Lincoln Electric METALUX M340 User's Manual
Contents
1. j th Tk ex I J I i i i L I l L i z i i shadi i j Waveform Control Technology Process Controls Unlike standard pulse welding which uses a single pulse wave shape Pulse On Pulse uses a sequence of varying pulse wave shapes to produce a GIAW like bead appearance to readily produce top quality aluminum welds with excellent appearance little spatter and good bead shape The waveform control in Pulse On Pulse welding is frequency modulation Frequency modulation controls the spacing of the ripples in the weld Use low values for slow travel speeds and wide welds and high values for fast travel speeds and narrower welds STT uses current controls to adjust the heat so changes in electrode extension do not affect heat input The Waveform Controls associated with STT welding are The STT Waveform controls heat input Peak Current Background Current and Tail Out Peak and reduces spatter and fume current controls the arc length which affects the shape i of the root face Background current controls heat input which affects the back bead Tailout current also contributes to control of heat input oS y ce re oa o The Power Mode uses Power V x W to regulate the arc length The preset power setpoint is the main control Increasing the power setpoint forces the power source to adjust BOTH voltage and current to maintain the watt energy programmed for that setpoint Inc2. Range 10 low frequency to 10 high frequency Pulse frequency controls arc stiffness The lower the frequency of the pulse the wider and softer the arc Trim Synergic GMAW GMAW P Range 0 5 to 1 5 Trim controls the length of the arc Trim values less than 1 00 decrease the arc length while values greater than 1 00 increase the arc length WaveDesigner Lincoln Electric created the Wave Designer software program to simplify the operator s experience with controlling various attributes of the waveform Wave Designer is a tool that allows the manipulation of current waveforms and arc characteristics with a live welding arc It can also monitor and analyze the critical parameters of the actual waveform at high resolution ArcScope The ArcScope utility allows the operator to view the actual arc voltage in real time This provides the necessary information to manipulate the arc characteristics to achieve a quality weld Custom Waveforms Customized welding software means even the most difficult materials can be welded with the Power Feed Power Wave system Copper Nickel and Silicon Bronze are a few of the unusual alloys the Waveform Control system welds with ease when special software is loaded Lincoln Electric will build custom waveforms for those customers experiencing difficulty with unique materials or joint configurations Wave Designer and ArcScope display real time readouts of welding arc activity
3. and hard automation PLCs Semi automatic applications are also supported e Optional DeviceNet and Ethernet communication modules provide networking capabilities and allow process and production monitoring e Software based controls can be upgraded as new features become available Power Wave 655R The Power Wave 655R was designed for Robotic and Hard Automation applications that require extra power 650 Amps at 100 Duty Cycle Digital Communications enable the Power Wave to connect seamlessly to robot controllers and hard automation PLCs Semi automatic applications are also supported The Ethernet DeviceNet Gateway provides networking capabilities and allows process and production monitoring e Software based controls can be upgraded as new features become available The Power Wave 655R has an output range of 20 to 880 Amps Power Wave 355 Power Feed 10M The Power Wave 355 is the smaller lighter version of the Power Wave 455M same machine just leaner and lighter The Power Wave 355 Power Feed 10M welding system is factory programmed with over 60 standard welding programs to optimize the arc for a variety of materials or applications including steel stainless steel aluminum nickel alloys and others e ArcLink Digital Communication between components allows unprecedented waveform control and expansion capability Simply select a program and you have the right arc Characteristics for y
4. products processes and applications are linked together to answer the important questions that all businesses face e How can we work faster smarter more efficiently e How can we get equipment and people to perform in ways they ve never had to before e How do we stay competitive NEXTWELD is the future of welding but its benefits are available to you today Ask your Lincoln Electric representative how to improve the flexibility efficiency and quality of your welding operations to reduce your cost of fabrication LINCOLN ELECTRIC THE WELDING EXPERTS THE LINCOLN ELECTRIC COMPANY www lincolnelectric com 1 216 481 8100 g9 i sS a O E S
