Pipe and Tube Operations - Daytona

LIBURDI DIMETRICS
PIPE and TUBE WELDERS

GTAW PORTABLE
WELDING SYSTEMS
OPERATIONS MANUAL
REV 7
Liburdi Dimetrics Corporation

404 ARMOUR STREET
DAVIDSON, NC 28036
+1-704-892-8872 PHONE
+1-704-892-4713 FAX
Pipe and Tube Operations Manual P/N 332-6000-906
1
LIBURDI DIMETRICS
PIPE and TUBE WELDERS
GTAW
PORTABLE
WELDING SYSTEM
OPERATIONS MANUAL
Rev 7
Liburdi Dimetrics Corporation

404 ARMOUR STREET
DAVIDSON, NC 28036
+1-704-892-8872 PHONE
+1-704-892-4713 FAX

2
THIS DOCUMENT AND THE INFORMATION
CONTAINED HEREIN ARE TRADE SECRETS OF AND
PROPRIETARY TO LIBURDI DIMETRICS CORP (LDC).
IN CONSIDERATION FOR LDC FURNISHING THIS

INFORMATION, RECIPIENT AGREES TO USE THE
INFORMATION ONLY FOR THE PURPOSES FURNISHED
BY LDC AND FURTHER AGREES NOT TO DISCLOSE
THIS INFORMATION TO OTHERS WITHOUT THE
PRIOR WRITTEN CONSENT OF LDC.
THIS NOTICE SHALL APPEAR ON ANY

REPRODUCTION OF THIS DOCUMENT, WHOLE OR IN
PART. THE FOREGOING PROVISIONS ARE SUBJECT
TO ANY RIGHTS WHICH THE GOVERNMENT OF THE
UNITED STATES OF AMERICA MAY HAVE ACQUIRED
IN SUCH INFORMATION.
THIS INFORMATION IS EXEMPTED FROM

DISCLOSURE UNDER 5 U.S.C §552(B)(4) OF THE
FREEDOM OF INFORMATION ACT.

3
Revision History
3-Aug-05
• Initial Documentation
Rev A. 26-Aug-05
• Added proprietary info page.
Rev B. 12-Dec-05
• Added Hotwire and IO expansion info.
Rev C. Aug 2006

• Combined operations manuals into single pipe and tube operations
Rev 4-Feb 2007

• Revised Installation Use and Precautions for UL conformance
• Added parameter definitions for MIG, DSP and PULSE MODE
• Added Torch Oscillation Diagram
• Added Trouble Shooting Section
• Added MFC Parameters and flow rate calibration
• Revision number modified to use numbers rather than letters
Rev 5-Aug 2007

• Added explanations of new features in software version 2.0 (Weld Head
management, HW Configuration)
• Updated calibration operations and screen layouts
Rev 6-Aug 2007

• Added keypad layout for new Daytona based PTW160. This is referred to as the
All-in-One keypad since it has the keypad and LCD screen integrated as a single
unit unlike the legacy keypad with a separate LCD.
Rev 7-Feb 2008

• Added descriptions for Heat Input, position fault and IPM, new features of the
software. Added oscillator calibration procedure description.

4
Table of Contents
Chapter 1 Introduction ........................................................................................................ 8
Copyright Notice............................................................................................................. 8
Disclaimer ....................................................................................................................... 8
Installation and Use Precautions..................................................................................... 8
A. Electromagnetic Compatibility ........................................................................... 9
B. Safety Precautions............................................................................................. 11
C. Glossary of Markings and Graphical Symbols ................................................. 17
D. Power Supply Duty Cycle................................................................................. 17
Chapter 2 System Installation ........................................................................................... 18
Introduction................................................................................................................... 18
Receiving Equipment.................................................................................................... 18
Preparation .................................................................................................................... 18
System Checks .............................................................................................................. 18
Prime Power Service Requirements and Connections.................................................. 18
Weld Parameter Specifications ..................................................................................... 18
Customer Service .......................................................................................................... 20
Chapter 3 Controls and Functions..................................................................................... 21
Production/Teach Mode................................................................................................ 21
Cursor Control Keys ................................................................................................. 23
Changing Display Screens ........................................................................................ 23
Screen Navigation Chart ............................................................................................... 24
START Key .............................................................................................................. 25
SEGMENT ADVANCE Modes ................................................................................... 25
HOME Key (Legacy Keypad) .................................................................................. 27
Travel Homing .............................................................................................................. 27
Servo Motor Jogging (Legacy Keypad)........................................................................ 28
Servo Motor Jogging (All-in-One Keypad).................................................................. 28
STOP Key ................................................................................................................. 30
NUMERIC Keys........................................................................................................... 31
ENTER Key .............................................................................................................. 32
Entering Parameters .................................................................................................. 32
CLEAR Key.............................................................................................................. 33
PURGE Key.............................................................................................................. 34
TEST / WELD Key....................................................................................................... 36
Calibration Features ...................................................................................................... 37
Travel Calibration ..................................................................................................... 37
Verifying the Current Calibration............................................................................. 41
Current Calibration ................................................................................................... 42
Voltage Calibration................................................................................................... 45
Wire Feed Rate Calibration ...................................................................................... 48
Lift Gap Test ............................................................................................................. 50
Hotwire Calibration .................................................................................................. 50
5
Oscillator Limit Calibration...................................................................................... 52
MFC Flow Rate Calibration...................................................................................... 54
DATA LOG Mode........................................................................................................ 56
REPORT Mode............................................................................................................. 57
PRINT Key (Legacy Keypad) ...................................................................................... 59
DATA Key and PRINT Softkey (All-in-One Keypad) ................................................ 59
Data Log Functions....................................................................................................... 59
COPY Key .................................................................................................................... 61
Copying a Weld Schedule............................................................................................. 61
Copying a Segment ....................................................................................................... 63
LOAD Key.................................................................................................................... 64
Loading a Weld Schedule ............................................................................................. 64
Scaling a Weld Schedule .............................................................................................. 66
SAVE Key .................................................................................................................... 68
Saving a Weld Schedule ............................................................................................... 68
Deleting and Renaming Weld Schedules...................................................................... 70
Changing Passwords ..................................................................................................... 72
CTRL Key..................................................................................................................... 75
Setting the Time and Date Stamp ................................................................................. 76
Chapter 4 Programming Operations ................................................................................. 78
LOGO Screen................................................................................................................ 78
INITIAL Screen ............................................................................................................ 78
INITIAL Screen Parameters ......................................................................................... 79
SETUP Screen .............................................................................................................. 80
SETUP Screen Parameters............................................................................................ 80
AVC SETUP Screen ..................................................................................................... 83
AVC SETUP Screen Parameters .................................................................................. 83
LIMITS Screen ............................................................................................................. 84
LIMITS Screen Parameters........................................................................................... 85
SEGMENT Screens ...................................................................................................... 86
Tube Welding Segment Screen with wire feed......................................................... 87
Pipe Welding Segment Screen with oscillation ........................................................ 87
Dual Synch Pulse Segment Screen ........................................................................... 87
MIG Welding Segment Screen ................................................................................. 88
Pipe Welding Segment Screen with Auxiliary Axis................................................. 88
Pipe Welding Segment Screen with Rotary Axis programmed in IPM.................... 88
SEGMENT Screen Parameters ..................................................................................... 88
Using Torch Oscillation................................................................................................ 92
Maximum Output Current............................................................................................. 92
Overriding a Weld Schedule......................................................................................... 93
LOAD DIRECTORY Screen........................................................................................ 93
SCHEDULE LOADING Screen................................................................................... 93
SAVE SCHEDULE Screen .......................................................................................... 94
SAVE CONFIRMATION Screen................................................................................. 94
COPY FUNCTIONS Screen......................................................................................... 94
COPY FUNCTIONS Screen Parameters...................................................................... 94
6
Some Notes about USB memory devices ..................................................................... 95
A/D CALIBRATION Screen........................................................................................ 96
TIME/DATE SETUP Screen........................................................................................ 96
WELD SERIAL NUMBER Screen .............................................................................. 96
OVERRIDE SETUP Screen ......................................................................................... 97
WELD HEAD MANAGEMENT screen...................................................................... 97
HW CONFIGURATION screen................................................................................. 100
Chapter 5 Modbus Network Interface............................................................................. 103
Digital Outputs........................................................................................................ 103
Digital Inputs .......................................................................................................... 106
Output Registers...................................................................................................... 108
Input Registers ........................................................................................................ 112
Enumerations .......................................................................................................... 116
Exception Status Byte ............................................................................................. 118
Chapter 6 Troubleshooting Guide................................................................................... 119
Error Messages............................................................................................................ 119
INDEX .................................................................................................................... 122

7
Chapter 1 Introduction
The Liburdi Dimetrics Corp., family of pipe and tube welders are technologically
advanced welding power supplies of superior design providing unsurpassed welding
capabilities. These technologies and design features allow for precise control of all
aspects of the weld current giving the operator the ability to make precision welds with
complete control over weld bead penetration.
Copyright Notice
Liburdi Dimetrics Corp., has prepared this manual for use by only Liburdi personnel and
its customers as a guide for the proper installation, operation and maintenance of Liburdi
Dimetrics equipment. The contents of this manual, including but not limited to all
drawings, specifications or information is proprietary and the property of Liburdi
Dimetrics Corp.. Any unauthorized use or disclosure of such contents or any of the
drawings, specifications or information contained herein for manufacture, sale or
otherwise is prohibited; nothing contained herein shall be reproduced, stored or
transmitted in whole or in part by any means whatsoever without the express prior written
consent of Liburdi Dimetrics Corp.. In receiving this manual, the recipient acknowledges
the proprietary nature of the material and agrees to take all steps necessary to preclude
disclosure of the manual and the proprietary information contained herein to any third
party and will maintain the manual and proprietary information in strictest confidence.
Disclaimer
WARNING! ! CAUTION!
A high voltage, high energy ignition system is used to ignite and establish the
welding arc. Liburdi Dimetrics does not warrant or assume responsibility for
damage to equipment not supplied by Liburdi Dimetrics Corp.
Installation and Use Precautions
WARNING! SHOCK HAZARD!

DO NOT OPEN THIS UNIT UNLESS YOU ARE PROPERLY TRAINED TO
SERVICE THE INTERNAL COMPONENTS!
DISCONNECT INPUT POWER BEFORE OPENING!

8
A. Electromagnetic Compatibility
The power supply is primarily intended for use in an industrial environment.
Difficulties in ensuring electromagnetic compatibility may be experienced if this
equipment is used in other environments, such as domestic or commercial office
establishments.
The user is responsible for installing and using this equipment in accordance
with instructions provided in the Maintenance and Service Manual. If electromagnetic
disturbances are detected, the user is responsible for resolving the situation with
technical assistance from Liburdi Dimetrics Corp. and from manufacturers of any other
associated equipment. In some cases the solution may be as simple as earthing the
welding circuit (see Note below). In more extreme cases it could involve constructing an
electromagnetic screen enclosing the power source and work, complete with associated
input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons. Changing the
earthing arrangements should only be authorized by a person who is competent to
assess whether the changes will increase the risk of injury, e.g. by allowing
parallel welding current return paths which may damage the earth circuits of other
equipment. Further guidance is given in IEC TC26(sec)94, Arc welding
equipment installation and use. Also see Paragraph A.2.e below.
1. Assessment of Area
Before installing welding equipment the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The following shall be taken
into account:
a. Other supply cables, control cables, signaling and telephone cables; above,
below and adjacent to the welding equipment.
b. Radio and television transmitters and receivers.
c. Computer and other control equipment.
d. Safety critical equipment, e.g. guarding of industrial equipment.
e. The health of the people around, e.g. the use of pacemakers and hearing aids.
f. Equipment used for calibration or measurement.
g. The immunity of other equipment in the environment. The user shall ensure
that other equipment being used in the environment is compatible. This may require
additional protection measures.
h. The time of day that welding or other activities are to be carried out.
Note: The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The surrounding area
may extend beyond the boundaries of the premises.
2. Methods of Reducing Emissions

9
a. Mains Supply: Welding equipment should be connected to the mains supply
according to the instructions provided in the "System Installation" section of this
Operations Manuals. If interference occurs, it may be necessary to take additional
precautions such as filtering of the mains supply. Consideration should be given to
shielding the supply cable of permanently installed welding equipment, in metallic
conduit or equivalent. Shielding should be electrically continuous throughout its length.
The shielding should be connected to the welding power source so that good electrical
contact is maintained between the conduit and the welding power source enclosure.
b. Welding Equipment Maintenance: The welding equipment should be
routinely maintained according to instructions provided in the Operations and
Maintenance Manuals, P/Ns 328-5000-902 and 328-5000-906, respectively. All access
and service doors and covers should be closed and properly fastened when the welding
equipment is in operation.
The welding equipment should not be modified in any way except for those
changes and adjustments specifically covered in the Operations Manual, the
Maintenance Manual, and/or other Liburdi Dimetrics' drawings or specifications. In
particular, the spark gaps of arc striking and stabilizing devices are factory set using Hi-
pot test equipment. To insure consistency and compatibility, the spark gap (spark plug)
and other arc ignition components should not be readjusted in the field, and replacement
parts should be obtained only from Liburdi Dimetrics.
c. Welding Cables: The electrode and work welding cables should be kept as
short as possible and should be positioned close together (preferably strapped together or
installed together within a common jacket), running at or close to floor level.
d. Equipotential Bonding: Bonding of all metallic components in the welding
installation and adjacent to it should be considered.

Metallic components bonded to the workpiece will increase the risk that the
operator could receive a shock by touching these metallic components and the
electrode at the same time. The operator should be insulated from all such bonded
metallic components. Unless using heavy, insulating gloves, the operator should not
hold or touch metallic portions of welding torches during arc ignition.
e. Workpiece Earthing: Where the workpiece is not bonded to earth for

electrical safety, nor connected to earth because of its size and position, e.g. ships hull or
building steel work, a connection bonding the workpiece to earth may reduce emissions
in some, but not all instances. Care should be taken to prevent the earthing of the
workpiece increasing the risk of injury to users, or damage to other electrical equipment.
Where necessary, the connection of the workpiece to earth should be made by a direct
connection to the workpiece; but in some countries where direct connection is not
permitted, the bonding should be achieved by suitable capacitance, selected according to
National regulations. Also see Note under Paragraph A above.

10
f. Screening and Shielding: Selective screening and shielding of other cables
and equipment in the surrounding area may alleviate problems of interference. For some
special applications, it may be necessary to screen the entire welding installation.
Note: If necessary to meet electromagnetic compatibility requirements, the
workpiece can also be bonded to earth, unless prohibited by government regulations;
however, any fixtures, tooling, mechanisms, or anything which is connected to other
electrical equipment should remain insulated from the workpiece (insulated in the
vicinity of the workpiece), even if these items are eventually connected back to earth or
protective grounds via separate paths. Also see Note under Paragraph A and see
Paragraph A.2.e above.
Alternative - Equipotential Bonding: Minimize the cable length between
the power supply and the workpiece; and more importantly, provide very short bonding
straps between the frame of the power supply, the workpiece, fixtures, tooling,
mechanisms, and the frames of all other interconnecting equipment. The best scenario is
to mount all interconnecting equipment on a large metallic plate in order to keep all
system components equipotential at high frequencies. See Paragraph A.2.d and its
WARNING!
Even when using equipotential bonding, it is still recommended that all direct
connections between the power supply and other electrical equipment be made
using optical or relay isolation or using the alternative method given in Paragraph
A.3.a.
IMPORTANT!
The equipotential bonding approach is particularly important when the part to be welded
is mounted to and electrically connected to fixtures, tooling, or mechanisms which are
controlled by and connected to other electrical equipment. Short bonding straps reduce
voltage stresses during ignition. They also provide a safe arc ignition return path in the
event the WORK cable is inadvertently disconnected.
! CAUTION!
If using the insulation approach and the insulation is inadequate, or if using equipotential
bonding and the bonding straps and/or weld cables are too long, the high voltage ignition
pulse may generate an equipment damaging (voltage breakdown) return path through
motors, encoders, sensors, transducers, and/or connecting equipment to earthing ground
and back to the weld power supply.
B. Safety Precautions

11

Conduct a workplace hazard assessment before attempting to operate the
equipment. The equipment is NOT suitable for supplying power to welding
operations carried out in environments with increased hazard of electric shock.
Hazardous environments include, but are not limited to environments with
standing water or extreme humidity when it is impossible to avoid excessive
accumulation of condensation or perspiration. The equipment should never be operated
in the rain.
WARNING!
Familiarize yourself with and follow all safety standards and regulations.
Welding is safe when appropriate safety precautions and procedures are properly
observed. This section provides a number of welding safety procedures and guidelines:
The information presented here is not exhaustive and does not cover every possible
situation. The appropriate government regulatory agencies should be contacted for
additional safety information relating to welding and special situations.
In the USA, further information on welding safety standards and practices can be
obtained from the American National Standards Institute (ANSI), the American Welding
Society (AWS), the Compressed Gas Association (CGA), the National Fire Protection
Association (NFPA), and the Occupational Safety and Health Administration (OSHA).
WARNING!
Welding can be hazardous: Protect yourself and others from serious injury or
death. Keep unauthorized persons and children well away from the welding area.
Welding operations should only be performed by qualified personnel.
The following are some of the hazards which can be experienced during welding:
Hazardous Radiation, Fields, and Acoustic Noise
Hazardous Fumes and Gases
Electric Shock
Hazardous Hot Metal, Flying Particles, and Chips
Compressed Gas Cylinder Hazards
Hazardous Mechanisms or Moving Parts
12
Fire and/or Explosion Dangers
Hazardous Locations
1. Hazardous Radiation, Fields, and Acoustic Noise
a. Radiation:
WARNING!
Welding produces intense heat, light, and ultraviolet radiation. These forms of
radiation can cause serious skin burns and damage to the eyes.
i) Protect your eyes by wearing approved safety glasses with side shields and
by using a welding helmet or eye shield with the proper filter shade.
ii) Protect others from arc burn and glare by using protective screens or
barriers. Post warnings about possible eye damage and about not watching the arc.
iii) Wear protective clothing, gloves, and foot protection made from heat and
flame resistant materials such as leather.
b. Fields
The arc, weld power source, and associated cabling produce electromagnetic
fields.
WARNING!
Personnel wearing pacemakers should consult with their doctor before entering
welding areas.
c. Acoustic Noise
Some welding processes and associated equipment (such as grinders) produce
excessive acoustic noise.
WARNING!
Excessive noise can damage hearing: use ear protection when subjected to high
levels of acoustic noise.
2. Hazardous Fumes and Gases
WARNING!
Welding can produces hazardous fumes and gases and reduce the availability of
breathing air: fumes, gases, and lack of fresh air can be harmful.
a. Avoid and do no breathe welding fumes.

