand display. The keys on the far left cannot be used during welding. After welding The average of the welding current and voltage measured during welding can be read by activating the RECALL key. 3. MMA Page 3-5

20 4. MIG/MAG WELDING This chapter explains how the machine can be operated for MIG/MAG and MIG pulse welding with and without synergy. The machine can be switched to MIG/MAG welding by selecting a MIG/MAG programme using the PROG key. The way in which a MIG/MAG and a MIG pulse programme can be loaded in the machine's memory is described below. Loading MIG/MAG Welding Programmes Select programme number Welding method Use the PROG key to select the programme number in which the new MIG/MAG programme is to be loaded. Select MIG/MAG welding by using the welding method key. Furthermore, switching from "Synergic" to "Manual" is done with the SYN-switch. When manual MIG/MAG welding is selected, the control panel will look like this: The primary parameters wire speed and voltage are set at their minimum values of 1.0 m/s and 0.0 Volt respectively. The secondary parameters are unchanged. The functions are set as follows: - trigger function set at two-stroke welding - sequence shift non-operational - wire feed internal in the machine is chosen, unless the machine is of the STB type, in which case external wire feed automatically is chosen. - cooling method set at water cooling - manual MIG/MAG welding chosen - the wire speed is set on the torch 4. Manual MIG/MAG welding Page 4-1

21 General function selection While loading a new MIG/MAG welding programme, the following general function selection should be observed: Wire feed unit If the machine has an external wire feed box, you can use this key to choose between internal and external wire feed. Cooling welding torch If the machine has water cooling installed the welding torch can be water cooled by using the COOL key. Synergy function Select manual welding using the SYN key. Synergic welding is dealt with later in this chapter. Regulation method Use the AMP key to select the position from which the wire speed shown in the left-hand display is to be set. 4. Manual MIG/MAG welding Page 4-2

22 Trigger function Use the TRIG key to select trigger method. Sequences If welding with sequence shift is required, each sequence should be loaded in accordance with the following instructions. Loading sequences Select sequence number 1 using the SEQ key. Set the wire speed and voltage which are to be used in the first half of the job in question, using the control keys around the left and right displays. Torch adjustment cannot be used in this connection. For pulse welding, pulse parameters must also be set by using the parameter selection keys and the control keys around the right-hand display. 4. Manual MIG/MAG welding Page 4-3

23 Shift to sequence number 2 by activating the SEQ key once. Set the parameters so they fit the next welding stage. Continue in this fashion until all sequences have been loaded, or if all four sequences are not needed set wire speed at zero in the first sequence number which is not to be used. For example, if two sequences are to be used, set wire speed at zero in sequence number 3. Activation of sequence shift function If welding with the loaded sequences is to be possible, one of these sequences must have been selected before welding starts (normally number 1). Primary parameters Once MIG/MAG welding has been selected, the left-hand display shows wire speed and the right-hand display shows voltage. Both parameters can be set using the control keys, and wire speed can also be set using torch regulation, if torch regulation (Torch) has been selected with the AMP key. Wire speed can be set between 1 and 24 metres per minute, and voltage between 0 and 50 V. Secondary parameters The secondary parameters which can be set for MIG/MAG welding are as follows: - Spot time - Pre-flow - Arc adjust - Pulse time - Pulse freq. - Base Amp - Burn back - Post-flow Arc adjust The arc adjust function is an adjustable control of an electronically-produced arc adjust. Arc adjust can be set between 0 and 100 per cent. 0% results in the hardest arc, and 100% in the softest arc. The parameters can be automated, and the automated value is 45%. 4. Manual MIG/MAG welding Page 4-4