5. LINCOLN E THE WELDING EXPERTS WAVEFORM CONTROL TECHNOLOGYT Waveform Control Technology LINCOLN ELECTRIC NEXTWELD a A Ae ju i f i n 1 i j LF E i ve i l Alterations to the waveform can be made during the weld using software created by Lincoln Electric BADESEEN AG E Metal transfer modes may be controlled to extend the stable operating range of the welding process Shapes the arc using computer software A single machine can quickly and easily adapt to A wide range of applications e Varying materials specifications e Varied weld positions Appearance requirements Optimized metal transfer reduces spatter and improves arc stability Higher deposition rates are possible at heat input equal to or less than traditional CV processes Output parameters may be adjusted for given welding waveform conditions and joint design to meet weld specifications and production rates o f w e l d in g i ss h e r e NX 1 10 11 03 Waveform Control Technology Waveform Control Technology is the ability to customize waveform output It is the ability to choose a weld program from a pre defined set of programs and to manipulate the parameters of that program to best fit your application Lincoln Electric strives to understand the customer s needs in order to make the job easier That is why Waveform Control Technology was designed to empower the people who u
6. ctric electrodes A mode number is assigned to each weld program The following lists include the most commonly used weld programs and are grouped according to material Find the mode number for your material and program specifications then select that mode number on the welding system user interface Steel Weld Programs GMAW Argon mix Pulse Crisp Argon mix Pulse Soft Argon mix 28 STT COs 0 035 109 No Tailout Argon CO 0 045 125 s CO STT II Argon CO Rapid Arc Argon CO 18 l 27 CO 0 035 109 These programs may not be available in certain machines O Waveform Control Technology Aluminum Weld Programs Stainless Steel Weld Programs GMAW Argon mix GMAW Argon He CO Pulse Argon CO ee 0 045 0 030 Pulse Argon Oz 0 035 0 045 0 030 Argon He CO gt 0 035 0 045 Alloy Weld Programs 0 035 170 Nickel Pulse Argon He 0 045 Silicon Bronze Argon 0 035 192 Pulse GMAW Argon COz Waveform Control Technology The amount of current applied in varying time intervals can be charted as a waveform This waveform characterizes the weld output Changing specific values during specific periods of the waveform directly affects the characteristics of the weld Lincoln Waveform Control Technology Welding Systems use high speed electronics to monitor the electrical signals from the welding arc and make appropriate changes to the current waveform All the desired factors which control
7. otic applications e This compact unit delivers 350 Amps 60 duty cycle for MIG Pulsed MIG or Flux Cored welding applications The Power Wave F355i ARC Mate R J3iB communicates via ArcLink allowing all welding procedures and process controls to be managed through the ARC Mate robot teach pendant one central control forsetup process control and diagnostics Ethernet access is available through the Ethernet port of the R J3iB Customer Assistance Policy The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equipment Our challenge is to meet the needs of our customer and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our possession at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such information or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with res
8. our application The software is upgradeable so your Power Wave 355 will grow with your business If you want to reduce costs by buying a versatile machine that will do multiple jobs and last for years to come the high efficiency Power Wave 355 delivers Power MIG 300 The Power MIG 300 a single phase multi process synergic power source wire feeder combination welding package for the professional welder The Power MIG 300 offers e Superior multi process welding e Synergic design for ultimate control over the arc by automatically aligning wire feed speed and voltage e Top quality aluminum welds with push pull wire feed capability not typically available in competitive models e True MIG pulsing and Pulse on Pulse capabilities which ensure that superior feeding is matched by high quality arc performance Waveform Control Products TECHNOLOGY Power Wave AC DC 1000 The Power Wave AC DC is a modular welding system with a single range of control from 100 to 1000 Amps per arc at 100 duty cycle The Power Wave AC DC provides DC DC and Variable frequency up to 200 Hertz Flexible Waveform Control e Variable Frequency Variable independent amplitudes e Variable timing The Power Wave AC DC is 100 software controlled Power Wave F355i The Power Wave F355i is fully integrated with the FANUC ARC Mate R J3iB controller and designed for the most demanding rob
9. pect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirement Subject to change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information T e a ee ee O es R o f wo eild i WHAT IS NEXTWELD The challenges facing industrial fabricators today are increasingly difficult Rising labor material and energy costs intense domestic and global competition a dwindling pool of Skilled workers more stringent and specific quality demands LINCOLN ELECTRIC Through our commitment to extensive research and investments in product development Lincoln Electric has established an industry benchmark for applying technology to improve the quality lower the cost and enhance the performance of arc welding processes Advancements in power electronics digital communications and Waveform Control Technology are the foundation for many of the improvements iA NEXTWELD NEXTWELD brings you a series of Process Technology Application and Success Story documents like this one NEXTWELD explains how technologies