13
b. In case of poor ventilation or when welding in confined spaces, use approved
and safe respiratory equipment.
c. When welding inside enclosures or buildings, use equipment to remove fumes
and gases in the vicinity of the welding arc.
d. Do not weld near degreasing, cleaning, or spraying operations. Welding
operations can react with vapors to produce highly toxic gases or possibly cause an
explosion.
e. Familiarize yourself with and follow manufacturer's safety instructions and
Material Safety Data Sheets covering consumables, coatings, cleaners, and metals being
used.
f. Unless coatings or platings are removed from the area to be welded, be very
careful when welding galvanized metals or metals coated or plated with zinc, lead, or
cadmium. Welding such metals can produce toxic fumes. Either remove the coating
from the area to be welded, use equipment to remove fumes and gases in the vicinity of
the arc, and/or use approved and safe respiratory equipment.
3. Electric Shock
CONTACT WITH ELECTRIFIED PARTS CAN CAUSE SHOCK, SEVERE
BURNS OR EVEN DEATH!
a. Insure the equipment is properly installed with the protective conductor
properly connected according to the installation instructions and government regulations.
When connecting input power, always connect the protective conductor first.
b. Do not touch uninsulated electrical contacts, wires, and parts: Remember, the
electrode and work circuits are electrified whenever welding power is turned on.
Remember, welding wire is also electrified when fed into the arc.
c. Wear hole-free, dry, insulating gloves and body insulating materials.
d. Use dry insulating mats or covers to insulate yourself from work and ground,
especially when working in wet, humid, or confined spaces where contact with work or
ground is likely or inevitable.
e. Avoid contact with the electrode, especially when your body is also in contact
with the workpiece or ground.
f. Insure cables are in good condition: don't use damaged or worn cables.
g. Provide a good earthing ground connection to the workpiece, unless such
grounding is strictly prohibited by government regulations.
h. Before operating equipment, insure all covers and panels are securely in place.
14
i. Welding equipment should be well maintained and in good working order.
Avoid using poorly maintained equipment: replace or repair any damaged or poorly
operating equipment.
j. Insure all equipment is turned off when not in use.
4. Hazardous Hot Metal, Flying Particles, and Chips
WARNING!
Slag, molten or hot metal, and flying particles and chips produced by grinding, and
chipping can cause serious injury. Slag may be expelled as the weld cools down. In
addition, tack welds may suddenly break loose due to build up of thermal stresses.
a. Wear approved face shields and/or safety goggles with side shields.
b. Protect your body by wearing proper protective clothing and shoes.
c. Insure others in the near vicinity are also wearing proper clothes, shoes, and
eye protection.
d. Keep unauthorized or unprotected personnel away from the welding area.
5. Compressed Gas Cylinder Hazards
WARNING!
If damaged, compressed gas cylinders can explode or become hazardous projectiles.
a. Prevent gas cylinders from tipping over or falling by installing them in the
normal upright position and properly securing them to an approved cylinder rack or
stationary support.
b. Insure the protective cap is always in place when the cylinder is not
connected.
c. Protect gas cylinders from excessive mechanical shock, heat, and welding
arcs. Keep welding electrodes and cables well away from gas cylinders.
d. Use only regulators, hoses, fittings, and components approved for the specific
application. Maintain all cylinder components and accessories in good working
condition.
e. Keep your face away from the outlet when opening the cylinder valve.
6. Hazardous Mechanisms or Moving Parts
WARNING!
Contact with fans, belts, gears, and other moving parts can cause serious injury.

15
a. Do apply power and/or operate any equipment unless all panels, covers, and
guards are in place and properly secured.
b. Do not open the equipment unless you are properly trained to service the
internal components. Disconnect input power before opening any equipment.
c. Insure all panels, covers, and guards are properly reinstalled and secured after
performing any equipment servicing or maintenance operations.
d. Keep hair, loose clothing, hands, tools, and other objects away from all
moving parts.
7. Fire and/or Explosion Dangers
WARNING!
Welding produces intense heat, sparks, spatter, and hot or molten metal which can
cause fire and/or explosion.
a. Do not weld in the vicinity of flammable materials or vapours. Remove all
flammable materials from the area. If this is impossible, shield or cover all flammable
materials with appropriate and approved covers.
b. Remain alert and on the lookout for fire. Insure a fire extinguisher is nearby:
know its location and be familiar with how to use it.
c. Connect the work cable to the workpiece as close as possible to the area being
welded. Avoid poor or long and involved work connections which could cause hot spots
and fire hazards.
d. Avoid welding on closed or liquid filled containers.
e. Avoid accidental arcing and sparking produced by inadvertent contact
between the electrode and the workpiece or ground. Don't leave the welding torch or
electrode in an area where it accidentally contacts the workpiece or ground.
f. Insure the welding power can not be accidentally turned on when not welding.
g. Wear protective oil-free clothing, such as leather gloves, a heavy shirt or
jacket, cuffless trousers, high shoes, and a cap.
8. Hazardous Locations
WARNING!
Be extra careful when welding in hazardous locations.
a. See guidelines under Paragraph B.7 above, "Fire and/or Explosion
Dangers."
b. Wear a safety harness when working in elevated positions.
c. When working in confined, humid, damp, or wet spaces where contact with
work or ground is likely or inevitable, use dry insulating mats or covers to insulate you
from work and ground.

16
d. Wear a "Hard Hat" in locations where there is any possibility of being hit by
falling objects.
e. Use proper means and equipment for lifting, supporting, and/or transporting
equipment. Do not exceed the capacity of any lifting, supporting, and/or transporting
equipment.
C. Glossary of Markings and Graphical Symbols
Marking or Symbol Meaning

For Operating Controls See the “Controls and Functions” section of this
manual
WARNING! WARNING means possible serious hazard: injury

or even death could occur!
! CAUTION! CAUTION means possible equipment damage or
minor injury could occur.
SHOCK HAZARD means possible injury or even
SHOCK HAZARD!
death could occur from electrical shock!
This symbol CAUTIONS that in order TO
CAUTION: TO REDUCE THE RISK OF ELECTRICAL SHOCK, REDUCE THE RISK OF ELECTRICAL SHOCK,
DO NOT OPEN COVER
DO NOT OPEN EQUIPMENT COVER: it also
notes there are NO USER SERVICEABLE PARTS
INSIDE and REFERS SERVICING TO
QUALIFIED SERVICE PERSONNEL. This
NO USER SERVICEABLE PARTS INSIDE
means there are potential shock hazards inside the
REFER SERVICING TO QUALIFIED SERVICE PERSONNEL equipment; therefore, only qualified service
personnel should open and service the equipment.
D. Power Supply Duty Cycle

Liburdi Dimetrics power supplies are capable of continuous operation and are
rated for 100% duty cycle. Duty cycle is defined as the ratio of arc time to total time.

17
Chapter 2 System Installation
Introduction
THANK YOU for purchasing your welding equipment from "LIBURDI DIMETRICS".
The pipe and tube welder, herein after referred to as the power supply, will provide many
years of service, if the GUIDELINES, NOTES, INSTRUCTIONS, WARNINGS and
CAUTIONS found in this manual are closely followed.
It is strongly recommended that the operator completely read and understand the
contents of this manual before attempting to install, program or operate this
equipment.
Receiving Equipment
Liburdi Dimetrics has packaged this equipment using the best of materials and proven
shipping methods. Once the shipment departs Liburdi Dimetrics, all responsibility is
transferred to the freight company for the safe delivery of equipment to its destination.
Upon delivery, the receiver will inspect the shipping container and note any minor crate
damage on the freight bill.
Should the crate be excessively damaged, INSTEAD OF UNCRATING notify the
shipper immediately.
After a thorough visual inspection of the exterior of the shipping container, place the
equipment in the general area where it will be used and carefully uncrate the equipment.
Perform a thorough inspection of the equipment externally and internally for any
concealed damage.
Please contact Liburdi Dimetrics immediately if the equipment has sustained concealed
shipping damage. The freight company will be called to inspect the package and
equipment before any claim can be settled on our part.
Preparation
Inventory and organize all items on the shipping manifest, including the Operations
Manual, to ascertain that all of the items were received and are in good condition.
System Checks
Once the preparation is satisfactorily completed the following system checks and
connections should be performed, in order, before the unit is actually turned on.
Prime Power Service Requirements and Connections
The prime power input required depends on the model of the Liburdi Dimetrics power
supply. Refer to the maintenance manual for the power requirements.
Weld Parameter Specifications
Parameter Descriptions Range Resolution
Number of Programs 1 – 100

Number of Segments per Program 1 – 16
18
INITIAL PARAMETERS:
Pre Purge 0 - 999 Seconds 1 Second
Post Purge 0 – 999 Seconds 1 Second
Travel Delay 0 – 99.9 Seconds 0.1 Second
Down Slope 0 – 99.9 Seconds 0.1 Second
Wire Delay 0 – 99.9 Seconds 0.1 Second
Wire Retract Distance 0 – 2.0 Inches 0.01 Inch
Segment Advance Mode TIMED, MANUAL or
POSITION
Operation Mode WELD or TEST
SEGMENT PARAMETERS:
Segment Time 0 - 999.9 Seconds 0.1 Second
Slope Time 0 – 999.9 Seconds 0.1 Second
Primary/Background Current Amperes** 0.1 Ampere
Pulse Frequency Hz** 0.1 Hz
Pulse Width 1 - 100 Percent 1 Percent
Primary/Background Travel Rate IPM/RPM* 0.01 RPM
Primary/Background Wire Rate IPM* 0.1 IPM
Primary/Background Voltage Volts** 0.1 Volt
Oscillation Width Inches* 0.01 Inch
Oscillation Excursion Time 0 – 2.5 Seconds 0.01 Second
Oscillation Dwell 0 – 2.5 Seconds 0.01 Second
Theta Angle Degrees* 0.1 Degree
Rotation Angle Degrees* 0.1 Degree
SETUP PARAMETERS:
Impulse Time 3 - 99 Milliseconds 1 Millisecond
Impulse Amps Amperes** 1 Ampere
Initial Amps Amperes** 0.1 Ampere
Final Amps Amperes** 0.1 Ampere
Travel Jog Rate IPM/RPM* 0.01 RPM
Osc Jog Rate IPM* 1 IPM
AVC Jog Rate IPM* 1 IPM
Wire Jog Forward IPM* 1 IPM
Wire Jog Reverse IPM* 1 IPM
Theta Jog Rate Degrees per second* 1 Degree/s
Rotation Jog Rate Degrees per second* 1 Degree/s
Overrides 1 - 100 Percent 1 Percent
Flow Rate CFH** 0.1 CFH
Gas Mix % 0 – 100 Percent 0.1 Percent
AVC Sensitivity 0.0 – 1.0 Scalar 0.01
AVC Start Delay 0 – 99.9 Seconds 0.1 Second
AVC Stop Delay 0 – 99.9 Seconds 0.1 Second
* Default value depends on the weld head selected.

** Default value depends on the power supply.
19
Customer Service
If you encounter a problem with your Liburdi Dimetrics equipment, call (800) 666-9353
or (704) 892-8872 and ask for Customer Service.

20
Chapter 3 Controls and Functions
This manual will cover the operation of the legacy keypad / LCD screen (which is a 2
piece unit) and the new all-in-one interface unit. The key functions are basically the
same on both interfaces but there are differences which will be noted. One large
difference is the presence of configurable softkeys below the LCD screen on the new
unit. These keys can be enabled/disabled and assigned to different functions depending
on the configuration of the machine or weldhead attached.
Legacy Keypad and LCD Screen
New All-in-One Unit
Production/Teach Mode
In the PRODUCTION mode, weld schedules may not be created, saved, deleted, edited,
or copied. Parameter scaling is limited to the scaling percentage entered in the SETUP
screen
In the TEACH mode, all keypad functions are active and schedules can be created,
saved, deleted, edited or copied as required.
To change the mode, do the following:

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1. Press the CTRL and STOP keys together. This will access the password
screen:
ENTER PASSWORD FOR PROGRAMMING
PASSWORD: XXXX
WWW.LIBURDI.COM VERSION X.XX.XX
To change to TEACH mode, do the following:

2. Enter the teach mode password.
3. Press the ENTER key.
To change to PRODUCTION mode, do the following:

2. Press the CLEAR key.
RED GREEN RED GREEN RED GREEN
POWER SEQ SEQ MANUAL WELD

HOME
ON START STOP PURGE TEST
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4 5 6 PRINT COPY
START HOME 7 8 9 LOAD SAVE
STOP ENTER 0 CLEAR CTRL

Legacy Keypad

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All-in-One Keypad
Cursor Control Keys

The CURSOR CONTROL keys will move the CURSOR in the direction of the arrow
indicated on that key. The CURSOR CONTROL keys are used during programming to
position the CURSOR over a given parameter so as to allow that value to be modified or
deleted using the key pad.
The CURSOR CONTROL keys are also used with the CTRL key to change to another
display screen.
Changing Display Screens

In order to access the various weld schedule parameters and to execute the different
operator functions of the power supply, the operator must navigate to the appropriate
screen. Display screens may be changed from one to another in a fixed order by using
the CURSOR CONTROL keys while the CTRL key is depressed and held. The
diagram labelled Screen Navigation Chart, which follows, illustrates how to change
from one display screen to another. For example, to go from the INITIAL screen to the
LIMITS screen, depress and hold the CTRL key and press the ← key. Note that
according to the diagram, this only works in TEACH mode. Refer to the legend that
accompanies the diagram. It indicates which key to use to go in which direction on the
diagram. Note also that the ↑ and ↓ keys are used to bring up each SEGMENT screen,
from segment 1 to segment 16 successively.

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Screen Navigation Chart

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Legacy Keypad

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All-in-One Keypad
START Key
The START key is associated with the SEQ START LED, located directly above the ↓
key. The SEQ START LED will be illuminated during a weld sequence.
When the power supply is not in sequence, the START key initiates a weld sequence.
When the power supply is already in sequence, the START key will cause the power
supply to advance the sequence to the next segment. If there are no more active
segments, the START key will cause the power supply to advance the sequence into
DOWN SLOPE. The START key is disabled during DOWN SLOPE and POST
PURGE.
SEGMENT ADVANCE Modes

There are 3 segment advance modes, TIMED, MANUAL and POSITION. The default
is TIMED.
TIMED mode indicates that the sequencing from one segment to the next is determined
by the SEG TIME programmed in each segment. The SEG TIME is expressed in
SECONDS. Depressing the START key while in sequence will advance the power
supply to the next segment, ignoring the SEG TIME that remains.
MANUAL mode disables segment timing by the power supply. In this mode, the SEG
TIME parameter is ignored, and the sequence will remain in the current segment until
the START key is depressed to cause a manual segment advance.
POSITION mode indicates that the sequencing from one segment to the next is
determined by the DISTANCE programmed in each segment. The DISTANCE is
expressed in DEGREES or REVOLUTIONS for orbital weld heads with travel speed
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expressed in RPM or INCHES for linear weld heads with travel speed expressed in IPM.
If the weld head is not able to supply position feedback to the controller for the travel
axis the controller will not work in POSITION mode. Depressing the START key while
in sequence will advance the power supply to the next segment, ignoring the DISTANCE
that remains.
To change the SEGMENT ADVANCE mode:

1. The power supply must be in TEACH mode, and the power supply must not be in
sequence.
2. The SEGMENT ADVANCE mode parameter appears on both the INITIAL and the
SEGMENT screens, but may be changed only from the INITIAL screen. Change the
display to the INITIAL screen, if it is not already displayed, which will appear as
follows:
SCHED: #### TOTAL SEGMENTS = ##
PRE PURGE = ### POST PURGE = ###

TRAVEL DELAY = ##.# DOWN SLOPE = ##.#
WIRE DELAY = ##.# WIRE RETRACT = #.##
----------------- MODES -----------------

TIMED TEACH
3. Position the cursor over the word MANUAL, TIMED or POSITION whichever is
displayed.
4. Depress the ENTER key on the key pad to change the value.

HOME
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Legacy Keypad

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All-in-One Softkey Screen
HOME Key (Legacy Keypad)

The HOME key and the associated HOME LED, located directly above the 3 key,
control two different functions: homing and jogging.
NOTE: A separate HOME key does not exist on the All-in-One

keypad but is set to one of the five softkeys. The softkey will only
function and only show the state of the HOME LED if the homing
function is supported by the weldhead. Since this is a softkey it
could be remapped to any of the five softkeys and may not by the
same as the above diagram.
Travel Homing
Depressing the HOME key by itself will cause the TRAVEL rotor to move to the open
rotor or HOME position on a closed weld head. The HOME LED will be illuminated
whenever the TRAVEL rotor is in motion while homing, and also during portions of the
Travel Calibration procedure. Refer to Travel Calibration (pg 37) for more
information about calibrating the TRAVEL rotor.
NOTE: The HOME key is disabled during a weld sequence.

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Servo Motor Jogging (Legacy Keypad)
Depressing both the CTRL key and the HOME key together will cause the TRAVEL
axis to begin jogging. The TRAVEL axis will continue to jog until the HOME key is
released. The jog speed will be slow at first and will accelerate to the programmed
TRAV JOG RATE after approximately 2 seconds. This action allows very accurate
positioning of the TRAVEL rotor, and also allows rapid movement for longer distances.
Each time a travel jog is initiated, movement will be in the opposite direction. To jog
again in the same direction, the operator must hold the CTRL key depressed and press
the HOME key twice. The HOME LED is extinguished during jogging.
If the weld head has additional servo motors these can also be jogged in the same manner
as the travel motor using different CTRL key combinations. The combinations are as
follows:
CTRL+HOME Travel CTRL+5 Theta

CTRL+1 Wire CTRL+6 Auxiliary Servo 0
CTRL+2 AVC CTRL+7 Auxiliary Servo 1
CTRL+3 Oscillation CTRL+8 Auxiliary Servo 2
CTRL+4 Wire #2 CTRL+9 Auxiliary Servo 3
Servo Motor Jogging (All-in-One Keypad)

Depressing both the CTRL key and a number key together will cause the jog axis to be
selected and displayed on the screen. Number keys 1 – 4 are labelled with their axis
selection, namely TRAVEL, WIRE, AVC and OSC (oscillation).
All-in-One Screen and Keypad
The selected axis (Travel in the above picture) will jog in the forward direction when the
JOG+ key is pressed and continue to jog until this key is released. The selected axis
(Travel in the above picture) will jog in the reverse direction when the JOG- key is
pressed and continue to jog until this key is released. The jog speed will be slow at first
and will accelerate to the programmed axis jog rate after approximately 2 seconds. This
action allows very accurate positioning of the axis, and also allows rapid movement for
longer distances.
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If the weld head has additional servo motors these can also be selected and jogged in the
same manner using different CTRL key combinations for selection. The combinations
are as follows:
CTRL+1 Travel CTRL+6 Theta

CTRL+2 Wire CTRL+7 Auxiliary Servo 0
CTRL+3 AVC CTRL+8 Auxiliary Servo 1
CTRL+4 Oscillation CTRL+9 Auxiliary Servo 2
CTRL+5 Wire #2 CTRL+0 Auxiliary Servo 3

HOME
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Legacy Keypad

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All-in-One Keypad
STOP Key
The STOP key is associated with the SEQ STOP LED. The SEQ STOP LED is
illuminated during the DOWN SLOPE and POST PURGE portions of the weld
sequence.
When the power supply is not in sequence, the STOP key is disabled. When the power
supply is in sequence, but has not yet progressed to DOWN SLOPE, the STOP key will
cause the sequence to advance into DOWN SLOPE. If the sequence is in DOWN
SLOPE, the STOP key will cause the arc to extinguish and the sequence to advance into
POST PURGE. Depressing the STOP key twice in succession will have the effect of
immediately extinguishing the arc and advancing directly into POST PURGE.

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Legacy Keypad

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All-in-One Keypad
NUMERIC Keys
The NUMERIC keys are used to enter new values into the numeric parameter fields in
each screen. The edited value will be accepted when the ENTER key is depressed, or
will be restored to the original value if the CLEAR key is depressed instead.

