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B-6
OPERATION
B-6
Instead, an arc length adjustment is provided. The
machine “knows” what the best arc length is at the
given wire feed speed but allows the operator to
change it.
The arc length trim (usually referred to simply as
“trim”) can be adjusted between 0.500 and 1.500 on
the control box’s Volts/Trim display. A Trim of 1.000
means that no adjustments will be made to the preset
arc lengths. A Trim greater than 1.000 increases the
preset arc lengths. A Trim setting less than 1.000
decreases the preset arc lengths. The arc length trim
adjustment is factored in at all wire feed speed set-
tings. Increasing the Trim by 10 percent at a given
wire feed speed also increases all the other arc length
trim settings of the procedure by 10 percent.
The Power Wave utilizes a control scheme known as
adaptive control in all pulse modes. Because the
Power Wave utilizes adaptive control, it can adjust the
pulsing parameters based on changes in the arc due
to changes in the electrical stickout of the electrode.
(Electrical stickout is the distance from the contact to
to the workpiece.) The Power Wave is optimized
for use with a 19 mm (.75”) stickout. The adaptive
behavior is programmed to support a stickout range
from 13 mm (.5”) to 32 mm (1.25”). In the low and
high end of the wire feed speed ranges of most
processes, the adaptive behavior may be restricted.
This is a physical restriction due to reaching the edge
of the operating range for the process.
The Arc Control adjustment allows the pulse frequen-
cy to be varied. Increasing the Arc Control causes the
frequency setting to increase, while decreasing the
Arc Control causes the frequency to decrease.
Varying the Arc Control, and hence, the pulse fre-
quency, affects the droplet transfer and allows fine-
tuning for different welding positions.
CONSTANT CURRENT (CC/STICK, CC/TIG)
PROCEDURES
Stick welding can be performed by choosing one of
the stick welding modes. Check the Power Feed wire
feeder Operator’s Manual for instructions on how to
energize the output terminals on the Power Wave.
(Certain options energize the terminals automatically
while other options require a manual adjustment to
energize the terminals.) The output current is set by
the Amps control on the Power Feed wire feeder. The
Volts/Trim adjustment has no effect in this mode.
The Arc Control adjusts the arc force. Increasing the
Arc Control setting increases the arc force, making
the arc more harsh but less likely to stick. Decreasing
the Arc Control setting decreases the arc force, mak-
ing the arc softer and smoother.
ARC GOUGING PROCEDURES
Arc gouging can be performed by choosing the arc
gouging weld mode. Doing so automatically ener-
gizes the output terminals on the Power Wave, mak-
ing the power source immediately ready to weld. The
output current is set by the Amps control on the
Power Weld wire feeder. The Volts/Trim adjustment
has no effect in this mode.
The Arc Control adjusts the arc force. Increasing the
Arc Control setting increases the arc force, making
the arc more harsh but less likely to stick. Decreasing
the Arc Control setting decreases the arc force, mak-
ing the arc softer and smoother.
SURFACE TENSION TRANSFER (STT)
PROCEDURES
The STT process is neither a constant current (CC)
nor a constant voltage (CV) process. It is a current
controlled process where the electrode current
changes quickly in response to the instantaneous
requirements of the arc.
In the Power Wave 455/STT, the ideal STT wave-
forms and current control alogorithms are pro-
grammed into the power source. These waveforms
are automatically adjusted as the wire feed speed is
varied on the Power Feed wire feeder. This is known
as synergic control of the STT process. Some adjust-
ments are available to the user, so that the arc can be
adjusted to meet the actual weld conditions.
The Arc Control setting is a coarse adjustment of the
heat input to the weld. It can be varied from -10.0 to
10.0, with a nominal setting nof 0.0. Reducing the Arc
Control too far may cause electrode stubbing. Raising
the Arc Control too high may cause the electrode to
be too fluid, increasing spatter. An Arc Control setting
of 0.0 is a good starting point for most conditions.
The Trim is a fine adjustment of the heat input to the
weld. It can be varied from 0.500 to 1.500. A Trim
setting of 1.000 is a good starting point for most condi-
tions.
POWER WAVE 455 STT