24 Spot time Pulse time Pulse freq. Base Amp If spot welding ( ) has been selected using the TRIG key, the spot time setting shows how long welding continues after activation of the TRIG key. Spot time can be set between 0.1 and 99.9 seconds. This parameter cannot be automated. The pulse parameters (pulse time, pulse frequency and base amp) are dealt with in chapter 3 above. However, there is one difference from MMA pulse welding; namely that pulse height is stated by the voltage setting in the right-hand display, i.e. pulse voltage. The functions of pre-flow, burn back and post-flow are illustrated in the figure below. Pre-flow Burn back Post-flow Pre-flow reflects the time that elapses from when the torch switch is activated until wire feed starts. Pre-flow can be set between 0 and 10 seconds. This parameter can be automated, and the automated value is 0.2 seconds. Burn back reflects the time that elapses from when the torch switch is deactivated and wire feed has stopped until the arc has extinguished. Burn back can be set between 0.05 and 0.5 seconds. This parameter can be automated, and the automated value is calculated during welding at the optimum time. Post-flow reflects the time that elapses from when the arc is extinguished until gas supply is disconnected. Post-flow can be set between 0 and 60 seconds. This parameter can be automated, and the automated value is the current level that is measured during welding multiplied by 0.02 seconds (minimum 3 seconds, however). As a result, the automated value can only be read by using the RECALL and AUTO keys after manual MIG/MAG welding. 4. Manual MIG/MAG welding Page 4-5

25 Welding with a MIG/MAG or MIG Pulse Programme Select a MIG/MAG or MIG pulse programme, using the PROG key. Before welding Set the required wire speed by using the keys around the left-hand display or torch regulation, and set welding voltage by using the keys around the right-hand display. During welding The left-hand display shows the welding current measured, but the control keys around the display continue to regulate wire speed. This is natural, due to the close relationship between wire speed and current level. Torch regulation can be used to set wire speed, if it has been selected. The right-hand display shows the welding voltage that has been measured, and the voltage can be adjusted using the relevant keys. After welding The average values of welding current and voltage during welding can be read by activating the RECALL key. If sequence shift has been used for welding, those values are read that have been measured in the sequences in question. 4. Manual MIG/MAG welding Page 4-6

26 5. SYNERGIC MIG/MAG WELDING This chapter assumes that the reader is familiar with the general MIG/MAG terms described in chapter 4 above. Synergic MIG/MAG welding means that the welding process can be controlled by using a single welding parameter i.e. Welding current. The other parameters that influence welding are regulated automatically by the machine itself, depending on the current level. During standard MIG/MAG welding various parameters must be adjusted manually to obtain the welding properties required by adjusting the current level. During synergic MIG/MAG welding the correct parameters can be set once and for all using four current levels covering the current areas in which welding is to be carried out. The machine will then automatically calculate the correct settings for all intermediate current levels. Analogy This figure shows the effect of synergic welding when it is transferred from a BDH welding machine to a conventional MIG/MAG welding machine which is operated using a knob for each parameter. In a welding machine such as this, synergy means that the other three knobs turn in predefined fashion whenever the current level knob is turned. The figure shows knobs for wire speed and voltage, but on a BDH welding machine there are more parameters which are controlled. Synergy is the connection between current and the controlled parameters, and is fixed as follows: The adjustment areas of the current and the controlled parameters are divided into three intervals (I, II and III), by using four points (1-4). When the current is adjusted within a specific interval, the controlled parameters will automatically be set within the equivalent interval. For example, when the current is adjusted from point 2 to point 3 (interval II), wire speed, voltage and the other controlled parameters will also change from point 2 to point 3. There is a linear connection between the current and the controlled parameters. In other words, if the current level is set in the middle of interval II the controlled parameters will also be set in the middle of their equivalent interval II. Controlled parameters Synergy can be used for MIG/MAG and MIG pulse welding. The following list shows the parameters which are controlled automatically in the two methods: MIG/MAG wire speed voltage arc adjust MIG-Pulse wire speed pulse voltage arc adjust pulse time pulse frequency base amp 5. Synergic MIG/MAG welding Page 5-1

27 Synergic curves The connection between welding current and the controlled parameters in the BDH welding machine is loaded in the form of synergic curves. These curves are defined by using four points, which means that the curves consist of three linear sections. III II I Control parameter Point 3 Point 2 Point 1 I II Regulating range III Point 4 Current When synergic welding is used in the MIG/MAG method, there are three curves in the machine. One shows wire speed depending on current level, the second shows welding voltage dependency, and the third shows arc adjust dependency. There are three more curves for the MIG pulse method, one for each of the three pulse parameters. During synergic welding the machine uses these curves to calculate the settings of the controlled parameters, depending on the current level in question. The user can load these connections himself to ensure that they match the welding operation in hand. When synergy is loaded it is not necessary to regard it as curves. Welding is simply carried out using four different current levels within the current area in question. Synergic welding is like standard welding, but the machine welds optimally thorughout the entire current range. Here is a description of the practical use of synergic welding in a BDH welding machine. This description is divided into a section dealing with synergic welding and a section explaining how to load your own synergies. Synergic Welding SYN key Synergic indicator Select synergic welding by activating the SYN key. The synergic indicator will be illuminated during synergic welding. Primary parameters When synergic welding has been chosen, the primary parameters in the two displays alternate between welding current and trim value. 5. Synergic MIG/MAG welding Page 5-2