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Legacy Keypad

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All-in-One Keypad
ENTER Key
The ENTER key is used to accept new values into the numeric parameter fields of the
display screens, and to choose one of several values for the alpha parameter fields. When
the CURSOR is positioned over an alpha field, a new text message will be displayed
each time the ENTER key is depressed. Incorrect keystrokes can be corrected by
depressing the CLEAR key.
Entering Parameters
The following steps illustrate the process of entering weld file parameters:
1. Move the cursor to the position where parameters are to be entered or edited.
2. Enter the desired value by depressing the appropriate NUMERIC keys.
3. Depress the ENTER key.
NOTE
If the ENTER key is not pressed after entering a value, the
new value will not be retained when the cursor is moved.
The key pad does not have a decimal point, so only whole number values can be
entered. It should be noted that some fields have an associated decimal point
permanently affixed and, if so, a decimal point will be displayed. If a decimal quantity is
needed, key in the quantity and you will note that the first digit entered will appear in the
right most position. As additional quantities are entered the numbers will shift to the left,
leaving the last digit(s) behind the decimal point.

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Example: To enter the decimal quantity of 50.25, enter the whole number 5025. The
display will show the proper quantity. Some parameters have no decimal point, while
others may have one, two or three places behind the decimal point.

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Legacy Keypad
All-in-One Keypad
CLEAR Key
The CLEAR key is used to clear incorrect keystrokes, terminate any system fault
indications and erase unwanted commands.

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HOME
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Legacy Keypad
All-in-One Keypad
PURGE Key
The PURGE key controls the MANUAL PURGE function, and is associated with the
MANUAL PURGE LED directly above it. The MANUAL PURGE LED is illuminated
when a PURGE operation is occurring. When the power supply is turned on, the
MANUAL PURGE LED is off, indicating that no PURGE is taking place.
When the power supply is sequencing in the WELD mode, the PURGE key is disabled,
and control of the PURGE operation is maintained automatically by the power supply.
When the power supply is not in sequence, the PURGE key is used to initiate a
MANUAL PURGE.

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The MANUAL PURGE operation consists of two steps. The first time the purge key is
pressed the coolant pump will turn on, allowing coolant to flow through the weld head.
The second time the purge key is pressed, the inert gas solenoid will open, allowing
shield gas to flow to the weld head. Pressing the PURGE key a third time will terminate
any PURGE operations in progress (except when sequencing in WELD mode). On
some systems the coolant pump and inert gas solenoid are electrically tied to the same
switch. On these systems, the purge key will turn on both the coolant pump and gas
solenoid with a single key press and turn off both the coolant pump and gas solenoid with
a second key press.

HOME
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Legacy Keypad
All-in-One Keypad

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TEST / WELD Key
The TEST key on the legacy keypad and the WELD key on the All-in-One keypad
enables the operator to choose between the WELD and TEST modes of operation, and is
associated with the WELD/TEST LED located directly above it. The WELD/TEST
LED is illuminated in WELD mode and extinguished in TEST mode.
When the power supply is turned on, the WELD/TEST LED is off, indicating that the
power supply is in the TEST mode. The WELD and TEST modes will determine which
course of action the power supply will take during a weld sequence. In the TEST mode,
the power supply will not strike an arc and gas and coolant will not flow, since the gas
supply valve will be closed and the coolant pump will be turned off. In the WELD
mode, gas and coolant will flow to the head, and the power supply will strike an arc.

Serious shock could occur to the operator if the power supply is
sequenced in WELD mode while the weld head is not attached to the
work piece.
In addition to its normal function, on the legacy keypad the TEST key is used in
conjunction with the CTRL key to access the A/D calibration menu. On the All-in-One
keypad the A/D calibration menu is accessed from one of the five softkeys.
All-in-One Softkey Screen

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Before the operator is granted access to the calibration menu, the power supply will
request the system administration password.
NOTE: The TEST / WELD key is disabled during a weld sequence.
Calibration Features
The A/D calibration menu provides access to the travel, current, voltage, wire, lift gap
and hotwire calibration functions. These features measure errors in the control signals
used by the system. These measurements are used to calculate a correction factor for the
analog/digital signals that interface the computer to the weld head and the power supply
and also calibrate the data acquisition system used to record the weld data. Depressing
the CTRL key and the TEST key at the same time will bring up the A/D Calibration
screen.
----------A/D CALIBRATION SCREEN-----------

TRAVEL
AMPS
VOLTS
WIRE
LIFT GAP
HOTWIRE
OSC LIMITS
FLOW RATE
The options available on the A/D Calibration Screen are dependant on the capabilities of
both the power supply and the weld head selected.
Travel Calibration
As a weld head is used over a period of time, small errors in travel calibration
may accumulate. To fully recalibrate the weld head requires a maintenance procedure
which must be done with the weld head removed from production. In order to avoid
removing the equipment from production for minor corrections, a procedure for
calibration has been implemented which enables the operator to apply a corrective gain
and offset to the commanded travel speed.

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NOTICE FOR CLOSED WELD HEADS
Due to the thermal characteristics of the motor/tachometer used in
the travel servo, a noticeable drift will occur in actual versus
commanded travel speed as the weld head warms up, resulting in
increasing travel speeds. The actual amount of drift will vary,
depending on the temperature of the weld head, but should not
exceed approximately 5% of the programmed travel speed, as
indicated by the Auto Calibrate Procedure. If this small drift is
significant to the application at hand, then the Auto Calibrate
Procedure should be performed periodically in between welds. As
the weld head reaches a stable temperature during successive weld
passes, the amount of further drift will diminish accordingly.
Follow these steps:
1. The power supply must not be in sequence, and the weld head to be calibrated
must be attached to the power supply. If the weld head has a HOME position
micro switch installed, the calibration will be performed automatically. If
there is no HOME position micro switch installed then the operator will have
to control the travel motor during calibration. Depress both the CTRL key
and the TEST key together to access the calibration screen. Select travel from
the menu. The start of the travel calibration sequence will be displayed.
TRAVEL CALIBRATION
ENTER TRAVEL SPEED

X.XX
PRESS ‘ENTER’ TO CONTINUE

PRESS ‘CLEAR’ to CANCEL
Auto-calibration (steps 2 and 3):
2. Enter the speed for the first point of calibration. Usually the primary travel
speed of the typical welding sequence is used for the first point of calibration
but the screen defaults to 80% of the maximum of the travel axis. After the
operator inputs the desired speed press the ENTER key. The screen above
will display again for the second point of calibration and default to 20% of the
travel axis maximum speed. Input the desired speed and press the ENTER
key to begin calibration. The auto calibration sequence will move the travel
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axis to the HOME position and then start moving showing the following
screen.
TRAVEL CALIBRATION
TEST IN PROGRESS...
3. When the travel axis has completed one revolution and reaches the HOME
position again the travel will stop to display the following screen. The actual
speed that the axis travelled will be displayed for reference. Press ENTER to
continue with the second calibration point and the axis will travel one
revolution again.
TRAVEL CALIBRATION
ACTUAL
X.XX

Manual calibration (steps 4, 5, and 6):
4. Enter the speed for the first point of calibration. Usually the primary travel
speed of the typical welding sequence is used for the first point of calibration
but the screen defaults to 0.00. If the operator leaves the speed at 0.00 the
calibration will exit back to the initial screen. After the operator inputs the
desired speed press the ENTER key to begin travelling at the primary travel
speed and will continue travelling until the operator presses the STOP key.

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TRAVEL CALIBRATION
PRESS ‘STOP’ to END TRAVEL

X.XX
5. When the weld head is stopped, the controller will ask the operator to enter
the distance travelled from the start position as in the following screen. This
distance will be measured in inches for a weld head that is programmed in
IPM or in rotations for a weld head that is programmed in RPM.
TRAVEL CALIBRATION
ENTER MEASURED (ACTUAL) DISTANCE:

X.XX

6. Pressing the ENTER key will accept the measurement and present the
operator with the results of the calibration on the following screen. To enter a
second calibration point the entire procedure will be repeated starting back to
the enter speed screen. Usually the background travel speed of the typical
welding sequence is used for the second point of calibration but the screen
defaults to 0.00 again. At this point if the operator accepts the 0.00 as the
speed the calibration results are based on the single point calibration (NOTE:
This is not recommended) otherwise the same procedure will be repeated as
outlined in steps 4 and 5.

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TRAVEL CALIBRATION
ACTUAL
X.XX

7. When the travel speed measurements are complete, the calibration results will
be displayed.
--------- TRAVEL CALIBRATION -----------
OLD NEW ERROR

GAIN: X.XXX X.XXX XXX.XX%
OFFSET: XX.XX XX.XX XX.XX
PRESS ENTER TO CORRECT

PRESS CLEAR TO IGNORE
The results screen shows the previous calibration values along with the new
calibration values. Depress the ENTER key to select the new calibration values
or depress the CLEAR key to ignore the new calibration values. If the new
values are accepted, the programmed travel speed in the weld schedule itself is
not affected, but the new correction factors are applied to the travel motor control
signals during the weld sequence. If the new values are ignored, the previous
values are retained and the actual travel speed will be in error by the indicated
percentage.
Verifying the Current Calibration

The current calibration screen has four options. The first two options allow the operator
to verify the operation of the power supply and check the calibration. The second two
options allow calibration of the system. You should use the either of the verification
options first to check or demonstrate that the system is still properly calibrated. The
system will have been fully calibrated before it was shipped and it is very unusual for the
system to lose this calibration. Over time it may eventually be required that the system
needs to be recalibrated but this should only be done after it is determined that the system
is now out of calibration.

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CURRENT CALIBRATION
VERIFY WITH ARC

VERIFY WITH LOAD BANK
CALIBRATE WITH ARC
CALIBRATE WITH LOAD BANK
POSITION CURSOR, THEN PRESS ENTER
The system calibration can be checked into an arc or done using a load bank, which ever
is most convenient. In either case, you will need a method for accurately measuring the
actual weld current.
The procedure will attempt to output a weld current equal to the initial current that is
specified in the setup parameters of the active weld schedule. If a load bank is used, the
load bank settings should be selected to create a voltage in the arc welding range. The
power supply may report that the arc could not be started if the initial voltage is too high
or too low. If a load bank is not being used, the power supply will execute a pre purge
cycle before initiating the arc. The pre purge duration is specified by the active weld
schedule but will not be less than 3 seconds. The verify routine allows the operator to run
the power supply at different currents. The power supply will sample the telemetry and
display it after a new current level is requested.
Current Calibration
Selecting calibration will begin the calibration routine. The power supply will display the
following series of current calibration screens.
CURRENT CALIBRATION
INITIAL AMPS
XX.X


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CURRENT CALIBRATION
PRI AMPS
XX.X

CURRENT CALIBRATION
BKG AMPS
XX.X

CURRENT CALIBRATION
TRAVEL
X.XX

The operator will be asked to select an initial, primary and background current to use in
the calibration routine. By default these values will be taken from the active segment.
Calibration using these values will guarantee the best possible result for the amperages
programmed in the active segment. These values can be edited. For the best results over
the largest range of amperages, the primary amperage value should be at least 80% of the
maximum continuous current and the background value should be no higher than 20% of
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the maximum continuous current. A travel speed parameter screen is provided in case a
weld head is connected and a stationary arc is not practical.
Before proceeding, connect a calibrated resistive shunt into the work lead and have a
meter ready to measure the current. If a torch or weld head is being used, do not connect
the meter until after the high frequency impulse arc start.
Follow these steps:
1. If a load bank is used, the load bank settings should be selected to create a
voltage in the arc welding range. The power supply may report that the arc
could not be started if the initial voltage is too high or too low.
2. Verify the calibration values selected on each of the above screens and press
the ENTER key to accept each one. The operator can press CANCEL on any
screen to abort the calibration.
3. If a load bank is not being used the power supply will begin the sequence by
going into pre purge. The pre purge duration is specified by the active weld
schedule but will not be less than 3 seconds.
4. The arc will be established and the current will increase to Primary Amps.
Allow a few seconds for the current to settle and then measure the current at
the calibrated shunt. The operator can press STOP while the test in progress
message is up abort the calibration. Enter the measured current on the power
supply.
5. The current will now change to the Background Amperage value. Allow a
few seconds for the current to settle and then measure the current at the
calibrated shunt. Enter the measured current on the power supply.
6. The power supply will display the calibration results.
------------CURRENT CALIBRATION------------
OLD NEW ERROR


values are accepted, the programmed amperages in the weld schedule itself are
not affected, but the new correction factors are applied to the power supply
control signals during the weld sequence. If the new values are ignored, the
previous values are retained and the actual amperages will be in error by the
indicated percentage.

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Voltage Calibration
The voltage calibration screen has four options. The first two options allow the operator
to verify the operation of the power supply and check the calibration. The second two
options allow calibration of the system.
VOLTAGE CALIBRATION
VERIFY WITH EXTERNAL SIGNAL

CALIBRATE WITH EXTERNAL SIGNAL
Selecting verify will sample a voltage signal on the electrode or run current through a
load bank. If a load bank is used, the initial current is specified in the active weld
schedule and the load bank settings should be selected to create a voltage in the arc
welding range. The power supply may report that the arc could not be started if the initial
voltage is too high or too low. If a load bank is not being used, a voltage must be applied
between the work piece and the electrode using an external voltage supply. The verify
routine samples the voltage telemetry and displays it when ENTER is selected.
Selecting calibration will begin the calibration routine. If the calibration is using a load
bank, the power supply will display the following voltage calibration screens.
VOLTAGE CALIBRATION
INITIAL AMPS
XX.X


45
VOLTAGE CALIBRATION
PRI AMPS
XX.X

VOLTAGE CALIBRATION
ENTER MEASURED (ACTUAL) VOLTS:

X.XX

PRESS ‘CLEAR’ TO CANCEL
The operator will be asked to select a primary and background current to use in the
calibration routine. By default these values will be taken from the active segment.
Calibration using these values will guarantee the best possible result for the amperages
programmed in the active segment. These values can be edited. For the best results over
the largest range of voltages, the primary amperage value should generate a voltage at
least 5 volts above the background amperage value.
If a load bank is not being used, the series of voltage calibration screens will appear as
follows:
VOLTAGE CALIBRATION
APPLY VOLTAGE SIGNAL

PRESS ‘STOP’ TO ABORT

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VOLTAGE CALIBRATION
ENTER MEASURED (ACTUAL) VOLTS:

X.XX

When using a load bank, follow these steps:
1. The load bank settings should be selected to create a voltage in the arc welding
range. The power supply may report that the arc could not be started if the initial
voltage is too high or too low.
2. Verify the calibration values selected on the screen and press the ENTER key to
begin the procedure. The operator can press CLEAR on any screen to abort the
calibration.
3. The current will run through the load bank and will increase to Primary Amps.
Allow a few seconds for the current to settle and then measure the voltage across
the work and electrode leads using a meter. Enter the measured voltage on the
power supply.
4. The current will now change to the Background Amperage value. Allow a few
seconds for the current to settle and then measure the voltage across the work and
electrode leads using a meter. Enter the measured current on the power supply.
When using an external voltage supply, follow these steps:
1. Connect the voltage supply across the electrode and the work piece. A variable
power supply with a digital display is preferred.
2. Measure the voltage from the electrode to the work piece. Enter the measured
voltage on the power supply.
3. Change the voltage across the electrode and work piece by at least 5 volts.
Measure the voltage from the electrode to the work piece. Enter the measured
voltage on the power supply.

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------------VOLTAGE CALIBRATION------------
OLD NEW ERROR


values are ignored, the previous values are retained and the reported voltages will
be in error by the indicated percentage.
Wire Feed Rate Calibration
The wire calibration displays a series of screens asking the operator to enter primary,
background wire feed rates and feed lengths for the calibration.
WIRE FEED CALIBRATION
ENTER WIRE RATE

XX.X

ENTER WIRE LENGTH

XX.X


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TEST IN PROGRESS...
XX.X
ENTER MEASURED (ACTUAL) WIRE:

X.XX

The wire feed rates for the calibrations should be taken from the active weld schedule.
Calibration using these values will guarantee the best possible result for the feed rates
programmed in the active segment. For the best result over the largest range of wire feed
rates, the primary value should be at least 80% of the maximum speed of the wire feed
and the background value should be no more than 20% of the maximum speed of the wire
feed.
Follow these steps:
1. Make sure the leading end of the wire is flush with the wire nozzle.
2. Enter the Primary Wire feed rate and press the ENTER key. Enter the length of
wire to feed in the calibration and press the ENTER key. Wait until the wire feed
has stopped. The operator can press STOP at any time to abort the calibration
while feeding wire.
3. Cut and measure the amount of wire fed. Enter the measurement on the power
supply.
4. The power supply will start the procedure over again in the same manner from
step 2 only this time the operator should enter the Background Wire feed rate.
5. Cut and measure the amount of wire fed. Enter the measurement on the power
supply.

49
------------ WIRE CALIBRATION -------------
OLD NEW ERROR


values are ignored, the previous values are retained and the actual feed rates will
Lift Gap Test

On systems with an AVC axis the lift gap can be tested. The operator is prompted for a
lift gap distance. This distance is the gap between the tip of the tungsten electrode and
the work piece. The system will jog the AVC axis down slowly until the electrode
touches the work piece and then retract the lift gap distance.
AVC LIFT TEST
LIFT GAP
X.XX
PRESS ENTER TO CONTINUE

PRESS CLEAR TO CANCEL
The lift gap test does not make any corrections to the gap distance; it only verifies proper
operation of the AVC motor.
Hotwire Calibration
The hotwire calibration screen has two options. The first option allows the operator to
verify the operation of the hotwire power supply and check the calibration. The second
option allows calibration of the system.

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HOTWIRE CALIBRATION

Selecting verify will initiate current through a load bank. The initial current is calculated
using the primary wire feed rate of the active weld segment. When properly calibrated
the hotwire power supply will provide ¼ amp of current for every 1 ipm of wire. The
verify routine allows the operator to run the power supply using different wire feed rates.
The power supply will sample the telemetry and display it after a new feed rate is
requested.
Selecting calibration will begin the calibration routine. The power supply will display the
following series of hotwire calibration screens.
HOTWIRE CALIBRATION
INITIAL AMPS
X.XX

HOTWIRE CALIBRATION
ENTER MEASURED (ACTUAL) CURRENT:

X.XX

The default wire feed rates for the calibration are taken from the first segment of the
active weld schedule. Calibration using these values will guarantee the best possible
result for the feed rates programmed in the active segment. These values can be edited.
For the best result over the largest range of wire feed rates, the primary value should be at
least 80% of the maximum speed of the wire feed and the background value should be no
more than 20% of the maximum speed of the wire feed.
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Before proceeding, connect a calibrated resistive shunt into the hotwire work lead and
have a meter ready to measure the current.
Follow these steps:
1. The load bank settings should be selected to create a voltage in the 8-12 volt
range.
2. Verify the calibration values selected on the initial amps screen and press the
ENTER key to begin the procedure. The operator can press CANCEL at any
time to abort the calibration.
3. The current through the load bank will increase to the initial hotwire amperage.
When properly calibrated the hotwire power supply will provide ¼ amp of current
for every 1 ipm of wire. Allow a few seconds for the current to settle and then
measure the current at the calibrated shunt. Enter the measured current on the
power supply.
4. The power supply will start the procedure over again in the same manner from
step 2 only this time the operator should enter a second set point. Allow a few
seconds for the current to settle and then measure the current at the calibrated
shunt. Enter the measured current on the power supply.
---------- HOTWIRE CALIBRATION ------------
OLD NEW ERROR


values are ignored, the previous values are retained and the actual hotwire
amperage will be in error by the indicated percentage.
Oscillator Limit Calibration

On systems with an Oscillator axis the soft limits can be set by selecting the OSC
LIMITS calibration routine. With the oscillator selected from the pendant the operator
can setup the limits by jogging the oscillator axis to the inner and outer limits.
*NOTE* during the oscillator calibration routine the existing limits are ignored so
new limits can be established. It is possible if the operator is not careful to crash the
weld head into the hard stop or run it off the rails. Care must be taken during this

52
process to stay away from hard limits as to avoid injury and damage to the
equipment.
The operator is prompted to jog the oscillator to the inner limit and press ENTER. This
position should be marked for future reference (using the work surface of the pipe usually
works well).
OSCILLATION CALIBRATION
MOVE TO INNER LIMIT

PRESS STOP TO ABORT
The controller will sample the oscillator position and display the voltage on screen.
VOLTS
X.XX

PRESS STOP TO ABORT
The operator will then be prompted to jog the oscillator axis to the outer limit and press
ENTER. This position should also be marked for future reference.
MOVE TO OUTER LIMIT

PRESS STOP TO ABORT
Again the controller will sample the oscillator position and display the voltage on screen.

