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Appendix A
A.7 APPLICATION EXERCISE
This application exercise steps the user through the development of a basic PowerWave welding
program using Wave Designer. Your application most likely will vary from this example but the
concepts outlined are recommended for all development work.
If you would like to follow along with this example, use the following set up:
Machine:
Wire:
Gas:
Computer: See Section 2 of this manual for minimum requirements and connection diagrams.
For this example, we developed a program to run wire feed speeds between 150 in/min. and
300 in/min. The user may want to develop more workpoints for practice.
Before starting the waveshape development process, confirm that the consumables are working
properly with the welder. We recommend using a standard waveshape such as mode 5 to
confirm that the welding system performs under normal conditions before attempting to develop
waveshapes.
1. Select a wave shape. (From the tool bar, select
'File', 'Open Waveform'.) For this exercise, select
the "pulse.swf" wave shape. This wave shape is
automatically loaded when the Wave Designer
program is first used. Generally, the user should
choose a waveshape file that has the closest
welding performance to the intended application.
2. Pick a wire feed speed from the Wire Feed
Speed pulldown menu. We started with the 150
in/min. WFS. Also, be sure to set the PowerFeed's
wire feed speed to the same WFS as the selected
workpoint and set the trim to 1.00. (In this exercise,
the WFS is 150 in/min.)
PULSE WAVE SHAPING PRINCIPLES
PowerWave 455, PowerFeed 10, Magnum 400 gun and cable, miscellaneous other
parts to complete welding cell
0.035 L-56
90% Argon 10% CO
2
Click on the Wave Designer icon to start the program.
WAVE DESIGNER
File
Tools
Print
Help
Open Waveform
Ctrl+O
Save Waveform As ...
Save Waveform
Ctrl+S
27850041
File
Tools
Print
Help
Pulse Waveform Editor
Wire Feed Speed
50
80
110
600
Ramp Up Rate
150
205
Ramp Overshoot %
-7
300
400
600
Peak Amps
280
700
27850047
A-17
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