28 Current Trim value The current can be regulated within the area covered by the synergy. The synergy function is not fully utilised until the current has been set by the torch or by remote control connected to the "Remote Interface" switch. The right-hand display normally shows voltage, and the trim value is also a form of voltage regulation. However, during synergic welding the voltage is controlled by a synergic curve. Consequently, trim value is a parameter which determines the number of volts by which the voltage synergic curve should be adjusted (up or down). The trim value can be set between volts and volts. The trim value can be used to regulate arc length in the same way as voltage can be regulated during manual MIG/MAG welding. This makes it possible to compensate for varying welding positions, material thicknesses, etc. The trim value has various other applications, too. For example, it can be used to compensate for the fact that a gas mixture is used which has not been loaded in the synergy. Slope down Synergic welding makes it possible to introduce slope down on completion of welding. During slope down, current is reduced from the level that has been set to the bottom limit of the current setting area. When the current is automatically reduced during slope down, the other parameters - which are synergically-connected with the current - will be altered in similar fashion. Slope down time can be set between 0.0 and 99.9 seconds. This parameter can be automated, and the automated value is 0.0 seconds. 5. Synergic MIG/MAG welding Page 5-3

29 Synergic welding Before welding Set welding current by using the keys around the left-hand display or by using the torch adjustment function. Set the trim value by using the keys around the righthand display. During welding Adjust welding current by using the keys around the left-hand display or by using the torch regulation function. Adjust the trim value by using the keys around the right-hand display. After welding Keep the RECALL key activated in order to read the mean welding current on the left-hand display and the mean welding voltage on the right-hand display. 5. Synergic MIG/MAG welding Page 5-4

30 Loading Synergy Each synergy is related specifically to the material, wire, gas mixture etc. used when loading. This means that users need to be able to load their own synergies. The following section contains a description of how to load synergies. When loading a synergy in a BDH welding machine, the fact that it is loaded as a collection of synergic curves is irrelevant. In order to load a new synergy, it is simply necessary to weld using four different current levels within the current area required. RECALL + SYN In order to load your own synergy, the machine must be set for synergic loading by activating the RECALL and SYN keys simultaneously. The first point on the symbolic synergic curve will then be illuminated. Symbolic curve Primary parameters First point Mean current Next points Err A- The symbolic synergic curve on the control panel can only be used for synergic loading. This means that you can always see if you are in synergic loading mode. During synergic loading the primary parameters are the same as those that apply to manual MIG/MAG welding, i.e. wire speed and voltage. A weld should now be carried out for later use at the lowest wire speed (and thus at the lowest current level). Adjust voltage, arc adjust and any relevant pulse parameters until the required welding properties have been achieved. Welding can be started and stopped as often as necessary. Each time welding is carried out, the machine registers mean current. With regard to the first point mean current is used to fix the bottom limit of the current setting area. With regard to points two and three mean current fixes the two points at which the curve alters direction, and with regard to point four mean current fixes the top limit of the current area. In other words, optimum welding should be maintained throughout the welding process if possible to ensure that the mean current does not deviate from its correct value. Once the required result has been obtained for point 1, continue to the next points on the synergic curve by activating the SYN key. For each new point, set a higher wire speed in order to achieve a higher current level. It is important to be aware of this, since it is not possible to proceed to the next point unless the current in the present point is higher than that of the previous point. If you try to proceed to the next point on the synergic curve without having established a current level which is higher than that of the previous point, the Err A- error code will appear in the displays. After a few seconds, this error code will disappear, and the loading of the point in question can be repeated. If you discover during synergic loading that you wish to start again from point 1, activate the RECALL and SYN keys again. 5. Synergic MIG/MAG welding Page 5-5

