ESAB BOMBARDIER SVI-450i User manual

F-15-565
February, 1999

2
BOMBARDIER, INC./ESAB WELDING SYSTEMS
Table of Content
Section I
1. Welding System Features
2. Operating Instructions
Section II
1. SVI  450i Po er Supply
Assembly D g. D-34055 ith Bill of Material
Schematic Diagram D-34308
Wiring Diagram D-34309
Wire Kit Bill of Material BM-31953
Control PCB D-31496
Po er PCB D-674991
Section III
1. Digipulse Dual Control
Assembly D g. D-(8) 33387
Schematic Diagram D-33380
Wiring Diagram D-33381
Wire Kit Bill of Material BM-33397
Display PCB D-675236
J-Gov PCB D-994236
I/O PCB D-674994
MPU PCB C-18155 & E-Prom A-18090
2. Digipulse Dual Wire Feeder
Assembly D g. D-37843 ith Bill of Material
(See Model No. 33299)
Section IV
1. The Welding System Revision History

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General
This dual pulse Mig elding system has been designed and manufactured to specifications provided by
Bombardier, Inc.. The soft are is modified to provide eight separate schedules for each torch. The first four
schedules (1-4) on each torch are dedicated to pulse elding of stainless steel in the synergic mode. The
second four schedules (5-8) are dedicated to short or spray arc elding and have no synergic relationships.
This means that IIPM and VOLTS are entered separately depending if a short arc or spray arc eld condition
is required. The follo ing ill detail the set-up and operation of this unique elding system.
Start Up
Assembly of the po er source, feeder and interconnect cable is the same as specified in the general oper-
ating instruction manuals provided ith the SVI-450i Po er Source and Digipulse Dual ire feeder. After
po er up of the SVI-450i (575 Vac) and the feeder, the indo s on the feeder ill display IPM=5 and
VOLTS=45 for a brief period. This indicates that the stainless steel program (same as a standard Digipulse)
is running and the synergic curve is for .045-inch (1.2 mm) diameter ire. These parameters CANNOT be
changed. The indo s ill then display the last elding parameters set by the operator. Place the Remote/
Panel s itch on the SVI-450i po er source in the Remote position and follo the instructions belo .
Selecting System Presets
System parameters are those that affect BOTH torches and ALL schedules. These parameters are al ays
active and should be set first. They are:
Gas preflo preset
Gas postflo preset
Cold inch preset
Trigger selection (dual schedule operation)
Half speed run-in
Set the shield gas preflo parameters by holding do n the Purge key and using the Inc/Dec key under
the IPM indo to set a preflo time in 1/10 seconds. Repeat the above for postflo using the key belo the
VOLTS indo .
The cold inching feature is a t o speed design. When placing the Inch key in the up position, the feed
motor ill operate at 50 ipm for a period of 2-1/2 seconds. This is for bumping the ire to adjust the ire
stick-out from the contact tip. After 2-1/2 seconds the ire feed speed ill transfer to the cold inching speed
sho n in the IPM indo . The ire feed speed can be further adjusted using the Inc/Dec key under the
IPM indo . This function is designed for ire threading.
The Trigger Selection option allo s dual schedule operation. This means that t o elding schedules are
available to the operator on each torch. This option is disabled hen Rocker S itch #4 on Dip S itch #2 is
in the closed position. Dip s itch #2 is located on the MPU board inside the feeder control box. Place this
s itch in the open position for Trigger selection (dual schedule operation). Welding ill al ays begin
using the current eld schedule selected. Double clicking the torch trigger s itch changes the elding
parameters to the next highest schedule number. See diagram belo .
Operating Instructions

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Example:
If pulse arc elding is being used in schedule #4, double click the torch trigger to s itch to the short/
spray arc parameters resident in schedule #5. Double click the torch trigger a second time causes
the eld parameters to s itch back to the pulse eld parameters in schedule #4. Releasing the torch
trigger stops elding.
The Trigger Selection function (dual schedule operation) is automatically disabled hen a spot eld time is
preset on that torch. See Torch Parameter Presets belo .
Half speed run-in is al ays on hen using the pulse arc schedules (1 to 4). Half speed run-in ill also be
on in the short/spray arc schedules (5 to 8) hen the arc voltage is 26 volts or higher. Belo 26 volts ill
result in full speed run-in of the elding ire. This option is enabled hen Rocker S itch #1 on Dip S itch #2
is in the open position. Dip s itch #2 is located on the MPU board inside the feeder control box . Place this
s itch in the closed position for full speed run-in for all elding schedules 1 to 8. This function is triggered
off the high open circuit voltage (OCV) of the SVI-450i po er source. Half speed run-in cannot be enabled
using po er sources having a lo OCV.

