Welding Operation - ESAB Digimig Dual Instruction Manual

SECTION 3
Match the Material number to the wire type being
used. (see 3.2-6-b)
b. Wire Diameter: operate the right Inc./Dec. switch
to select the Wire Diameter you intend to use. One
of five diameter designations will appear in the
VOLTS window; #30 for .030" dia., #35 for .035"
dia., #45" for .045" dia., #52 for .052" dia., or #63
for .063" dia. Match the Diameter number to the
wire diameter being used. (see 3.2-6-b)
3. Set the Rotary switch to the RUN (Sch. I) Position
#6 (Must be set), and then program the following:
a. To set the Wire Feed Speed parameter, raise
and hold the toggle of the "left" Inc/Dec switch in its
INC position until the desired hot wire speed (e.g.:
185 ipm) appears in the IPM window. Notice that
this parameter will start at zero and immediately
jump to 20 and then will rapidly increment (ipm at
a time) until the planned wire speed setting is
reached.
b. To set the Arc Voltage parameter, raise and hold
the toggle of the "right" Inc/Dec switch in its INC
position until the desired arc voltage (e.g.: 17.9
volts) appears in the VOLTS window. Notice that
this parameter will start at zero and immediately
jump to 12 and then will rapidly increment (1/10
volt at a time) until the desired arc voltage setting
is reached.
4. The following parameters are "optional" func-
tions which can also be added to the torch setup:
a. A Second Schedule (II). Set the rotary switch to
Position #4, and program another set of conditions
as described in B-3 above and in Section 3.2-6d.
b. Preflow/Postflow function. Set the rotary switch
to Position #5, and program as described in Sec-
tion 3.2-6e.
c. Spotweld/Burnback function. Set the rotary
switch to Position #3, and program as described in
Section 3.2-6c.
5. Using the torch switch, the parameters for Sched-
ules I and II (of the selected torch) can be weld-
tested and if necessary readjusted to provide stable
start and welding conditions.
NOTE: The control is designed to provide excellent
starting characteristics with the latest ESAB
inverter power sources. However, arc starting
can be affected by many external factors such
as cable length, type of torch used (water ver-
sus gas cooled), shielding gas, condition of
weldment, type of welding wire, etc. To mini-
mize the effect of these variables, a simple
adjustment will allow you to increase or de-
16
crease the initial arc striking voltage to optimize
starting. The following procedure (5-A) allows
you to make this correction.
5A. Setting Controller For Optimum Starts.
1. Increase Starting Voltage;
a. Prior to striking the arc, depress the Purge key on
the right side of the feeder. This can be done in
either the RUN (Sch. I) or Sch. II mode of the
Rotary switch.
b. Initially, the display in both windows will show the
number 100. This number has an adjustment
range of 0 to 200, so that 100 is right in the middle
of the range.
c. To increase the starting voltage by 1-volt, the
number in the right (VOLTS) window must be
increased to 105 using its Inc./Dec. key.
d. To see if this adjustment is adequate, start a new
weld and observe the start. If it is still not "hot"
enough, increase the adjusted number until the
starts are optimized.
e. The number in the left (IPM) window controls initial
motor speed and, in most cases, the number 100
will work well for the whole speed range.
2. Decrease Starting Voltage.
a. Follow the same procedures outlined above (in 1),
but instead of increasing the numbers decrease
them until the starts are optimized.
Please note that if either schedule for either torch
required a voltage adjustment to the present con-
dition, you will more than likely require additional
adjustments when a different condition is used.
C. PROGRAM REMAINING (e.g. LEFT) TORCH
If you wish to program a different set of conditions for the
remainng (or left) torch, simply "click" its trigger switch
lever and then repeat the procedures outlined in the
preceding section B-2 through B-5.

3.5. WELDING OPERATION

After the desired welding modes have been weld-tested
(with control to SET position) and satisfactory results
achieved, the program parameters can be "lock-in" by
placing the key switch in the RUN (Lock-In) position. In
the Lock-In position, and the key removed, none of the
preset parameters can be changed.
CAUTION: Power source contactor becomes ener-
gized the moment the torch trigger is de-
OPERATION