F-15-699 February, 2002 MultiPower 460 Pulse Control Panel Kit P/N 0558002671 Installation and Operation Instructions Read and understand the entire contents of this manual, the power source manual, and the wire feeder manual used with this unit. Special emphasis should be given to the safety material throughout all manuals, before installation, operation, or maintenance of this equipment.
USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately.
SAFETY PRECAUTIONS WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
SAFETY PRECAUTIONS EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore: FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation. Therefore: 1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work. 2.
PRECAUCION DE SEGURIDAD ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc.
HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. No inhale el humo o gases. El gas de protección puede causar falta de oxígeno. Por lo tanto: 1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva .
PRÉCAUTIONS DE SÉCURITÉ AVERTISSEMENT: Ces règles de sécurité ont pour objet d’ assurer votre protection. Veillez à lire et à observer les précautions énoncées ci-dessous avant de monter l’ équipement ou de commercer à l’utiliser. Tout défaut d’observation de ces précautions risque d’entraîner des blessures graves ou mortelles. 1.
PRÉCAUTIONS DE SÉCURITÉ l evage, des câbles de grue ou divers chemins électriques. g. Empêchez l’apparition de toute humidité, notamment sur vos vêtements, à la surface de l’emplacement de travail, des câbles, du porte-électrode et du poste de soudage/coupage. Réparez immédiatement toute fuite d’eau. 4. VENTILATION-- La respiration prolongée des fumées résultant des opérations de soudage/coupage, à l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels.
SECTION 1 DESCRIPTION I. SAFETY Before the MultiPower 460 Pulse Control Panel Kit is installed, the safety section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper installation. The definitions relating to the: safety notations are described at the end of the Safety Section in the front of this manual — read them and their specific text references carefully. II.
SECTION 1 DESCRIPTION A. PULSE CONTROL PANEL DESCRIPTION (Refer to Figure 2-1) 1. FAULT LAMP The RED fault light on the MultiPower 460 Pulse front panel indicates a problem with set-up parameters. A "Steady" light "On" indicates there is no program for the material and wire diameter selected. A "Blinking" light indicates the wire feed speed is out of the recommended range.. 2. TEMPERATURE LAMP The TEMP lamp illuminates if an over temperature condition occurs within the MultiPower 460 Pulse power source.
SECTION 1 DESCRIPTION Preset Button Digital Meters Amps/Volts/WFS Power “ON” Lamp WFS - IPM Lamp Pulse Remote Standard Standard Weld Process Switch Switch Amps Switch Current Lamp Voltage Pulse Trim Inductance Adjustment Temperature Lamp Pulse Wire Type No Program Out of Range Lamp Pulse Wire Diameter Figure 3-1- Pulse Mig Control Panel 6.
SECTION 2 INSTALLATION IV. PULSE CONTROL PANEL INSTALLATION The standard MultiPower 460 control panel are easily removed and replaced with the MultiPower 460 Pulse version using the following procedure. Refer to Figure 4-1. Step 1. Disconnect ALL primary power from the MultiPower 460 by unplugging the unit or removing the line fuses. Step 2. Remove the four screws (one at each corner) holding the standard MultiPower 460 control panel in place. Step 3.
SECTION 3 OPERATION V. OPERATION A. WIRE FEEDER COMPATIBILITY The MultiPower 460 Pulse power source can be used with several ESAB 42 volt wire feeders. The model wire feeder being used will determine the setup method and operator interface. The position of the REMOTE/PANEL switch determines the location of the voltage preset and TRIM locations. The wire feed speed is always set from the wire feeder using the wire speed knob on the feeder control panel.
SECTION 3 OPERATION 4 1 2 3 Figure4-1 Standard Mig Setup Procedure D. STANDARD MIG (CV) WELDING When the PROCESS switch is placed in the MIG position the MultiPower 460 Pulse is set for CV (constant voltage) welding. The power source will output open circuit voltage (OCV) when the Mig Gun trigger is depressed. The following procedure assumes the wire feed and voltage adjustments will be made from the wire feeder front panel and wire and gas have been installed.
SECTION 3 OPERATION E. MIG PULSE WELDING The MultiPower 460 Pulse is designed to provide simple to use, high quality, preprogrammed synergic and non-synergic pulsed Mig welding. Synergic pulsed Mig welding means that pulse parameters (such as pulse height, pulse width, background current and pulse frequency) are automatically adjusted by the MultiPower 460 Pulse as the wire feed speed is changed by the operator.