31 Final point AUTO setting Example The mean current registered at point 4 fixes the top limit of current level possible for synergic welding. Once all four points have been loaded, leave synergic loading by a final touch of the SYN key, from where synergic welding is selected. The AUTO key has a special function during synergic loading. It can be used to transfer the value of a secondary parameter (arc adjust or one of the pulse parameters) to the next point on the synergic curve. For example, if you have set pulse time at 0 at the first point on the synergic curve in order to weld without pulse, the pulse time can be set at 0 in advance for the last three points as well by activating the AUTO key while the parameter selector is set at Pulse time. This makes it unnecessary to set all secondary parameters for each point if they are required to be the same in all four points. 5. Synergic MIG/MAG welding Page 5-6

32 Loading MIG/MAG or MIG Pulse Synergic Curves Before welding 1. Select programme using PROG key. 2. Select synergy alteration by activating RECALL and SYN keys simultaneously. 3. Set wire speed and welding voltage. During welding 4. For MIG pulse welding, set pulse parameters (pulse time, pulse frequency and base amp). 5. Adjust wire speed, welding voltage and pulse parameters in the same way as for welding. After welding 6. During welding, the machine registers mean welding current. Keep the RE- CALL key activated in order to read mean welding current on the left-hand display. By pressing the RECALL key again, the wire speed is shown. 7. If the result is satisfactory, select the next point on the synergic curve by activating the SYN key. Otherwise, repeat points 3-6 above. 8. Repeat points 3-7 until all points on the synergic curve have been entered. Wire speed should be increased from point to point so welding current increases. 9. Switch to synergic welding from the final point on the synergic curve. 5. Synergic MIG/MAG welding Page 5-7

33 Correcting Synergic Curves Loading an optimum synergic curve often requires considerable experience and a number of experiments. Consequently, the use of existing synergic curves is advisable whenever possible. Sharing the same synergy requires that operators are able to read a synergy that has already been loaded and load it again in another machine. Synergy reading Entering synergies Synergies can be read by entering synergy editing in the same was as that used when a new synergy is to be loaded. Activate RECALL and SYN simultaneously. Read all parameters at each point on the synergic curve. The left-hand display shows wire speed, and the current by use of the RECALL key. Voltage and the secondary parameters can be read on the right-hand display by using the parameter selection keys. The synergies that are read can be entered in the same way as when new synergies are entered, apart from the fact that the current should not be welded but entered by using the keys. Enter wire speed, voltage, arc adjust and the pulse parameters in the same way as for normal synergic loading. In order to enter current, activate the RECALL key, and the left-hand display will then show current, which can be set using the appropriate keys. Welding must not commence at this point until RECALL has been activated to change to current entering. If welding has been commenced, activation of the RECALL key will only have its normal function, i.e. to show mean current, which cannot be set. It is possible to return to a display of entering of wire speed by activating the RECALL key again. Synergy correction If you discover that a synergy has been loaded incorrectly (e.g. if the changes on the curve do not correspond to the correct current), it is possible to alter a single point on the curve. Synergy correction can be carried out by activating the RECALL and SYN keys. It will then be possible to change to the required point on the curve by activating the SYN key. This point can then be corrected, and synergy correction left by activating the SYN key once or more. 5. Synergic MIG/MAG welding Page 5-8

34 Appendix A. Programmes entered by the factory As described in Chapter 1 above, the machine is normally operated by means of ten programmes, which can be selected directly by using the PROG key. These programmes can be edited by the user. However, the machine also has a library of fixed processes which have been entered by the factory. A process is here defined as setting one of the 10 programmes that come with the machine. This means that a process contains a complete front panel setting. The processes are located in the process library. A process from the library must be placed in one of the ten programmes if it is to be used either in its current form or as the basis of a user-edited programme. A brief description of the contents of the process library is located on the inside of the flap which covers the right-hand side of the control panel. The use of the process library is described below. Activate process library Before a library process can be retrieved, the programme number in which it is located must be selected using the PROG key. Then activate the RECALL and PROG keys simultaneously in order to activate the process library. The left-hand display shows a "P" and the right-hand display shows the process number on which the programme number that has been selected is based. Select process number The process number you require can now be selected, using the arrow keys surrounding the right-hand display. Accept process number Once the required process number has been selected, it should be transferred to the programme using the AUTO key. The machine will now return to normal operation. Cancel process selection The process selection function can be cancelled using the RECALL key without changing the programme number that has been selected. This function can be used if the user merely wishes to see which process has been used as the basis for a given programme. A. Programmes loaded by the factory Page A-1