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VOLTS
X.XX

PRESS STOP TO ABORT
Using the 2 marks previously made the operator should measure the actual distance that
was travelled during the calibration, the distance between the inner and outer limits.
Enter the distance on screen and press ENTER to save and use these new settings.
ENTER MEASURED (ACTUAL) DISTANCE:

X.XX

MFC Flow Rate Calibration

Flow rate calibration is accomplished by calibrating the voltage inputs and outputs of the
power supply and using calibrated MFCs.
If there is more than one MFC connected to the system the power supply will prompt for
the gas type to be calibrated. The gas types are numbered according to the MFC channel,
starting from channel 0.
MFC CALIBRATION
GAS TYPE
X


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The calibration routine will prompt for the calibration type. The output or input may be
calibrated. There is also a selection for verifying the input signal.
MFC CALIBRATION
ANALOG OUTPUT
ANALOG INPUT
VERIFY WITH EXTERNAL SIGNAL
POSITION CURSOR THEN PRESS ENTER
Analog Output Calibration
Follow these steps:
1. Select Analog Output from the MFC Calibration menu.

2. Enter the first voltage set point for the analog output channel. The first voltage
set point should be 80% of full output command signal. For an MFC using a 0-5
volt command signal this would be 4.00 volts.
3. Measure the voltage between pins 8 (+ ve) and 6 (common) on the connector for
the MFC channel being calibrated. Enter the measured voltage.
4. Enter the second voltage set point for the analog output channel. The second
voltage set point should be 20% of full output command signal. For an MFC
using a 0-5 volt command signal this would be 1.00 volt.
5. Measure the voltage between pins 8 (+ ve) and 6 (common) on the connector for
the MFC channel being calibrated. Enter the measured voltage.
------------ MFC CALIBRATION -------------
OLD NEW ERROR


values are ignored, the previous values are retained and the actual flow rates will

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Analog Input Calibration
Follow these steps:
1. Select Analog Input from the MFC Calibration menu.

2. Using a calibrated variable power source, set the voltage to 80% of the full output
command signal of the MFC. For an MFC using a 0-5 volt command signal this
would be 4.00 volts.
3. Apply the voltage across pins 2 (+ ve) and 3 (common) on the connector for the
MFC channel being calibrated. Enter the voltage applied to the connector pins.
4. Set the voltage of the power source to 20% of the full output command signal of
the MFC. For an MFC using a 0-5 volt command signal this would be 1.00 volts.
5. Apply the voltage across pins 2 (+ ve) and 3 (common) on the connector for the
MFC channel being calibrated. Enter the voltage applied to the connector pins.
------------ MFC CALIBRATION -------------
OLD NEW ERROR


values are ignored, the previous values are retained and the displayed flow rates
will be in error by the indicated percentage.
Verify with External Signal
To verify the MFC analog input with an external signal use a calibrated variable
power source. Set the voltage to be within the range of the MFC command voltage.
Apply the voltage across pins 2 (+ ve) and 3 (common) on the connector for the MFC
channel being calibrated. Press the ENTER key to display the sampled voltage and
verify the input is properly calibrated. Press the STOP key to exit.
DATA LOG Mode

The data logging capability is one of the most useful features available for developing
weld schedules. Use of this feature allows offsite study of weld samples by analysis of
the actual values of currents, times, voltages, etc. that produced the specific weld
samples. The DATA LOG mode must be set to ON in order for the power supply to
record actual weld data into memory in the form of DATALOG files. The DATA LOG

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mode also acts in conjunction with the REPORT mode to specify which reports to print
and when to print them.
To change the Data Log mode, do the following:
1. The power supply must be in TEACH mode, and the power supply must not
be in sequence.
2. Change the display to the LIMITS screen, which will appear as follows:
--------------- LIMITS --------------

ERROR FAULT VOLTS
PRI AMPS ##.# ##.# HIGH LOW
BKG AMPS ##.# ##.# ## ##
TRAVEL ##.# ##.#
---------------- MODES -----------------
DATA LOG = OFF PRINT REPORT
3. Position the CURSOR over the word OFF and depress the ENTER key to
change it to ON. The power supply will now begin recording weld data while
sequencing in WELD mode.
REPORT Mode
The power supply can be made to generate a variety of reports under various conditions.
These reports and conditions are specified by the REPORT mode, in conjunction with
the DATA LOG mode. The settings for the REPORT mode are PRINT ALL, PRINT
ERRORS, PRINT REPORT, and STORE REPORT. In general, the REPORT mode
determines whether or not a Data Acquisition report will be printed after each weld
sequence (PRINT ALL), or only if error limits were exceeded (PRINT ERRORS), or
not at all (PRINT REPORT), or stored in DATA LOG memory (STORE REPORT).
The DATA LOG mode must be set to ON for any of these options to be enabled.
To change the REPORT mode, do the following:
1. The power supply must be in the TEACH mode, and the power supply must
not be in sequence.

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2. Change the display to the LIMITS screen, which will appear as follows:
--------------- LIMITS --------------

ERROR FAULT VOLTS
BKG AMPS ##.# ##.# ## ##
TRAVEL ##.# ##.#
---------------- MODES -----------------
3. Position the CURSOR over the REPORT mode message and depress the
ENTER key to change it to the next setting. Continue depressing the
ENTER key until the desired setting is reached.

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Legacy Keypad
All-in-One Keypad

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PRINT Key (Legacy Keypad)
When the optional Printer is installed, the PRINT key is used to print a hard copy of the
active weld schedule. When used with the CTRL key, the PRINT key will access the
DATA LOG FUNCTIONS screen.
DATA Key and PRINT Softkey (All-in-One Keypad)

When the optional Printer is installed, the PRINT softkey is used to print a hard copy of
the active weld schedule. The DATA key will access the DATA LOG FUNCTIONS
screen.
Data Log Functions

When accessing the Data Log Functions either depress CTRL and PRINT
simultaneously on the legacy keypad or press DATA on the All-in-One keypad. The
following screen will appear:
------------ DATA LOG FUNCTIONS -----------
VIEW DATALOG
STORE DATALOG
PRINT DATALOG
PRINT STORED DATALOGS: XX – XX
CLEAR DATA LOGS
CHANGE WELD NUMBER
1. VIEW DATALOG
The view data log screen displays data from the last weld performed. If no welds
were performed since the machine has been powered up, then the VIEW
DATALOG option will not appear on the screen. Using CTRL and ↑ or ↓ keys
lets you scrolls through segments of the data log.
LOG NUMBER = XXX SEG TIME = XXX.X

SEGMENT = XX ACTUAL = XXX.X
PRI BKG ACTUAL

AMPS = XXX.X XXX.X XXX.X XXX.X
TRAVEL = XX.XX XX.XX XX.XX XX.XX
VOLTS = XX.XX XX.XX XX.XX XX.XX
WIRE = XXX.X XXX.X XXX.X XXX.X
CWIRE = XXX.X XXX.X XXX.X XXX.X
HEAT INPUT = XXX.X
*Note on Heat Input. This calculation is based on the calibrated travel speed
which should be calibrated at the surface of the part (tungsten tip). If the
calibration is done at a point other than the surface of the weld the travel

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telemetry will not be accurate and thus the heat input calculation will be
misleading. If the travel axis is a linear axis the heat input will be in kJ / inch (or
kJ / mm if metric conversion is turned on), but on a rotary axis this is the total
heat input into the part as opposed to the heat per unit distance.
2. STORE DATALOG
If the Log has not been stored to the disk then using STORE DATALOG option
will store the log. If the Log has already been stored then the STORE
DATALOG option will not appear on the screen.
3. PRINT DATALOG
The print data log option will print the last weld performed. If no welds were
performed since the machine has been powered on or there is no optional printer
installed then the PRINT DATALOG option will not appear on the screen.
4. PRINT STORED DATALOG
Print Stored data log option will print a series of logs already stored on the
machine.
5. CLEAR DATALOGS
This option will delete all stored data logs on the machine. Maximum number of
stored data logs can not exceed 100. NOTE: Data logs can be backed up to the
usb memory device before they are cleared. Refer to COPY FUNCTIONS (pg
94 ).
6. CHANGE WELD NUMBER
The starting point for this series of numbers may be changed as required by the
operator for documentation purposes. Once a starting serial number is assigned
by the operator, each WELD will be assigned the next sequential number from
that point. The default starting serial number is 1, and will be used if no other
number is assigned.
NOTE
The current serial number IS RETAINED in memory at all
times and will be restored whenever the power supply is turned
on, so that a series of welds may be properly serialized even if
new weld schedules are loaded, or power is shut off between
welds.

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Legacy Keypad
All-in-One Keypad
COPY Key
The COPY key is used to copy segment data parameters from one segment to another,
and to copy weld schedules to and from a USB memory device. Use of the COPY key
while making new schedules that are similar to existing ones will save programming time
when only one or two parameters change from segment to segment.
Copying a Weld Schedule
This procedure allows the operator to copy the entire contents of an existing weld
schedule and/or create a new weld schedule without deleting the original. This is useful
when minor changes to welding parameters are required to accommodate a different
application. Always assign a different ID number to altered weld schedules unless it is

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an identical copy. When a weld schedule is loaded it is difficult for the operator to know
which of two or more weld schedules with the same number will be loaded into the active
weld schedule.
To copy a weld schedule, do the following:
1. The power supply must be in TEACH mode, and the power supply must not
be in sequence.
2. LOAD the weld schedule to be copied, and make the necessary changes to
AMPS, TOTAL SEGMENTS, etc.
3. On the legacy keypad hold the CTRL key depressed and press the SAVE key
but on the All-in-One keypad press SAVE to display the SAVE screen, as
follows:
SCHD O.D. WALL TYPE MAT HEAD POS NO

---- ---- ---- ------ ---- ----- --- --
0001 2.0 .075 TUBE SS 52/54 1G 01
POSITION CURSOR, THEN DEPRESS ENTER
4. The SAVE screen displays 8 columns of descriptive information that is stored

with the weld schedule. These columns represent the outer diameter, wall
thickness, weld type, material, weld head, position and pass number. All of
the data in each of these fields can be edited to change the description of the
weld schedule. To save the schedule, use the arrow/cursor keys to move the
cursor to the SCHD column and type in a new id.
5. Depress the ENTER key. A new weld schedule will be created containing the
updates, and the original weld schedule will remain unchanged. However, if a
schedule id is selected that is already in use on the system a prompt will be
displayed:

---- ---- ---- ------ ---- ----- --- --
0001 2.0 .075 TUBE SS 52/54 1G 01
OVERWRITE?
0001 2.0 .075 TUBE SS 52/54 1G 01
YES NO

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6. Cursor to YES and press ENTER to overwrite the existing data with the new
schedule data. Cursor to NO and press ENTER to abort the save. If the save
is aborted, another id can be selected.
Copying a Segment
This function is used to copy segment data from one segment to another in the
same weld schedule. It is useful when creating a new weld schedule having
several segments that are very similar.
To copy one segment to another, do the following:
1. On the legacy keypad hold the CTRL key depressed and press the COPY key
but on the All-in-One keypad press COPY. The following COPY
FUNCTIONS screen will be displayed:
------------ COPY FUNCTIONS ------------

COPY SEGMENT TO SEGMENT: ## - ##
COPY SCHEDULE FROM USB DRIVE
COPY SCHEDULE FROM TEMPLATES
COPY SCHEDULE TO USB DRIVE
SAVE ALL SCHEDULES TO USB DRIVE
RESTORE ALL SCHEDULES FROM USB DRIVE
COPY DATALOGS TO USB DRIVE: ## - ##
The cursor will be located over the FROM SEG number.
The active segment number will be displayed.
2. If a different segment is to be copied FROM, enter its number.

3. Depress the ENTER key. The cursor will automatically move to the right
over the TO SEG number.
4. Enter the desired segment number to copy to. Normally, the next higher
segment number is entered.

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Legacy Keypad
All-in-One Keypad
LOAD Key
The LOAD key is used to retrieve a weld schedule from internal memory and make it the
active weld schedule. The LOAD key is active in both PRODUCTION and TEACH
modes, but is disabled during a weld sequence. On the legacy keypad the LOAD key is
only functional when the CTRL key is also pressed but on the All-in-One keypad the
LOAD key operates without the CTRL key.
Loading a Weld Schedule
A weld schedule may be loaded from the internal schedule library or an external usb
memory device. Simple tube schedules can also be automatically generated by entering
the tube outer diameter and wall thickness. Schedules for closed weld heads may be
adjusted, or scaled, as they are being loaded.
To cancel the LOAD procedure without loading any weld schedules, depress the
CLEAR key while the LOAD DIRECTORY screen is being displayed. The screen will
display the message
LOAD OPERATION CANCELLED
After a few seconds, the INITIAL screen will again be displayed.
To load a weld schedule do the following:

1. On the legacy keypad, hold the CTRL key depressed and press the LOAD
key. On the All-in-One keypad press the LOAD key.

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2. The following menu screen will be displayed:
----------- SCHEDULE LOADING --------------
BROWSE SCHEDULE LIBRARY

BROWSE USB DRIVE
LOAD SCHEDULE
MAKE NEW TUBE SCHEDULE
3. If the id number of the schedule to be loaded is known, cursor to LOAD

SCHEDULE, press ENTER and then type in the schedule id.
4. To search for a schedule, cursor to BROWSE SCHEDULE LIBRARY if the
schedule is stored in the internal library or cursor to BROWSE USB DRIVE
if the schedule is stored on the external usb memory device. Press ENTER to
view the LOAD DIRECTORY:

---- ---- ---- ------ ---- ----- --- --
0001 2.00 .125 TUBE SS 52/54 1G 01
0002 1.50 .075 TUBE SS VIP-3 1G 01
0003 1.00 .063 TUBE SS 52/54 1G 01
0004 1.00 .063 TUBE SS 52/54 1G 01
0005 1.00 .063 TUBE SS 52/54 1G 02
The LOAD DIRECTORY displays 5 weld schedules per page.
5. Cursor to a column heading and depress ENTER to sort all of the schedules
by that column. For instance moving the cursor to O.D. and depressing the
ENTER key will sort the schedules by their outer diameters in ascending
order. Depressing the ENTER key again will sort the schedules in
descending order. By default, the schedules are sorted by SCHD id in
ascending order.
6. Depress and hold the CTRL key and depress cursor UP or
DOWN to page up or down to the previous or next 5 weld
schedules located in the library or on the memory device.
7. When the schedule to be loaded has been found, move the cursor to the id
number of the schedule and press the ENTER key.

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8. If the schedule uses a closed weld head, the following SCHEDULE
LOADING screen will be displayed:

---- ---- ---- ------ ---- ----- --- --
0001 2.0 .075 TUBE SS 52/54 1G 01
SCALE SCHEDULE BY: +00%
9. Depress the ENTER key to accept the selected weld schedule without
modification or refer to Scaling a Weld Schedule (pg 66) to scale the
amperage parameters.
10. The selected weld schedule will then be loaded as the active weld schedule
and the INITIAL screen will be displayed.
To make a new tube schedule do the following:
1. On the legacy keypad, hold the CTRL key depressed and press the LOAD
key. On the All-in-One keypad press the LOAD key.
2. The following menu screen will be displayed:
----------- SCHEDULE LOADING --------------
BROWSE SCHEDULE LIBRARY

BROWSE USB DRIVE
LOAD SCHEDULE
MAKE NEW TUBE SCHEDULE
6. Cursor to MAKE NEW TUBE SCHEDULE and press ENTER.

7. Enter the outer diameter of the tube to be welded.
8. Enter the wall thickness of the tube to be welded.
9. Select TUBE for a continuous travel tube weld, FTG for a stepped travel tube
weld or TACK for a tacking schedule.
10. If TACK is selected, the number of tacks will have to be entered. The tack
schedule will space the tacks evenly around the tube.
11. The auto-generated weld schedule will then be loaded as the active weld
schedule and the INITIAL screen will be displayed.
Scaling a Weld Schedule

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The SCALING feature allows the operator to scale up or down, in percentages, the
primary and background amperage value for all segments of a weld schedule as it is
being loaded. This feature is only enabled for weld heads that are configured to allow
weld current scaling. This feature provides an easy way to adjust the entire schedule so
that you have either a little more heat or a little less heat. In the PRODUCTION mode,
the scale percentage value is limited to the MAX value entered on the OVERRIDE
screen. In the TEACH mode, the scale percentage value may be anything between 0 and
100%.
To scale a weld schedule, do the following:

1. Follow the procedure described in Loading a Weld Schedule until the
following SCHEDULE LOADING screen is displayed:

---- ---- ---- ------ ---- ----- --- --
0001 2.0 .075 TUBE SS 52/54 1G 01
2. If an INCREASE in the PRI/BKG AMPS is desired, enter the desired

percentage value.
3. If a DECREASE in PRI/BKG AMPS is desired, move the CURSOR over
the PLUS sign and depress the ENTER key to change the sign to a MINUS sign.
The CURSOR will automatically move to the right over the percentage
parameter. Enter the desired percentage value.
4. Depress the ENTER key. The scaled weld schedule will then be loaded as the
active weld schedule and the INITIAL screen will be displayed.
NOTE
The scaled values will not be saved in the storage memory
unless the SAVE procedure is used after scaling.

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Legacy Keypad
All-in-One keypad
SAVE Key
The SAVE key is used to save the active weld schedule into internal memory, so that it
will be retained while another schedule is loaded, or when the primary power is shut off.
In addition, the SAVE key is used to delete weld schedules from memory. The SAVE
key is disabled during a weld sequence and when the power supply is in PRODUCTION
mode. On the legacy keypad the SAVE key is only functional when the CTRL key is
also pressed but on the All-in-One keypad only the SAVE key need be pressed. The
power supply will retain a maximum of 100 different welding schedules.
Saving a Weld Schedule

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This procedure is used to SAVE data entered or edited on the INITIAL, SETUP, and
SEGMENT screens into internal memory.
A weld schedule may be saved only when the power supply is in TEACH mode.
Weld schedules can be identified with any number from 0001 to 9999, and may be saved
in any one of 100 internal locations.
To cancel the SAVE procedure without saving any weld schedules, depress the CLEAR
key before entering any ID numbers. The screen will display the message
SAVE OPERATION CANCELED
After a few seconds, the INITIAL screen will again be displayed.
To save a weld schedule do the following:
1. On the legacy keypad, hold the CTRL key depressed and press the SAVE
key. On the All-in-One keypad press the SAVE key.
2. The following SAVE SCHEDULE screen will be displayed:

---- ---- ---- ------ ---- ----- --- --
0001 2.0 .075 TUBE SS 52/54 1G 01
3. Move the cursor to the SCHD column to SAVE a weld schedule to internal
memory.
4. Enter the desired weld schedule ID number.
6. A mistake may be cleared by depressing the CLEAR key after at least 1 digit
has been entered.