10. reasing the power setpoint will increase voltage and decrease current simultaneously Tandem MIG uses two independently generated arcs contributing to the same weld puddle Tandem MIG can operate in one of two configurations a lead CV arc with a pulsed trail or two synchronized pulsed arcs The Waveform Controls for Tandem MIG are pulse frequency background current and trim which control heat input and arc stiffness The Tandem MIG relies on Waveform Control to synchronize its dual arc system Submerged Arc welding involves as many as five independently generated arcs contributing to the same weld puddle under a blanket of flux Waveform Control allows for infinite phase shifting of the AC waveform through the frequency modulation control Also ultimate control of deposition and penetration can be obtained by adding positive or negative DC offsets to the waveform AC DC Submerged Arc uses Waveform control for infinite phase shifting to accommodate up to 5 arcs without arc blow G Nae Carl eee Le TECHNOLOGY Waveform Control Products Power Wave 455M Power Wave 455M STT These Power Waves are designed to be part of a modular multi process welding system e The Power Wave 455M and 455M STT are high performance digitally controlled inverter welding power sources capable of complex high speed waveform control Digital Communications enable the Power Wave to connect seamlessly to robot controllers
11. ropriate changes to the current waveform The electronics must be STT I rable fast accurate and rugged to control the arc and withstand the harsh welding environment Amperage TECHNOLOGY Waveform Control Technology Waveform Control Weld Programs Equipped with our most up to date welding programs Waveform Control Technology systems suit the majority of welding applications The flexibility of choosing from a variety of welding programs not only increases productivity but also promotes consistently high quality welds Power MIG 300 Invertec V350 PRO and Power Wave welding systems are all Waveform Control Technology systems They come fully loaded with a software library that is accessible from the user interface With the Power Wave software programming enables the flexibility of uploading the weld programs to a PC or Ethernet and DeviceNet applications hard automation General Weld Programs Process Procedure Description Description GMAW Standard CV 5 D x gt z Y C 9 O Constant Current FCAW Standard CV oe The programs listed in the following tables were developed by Lincoln Electric It is important to note that although we attempted to provide a broad operating window for each program they were developed using Lincoln consumables Therefore Lincoln Electric cannot guarantee that these procedures will operate at optimum level when used with non Lincoln Ele
12. se the equipment The Arc Action Tool shows the behavior of the arc in the form of a Voltage Amperage our customers VI plot To further illustrate what the changes in voltage and current mean to the arc Lincoln Electric uses high speed photography to capture arc behavior Waveform Control Technology allows the user to choose from values within a programmed range to use a single source to perform a library of pre programmed to find the combination of wire feed Stick TIG MIG MAG Flux cored weld modes that have been speed voltage current and arc and Submerged Arc welding developed by expert welders control that the application requires procedures With a Waveform Then Waveform Control Control Technology product the Technology offers the But Lincoln has even taken it one days of configuring different systems opportunity to change those step further Waveform Control to make different welds are over Technology also provides the ability There are many physical forces that affect the welding arc and the transfer of metal from the electrode to the weld puddle Surface tension magnetic and aerodynamic forces are the most significant The welding current directly affects the magnetic and aerodynamic forces in the welding arc The welding current and surface tension forces can be balanced to control metal transfer within the arc High speed electronics monitor the electrical signals a e a m a aE from the welding arc and make app
13. the welding arc from arc start to arc stop are written in software Changes to the waveform can be made in real time that is during the weld or after the weld if it is evident that the weld does not meet requirements Arc Control Controlling the Waveform Waveform Control Technology Welding Systems provide the operators with a simple control knob Arc Control also known as Inductance or Wave Control It allows the operator to vary the arc characteristics from soft to crisp in most weld modes It is adjustable from 10 0 to 10 0 with a nominal setting of 00 0 The following are descriptions of the arc control functions for different weld processes Arc Force SMAW Range 10 soft to 10 crisp Arc force adjusts the short circuit current for a soft arc or a forceful driving arc to prevent sticking and shorting of electrodes Arc force is especially effective for the root pass on pipe with a stainless electrode and helps minimize spatter Pinch GMAW CV Range 10 soft to 10 crisp Pinch controls the current applied at a short circuit during short arc welding Frequency Modulation GMAW PP Range 10 low frequency to 10 high frequency Frequency Modulation controls the spacing of the ripples in the pulse on pulse weld Low frequency modulation is used for slow travel speeds while high frequency modulation is used for narrower welds Pulse Frequency GMAW P
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