5
Torch Parameter Presets
Each torch can have the follo ing parameters or variables preset:
Schedule number preset
Wire burnback preset
Shielding gas type
Spot eld time
The soft are ill automatically s itch to the torch being used hen the torch trigger is depressed. Each torch
may have t o elding schedules assigned at a time hen using the Trigger Selection mode (described
above). The right side torch (vie ed from the front of the feeder) is the default torch setting. This means that
hen the feeder is first po ered up this torch and its parameters ill be displayed. If a red light bet een the
IPM and VOLTS display indo s is illuminated, the left side torch parameters are being displayed.
Choose the schedule number (1- 8) for each torch by depressing the Schedule Selection key and setting the
desired schedule number in IPM indo for the left torch and the VOLTS indo for the right torch.
Preset the desired bumback by depressing the torch trigger s itch to be preset. This action displays the
current elding parameters for that torch. Hold Burnback/Spot key in the up position and set a burnback
number in VOLTS indo . Repeat this procedure for the other torch.
Attach the desired gas mixture to the appropriate torch for the type of elding to be completed.
Caution - Some shielding gases ill not pulse arc and short arc equally ell. Therefore, the
optimization of both pulse arc and short/spray arc parameters ill be dependent on the shielding
gas and its ability to support both processes.
If spot elding is desired, depress the torch trigger s itch to be preset. This action displays the current
elding parameters for that torch. Hold the Burnback/Spot key in the up position and set a spot time in
seconds in the IPM indo . Repeat this procedure for the other torch if desired. Entering a spot eld time
automatically disables the Trigger Selection mode and dual schedule operation is not possible.
Wel Sche ule Parameter Presets
Pulse Arc Wel ing
Schedules 1 through 4 are dedicated pulse arc elding schedules for stainless steel using .045" (1.2 mm)
diameter ire. The synergic relationship is the same on each torch and for each schedule. When entering a
schedule number 1 to 4, the feeder control and po er source is automatically set for pulse elding ith .045"
stainless steel ire.
Note - The SVI-450i po er source slope s itch should be set to the STEEP slope position. The
INUCTANCE & VOLTAGE knob on the SVI-450i is deactivated.
The !PM indo ill display the ire feed speed in inches per minute and the VOLTS indo ill sho a
number bet een 0 and 200 ith 100 being the default value. These numbers relate to the synergic relation-
ship programmed into the soft are and correspond to a pulse frequency. The number 100 is the nominal
pulse frequency required for the ire feed speed selected in the IPM indo . This number ill also affect the
arc length. If the elding arc length is too long the number can be decreased hich shortens the arc length.
If the elding arc is too short, increase the number in the VOLTS indo . Each count in the indo changes
the pulse frequency by one pulse per second.