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7. If the selected ID is already in use by a weld schedule, the following
confirmation screen will appear:

---- ---- ---- ------ ---- ----- --- --
0001 2.0 .075 TUBE SS 52/54 1G 01
OVERWRITE?
0001 2.0 .075 TUBE SS 52/54 1G 01
YES NO
8. Position the cursor over the word YES to authorize the existing weld schedule
to be over-written with the new one.
9. Position the cursor over the word NO to abandon the SAVE operation and
select a new ID.
Deleting and Renaming Weld Schedules

It is sometimes necessary to delete or rename a stored weld schedule. Weld
schedules may be renamed or deleted from internal memory in the schedule library. The
schedule library is accessible from the administration screen. Accessing the
administration screen requires the administrator password.
To enter the administrator password do the following:
screen:
PASSWORD: XXXX
WWW.LIBURDI.COM VERSION: X.XX.XX
To access the system administration screen, do the following:

1. Enter the administrator password.

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-----------SYSTEM ADMINISTRATION-----------
BACKUP SYSTEM FILES TO USB DRIVE
CONFIGURATION
IO TEST
CHANGE PASSWORDS
UPGRADE SOFTWARE
EXIT TO DOS
To delete or rename a weld schedule, do the following:

1. Cursor to CONFIGURATION and press ENTER. The following screen is
displayed:
---------------CONFIGURATION---------------
SCHEDULE LIBRARY
SET TIME AND DATE
HW CONFIGURATION
WELD HEAD MANAGEMENT
LANGUAGE SETUP
METRIC UNITS: OFF

LANGUAGE: English
2. Cursor to SCHEDULE LIBRARY and press ENTER. The following screen

is displayed:
--------------SCHEDULE LIBRARY-------------
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX
NO. SCHEDULES = 99 PAGE: 1/2
To delete a weld schedule, do the following:

1. While the SCHEDULE LIBRARY screen is displayed, position the
CURSOR to the location of the weld schedule to be deleted.

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2. Enter an ID number of 0000 and depress the ENTER key. The following
DELETE SCHEDULE?

---- ---- ---- ------ ---- ----- --- --
0001 2.0 .075 TUBE SS 52/54 1G 01
YES NO
3. Position the cursor over the word YES to authorize the weld schedule to be
deleted.
4. Position the cursor over the word NO to abandon the delete operation and
retain the weld schedule.
To rename a weld schedule, do the following:
1. While the SCHEDULE LIBRARY screen is displayed, position the

CURSOR to the location of the weld schedule to be renamed.
2. Enter a new ID number and depress the ENTER key. The following
RENAME SCHEDULE TO XXXX?

---- ---- ---- ------ ---- ----- --- --
0001 2.0 .075 TUBE SS 52/54 1G 01
YES NO
3. Position the cursor over the word YES to authorize the weld schedule to be
renamed.
4. Position the cursor over the word NO to abandon the rename operation and
retain the existing schedule ID.
Changing Passwords
The system has two passwords that are used to block access to certain functions.
In order to maintain the secrecy of the passwords it may be necessary to change them
periodically. The teach mode and administrator passwords can be changed from the
administrator screen. Accessing the administration screen requires the administrator
password.
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To enter the administrator password do the following:
screen:
PASSWORD: XXXX
WWW.LIBURDI.COM VERSION: X.XX.XX
To access the system administration screen, do the following:
2. Enter the administrator password.

CONFIGURATION
IO TEST
CHANGE PASSWORDS
UPGRADE SOFTWARE
EXIT TO DOS
To change a password, do the following:
1. Cursor to CHANGE PASSWORDS

2. Press ENTER. The following screen is displayed:
------------ENTER NEW PASSWORD-------------
TEACH
SYSTEM ADMINISTRATION
3. Cursor to the password that is to be changed (example: TEACH) and press

ENTER.
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CHANGE PASSWORDS
TEACH
XXXX

4. Type in a new password

5. Press ENTER. The following screen is displayed:
CONFIRM NEW PASSWORD
TEACH
XXXX

6. To ensure the new password has been typed correctly, it must be entered a
second time. Type in the new password again.
7. Press ENTER. The password has been changed.

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Legacy Keypad

74
All-in-One Keypad
CTRL Key
The CTRL key has no function when used alone, but serves to expand the uses of
the TEST, PRINT, COPY, LOAD, SAVE, HOME, and CURSOR CONTROL keys.
Refer to the descriptions of these key functions for more information.

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Setting the Time and Date Stamp
In order to properly document weld samples using the Data Acquisition report,
the time and date of the weld must be included. A TIME/DATE SETUP screen has
been provided to maintain the current time and date for the Data Acquisition report. This
screen can only be accessed through the system administration menu.
To change the current time and date, do the following:
1. Press CTRL + STOP to bring up the system administration menu. You will
be prompted for the system administration password.
2. Move the cursor to CONFIGURATION and press the ENTER key.
CONFIGURATION
IO TEST
CHANGE PASSWORDS
UPGRADE SOFTWARE
EXIT TO DOS
3. Move the cursor to SET TIME AND DATE and press the ENTER key.
---------------CONFIGURATION---------------
SCHEDULE LIBRARY
SET TIME AND DATE
HW CONFIGURATION
LANGUAGE SETUP
METRIC UNITS: OFF

LANGUAGE: English
4. This will take you to the TIME/DATE SETUP screen, which will appear as
follows:

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SET TIME/DATE
(HH:MM:SS)
TIME:(##:##:##)
(MM:DD:YY)
DATE:(##:##:##)
POWERED UP SINCE: ##/##/## ##:##:##
5. Position the CURSOR over the field to be changed and enter the desired
value.
6. Depress the ENTER key. Repeat as necessary to set the correct time and
date.

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Chapter 4 Programming Operations
General Information
The power supply includes a display with easy to follow screens for operator
programming and system messages for safe operation. The programming operations
section will describe the parameters displayed on each of the programming screens.
LOGO Screen
The LOGO screen is the first screen to appear, and will only be displayed while the
power supply is performing initial self-testing. This happens when the main power is
first turned on, and will last for a few seconds. During this time, the software revision
level is displayed. The revision level should be noted when it becomes necessary to
contact Liburdi Dimetrics Customer Support in the event of problems with the
equipment.
SCHED ID = #### NO. SEGMENTS = ##

WIRE DELAY = ##.# WIRE RETRACT = ##.#
---------------- MODES -----------------

TIMED F PRODUCTION
INITIAL Screen
The INITIAL screen is the first to be displayed after power up (in TEACH mode), or
after a weld schedule is loaded. It contains the basic global parameters used to control
the initial and final conditions of the weld sequence. The parameters in the INITIAL
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screen can be altered only in TEACH mode. Refer to Production/Teach Mode (pg 21)
for more information.
The active weld schedule is maintained in a battery powered portion of memory while the
primary power is shut off, and will be restored when power is again applied (in TEACH
mode). If desired a different weld schedule may be accessed using the LOAD function.
Refer to Loading a Weld Schedule (pg 64) for more information.
INITIAL Screen Parameters
The following parameters are available from the INITIAL screen:
SCHED - The ID number of the active weld schedule. It is used as a unique identifier
to allow selection of the desired weld schedule.
NO. SEGMENTS - The number of active segments in the weld schedule. Although
all 16 weld schedule segments can be displayed and modified, only the active segments
will be executed during a weld sequence. During a weld sequence, segments will be
processed beginning with 1 and continuing until the numbers of segments specified by
NO. SEGMENTS have been executed, whereupon the weld sequence will proceed into
DOWNSLOPE. Change this parameter to add or delete active segments from the weld
sequence.
PRE PURGE - The duration in seconds that shield gas will flow onto the work piece
before the arc is initiated and the weld sequence proceeds into segment 1. The
PREPURGE period allows the area surrounding the arc to be purged of contaminating
atmosphere and the proper inert gas envelope to be established.
POST PURGE - The duration in seconds that shield gas will flow after
DOWNSLOPE has been completed and the arc has been extinguished. The
POSTPURGE period allows the tungsten tip to cool down to a point at which it will
remain unaffected by oxidation from surrounding atmosphere.
DOWN SLOPE – The duration in seconds, beginning when the weld sequence has
finished the final segment, during which the weld current will decrease linearly from the
programmed PRI AMP/BKG AMP values to the FINAL AMPS value. The DOWN
SLOPE period is used to "tie out" the end of the weld neatly.
TIMED/MANUAL/POSITION - This parameter displays the SEGMENT

ADVANCE mode, which can be set to one of three values, TIMED, MANUAL, or
POSITION. The SEGMENT ADVANCE mode determines which action will trigger
the sequence to move from one segment to the next. In the TIMED mode, the segment
duration is the number of seconds the segment will remain active before the weld
sequence proceeds to the next segment. The segment time is established by the SEG
TIME parameter on the SEGMENT screen. In the MANUAL mode, the segment
duration is ignored, and the current segment will remain active until the weld sequence is
advanced manually by the operator through use of the START key. In the POSITION
mode, the segment duration is the travel distance the segment will remain active before

79
the weld sequence proceeds to the next segment. The segment distance is established by
the DISTANCE parameter on the SEGMENT screen. The distance is expressed in
DEGREES or REVOLUTIONS for orbital weld heads with travel speed expressed in
RPM and INCHES for weld heads with a linear travel axis that has travel speed
expressed in IPM. POSITION mode is not available if the weld head does not provide
position feedback through an encoder or potentiometer. Refer to SEGMENT
ADVANCE Modes (pg 25) for more information.
TRAVEL DELAY - The duration in seconds, beginning after the arc is established,
during which movement of the TRAVEL axis will be inhibited. The purpose of the
TRAVEL DELAY period is to establish a stable arc and a proper initial puddle of
molten metal before proceeding with the remainder of the weld. When the travel delay
period has elapsed, the travel axis will begin moving at the speed programmed in the
active segment.
WIRE DELAY - The duration in seconds, beginning after the arc is established,
during which wire feed will be inhibited. The purpose of the WIRE DELAY period is to
establish a stable arc and a proper initial puddle of molten metal before introducing filler
wire to the weld. When the wire delay period has elapsed, the wire will begin to feed at
the speed programmed in the active segment.
WIRE RETRACT - The distance in inches, the wire will be retracted by the wire
feeder before it is disabled just prior to downslope. The purpose of WIRE RETRACT is
to pull the filler wire away from the arc and eliminate balling or dripping of the wire once
the wire feeder has been disabled.
------------ SETUP OPTIONS --------------

IMPULSE TIME = ## IMPULSE AMPS = ###
INITIAL AMPS = ##.# FINAL AMPS = ##.#
TRAVEL JOG =##.## TRAVEL DIR = ###
WIRE JOG FWD = ### WIRE JOG REV = ###
CWIRE JOG F = ### CWIRE JOG R = ###
OSC STEP = #.## OSC JOG = ##
WIRE FEEDER = # HOTWIRE = #.##
THETA JOG = ###
VP MODE = ### REV CUTOFF = ###
SETUP Screen
The SETUP screen contains several global weld schedule parameters. The parameters in
the SETUP screen can be altered only in TEACH mode. Refer to Production/Teach
Mode (pg 21) for more information.
SETUP Screen Parameters
The following parameters are available from the SETUP screen:

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IMPULSE TIME – The duration in milliseconds, of the current impulse at the
beginning of the high frequency arc start operation. During IMPULSE TIME,
IMPULSE AMPS are output by the power supply. At the end of IMPULSE TIME,
the arc current will drop to the value of the INITIAL AMPS setting. This parameter will
only appear if a high frequency arc starter is being used.
IMPULSE AMPS - The amount of current output by the power supply to preheat the
tungsten tip and to help stabilize the arc during a high frequency arc start operation. The
impulse occurs at the beginning of the high frequency arc start operation and lasts for
IMPULSE TIME. At the end of IMPULSE TIME the arc current will drop to the
value of the INITIAL AMPS setting. This parameter will only display if a high
frequency arc starter is being used.
INITIAL AMPS - The amount of arc current which will flow immediately after a
transfer arc has been established. This occurs after IMPULSE TIME in a high
frequency arc start operation or after the electrode has lifted away from the work piece in
a touch start operation. This is the value that the arc current starts from when the weld
sequence enters the first segment.
FINAL AMPS - The value toward which the arc current slopes during the
DOWNSLOPE period. Change this parameter to allow the arc to extinguish properly at
the end of the weld.
TRAVEL JOG - The speed at which the TRAVEL axis will move while the operator
is jogging from one position to another. The TRAVEL axis will begin to move at 1/4 of
this speed and will accelerate for 2 seconds before reaching the full jog rate.
TRAV DIR - The direction of TRAVEL. This parameter can be used to reverse the
direction the weld.
OSC JOG RATE - The speed at which the OSCILLATION slide will move while
the operator is jogging from one position to another. The OSCILLATION slide will
begin to move at 1/4 of this speed and will accelerate for 2 seconds before reaching the
jog rate. This parameter will only display if the selected weld head has a cross seam slide
or torch oscillation capability.
OSC STEP - The distance in inches the torch will move along the cross seam slide
when the oscillator step function is used. This parameter will only display if the selected
weld head has a cross seam slide or torch oscillation capability
.
WIRE JOG FWD - The rate at which the WIRE FEEDER will feed while the
operator is jogging the wire out. The WIRE will begin to feed at 1/4 of this speed and
will accelerate for 2 seconds before reaching the jog rate. This parameter will only
display if the selected weld head has wire feed capability.

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CWIRE JOG F - The rate at which the CHILL WIRE FEEDER will feed while the
operator is jogging the wire out. The WIRE will begin to feed at 1/4 of this speed and
will accelerate for 2 seconds before reaching the jog rate. This parameter will only
display if the selected weld head has a second wire feed capability, usually for dual sync
pulse.
WIRE JOG REV - The rate at which the WIRE FEEDER will feed while the
operator is jogging the wire in. The WIRE will begin to feed at 1/4 of this speed and will
accelerate for 2 seconds before reaching the jog rate. This parameter will only display if
the selected weld head has wire feed capability.
CWIRE JOG R - The rate at which the CHILL WIRE FEEDER will feed while the
operator is jogging the wire in. The WIRE will begin to feed at 1/4 of this speed and will
accelerate for 2 seconds before reaching the jog rate. This parameter will only display if
the selected weld head has a second wire feed capability, usually for dual sync pulse.
WIRE FEEDER - The wire feeder to be used when TRAV DIR is in the FWD
direction if the selected weld head is equipped with multiple wire feeders. This can be 1,
2 or 1+2 which would indicate dual sync pulse mode.
VP MODE - There are two variable polarity modes, ON and OFF. If the VPMODE
is ON the variable polarity unit is enabled and reverse polarity current is available. If the
VPMODE is off, the variable polarity unit is disabled. This parameter will only display
if the welding power supply is equipped with a variable polarity unit.
REV CUTOFF - The minimum reverse current level. When the reverse current
setpoint is below the REV CUTOFF level the power supply outputs only straight
current. This parameter is useful for turning on or off the variable polarity unit when
current is sloped up or down through the REV CUTOFF level. The reverse polarity arc
tends to become unstable at lower currents. This parameter will only display if the
welding power supply is equipped with a variable polarity unit.
HOTWIRE – This parameter scales the amount of hotwire current flowing through the
wire. Increasing this value increases the current. Setting this value to 0 will disable the
HOTWIRE power supply. This parameter will only display if the welding power supply
is equipped with a hot wire power supply and the selected weld head has hot wire
capability.
THETA JOG RATE - The speed at which the THETA axis will move while the
operator is jogging from one position to another. The THETA axis will begin to move at
1/4 of this speed and will accelerate for 2 seconds before reaching the jog rate. This
parameter will only display if the selected weld head has theta torch oscillation
capability.

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FLOW RATE - The total flow rate of the shielding gas mixture. This parameter will
only display if the system is configured to use MFCs.
GAS MIX % - The percentage of the total FLOW RATE that is supplied by the
second MFC when two MFCs are used to create a shielding gas mixture. This parameter
will only display if the system is configured to use MFCs.
NOTE
A value of 0 for any of the JOG RATE parameters will prevent that axis from
jogging. If the operator attempts to jog an axis with the JOG RATE set to 0 a
warning message will be displayed.
AVC SETUP SCREEN
LIFT GAP = ## TOUCH ARC = ###

AVC JOG = ##.# SENSITIVITY = ##.#
START DELAY = ##.# STOP DELAY = ##.#
AVC RETRACT = #.##
AVC SETUP Screen

The AVC SETUP screen contains several global weld schedule parameters that are used
to control operation of the automatic voltage control system. This screen will not appear
if the selected weld head does not support AVC operation. Automatic voltage control
attempts to maintain consistent torch tip to work distance by maintaining a constant
voltage, the voltage being a function of the arc gap. The parameters in the AVC SETUP
screen can be altered only in TEACH mode. Refer to Production/Teach Mode (pg 21)
for more information.
AVC SETUP Screen Parameters

The AVC Setup Screen is accessible when the selected weld head has AVC capability.
The following parameters are available from the AVC SETUP screen:
LIFT GAP – The distance in inches that the system will lift the electrode away from
the workpiece when an arc is initiated using a TOUCH ARC. If a touch and retract start
is used then this is the distance from the electrode to work at which a high frequency arc
start will occur.
AVC JOG – The jog speed in inches per minute of the AVC axis. The AVC axis will
begin to move at 1/4 of this speed and will accelerate for 2 seconds before reaching the
full jog rate.

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START DELAY – The duration in seconds during which the AVC is inhibited after
arc initiation. This delay is used to allow the arc to stabilize before making adjustments
to the arc gap. Arc gap or length is only one factor affecting the arc voltage and during
arc starts when the arc is unstable, it may be only a minor factor contributing arc voltage.
TOUCH ARC – This parameter determines the type of arc initiation method used. If
this parameter is set to YES, the system will initiate the arc by moving the AVC axis
downward and touching the part. After contact, the power supply will output the
INITIAL AMPS, and then lift the AVC axis rapidly until the arc length is equal to the
LIFT GAP. If this parameter is set to NO, the system will move the AVC axis
downward, touch the part and then retract the AVC axis until the LIFT GAP is reached.
The power supply will then initiate a transfer arc using the high frequency method.
SENSITIVITY – This is a measure of how quickly the AVC responds to changes in the
arc voltage. Increasing this number increases the sensitivity and the quickness of the
response. Setting this value to 0 will disable the AVC system.
STOP DELAY – The duration in seconds that the AVC will continue to operate into
the final downslope. In order to maintain the arc gap it may be required to delay the end
of the AVC for a portion of the downslope segment. Since the arc voltage is not entirely
dependant on the arc gap but is also a function of the weld current, leaving the AVC on
during the entire downslope could result in the electrode getting very close to the work
piece, possibly even touching and causing an electrode short circuit fault.
AVC RETRACT - The distance in inches the AVC axis will move upward after the
POST PURGE time has elapsed.
--------------- LIMITS --------------

ERROR FAULT VOLTS
BKG AMPS ##.# ##.# ## ##
TRAVEL ##.# ##.#
---------------- MODES -----------------

LIMITS Screen
The LIMITS screen contains the parameters used by the data logging process to establish
the boundaries of normal operation. Both the current and the travel parameters have an
ERROR limit and a FAULT limit. The ERROR limit merely reports an error when
exceeded, but the FAULT limit will terminate the weld sequence when exceeded. The
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voltage parameters specify only LOW and HIGH fault limits, which will terminate the
weld sequence when exceeded. None of these parameters are used unless data logging
has been activated by setting the DATA LOG parameter to ON.
LIMITS Screen Parameters
The following parameters are available from the LIMITS screen:
ERROR- A value that specifies the maximum deviation from the weld schedule setting
allowed before an error will be printed on the Data Acquisition Report. If the deviation
has not yet exceeded the FAULT value, then the error will merely be reported and the
weld sequence will not be interrupted. There is an ERROR parameter on the screen for
PRI AMP, BKG AMP, and TRAVEL
FAULT- A value that specifies the maximum deviation from the weld schedule setting
allowed before the weld sequence will be terminated, in addition to printing an error on
the Data Acquisition Report. There is a FAULT parameter on the screen for PRI
AMP, BKG AMP, and TRAVEL.
LOW - A value that specifies the minimum value of actual arc voltage below which the
weld sequence will be terminated and an error printed on the Data Acquisition Report.
HIGH - A value that specifies the maximum value of actual arc voltage above which
the weld sequence will be terminated and an error printed on the Data Acquisition
Report.
DATALOG - This parameter sets the data log mode ON and OFF. When the data log
mode is ON, a sample of the actual values of current, voltage, and travel speed will be
recorded every 2 milliseconds. These samples will be averaged for each segment in the
weld and printed on the Data Acquisition Report. Samples will be taken beginning
immediately after SLOPE TIME has elapsed (data logging is not active during sloping).
A minimum of 1 second must be available in the segment TIME in addition to the
SLOPE TIME to allow a reasonable average value to be computed; otherwise no data
will be printed on the report.
The next 4 definitions are the values of the REPORT mode which appear in the lower
right-hand portion of the LIMITS screen.
PRINT REPORT - This report mode setting instructs the power supply to print a
Data Acquisition Report only when requested from the front panel. Nothing will be
printed automatically at the end of the weld sequence.
NOTE
If another weld is made, or the system is powered down before a report is requested,
the data samples from the last weld will be lost.