SECTION 3 OPERATION switch characteristics. The TRIM adjustment is calibrated such that the preprogrammed synergic pulse data is approximately at 12 o'clock of the TRIM knob position. The operator should preset the voltage control on the wire feeder to the 12 o'clock position and adjust for best arc characteristics. The operator can change to STANDARD MIG (CV) by simply moving the MIG STANDARD/PULSE switch to the STANDARD position.
SECTION 3 OPERATION Step 8 Set the voltage knob on the wire feeder to the "5" or center 12 o'clock position. Step 9. Connect the work cable to the workpiece and pull the gun trigger to start welding. Step 10 The voltage knob on the wire feeder becomes the ARC TRIM and is used to fine tune the arc length for best arc performance. Turn the knob clockwise to increase the arc length or counterclockwise to decrease the arc.
SECTION 3 OPERATION J. NON-SYNERGIC PULSE OPERATION The MultiPower 460 Pulse has the unique ability to Pulse MIG weld in the NONSYNERGIC mode. Non-synergic operation means the pulse parameters can be selected by choosing the WIRE TYPE, WIRE DIAMETER, and presetting a WIRE FEED SPEED on the MultiPower 460 Pulse panel. The pulse frequency or arc length (TRIM) is controlled by the TRIM knob. The TRIM knob is adjustable from the minimum to maximum pulse frequency.
SECTION 3 OPERATION K. PULSE PARAMETERS Tables 5-3 through 5-8 list the approximate pulse weld parameters for each material and diameter available. These are provided for general reference only. Actual pulse parameters can vary with the equipment set-up, welding application and shielding gas being used. The wire feed speed ranges shown in the tables are the same as programmed into the MultiPower 46 Pulse program.
SECTION 5 OPERATION Table 5-3 Carbon Steel Pulse Weld Data .035 Steel WFS Range (IPM) Pulse Peak (Amps) 75 125 175 225 275 325 375 425 475 525 575 625 675 725 312 318 325 331 337 343 350 356 362 368 375 381 387 394 .040 Steel Pulse Pulse BackPulse Width ground Frequency (ms) (Amps) (Hz) 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.
SECTION 5 OPERATION Table 5-4 Stainless Steel Pulse Weld Data .035 Stainless WFS Range (IPM) Pulse Peak (Amps) 100 150 200 250 300 350 400 450 500 550 600 650 700 300 300 300 300 300 300 300 300 300 300 300 300 300 .040 Stainless Pulse Pulse BackPulse Width ground Frequency (ms) (Amps) (Hz) 1.64 1.71 1.78 1.86 1.93 2.00 2.07 2.14 2.21 2.28 2.35 2.42 2.
SECTION 5 OPERATION Table 5-5 4000 Aluminum Pulse Weld Data .035 4043 AIuminum WFS Range (IPM) Pulse Peak (Amps) 200 250 300 350 400 450 500 550 600 650 239 246 253 260 266 273 280 287 294 301 .040 4043 Aluminum Pulse Pulse BackPulse Width ground Frequency (ms) (Amps) (Hz) 1.80 1.80 1.80 1.80 1.80 1.80 1.80 1.80 1.80 1.
SECTION 5 OPERATION Table 5-6 5000 Aluminum Pulse Weld Data .035 5356 Aluminum WFS Range (IPM) Pulse Peak (Amps) 200 250 300 350 400 450 500 550 600 650 260 264 268 272 276 280 284 288 292 296 .040 5356 Aluminum Pulse Pulse BackPulse Width ground Frequency (ms) (Amps) (Hz) 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.
SECTION 3 OPERATION Table 5-7 Metal Core Carbon Steel Pulse Weld Data .035 Metal Core CS WFS Range (IPM) Pulse Peak (Amps) Pulse Width (ms) 300 350 400 450 500 550 600 300 306 313 320 326 333 340 2.50 2.50 2.50 2.50 2.50 2.50 2.50 Pulse Background (Amps) 39 49 58 68 77 86 96 .
SECTION 3 OPERATION Table 5-8 Metal Core Stainless Steel Pulse Weld Data .035 Metal Core SS WFS Range (IPM) Pulse Peak (Amps) Pulse Width (ms) Pulse Background (Amps) .040 Metal Core SS Pulse Frequency (Hz) WFS Pulse Peak Range (Amps) (IPM) NO PROGRAM Pulse Peak (Amps) Pulse Width (ms) 125 200 275 350 425 500 575 650 725 343 357 370 384 397 411 425 438 452 1.90 1.90 1.90 1.90 1.90 1.90 1.90 1.90 1.
Figure 3.
NOTES 27
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