6
Short/Spray Arc Wel ing
When setting a schedule number 5 to 8, the feeder control and po er source is automatically set for short/
spray elding. The operator has full control over the slope and inductance of the po er source. The IPM
indo ill display the preset ire feed speed in inches per minute. The VOLTS indo ill display arc
voltage and can be adjusted to any arc voltage needed for a good elding condition by using the Inc/Dec
key under the VOLTS indo . The feeder control ill automatically adjust the po er source to maintain the
arc voltage set in the VOLTS indo . There is no synergic relationship present in the short/spray arc sched-
ules.
Arc Start (Servo) Settings
Each schedule on each torch can have its o n starting characteristic for any given eld parameter. The arc
start level must be set during elding. Choose desired schedule number and set a good elding condition.
If the arc starting is less than desirable it can be adjusted as follo s:
Depress the Purge and Schedule Select key simultaneously hile making a eld (t o man operation).
The VOLTS indo ill display a number bet een 0 and 200 (95 is the typical setting). Using the Inc/Dec
key belo the VOLTS indo , reduce the number sho n to give a hotter arc start or increase the number
for a colder arc start. Your setting ill be saved to that schedule and ill be recalled hen you select that
schedule again. Changes in ire feed speed and/or voltage might necessitate readjusting the voltage servo
to optimize starting characteristics. Repeat this procedure for other elding schedules being used.
Motor Servo Setting
You can adjust the feed motor response by presetting the motor speed servo. Release the pressure roll and
pull the torch s itch hile depressing the Purge and Schedule Select key simultaneously. Change the
number (110 is standard) in the IPM indo using the Inc/Dec key to a lo er value if a faster motor
acceleration is needed or a higher number for a slo er motor acceleration.
Warning - The motor response adjustment ill be in effect for ALL schedules and BOTH
torches. The servo number set in the IPM indo can be set exactly for the schedule
being used and ire feed speed preset but s itching to a different schedule having a
different ire feed speed setting ill cause the servo number in the IPM indo to vary
slightly. This is normal and should have little affect on elding performance.
Power Source Changes
The standard SVI-450i po er source has been modified to achieve the performance requested by Bombar-
dier, Inc. Pulse arc capability has been added and the V/A slope has been adjusted to Flat Slope = 3 V/100
Amps, Medium Slope = 4.5 V/100 Amps and Steep Slope = 6 V/100 Amps. A separate part number and
special dra ings have been established for this machine hich include a unique calibration procedure. Do
not attempt to use a standard SVI-450i po er source as a substitute.
A itional Features
Displaying Wel ing Parameters
The feeder ill display the actual elding conditions (IPM and Volts) during elding and ill retain these
values for 2-1/2 seconds after elding. After 2-1/2 seconds the display ill revert to the preset parameters.
To vie the last elding condition used, bump the torch trigger. The elding conditions ill be displayed.
Displaying Sche ule Numbers
The schedules selected for each torch can be vie ed by depressing the Schedule Select key on the feeder
control or depress and hold the torch trigger ( ithout elding).

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SVI-450i Power Supply Revision History
Rev. B
Changed the digital meter from P/N 951042 to P/N 951795 (Ref. Schematic Diagram Rev.A and Wiring
Diagram Rev. B)
Rev. C
Changed the color from L-TEC green to ESAB yello .
Rev. D
Added paint color suffix to Bill of Material for sheet metal P/Ns.
Rev. E
Changed the knobs from P/N 950814 (Alum) to P/N 13730611 (blk. / skirt).
Rev. F
Changed the 110V receptacle P/N 951033 (round) to P/N 952219 (square type snap-in).
Rev. G
Added a note to clarify assembly of isotrate insulators.
Rev. H
Changed C5 and C6 capacitors from P/N 950516 (.05 uf, 600 VDC) to P/N 951313 (.01 uf, 1000V),
moved cable assembly P/N 37096 from ire kit to top assembly, added resistors R11 and R12 P/N
17120110 (100 OHM, ½ W) (Ref. Schematic Diagram Rev. C and Wiring Diagram Rev. D)
Rev. J
Removed R11 and R12 Resistors P/N 17120110 (100 OHM, ½ W)
Changed R9 and R10 Resistors from P/N 17120110 (100 OHM, ½ W) to P/N 17130110 (100 OHM, 1W)
(Ref. Schematic Diagram Rev. B and Wiring Diagram Rev. C)
Schematic Diagram D-34308 Rev D
Updated schematic layout
Wiring Diagram D-34309 Rev E
Removed reference to: ICB P2-9 from ICB-P3-2 and ICB P3-2 from ICB-P2-9
Note:The most current revision of the rawing is always on top
Digipulse Dual Control Revision History
Rev. A
Added label P/N 954232 (Schedule Select) to front panel.
Rev. B
Removed the 6 pin (P/N 634772) and 8 pin (P/N 2062106) box receptacles and added a 19 pin (P/N
950762) box receptacle P/N 950762. (Ref. Schematic Diagram Rev.A and Wiring Diagram Rev. A)
Rev. C
Modified note 7 of the assembly dra ing and added the accessory support leads 1&2 to T1-20 of the
iring diagram. (Ref. Schematic Diagram Rev.A and Wiring Diagram Rev. B)
Rev. D
Changed from a green/light green cabinet ith L-Tec decals to a gray/yello cabinet ith ESAB decals,
changed CTR1 and CTR2 from a elded assembly ,added mounting bracket P/N 35477, and changed
the signal lead assembly from P/N 30685 to P/N 36644. Title Digmig Dual as changed to Digipulse
Dual. (Ref. Schematic Diagram Rev.B and Wiring Diagram Rev. C)
Digipulse Dual Wire Feeder Revision History
Rev. A
Re-designed the base and reel support , changed the color from L-Tec green to ESAB gray/yello
Note:The most current revision of the rawing is always on top

F-15-565 2/99