85
PRINT ERRORS- This report mode setting instructs the power supply to print a Data
Acquisition Report at the end of the weld sequence only if an exceptional condition
occurs as specified by the preceding parameters of the LIMITS screen. A Data
Acquisition Report must be requested from the front panel for welds with no error
conditions.
PRINT ALL - This report mode setting instructs the power supply to print a Data
Acquisition Report after each weld sequence, even for welds with no error conditions.
An additional copy may also be requested from the front panel.
STORE REPORT - This report mode setting instructs the power supply to store the
data samples into non-volatile DATALOG memory at the end of the weld, instead of
printing the Data Acquisition Report. Up to 99 welds can be stored simultaneously in
DATALOG memory. Any one or all of the stored weld data files can be printed at the
convenience of the operator.
SEGMENT Screens
In addition to global parameters contained in the INITIAL, SETUP, and LIMITS
screens, the weld schedule contains 16 sets of parameters used to adjust the weld
sequence for the changing conditions encountered as the arc progresses along the work
piece being welded. Each of these parameter sets is accessed sequentially as the operator
changes the display from one SEGMENT screen to the next. Refer to Changing
Display Screens (pg 23) for more information about navigating through display screens.
The parameters available on the SEGMENT screen change depending on the capabilities
of the weld head selected on the INITIAL SCREEN.

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Tube Welding Segment Screen with wire feed
SEGMENT =## NO. SEGMENTS = ##
SEG TIME =###.# SLOPE TIME = ##.#

PRI AMP =###.# BKG AMP =###.#
PULSE FREQ = ##.# PULSE WIDTH = ###
PRI TRAV =##.## BKG TRAV =##.##
PRI WIRE =###.# BKG WIRE =###.#
---------------- MODES -----------------

TIMED F PRODUCTION
Pipe Welding Segment Screen with oscillation
SEGMENT = ## SEG TIME =###.#

PULSE MODE = #### SLOPE TIME = ##.#
AVC MODE = ####
OSC WIDTH = #.##
PRI BKG EXCURSION = #.##
AMPS = ###.# ###.# IN DWELL = #.##
VOLTS = ##.# ##.# OUT DWELL = #.##
TRAVEL = ##.## ##.## PULSE FREQ = ##.#
WIRE = ###.# ###.# PULSE WIDTH = ###
CWIRE = ###.# ###.# OSC STEP =+#.###
Dual Synch Pulse Segment Screen

AVC MODE = ####
ROTATE ANGLE =###.#
PRI BKG OSC WIDTH = #.##
AMPS =###.# ###.# IN DWELL = #.##
VOLTS = ##.# ##.# EXCURSION = #.##
TRAVEL =##.## ##.## OUT DWELL = #.##
WIRE =###.# ###.# PULSE FREQ = ##.#
CWIRE =###.# ###.# PULSE WIDTH = ###

87
MIG Welding Segment Screen

SLOPE TIME =###.#
VOLTS = ##.# THETA ANGLE = #.#

TRAVEL = ##.## OSC WIDTH = ##.#
WIRE = ###.# IN DWELL = ##.#
PROX = ##.# EXCURSION = ##.#
OUT DWELL = ##.#
MIG PROGRAM = ##
Pipe Welding Segment Screen with Auxiliary Axis
PRI BKG SLOPE TIME = ##.#

AMPS = ###.# ###.# PULSE FREQ = ##.#
VOLTS = ##.# ##.# PULSE WIDTH = ###
TRAVEL = ##.## ##.## AVC MODE = ####
WIRE = ###.# ###.#
##### =##.### ##### =##.###
Pipe Welding Segment Screen with Rotary Axis programmed in IPM

AVC MODE = ####
PRI BKG OSC WIDTH = #.##
AMPS = ###.# ###.# EXCURSION = #.##
VOLTS = ##.# ##.# IN DWELL = #.##
IPM = ##.## ##.## OUT DWELL = #.##
WIRE = ###.# ###.# PULSE FREQ = ##.#
O.D. = ###.### PULSE WIDTH = ###
SEGMENT Screen Parameters

The following parameters are available from the SEGMENT screen:

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SEGMENT - The number of the segment this is currently being displayed. This
number will be incremented or decremented as the operator changes the display from one
segment to another, and cannot be altered directly from the keypad.
NO. SEGMENTS - The number of active segments in the weld schedule. This
parameter is identical to the NO. SEGMENTS parameter found in the INITIAL screen,
and changes made to it from either screen have the same effect. Change this parameter to
add or delete active segments from the weld sequence.
PULSE MODE - There are 3 current pulsation modes, PARC, SYNC and OFF. The
default is PARC. In PARC mode the current will pulse between PRI AMPS and BKG
AMPS at a frequency and pulse width defined by PULSE FREQ and PULSE WIDTH.
In SYNC mode the current will pulse between PRI AMP and BKG AMP with the
primary cycle occurring during DWELL times and the background cycle occurring
during EXCURSION times. In OFF mode the current will not pulse and will remain at
the PRI AMP level. This parameter will only display if the selected weld head has a
cross seam slide or torch oscillation capability.
SEG TIME – The duration of the weld segment in seconds. This parameter appears
when the SEGMENT ADVANCE mode is set to TIMED or MANUAL. For more
information refer to the section on SEGMENT ADVANCE modes (pg 25). In TIMED
mode, when the SEG TIME has elapsed, the segment will advance to the next one, or
into DOWNSLOPE if this is the final segment. In MANUAL mode the SEG TIME
displays the number of seconds that have elapsed since the start of the segment.
DISTANCE – The duration of the weld segment in degrees or inches. This parameter
appears when the SEGMENT ADVANCE mode is set to POSITION. For more
information refer to the section on SEGMENT ADVANCE modes (pg 25). When the
DISTANCE has been travelled, the segment will advance to the next one, or into
DOWNSLOPE if this is the final segment.
SLOPE TIME – The duration in seconds, beginning at the start of the segment, during
which the weld current will linearly increase or decrease from the PRI AMP/BKG AMP
values established in the previous segment to the PRI AMP/BKG AMP values for the
current segment. The slope will not continue past the current segment should the weld
sequence advance to the next segment before the SLOPE TIME has elapsed. The
SLOPE TIME parameter for segment 1 is also referred to as UPSLOPE time. During
UPSLOPE time, the weld current will slope from the INITIAL AMPS value in the
SETUP screen to the PRI AMP/BKG AMP values for segment 1.
PRI AMP - The welding current output by the power supply during the PRIMARY
portion of the pulsation cycle. Generally, this is the high current, or "hot" portion of the
weld. If pulsation is not being used, the PRI AMP parameter will establish the level of
continuous weld current output by the power supply. For more information on
programming PRI AMP refer to the note on Maximum Output Current (pg 92).

89
BKG AMP - The welding current output by the power supply during the
BACKGROUND portion of the pulsation cycle. Generally, this is the low current, or
"cool" portion of the weld. If pulsation is not being used, the BKG AMP parameter is
ignored. For more information on programming BKG AMP refer to the note on
Maximum Output Current (pg 92).
FWD AMP - The welding current output by the power supply during the FORWARD
portion of the variable polarity pulsation cycle. This parameter will only display if the
power supply is equipped with a variable polarity unit and the VP MODE is ON.
REV AMP - The welding current output by the power supply during the REVERSE
portion of the variable polarity pulsation cycle. This parameter will only display if the
power supply is equipped with a variable polarity unit and the VP MODE is ON.
PULSE FREQ - The pulse frequency in hertz (pulses per second). PULSE FREQ
establishes the rate at which the power supply will switch the output current flow
between the PRI AMP level and the BKG AMP level. TRAVEL speeds, WIRE feed
rates and VOLTAGE targets are also switched between the PRI and BKG values at the
PULSE FREQ rate. If the power supply is equipped with a variable polarity unit and
VP MODE is ON, the PULSE FREQ establishes the rate at which the power supply will
switch the output current flow between the FWD AMP and REV AMP level. TRAVEL
speed, WIRE feed rate and the VOLTAGE target cannot be pulsed when VPMODE is
ON.
PULSE WIDTH - The percentage of time that the pulse spends in its PRIMARY
cycle. For example, a value of 60 would mean that for 60 percent of the time, the cycle
would be in the PRIMARY portion, and for the remaining 40 percent of the time, the
cycle would be in the BACKGROUND portion. A value of 100 percent will cause the
pulsation cycle to remain in PRIMARY at all times, effectively disabling pulsation. If
the power supply is equipped with a variable polarity unit and VP MODE is ON, the
PULSE WIDTH is the percentage of time that the pulse spends in its FORWARD
cycle. For more information on programming PULSE WIDTH refer to the note on
Maximum Output Current (pg 92).
PRI TRAV - The speed at which the TRAVEL axis will move during the PRIMARY
portion of the pulsation cycle.
BKG TRAV - The speed at which the TRAVEL axis will move during the
BACKGROUND portion of the pulsation cycle. As long as the BKG TRAV matches
the PRI TRAV, the value for BKG TRAV will automatically be set to the PRI TRAV
value by the power supply when the PRI TRAV value is changed.
PRI WIRE – The speed at which the wire will feed in inches per minute during the
PRIMARY portion of the pulsation cycle. This parameter will only display if the
selected weld head has wire feed capability.

90
BKG WIRE – The speed at which the wire will feed in inches per minute during the
BACKGROUND portion of the pulsation cycle. This parameter will only display if the
selected weld head has wire feed capability.
PRI VOLTS – The target voltage of the AVC during the PRIMARY portion of the
pulsation cycle. The PRI VOLTS value sets the AVC MODE (see below). This
parameter will only display if the selected weld head has AVC capability.
BKG VOLTS – The target voltage of the AVC during the BACKGROUND portion of
the pulsation cycle. The BKG VOLTS value sets the AVC MODE (see below). This
AVC MODE – The AVC MODE can be either CONT, SAMP or OFF. The AVC
MODE is determined by the PRI and BKG VOLTS settings. If both PRI and BKG
VOLTS are greater than 5, the AVC is in CONT (continuous) mode. If the PRI
VOLTS setting is above 5, but the BKG VOLTS setting is less than 5, then the AVC is
in SAMP mode. In SAMP mode the AVC is only active during the PRIMARY pulse
cycle. If neither of PRI or BKG VOLTS is above 5, the AVC will be OFF. This
OSC WIDTH – The total width in inches of the cross seam oscillation. This parameter
will only display if the selected weld head has a cross seam slide or torch oscillation
capability. For more information see Using Torch Oscillation (pg 92).
EXCURSION – The duration in seconds the cross seam oscillator takes to move
between the IN DWELL and OUT DWELL positions as established by OSC WIDTH.
This parameter will only display if the selected weld head has a cross seam slide or torch
oscillation capability. For more information see Using Torch Oscillation (pg 92).
IN DWELL – The duration in seconds the cross seam oscillator will pause when it has
reached the inside position of the OSC WIDTH before beginning EXCURSION to the
OUT DWELL position. This parameter will only display if the selected weld head has a
cross seam slide or torch oscillation capability. For more information see Using Torch
Oscillation (pg 92).
OUT DWELL – The duration in seconds the cross seam oscillator will pause when it
has reached the outside position of the OSC WIDTH before beginning EXCURSION to
the IN DWELL position. . This parameter will only display if the selected weld head has
a cross seam slide or torch oscillation capability. For more information see Using Torch
Oscillation (pg 92).
THETA ANGLE - The total angle in degrees of torch oscillation. This parameter will
only display if the selected weld head is designed for MIG welding.
ROTATE ANGLE - The total angle in degrees of electrode rotation. This parameter
will only display if the selected weld head is designed for dual synch pulse.
91
MIG PROGRAM - The number of the program to be executed on the MIG welding
power supply. This parameter will only display if the selected weld head is designed for
MIG welding.
OSC STEP – The rate to move the oscillator centre position in relation to travel during
the weld sequence. This is only supported and will only appear with weld heads that are
capable of spiral motion welding.
IPM (PRI and BKG) – The linear travel speed at the surface of the part for a rotational
axis. This inch per minute value is used along with the diameter of the part to calculate
the travel speed in RPM needed to achieve this linear speed. This parameter is a
replacement for the regular TRAVEL parameter and behaves in the same manner, if
primary and background are the same then changing primary will automatically change
background. This is only supported on some custom weld heads that have this particular
feature enabled in their configuration.
O.D. – The Outer Diameter of the work piece. This is used to determine the rotational
speed needed for travel to achieve the desired IPM linear travel. This is only supported on
some custom weld heads that have this particular feature enabled in their configuration.
Using Torch Oscillation

When oscillation width is programmed, the cross seam slide and travel axis will move
together to create the weaving motion shown below. The dimensions of the welding path
can be altered by changing the parameters shown in the diagram.
Maximum Output Current

The maximum output current of the welding power supply will be listed on the ratings
plate. Amperages above the 100% rating can be programmed when using current
pulsation. The pulsation frequency must be at least 2 Hz. The average of the primary
and background amperages must be lower than the 100% rating. The average output
current can be determined by weighting the primary amperage by the percentage pulse
width.
AVG AMPS = ((PRI AMPS x PULSE WIDTH) + (BKG AMPS x (100 – PULSE WIDTH))) / 100

92
Overriding a Weld Schedule
Some of the segment screen parameters may be adjusted in PRODUCTION mode to
allow the operator some variation in programmed values. These parameters are listed on
the OVERRIDE SETUP screen. The OVERRIDE SETUP screen lists the amount of
percentage adjustment available to the operator. While in PRODUCTION mode, the
segment parameters can never exceed the programmed value plus the maximum
percentage adjustment. To apply an override to one of the above parameters, cursor to
the desired parameter value, type a new value from the keypad and press ENTER.

---- ---- ---- ------ ---- ----- --- --
0001 2.00 .125 TUBE SS 52/54 1G 01
0002 1.50 .075 TUBE SS VIP-3 1G 01
0003 1.00 .063 TUBE SS 52/54 1G 01
0004 1.00 .063 TUBE SS 52/54 1G 01
0005 1.00 .063 TUBE SS 52/54 1G 02
LOAD DIRECTORY Screen
The LOAD DIRECTORY screen is used during the LOAD procedure to display the
possible selections to be loaded into the active weld schedule. Pressing CTRL and UP or
DOWN will display additional pages of schedules. Refer to Loading a Weld Schedule
(pg 64) for more information about loading weld schedules.

---- ---- ---- ------ ---- ----- --- --
0001 2.0 .075 TUBE SS 52/54 1G 01
SCHEDULE LOADING Screen

The SCHEDULE LOADING screen is used during the LOAD procedure to apply the
desired scale factor to the values of weld current in the weld schedule being loaded.
Refer to Scaling a Weld Schedule (pg 66) for more information about scale factors.

93
---- ---- ---- ------ ---- ----- --- --
0001 2.0 .075 TUBE SS 52/54 1G 01

SAVE SCHEDULE Screen
The SAVE SCHEDULE screen is used during the SAVE procedure to display the
schedule description. If the active weld schedule is stored with an ID that already exists
in the schedule library, that weld schedule may be overwritten with the active weld
schedule. Refer to Saving a Weld Schedule (pg 68) for more information about saving
weld schedules.

---- ---- ---- ------ ---- ----- --- --
0001 2.0 .075 TUBE SS 52/54 1G 01
OVERWRITE?
0001 2.0 .075 TUBE SS 52/54 1G 01
YES NO
SAVE CONFIRMATION Screen
The SAVE CONFIRMATION screen is used during the SAVE procedure to reduce the
risk of accidentally destroying useful data when saving the active weld schedule over an
existing weld schedule. Refer to Saving a Weld Schedule (pg 68) for more information
about saving weld schedules.
------------- COPY FUNCTIONS -------------

COPY SEGMENT TO SEGMENT: ## - ##
COPY SCHEDULE FROM USB DRIVE
COPY SCHEDULE FROM TEMPLATES
COPY SCHEDULE TO USB DRIVE
SAVE ALL SCHEDULES TO USB DRIVE
RESTORE ALL SCHEDULES FROM USB DRIVE
COPY DATALOGS TO USB DRIVE: ## - ##
COPY FUNCTIONS Screen
The COPY FUNCTIONS screen is used to select the source and destination for the
COPY procedure. The COPY procedure is very useful for making archive and backup
copies of weld schedules and to make the process of creating new weld schedules easier.
COPY FUNCTIONS Screen Parameters
The following parameters are available from the COPY FUNCTIONS screen:

94
FROM SEG - The segment number of the segment to be copied. This parameter is
used for copying from segment to segment in the same weld schedule. Refer to Copying
a Segment (pg 63) for more information about segment copying.
TO SEG - The segment number of the segment to be written to. This parameter is
used for copying from segment to segment in the same weld schedule. The actual data
transfer will begin when this parameter is entered. Refer to Copying a Segment (pg 63)
for more information about segment copying.
COPY SCHEDULE FROM USB DRIVE - This option allows a schedule to be
loaded from a usb memory device that has been connected to the front of the power
supply. This schedule can be generated offline using the optional available software for
the windows operating system. This schedule could also have come from another power
supply.
COPY SCHEDULE FROM TEMPLATE - This option allows a schedule to be
loaded from the internal library of Dimetrics weld schedules.
COPY SCHEDULE TO USB DRIVE - This option allows a weld schedule to be
saved to a usb memory device that has been connected to the front of the power supply.
This allows weld schedules to be transferred to other power supplies or moved to another
computer for archiving.
SAVE ALL SCHEDULES TO USB DRIVE - This option allows all of the weld
schedules to be saved to a usb memory device that has been connected to the front of the
power supply.
RESTORE ALL SCHEDULES FROM USB DRIVE - This option allows all of the
weld schedules on a usb memory device to be copied back into the internal memory of
the power supply.
COPY DATALOGS TO USB DRIVE - This option allows the data log files to be
transferred to a usb memory device for review or storage on an external computer system.
Some Notes about USB memory devices

The power supply has limited support for USB memory devices. Removable devices
are only recognized by the system at power up. If the device is connected to the
power supply after power up, the controller will notify the operator that the usb drive
is not installed if an attempt is made to use the device. To use the device, the power
supply must be powered down and then powered up again with the device properly
connected to the usb connection on the front panel. If the device is removed at any
time, it cannot be re-connected to the system again without cycling the power.