35 Appendix B. ERROR CODES Eight error situations can be registered in all: power error 1, power error 2, overheat error, gas error, wire error, motor error, external wire box error and torch cooling error. These errors are divided into two levels, one at which users can attempt to repair errors themselves and another at which service assistance must be called for. If more than one error occurs at the same time, they will be displayed alternately. All errors are displayed until they have been repaired. ERR P-1 Power error 1: Cause : Power error 1 occurs if there is an error in current supply, i.e. if the voltage of mains current is too high or too low. Reaction : The welding machine disconnects welding current and commences postflow. Action : User tries to adjust current supply to welding machine. ERR P-1 appears in both displays. ERR P-2 Power error 2: Cause : Power error 2 occurs if the inverter module is defect. Reaction : The welding machine disconnects welding current and commences postflow. Action : Call for service. ERR P-2 appears in both displays. Overheat Overheat error: Cause : Overheating of the inverter module as a result of incorrect use or defects in inverter module. Reaction : The welding machine stops the welding process by commencing slope down and then running through post-flow. Action : If the error has not been caused by incorrect use, service should be called. Otherwise wait until the inverter module has cooled down. The error is indicated by a yellow light diode next to the caption "Overheat" on the control panel. ERR GAS Gas error: Cause : Pressure of gas supply is too low. Reaction : The welding machine disconnects welding current and commences postflow. Action : User tries to remedy defects in gas supply. ERR GAS appears in both displays. ERR C-1 Torch cooling error: Cause : Pressure of cooling water is either too low or too high. Reaction : The welding machine stops the welding process by starting slope down and then running through post-flow. Action : User tops up water container and checks hoses. If the problem cannot be solved, service should be called for. ERR C-1 appears in both displays. B. Error codes Page B-1

36 ERR F-1 Wire error: Cause : No wire in internal wire feed system. Reaction : The welding machine disconnects welding current and starts post-flow. Action : User inserts wire in wire feed system. ERR F-1 appears in both displays. ERR F-2 Motor error: Cause : Wire feed motor has been overloaded. Reaction : The welding machine stops the welding process by starting slope down and then post-flow. Action : If the wire feed system has been used in accordance with instructions, service should be called for. ERR F-2 appears in both displays. ERR F-E External wire box error: Cause : One of the following errors has arisen in the external wire box: a. Motor error : Wire feed motor overloaded. b. Wire error : No wire in wire feed system. c. Gas error : Pressure of gas supply too low. Reaction : The welding machine disconnects welding current and starts post-flow. Action : a. Contact service staff if the wire feed system has been used correctly. b. User inserts wire in wire feed system. c. User tries to remedy defect in gas supply. ERR F-E appears in both displays. ERR A- This is a special error which sometimes occurs during synergic loading. See chapter 5 for more information. Two secondary error situations are also registered, i.e. ignition latchup and torch lift. Ignition latchup: Cause : During four-stroke triggering the operator may start a welding sequence and then put the welding hose down somewhere by mistake. The machine remains in ignition state, and constitutes a risk for the user (HF and gas). The gas cylinder will also be emptied. Reaction : Ignition that lasts for more than 10 seconds will result in complete disconnection of welding. Torch lift: Cause : During welding the welder may lift the torch from the workpiece by mistake, thereby extinguishing the arc. Reaction : During slope up or stationary welding the machine will attempt to re-ignite the arc. Ignition will be attempted for 10 seconds, as described above. B. Error codes Page B-2

37 Appendix C. Switching the robot-interface on and of If the machine has been extended with a robotinterface, it will to a certain extent be controlled from that. This control can be switched off by pressing down the AUTO key simultaneously with the central arrow key under the left display. The machine will now function manually in a normal way. The robot-interface can be switched on again by pressing down the AUTO key and the central arrow key over the left display at the same time. When starting the machine, the robot-interface is always switched on. C. Connection and disconnection of robot-interface Page C-1

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