95
----------A/D CALIBRATION SCREEN-----------
TRAVEL
AMPS
VOLTS
WIRE
LIFT GAP
HOTWIRE
A/D CALIBRATION Screen

The A/D CALIBRATION screen displays a menu of auto-calibration procedures
available on the system. Refer to Calibration Features (pg 37) for more information
about this screen.
SET TIME/DATE
(HH:MM:SS)
TIME:(##:##:##)
(MM:DD:YY)
DATE:(##:##:##)
TIME/DATE SETUP Screen

The power supply maintains an internal time clock which is read during the process of
recording weld data when data logging is active. The current time and date appear in the
DATALOG reports. The TIME/DATE SETUP screen is needed to set the time and
date for this clock. Refer to Setting the Time and Date Stamp (pg 76) for more
information about the internal time clock.
SERIAL NUMBER (####) ####
WELD SERIAL NUMBER Screen

When data logging is active, the power supply will automatically assign a unique serial
number to each set of weld data parameters that it records into a DATA LOG file. The
serial number will be incremented for each new DATA LOG file. However, the operator
may establish the starting serial number for the sequence, and may change it at any time
using this screen.

96
------------OVERRIDE SETTINGS------------
MAX RATE MAX RATE

AMPS XXX XX P.WIDTH XXX XX
TRAVEL XXX XX P.FREQ XXX XX
WIRE XXX XX O.WIDTH XXX XX
VOLTS XXX XX EXCUR. XXX XX
DWELL XXX XX
OVERRIDE SETUP Screen
MAX SETTING - The maximum amount, expressed as a percentage, that the operator
will be able to adjust the specified parameter value while in PRODUCTION mode. In
the TEACH mode, the MAX value is ignored, and the parameter may be scaled or
overridden by any amount. The MAX value for AMPS is applied when the operator uses
the SCALING feature while loading a weld schedule in PRODUCTION mode. The
MAX value can be changed to establish the permissible range of variation that can be
applied using the OVERRIDE function in PRODUCTION mode. Refer to Overriding
a Weld Schedule (pg 93) for more information about the OVERRIDE function. Refer
to Scaling a Weld Schedule (pg 66) for more information about the SCALING feature.
RATE SETTING - The amount in parameter units the parameter is incremented or

decremented with each click of the override button on the pendant.
WELD HEAD MANAGEMENT screen
Different weldheads have different configurations in regards to a number of features

provided by the controller. Not all heads have the same number of servos, position
feedback or home switches. To turn on/off the different features of the controller for the
weldhead that is attached to the system the operator (while in TEACH mode) can select a
weldhead from a list of active heads. While on the initial screen (displayed below) the
operator can cursor to the middle of the bottom row and select a different weldhead than
the default configuration.

97

---------------- MODES -----------------

TIMED F TEACH
To change weldheads, do the following:
1. Place the cursor over the current weldhead displayed in the middle of the bottom
row and press ENTER. The screen should display the following drop down
menu (the displayed weldheads depend on which are active on the controller):

---------------- MODES -----------------

TIMED F TEACH
UNKNOWN
F-HOTWIRE
2. The weldheads that are available on the controller will be displayed in groups of 3
in a scrolling style menu. To cycle through the list of weldheads use the arrow
keys to move your selection up or down. This menu is a list of all the active
weldheads on the controller and will wrap around as the operator scrolls their
selection. With the desired weldhead selected press ENTER to re-configure the
controller and accept the new head. The screen will return to the original initial
screen with the new head displayed in the middle of the bottom row.
To change the list of active weldheads, do the following:
1. Access the password screen by pressing the CTRL and STOP keys, then
enter the system administration password and press the ENTER key.
98
CONFIGURATION
IO TEST
CHANGE PASSWORDS
UPGRADE SOFTWARE
EXIT TO DOS
2. From the system administration screen move the cursor to the Configuration
option and press the ENTER key which will bring up the following
Configuration screen:
---------------CONFIGURATION---------------
SCHEDULE LIBRARY
SET TIME AND DATE
HW CONFIGURATION
LANGUAGE SETUP
METRIC UNITS: OFF

LANGUAGE: English
3. Move the cursor to Weld Head Management and press the ENTER key which
will display a screen of all weld heads on the controller similar to the
following (all weld heads that are in the controllers weld head library will be
displayed on this screen):
-----------WELD HEAD MANAGEMENT------------

*UNKNOWN *F *F-HOTWIRE
*5002/5004 P16 FFIP
G 5001 MH170
SAVE PAGE: 1/ 1
4. To add/remove a weld head position the cursor to the left of the weld head and
press the ENTER key to cycle through the selection options. This can be
done to a number of different weld heads before committing to changes. The
3 options are: asterisk, blank space or ‘x’. All weld heads with the asterisk
99
beside them indicate weld heads that can be selected by the operator from the
initial screen in the weld head list. All weld heads that have a blank space
beside them (or no asterisk) are inactive and only held in the controllers weld
head library. All weld heads with an x beside them will be removed from the
library and the controller entirely (they are deleted).
5. Once all changes are decided on move the cursor to the SAVE option at the
bottom and press the ENTER key. All changes to the list of active heads will
be done then changes to the library will be done. If any weld heads are being
deleted (have an ‘x’ beside them) from the library there will be a confirmation
message displayed to confirm the changes. Press the ENTER key to accept or
the STOP key to abort the changes to the library.
6. Power down the machine to reset the controller and power on again to resume
operations with the new weld head configuration.
HW CONFIGURATION screen
A few hardware options can be changed from the user interface through the HW
CONFIGURATION menu. To access this menu the user much press CTRL and STOP
to bring up the password screen and enter the system administration password.
CONFIGURATION
IO TEST
CHANGE PASSWORDS
UPGRADE SOFTWARE
EXIT TO DOS
From the System Administration screen move the cursor to CONFIGURATION and
press the ENTER key.
---------------CONFIGURATION---------------
SCHEDULE LIBRARY
SET TIME AND DATE
HW CONFIGURATION
LANGUAGE SETUP
METRIC UNITS: OFF

LANGUAGE: English
Move the cursor to HW CONFIGURATION and press the ENTER key. This will bring
up the following screen:
100
-------------HW CONFIGURATION--------------
PENDANT:TERMIFLEX
NETWORK MODE:NONE
IP ADDRESS:XXX.XXX.XXX.XXX
NETMASK:XXX.XXX.XXX.XXX
GATEWAY:XXX.XXX.XXX.XXX
PROTOCOL:NONE
ACCEPT SAVE
PENDANT – This option shows the current selected remote operator pendant configured
for the controller. Pressing the ENTER key will cycle through the following choices:
Termiflex, HDPendant, QTerm, Unknown and None. Termiflex is the standard operator
pendant with customizable overlays. HDPendant is the original Diametrics operator
pendant (called a Hardened Pendant) with toggle switches and dials for all the common
functions. QTerm is the QSI Corporation operator pendant with the fix green keypad
layout. Unknown is used for internal testing and emulates a Termiflex pendant with
different communication settings. None will instruct the controller to ignore the pendant
altogether.
NETWORK MODE – The option will display the current network operating mode for
the controller. There are 3 modes of operation: None, DHCP, Manual. None means that
the network is turned off and not serviced by the controller. DHCP instructs the
controller to request an address at startup from a DHCP server, if there is network
connection in this mode the controller will display a network error when the DCHP
server does not respond. Manual will allow the rest of the network settings to be set by
the user which is used in an environment where IP addresses are static and no dynamic
reconfiguration is needed.
IP ADDRESS, NETMASK, and GATEWAY – The four number fields beside these
options will display the IP addresses and mask assigned to this controller. Only in
manual mode can the changes to these fields have meaning, in DHCP and None mode
they are ignored. The fields are displayed in standard IP 0 – 255 dot notation.
NOTE
If the controller is connected to a managed corporate network please consult your
network Administrators before changing any network settings.
PROTOCOL – This option gives the protocol mode the controller is operating in. The
choices are MODBUS, HTTP or None. Most communications with the controller will
use the MODBUS protocol so this is the default when networking is enabled. HTTP is a
standard Web browser type protocol that is only support in certain applications. None

101
turns off protocol handling so standard IP traffic is serviced but other protocols are
ignored.
The bottom two options, ACCEPT and SAVE, are used to make changes to the
configuration. After all the above fields are updated they will be applied to the controller
configuration by moving the cursor to ACCEPT and pressing the ENTER key. At this
time the pendant is re-initialized and the network is restarted. There will be a slight delay
depending on the state of the pendant/network. To save the settings to be used when the
controller is powered on move the cursor to SAVE and press the ENTER key. Saving
the settings will exit the HW CONFIGURATION screen and save the current
configuration.
NOTE
The HDPendant can only be initialized once after powerup. If the settings on this
screen are changed with a hardened pendant attached to the system the pendant will
not respond and an error will be displayed. This is normal for this pendant, simply
power down the unit after the settings have been saved and the pendant will be
initialized on the next startup.

102
Chapter 5 Modbus Network Interface
The power supply controller supports MODBUS TCP/IP communications with another
device through the network port. The power supply can be configured to act as a
MODBUS slave. The controller will respond to the following modbus function codes:
Supported Modbus Functions
Code Description
1 Read Multiple Outputs (Coils)

2 Read Multiple Inputs
3 Read Multiple Output (Holding) Registers
4 Read Multiple Input Registers
5 Write Single Output (Coil)
6 Write Output (Holding) Register (16-bit only)
7 Read Exception Status
8 Loop Back
15 Write Multiple Outputs (Coils)
16 Write Multiple Output (Holding) Registers
Digital Outputs
Address range 0-255 corresponds to the hardware layer and is protected. These outputs
are read only through Modbus. Addresses above 255 contain output actuators that are
read/write. Only 8 digital outputs may be written in a single request.
Protected Outputs
Address Description
0 A0 - VP Enable
1 A1 - Arc Starter Enable
2 A2 - Hot Wire Enable
3 A3 - Pilot Arc Enable
4 A4 - Arc Enable
5 A5 - Power Enable
6 A6 - AVC Sense Enable
7 A7 - Unused
8 B0 - Panel LED: Power
9 B1 - Panel LED: Seq. Start
10 B2 - Pendant LED: Seq. Start
11 B3 - Panel LED: Seq. Stop
12 B4 - Panel LED: Purge
13 B5 - Panel LED: Home
14 B6 - Panel LED: Weld Mode
15 B7 - Unused
103
16 C0 - Travel Back EMF Enable
17 C1 - Wire Back EMF Enable
18 C2 - Osc Back EMF Enable
19 C3 - AVC Back EMF Enable
20 C4 - Travel Motor Enable
21 C5 - Wire Motor Enable
22 C6 - Osc Motor Enable
23 C7 - AVC Motor Enable
24 D0 - Shield Gas Solenoid Enable
25 D1 - Coolant Pump Enable
26 D2 - Beeper Enable
27 D3 - Touch Sense Enable
28 D4 - Unused
29 D5 - Unused
30 D6 - Unused
31 D7 - Unused
32 E0 - Keypad Col 0 Excite
37 E5 - Unused
38 E6 - Unused
39 E7 - Unused
40 F0 - Unused
41 F1 - Unused
42 F2 - Unused
43 F3 - Unused
44 F4 - Unused
45 F5 - Unused
46 F6 - Unused
47 F7 - Unused
48 G0 - Aux Connector Pin d
49 G1 - Aux Connector Pin e
50 G2 - Aux Connector Pin f
51 G3 - Aux Connector Pin g
52 G4 - Aux Connector Pin h
53 G5 - Aux Connector Pin i
54 G6 - Aux Connector Pin j
55 G7 - Aux Connector Pin k
56 H0 - Aux Servo 0 Back EMF Enable
60 H4 - Aux Servo 0 Motor Enable
64 + Unused

104
Output Actuators
Address Description
256 Purge
257 Coolant Pump
258 Test Mode
259 Travel Fwd Select
260 Wire Enable
261 AVC Enable
262 Start Sequence
263 Stop Sequence
264 Go Home
265 Find In Pos
266 Find Out Pos
267 Travel Jog Fwd
268 Travel Jog Rev
269 Wire Jog Out
270 Wire Jog In
271 AVC Jog Up
272 AVC Jog Down
273 Osc Jog In
274 Osc Jog Out
275 Aux Servo 0 Jog +ve
276 Aux Servo 0 Jog -ve
283 Override Increment
284 Override Decrement
285 Clear
286 Enter
287 Osc Step In
288 Osc Step Out
289 Aux Connector Pin d
290 Aux Connector Pin e
291 Aux Connector Pin f
292 Aux Connector Pin g
293 Aux Connector Pin h
294 Aux Connector Pin i
295 Aux Connector Pin j
296 Aux Connector Pin k
297 Pilot Arc Enable
298 Modbus Lockout

105
299 Travel Position Zero
300 Wire Position Zero
301 AVC Position Zero
302 Osc Position Zero
303 Wire2 Position Zero
304 Theta Position Zero
305 Rotation Position Zero
306 Aux0 Position Zero
328 Segment Advance
Digital Inputs
Address range 0-255 corresponds to the hardware layer. Addresses above 255 contain
status flags. Only 32 digital inputs may be read in a single request.
Address Description
0 A0 - Pilot Arc On
1 A1 - Unused
2 A2 - P250 Overload Fault
3 A3 - Estop
4 A4 - P250 Thermal Fault
5 A5 - Sequence Enable
6 A6 - Work Detect
7 A7 - Unused
8 B0 - Weld Head Toggle: Trav +

106
9 B1 - Weld Head Toggle: Trav -
10 B2 - Weld Head Toggle: Wire +
11 B3 - Weld Head Toggle: Wire -
12 B4 - Weld Head Toggle: AVC +
13 B5 - Weld Head Toggle: AVC -
14 B6 - Weld Head Toggle: Osc +
15 B7 - Weld Head Toggle: Osc -
16 C0 - Weld Head Toggle: Seq Start
17 C1 - Weld Head Toggle: Seq Stop
18 C2 - Unused
19 C3 - Weld Head Toggle: Wire Enable
20 C4 - Unused
21 C5 - Unused
22 C6 - Unused
23 C7- Unused
24 D0 - Plasma Flow Detect
25 D1 - Shield Flow Detect
26 D2 - Trail Flow Detect
27 D3 - Servo Power Detect
28 D4 - Hotwire Thermal Fault
29 D5 - Unused
30 D6 - Unused
31 D7 - Unused
32 E0 - Keypad Row 0 Detect
39 E7 - Unused
40 F0 - Unused
41 F1 - Unused
42 F2 - Unused
43 F3 - Unused
44 F4 - Unused
45 F5 - Unused
46 F6 - Unused
47 F7 - Unused
48 G0 - Pendant Switch: Seq Start/Stop
49 G1 - Pendant Switch: Seq Stop
50 G2 - Home Detect
51 G3 - Sequence Interlock
52 G4 - Pendant Switch: Trav Jog Enable
53 G5 - Pendant Switch: Purge Enable
54 G6 - Pendant Switch: Go Home
55 G7 - Unused
56 H0 - Coolant Flow Bit0
107
64 I0 - Aux Connector Pin n
65 I1 - Aux Connector Pin p
66 I2 - Aux Connector Pin q
67 I3 - Aux Connector Pin r
68 I4 - Aux Connector Pin s
69 I5 - Aux Connector Pin t
70 I6 - Aux Connector Pin u
71 I7 - Aux Connector Pin v
72+ Unused
Status Flags
Address Description
256 In Sequence
257 Arc On
258 Emergency Stop
259 Waiting for Clear
260 Fault
261 Unused
262 Unused
263 Unused
Output Registers
Address range 0-31 corresponds to the hardware layer and is protected. These outputs
are read only through Modbus. Addresses above 31 contain command registers that are
read/write. The address range from 0-1023 contains 32-bit registers. Addresses at 1024
and above are 16-bit registers. Any single write request may target either 32-bit or 16-bit
registers but not both. A maximum of 8 words may be written in any single request.
Protected 32-bit Analog Output Registers
Address Description
0 A0 - Current Command
1 A1 - Wire Feed Command
2 A2 - Travel Speed Command
3 A3 - Oscillation Speed Command
4 A4 - AVC Speed Command
5 A5 - Hot Wire Current Command
6 A6 - Unused
7 A7 - Unused

108
8 B0 - Aux Servo 0 Speed Command
12 B4 - MFC 0 Command
13 B5 - MFC 1 Command
14 B6 - MFC 2 Command / Aux Connector Pins x,y
15 B7 - Aux Connector Pins BB, CC
16-31 Unused
32-bit Floating Point Command Registers
Address Description
32 Cursor Value
33 Aux Connector Pins x,y
34 Aux Connector Pins BB,CC
35 Travel Position Target
36 Wire Position Target
37 AVC Position Target
38 Osc Position Target
39 Wire2 Position Target
40 Theta Position Target
41 Rotation Position Target
42-51 Aux0 - Aux9 Position Target
52 Distance Scale Factor
53 Speed Scale Factor
54 Travel Speed Scale Factor
55 - 256 Unused
257 Segment Count
258 Active Segment Time
259 Active Segment Slope Time
260 Active Segment Pri Amps
261 Active Segment Bkg Amps
262 Active Segment Pulse Freq
263 Active Segment Pulse Width
264 Active Segment Pri Travel
265 Active Segment Bkg Travel
266 Unused
267 Unused
268 Unused
269 Unused
270 Unused
271 Unused
272 Impulse Time
273 Impulse Amps
274 Initial Amps
275 Final Amps
276 Travel Jog Rate

109
277 Unused
278 Unused
279 Pre Purge Time
280 Post Purge Time
281 Travel Delay
282 Downslope Time
283 Pri Amp Error Band
284 Pri Amp Fault Band
285 Bkg Amp Error Band
286 Bkg Amp Fault Band
287 High Voltage Threshold
288 Low Voltage Threshold
289 Travel Error Band
290 Travel Fault Band
291 Unused
292 Unused
293 Unused
294 Unused
295 Unused
296 Unused
297 Unused
298 Unused
299 Unused
300 Reverse Cut Off Amps
301 Unused
302 Unused
303 Unused
304 Unused
305 Active Segment Pri Volts
306 Active Segment Bkg Volts
307 Active Segment Pri Wire
308 Active Segment Bkg Wire
309 Active Segment Osc Width
310 Active Segment Excursion
311 Active Segment In Dwell
312 Active Segment Out Dwell
313 Wire Delay
314 Wire Retract Distance
315 Wire Jog Out Rate
316 Wire Jog In Rate
317 Osc Jog Rate
318 AVC Jog Rate
319 AVC Lift Gap Distance
320 AVC Delay
321 AVC Stop Delay
322 AVC Sensitivity
323 Unused
324 Unused
325 Unused
326 Unused
110
327 Amps Override Max %
328 Amps Override Rate
329 Osc Width Override Max %
330 Osc Width Override Rate
331 Volts Override Max %
332 Volts Override Rate
333 Travel Override Max %
334 Travel Override Rate
335 Wire Override Max %
336 Wire Override Rate
337 Dwell Override Max %
338 Dwell Override Rate
339 Excursion Override Max %
340 Excursion Override Rate
341 Pulse Freq Override Max %
342 Pulse Freq Override Rate
343 Pulse Width Override Max %
344 Pulse Width Override Rate
345 Unused
346 Unused
347 Unused
348 Unused
349 Unused
350 Unused
351 Unused
352 Unused
353 Unused
354 Unused
355 Unused
356 Unused
357 Unused
358 Unused
359 Unused
360 Unused
361 Unused
362 Unused
363 Unused
364 Unused
365 Unused
366 Unused
367 Unused
368 Unused
369 Unused
370 Unused
371 Hot Wire Gain
372 Unused
373 Aux Servo 0 Jog Rate
111
383 AVC Retract Rate
384 Theta Angle
385 Theta Jog Rate
16-bit Integer Command Registers
Address Description
1024 Teach Password Register

1025 Load Schedule Register
1026 Save Schedule Register
1027 Active Segment
1028 Selected Weld Parameter (see Enumerations pg 116)
1029 Override Rate Multiplier (1-100)
1030 Number Register
1031 Screen Select (see Enumerations pg 116)
1032 Watchdog Timer
Input Registers
Address range 0-31 corresponds to the hardware layer. Addresses above 31 contain
variable registers. The address range from 0-1023 contains 32-bit registers. Addresses at
1024 and above are 16-bit registers. Any single read request may target either 32-bit or
16-bit registers but not both. A maximum of 8 words may be read in any single request.
32-bit Floating Point Analog Input Registers
Address Description
0 A0 - Current Telemetry
1 A1 - Oscillator Steering
2 A2 - Travel Speed Telemetry
3 A3 - Wire Feed Telemetry
4 A4 - Voltage Telemetry
5 A5 - Hot Wire Current Telemetry
6 A6 - Input Power Voltage Telemetry
7 A7 - Oscillator Position
8 B0 - Aux Servo 0 / MFC 0 Telemetry
9 B1 - MFC 1 Telem
10 B2 - MFC 2 Telem / Aux Conn Pins z, AA
11 B3 - Aux Conn Pins DD, EE

112
12 B4 - Unused
13 B5 - Unused
14 B6 - Unused
15 B7 - Unused
16-31 Unused
32-bit Floating Point Display Variables
Address Description
32 Active Segment Number

33 Segment Count
34 Active Segment Time
35 Active Segment Slope Time
36 Active Segment Pri Amps
37 Active Segment Bkg Amps
38 Active Segment Pulse Freq
39 Active Segment Pulse Width
40 Active Segment Pri Travel
41 Active Segment Bkg Travel
42 Unused
43 Unused
44 Unused
45 Unused
46 Unused
47 Unused
48 Impulse Time
49 Impulse Amps
50 Initial Amps
51 Final Amps
52 Travel Jog Rate
53 Log Number
54 Schedule ID
55 Pre Purge Time
56 Post Purge Time
57 Travel Delay
58 Downslope Time
59 Pri Amp Error Band
60 Pri Amp Fault Band
61 Bkg Amp Error Band
62 Bkg Amp Fault Band
63 High Voltage Threshold
64 Low Voltage Threshold
65 Travel Error Band
66 Travel Fault Band
67 Weld Serial Number
68 Unused
69 Unused
70 Unused
71 Unused
113
72 Unused
73 Unused
74 Unused
75 Unused
76 Reverse Cut Off Amps
77 Unused
78 Unused
79 Unused
80 Unused
81 Active Segment Pri Volts
82 Active Segment Bkg Volts
83 Active Segment Pri Wire
84 Active Segment Bkg Wire
85 Active Segment Osc Width
86 Active Segment Excursion
87 Active Segment In Dwell
88 Active Segment Out Dwell
89 Wire Delay
90 Wire Retract Distance
91 Wire Jog Out Rate
92 Wire Jog In Rate
93 Osc Jog Rate
94 AVC Jog Rate
95 AVC Lift Gap Distance
96 AVC Delay
97 AVC Stop Delay
98 AVC Sensitivity
99 Unused
100 Unused
101 Unused
102 Schedule Count
103 Amps Override Max %
104 Amps Override Rate
105 Osc Width Override Max %
106 Osc Width Override Rate
107 Volts Override Max %
108 Volts Override Rate
109 Travel Override Max %
110 Travel Override Rate
111 Wire Override Max %
112 Wire Override Rate
113 Dwell Override Max %
114 Dwell Override Rate
115 Excursion Override Max %
116 Excursion Override Rate
117 Pulse Freq Override Max %
118 Pulse Freq Override Rate
119 Pulse Width Override Max %
120 Pulse Width Override Rate
121 Unused
114
122 Unused
123 Unused
124 Unused
125 Unused
126 Unused
127 Unused
128 Unused
129 Unused
130 Unused
131 Unused
132 Unused
133 Unused
134 Unused
135 Unused
136 Unused
137 Unused
138 Unused
139 Unused
140 Unused
141 Unused
142 Unused
143 Unused
144 Unused
145 Log Number
146 Unused
147 Hot Wire Gain
148 Arc Hours
159 AVC Retract Rate
160 Theta Angle
161 Theta Jog Rate
32-bit Floating Point System Variables
Address Description
256 Sampled Pri Amps

257 Sampled Bkg Amps
258 Sampled Pri Travel
259 Sampled Bkg Travel
260 Sampled Pri Volts
115
261 Sampled Bkg Volts
262 Sampled Pri Wire
263 Sampled Bkg Wire
264 Sampled Hot Wire Amps
265 Timer Elapsed
266 Timer Remaining
267 Travel Position
268 Wire Position
269 AVC Position
270 Osc Position
271 Wire2 Position
272 Theta Position
273 Rotation Position
274 - 283 Aux0 - Aux9 Position
284 Digital Drive 0 - Current
285 Digital Drive 1 - Current
16-bit Integer System Variables
Address Description
1024-1123 Schedule List

1124-1139 Encoders 0-7 (Hi Word, Lo Word)
1140 Weld State (see Enumerations pg 116)
1141 Fault Type (see Enumerations pg 116)
Enumerations
Weld State
0 Idle
1 Sequece Start
2 Pre Purge
3 Electrode Touch
4 Electrode Lift
5 Arc Start - HF
6 Arc Start - Touch
7 Arc Start - Scratch
8 Weld Start
9 Segment
10 Downslope
11 Arc Stop
12 Weld Stop
13 Post Purge
14 Sequence Stop
Weld Parameters
5 Primary Amps
6 Background Amps

116
7 Pulse Frequency
8 Pulse Width
9 Primary Travel
10 Background Travel
50 Primary Volts
51 Background Volts
52 Primary Wire
53 Background Wire
54 Oscillation Width
55 Excursion
56 In Dwell
57 Out Dwell
Fault Types
0 None
1 Sheild Gas
2 Coolant
3 Thermal
4 Ground
5 Arc Start Fail
6 ShortCircuit
7 Arc Out
8 Segment Advance
9 Excessive Voltage
10 Low Voltage
11 Excessive Current
12 Low Current
13 Excessive Travel
14 Low Travel
15 Travel Limit
16 Emergency Stop
17 User Abort
Screen Indexes
-3 Select Menu
-2 Message
-1 Title
0 Tube Segment
1 Password Entry
2 Load Schedule
3 Copy
4 Save Schedule
5 Scale Schedule
6 Setup
7 Initial
8 Limits
9 Data Log Menu
10 Set Date Time
11 Calibration Select
12 Travel Cal 1
117
13 Travel Cal 2
14 System Administration
15 Amps Cal 1
16 Amps Cal 2
17 Pipe Segment
18 AVC Setup
19 Volts Cal 1
20 Volts Cal 2
21 Wire Cal 1
22 Schedule Library
23 Delete Schedule
24 Rename Schedule
25 Overrides
26 Wire Cal 2
27 Log View
28 Tube AVC Segment
29 Digital IO Test
30 Analog IO Test
31 Hot Wire Cal 1
32 Hot Wire Cal 2
Exception Status Byte
Bit Description
0 In Sequence
1 Arc On
2 Emergency Stop
3 Waiting for Clear
4 Fault
5-7 Unused

118
Chapter 6 Troubleshooting Guide
Error Messages
This chapter will explain the displayed error messages and provide some general
suggestions for corrective action. In general, error messages must be cleared by the
appropriate corrective action and then the CLEAR key on the front panel must be
depressed. In some cases, the STOP key on the front panel or the SEQ STOP key on the
remote pendant may also be used.
SYSTEM FAULT: POSITION ERROR

When a weld head has an axis with position feedback (an encoder or pot) the controller
will attempt to hold the axis position. If the feedback begins to drift (possibly from
gravity) the controller will attempt to bring the axis back to the hold position by slowly
adding drive command to the axis until there is a reduction of the position error. If this
attempt actually causes the position error to grow and drift even further away from the
target hold position the controller will display this fault and disable this axis. Usually this
means one of two problems have occurred; lost of feedback so the position “floats”
regardless of actually axis position or inverted feedback so that positive drive command
actually causes negative movement. The former is a possible wiring or component
failure and the latter is usually an incorrect configuration.
ENTRY EXCEEDS MIN OR MAX

A numeric value being entered into a display screen parameter is beyond the range of
acceptable values. The parameter will automatically be set to its minimum or maximum
value.
SCALED AMP VALUE WILL EXCEED MIN OR MAX

The value being entered for the scale factor during a LOAD operation will cause the
PRI/BKG AMP values to exceed the permissible range. The PRI/BKG AMP values
will automatically be set the minimum or maximum values.
EMERGENCY STOP
An emergency stop button has been depressed. Make sure all of the
emergency stop buttons are unlatched before clearing the message using the
CLEAR key.
NO COOLANT FLOW
The power supply has detected insufficient coolant flow.
1. Make sure that the coolant hose connections are properly attached to the
power supply.
2. Make sure that the coolant tank inside the power supply is filled to the proper
level.
3. Make sure that there are no leaks in the pump, hoses, and weld headMake sure
that the coolant hoses are not kinked or pinched.
119
4. Make sure that there are no obstructions in the coolant hoses.
5. Make sure that the coolant pump motor is functioning properly.
NO GAS FLOW
The power supply has detected insufficient shield gas flow.
1. Make sure that the inert gas hose connections are properly attached to the
power supply.
2. Make sure that the gas supply valve is turned on.
3. Make sure that the inert gas hose is not kinked or pinched.
4. Check the gas flow sensor for proper operation.
GROUND FAULT FAILURE

The power supply cannot detect a connection to the work piece.
1. Make sure that the work cable connection is properly attached to the power
supply.
2. Make sure that the work cable is properly attached to the work piece.
3. Make sure that there is no paint, oxide or other coating between the work
cable connection and the work piece.
THERMAL OVERLOAD
The power supply has overheated.
1. Make sure that the input filters are clean.

2. Make sure that the input and output air vents are not obstructed.
3. Make sure that the cooling fans are working
4. At extreme ambient temperatures it may be required to allow cooling time in
between cycles if the power supply is overheating. Make sure to leave the
unit powered up with the cooling fans running.
ELECTRODE IS TOUCHING
The power supply has detected a short circuit between the electrode and
the work piece.
1. Make sure that the electrode is not contacting the work piece.
2. Check the integrity of the electrode cable and make sure it is properly
insulated.
3. If the system is using the AVC sense circuit. Check the AVC sense wire.
ARC START FAILURE

The power supply has failed to strike an arc after several attempts.
1. Check the tungsten tip.

2. Check gas coverage. Increase the value of PRE PURGE time.
3. Check gas purity.
120
4. For high frequency arc starts, increase the value of IMPULSE AMPS on the
SETUP screen.
5. For high frequency arc starts, increase the value of IMPULSE TIME on the
SETUP screen.
6. Rebuild the torch.
NOTE
The power supply will keep trying to start the arc, and will abort
with an ARC START FAILURE error message only after having
made 5 unsuccessful attempts. To abort the arc start retry process
at any time during these 5 retry attempts, depress and hold the
STOP key until the ARC START FAILURE appears.
ARC WAS LOST - SHORT CIRCUIT

The power supply has detected a short circuit between the electrode and the work piece.
1. Make sure that the electrode is not contacting the work piece.
2. Check the integrity of the electrode cable and make sure it is properly
insulated.
3. If the system is using the AVC sense circuit. Check the AVC sense wire.
ARC WAS LOST - OPEN CIRCUIT

The power supply has detected an unexpected loss of the arc during a weld
sequence.
1. Make sure the arc gap distance from electrode to work is not excessive.
2. Make sure the shield gas flow is not excessive.
3. Check gas coverage.
4. Check gas purity.
5. Check part cleanliness.
6. Make sure the values of PRI AMP and/or BKG AMP are not excessively low
or PRI TRAV and/or BKG TRAV are not excessively fast.
WELD FAILURE - EXCESSIVE/LOW PARAMETER FEEDBACK

The power supply has detected that a weld parameter has gone outside of
the fault band specified on the LIMITS screen.
1. Increase the FAULT value for the parameter on the LIMITS screen.
2. Set DATALOG = OFF on the LIMITS screen.

121
INDEX
AVC JOG Parameter, 83 HOME Key, 27
AVC MODE Parameter, 91 HOTWIRE Parameter, 82
AVC RETRACT Parameter, 84 IMPULSE AMPS Parameter, 81
BKG AMP Parameter, 90 IMPULSE TIME Parameter, 80
BKG TRAVEL Parameter, 90 IN DWELL Parameter, 91
BKG VOLTS Parameter, 91 INITIAL AMPS Parameter, 81
BKG WIRE Parameter, 91 LIFT GAP Parameter, 83
CLEAR Key, 33 LOAD Key, 64
COPY Key, 61 LOW VOLTS Parameter, 85
CTRL Key, 75 MANUAL Mode, 79
DATALOG ON/OFF Modes, 85 MAX OVERRIDE Parameter, 97
DATE Parameter, 76 MIG PROGRAM Parameter, 92
DISTANCE Parameter, 89 NO. SEGMENTS Parameter, 79
DOWN SLOPE Parameter, 79 NUMERIC Keys, 31
ENTER Key, 32 OSC JOG RATE Parameter, 81
ERROR MESSAGE OSC STEP Parameter, 81
ARC START FAILURE, 119, 120 OSC WIDTH Parameter, 91
ARC WAS LOST – OPEN OUT DWELL Parameter, 91
CIRCUIT, 121 POSITION Mode, 79
ARC WAS LOST – SHORT POST PURGE Parameter, 79
CIRCUIT, 121 PRE PURGE Parameter, 79
ELECTRODE IS TOUCHING, 120 PRI AMP Parameter, 89
ENTRY EXCEEDS MIN OR MAX, PRI TRAVEL Parameter, 90
119 PRI VOLTS Parameter, 91
GROUND FAULT FAILURE, 120 PRI WIRE Parameter, 90
PRINT ALL Mode, 86
NO COOLANT FLOW, 119
PRINT ERRORS Mode, 85
NO GAS FLOW, 120
PRINT Key, 59
SCALED AMP VALUE WILL
PRINT REPORT Mode, 85
EXCEED MIN OR MAX, 119 PRODUCTION Mode, 21
THERMAL OVERLOAD, 120 PULSE FREQ Parameter, 90
WELD FAILURE – PULSE WIDTH Parameter, 90
EXCESSIVE/LOW PARAMETER PURGE Key, 34
FEEDBACK, 121 RATE OF OVERRIDE Parameter, 97
ERROR Parameter, 85 REV AMP Parameter, 90
EXCURSION Parameter, 91 REV CUTOFF Parameter, 82
FAULT Parameter, 85 ROTATE ANGLE Parameter, 91
FINAL AMPS Parameter, 81 SAVE Key, 68
FLOW RATE Parameter, 82 SCHED Parameter, 79
FWD AMP Parameter, 90 Screen Navigation Chart, 24
GAS MIX % Parameter, 83 SEG TIME Parameter, 89
HIGH VOLTS Parameter, 85 SEGMENT Parameter, 89
122
SENSITIVITY Parameter, 84 TOTAL SEGMENTS Parameter, 89
SLOPE TIME Parameter, 89 TOUCH ARC Parameter, 84
START DELAY Parameter, 83 TRAV DIR Parameter, 81
START Key, 25 TRAV JOG RATE Parameter, 81
STOP DELAY Parameter, 84 TRAVEL DELAY Parameter, 80
STOP Key, 30 USB Memory Devices, 95
STORE REPORT Mode, 86 VP MODE Parameter, 82
TEACH Mode, 21 WIRE DELAY Parameter, 80
TEST Key, 36 WIRE FEEDER Parameter, 82
THETA ANGLE Parameter, 91 WIRE JOG FWD Parameter, 81
THETA JOG RATE Parameter, 82 WIRE JOG REV Parameter, 82
TIME Parameter, 76 WIRE RETRACT Parameter, 80
TIMED Mode, 79

123

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LIBURDI DIMETRICS

PIPE and TUBE WELDERS

Liburdi Dimetrics Corporation

Liburdi Dimetrics Corporation

Pipe and Tube Operations Manual P/N 332-6000-906

IN CONSIDERATION FOR LDC FURNISHING THIS

THIS NOTICE SHALL APPEAR ON ANY

THIS INFORMATION IS EXEMPTED FROM

Pipe and Tube Operations Manual P/N 332-6000-906

Rev C. Aug 2006

Rev 4-Feb 2007

Rev 5-Aug 2007

Rev 6-Aug 2007

Rev 7-Feb 2008

Pipe and Tube Operations Manual P/N 332-6000-906

Pipe and Tube Operations Manual P/N 332-6000-906

Installation and Use Precautions

WARNING! SHOCK HAZARD!

Pipe and Tube Operations Manual P/N 332-6000-906

Pipe and Tube Operations Manual P/N 332-6000-906

WARNING! SHOCK HAZARD!

e. Workpiece Earthing: Where the workpiece is not bonded to earth for

Pipe and Tube Operations Manual P/N 332-6000-906

Pipe and Tube Operations Manual P/N 332-6000-906

WARNING! SHOCK HAZARD!

1. Hazardous Radiation, Fields, and Acoustic Noise

2. Hazardous Fumes and Gases

a. Avoid and do no breathe welding fumes.

Pipe and Tube Operations Manual P/N 332-6000-906

4. Hazardous Hot Metal, Flying Particles, and Chips

6. Hazardous Mechanisms or Moving Parts

Pipe and Tube Operations Manual P/N 332-6000-906

Pipe and Tube Operations Manual P/N 332-6000-906

C. Glossary of Markings and Graphical Symbols

Marking or Symbol Meaning

WARNING! WARNING means possible serious hazard: injury

D. Power Supply Duty Cycle

Pipe and Tube Operations Manual P/N 332-6000-906

Weld Parameter Specifications

Parameter Descriptions Range Resolution

Number of Programs 1 – 100

* Default value depends on the weld head selected.

Pipe and Tube Operations Manual P/N 332-6000-906

Legacy Keypad and LCD Screen

New All-in-One Unit

To change the mode, do the following:

ENTER PASSWORD FOR PROGRAMMING

WWW.LIBURDI.COM VERSION X.XX.XX

To change to TEACH mode, do the following:

To change to PRODUCTION mode, do the following:

RED GREEN RED GREEN RED GREEN

POWER SEQ SEQ MANUAL WELD

START HOME 7 8 9 LOAD SAVE

STOP ENTER 0 CLEAR CTRL

Pipe and Tube Operations Manual P/N 332-6000-906

Cursor Control Keys

Changing Display Screens

Pipe and Tube Operations Manual P/N 332-6000-906

RED GREEN RED GREEN RED GREEN

POWER SEQ SEQ MANUAL WELD

START HOME 7 8 9 LOAD SAVE

STOP ENTER 0 CLEAR CTRL

Pipe and Tube Operations Manual P/N 332-6000-906