ESAB Digipulse Dual Wire Feeder Bombardier User manual

ESAB Digipulse Dual Wire Feeder Bombardier User manual

INSTRUCTIONS for

DIGIPULSE DUAL

WIRE FEEDER

Bombardier

P/N 33299

F-15-496-A

May, 1999

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding equipment we urge you to read our booklet Precautions and Safe Practices for Arc Welding, Cutting and Gouging, Form

52-529. Do NOT permit untrained persons to install, operate or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions contact your supplier for further information. Be sure to read the Safety Precautions on page 2 before installing or operating this equipment.

Be sure this information reaches the operator.

You can get extra copies through your supplier.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

TABLE OF CONTENTS

SECTION

PARAGRAPH

TITLE PAGE

SAFETY PRECAUTIONS ..........................................................................................................................

3

SECTION 1 DESCRIPTION .................................................................................................

7

SECTION 2

SECTION 3

SECTION 4

SECTION 5

INSTALLATION ................................................................................................ 12

OPERATION ..................................................................................................... 16

MAINTENANCE ................................................................................................ 19

REPLACEMENT PARTS .................................................................................. 22

2

SAFETY PRECAUTIONS

WARNING:

T hese Safety Precautions are for your protection. They summarize precautionary information from the references listed in

Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS

--

Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns.

Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing

5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far.

Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective nonflammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary.

7. For additional information, refer to NFPA Standard 51B,

"Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling.

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —

May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields

(EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

3

1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together. Secure them with tape when possible.

B. Never coil the torch or work cable around your body.

C. Do not place your body between the torch and work cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as possible to the area being welded.

E. Keep welding power source and cables as far away from your body as possible.

10/98

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.

5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of

California to cause birth defects and, in some cases, cancer. (California Health &

Safety Code

§

25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors.

Maintain hoses and fittings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in

Cylinders", which is available from Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington,

VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:

1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and

Safe Practices for Arc Welding, Cutting and

Gouging", Form 52-529.

The following publications, which are available from the

American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten

Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert!

Your safety is involved.

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

4

SP98-10

AVERTISSEMENT: Ces règles de sécurité ont pour objet d’ assurer votre protection. Veillez à lire et à observer les précautions énoncées ci-dessous avant de monter l’

équipement ou de commercer à l’utiliser. Tout défaut d’observation de ces précautions risque d’entraîner des blessures graves ou mortelles.

1. PROTECTION INDIVIDUELLE-- Les brûlures de la peau et des yeux dues au rayonnement de l’arc

électrique ou du métal incandescent, lors du soudage au plasma ou à l’électrode ou lors du gougeage à l’arc, peuvent s’avérer plus graves que celles résultant d’une exposition prolongée au soleil. Aussi convient-il d’observer les précautions suivantes: a. Portez un écran facial adéquat muni des plaques protectrices et des verres filtrants appropriés afin de vous protéger les yeux, le visage, le cou et les oreilles des étincelles et du rayonnement de l’arc électrique lorsque vous effectuez des soudures ou des coupes ou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximité de façon à ce qu’elles ne regardent pas l’arc et à ce qu’elles ne s’exposent pas à son rayonnement, ni à celui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tunique

épaisse à manches longues, des pantalons sans rebord, des chaussures à embout d’acier et un casque de soudage ou une calotte de protection, afin d’éviter d’exposer la peau au rayonnement de l’arc

électrique ou du métal incandescent. ll est également souhaitable d’utiliser un tablier ininflammable de façon à se protéger des étincelles et du rayonnement thermique.

c. Les étincelles ou les projections de métal incandescent risquent de se loger dans des manches retroussées, des bords relevés de pantalons ou dans des poches.

Aussi convient-il de garder boutonnés le col et les manches et de porter des vêtements sans poches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arc

électrique les autres personnes travaillant à proximité

à l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécurité lorsque vous vous trouvez dans un secteur où l’on effectue des opérations de soudage ou de coupage à l’arc. Utilisez des lunettes de sécurité à écrans ou verres latéraux pour piquer ou meûler le laitier. Les piquetures incandescentes de laitier peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasma produisent un niveau de bruit extrêmement élevé (de

100 à 114 dB) et exigent par conséquent l’emploi de dispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections de laitier incandescent ou d’étincelles peuvent provoquer de graves incendies au contact de matériaux combustibles solides, liquides ou gazeux.

Aussi faut-il observer les précautions suivantes:

PRÉCAUTIONS DE SÉCURITÉ

a. Éloigner suffisamment tous les matériaux combustibles du secteur où l’on exécute des soudures ou des coupes à l’arc, à moins de les recouvrir complètement d’une bâche non-inflammable. Ce type de matériaux comprend notamment le bois, les vêtements, la sciure, l’essence, le kérosène, les peintures, les solvants, le gaz naturel, l’acétylène, le propane et autres substances combustibles semblables.

b. Les étincelles ou les projections de métal incandescent peuvent tomber dans des fissures du plancher ou dans des ouvertures des murs et y déclencher une ignition lente cachée. Veiller à protéger ces ouvertures des

étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérations de gougeage ou autres travaux à chaud à la surface de barils, bidons, réservoirs ou autres contenants usagés, avant de les avoir nettoyés de toute trace de substance susceptible de produire des vapeurs inflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, il convient de disposer d’un matériel d’extinction prêt à servir immédiatement, tel qu’un tuyau d’arrosage, un seau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteur de façon à vous assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc au plasma exige l’emploi de tensions à vide relativement importantes; or, celles-ci risquent de causer des dommages corporels graves et même mortels en cas d’utilisation inadéquate. La gravité du choc électrique reçu dépend du chemin suivi par le courant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous tension venir au contact direct de la peau ou de vêtements humides. Veillez à porter des gants bien secs.

b. Si vous devez effectuer un travail sur une surface métallique ou dans un secteur humide, veillez à assurer votre isolation corporelle en portant des gants secs et des chaussures à semelles de caoutchouc et en vous tenant sur une planche ou une plate-forme sèche.

c. Mettez toujours à la terre le poste de soudage/coupage en le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Ne surchargez jamais le câble. Utilisez toujours un

équipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas en service. une mise à la masse accidentelle peut en effet provoquer une surchauffe de l’équipement et un danger d’incendie. Ne pas enrouler ou passer le câble autour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce en un point aussi proche que possible de la zone de travail. Le branchement des câbles de masse à l’ossature du bâtiment ou en un point éloigné de la zone de travail augmente en effet le risque de passage d’un courant de sortie par des chaînes de

9/97

5

levage, des câbles de grue ou divers chemins

électriques.

g. Empêchez l’apparition de toute humidité, notamment sur vos vêtements, à la surface de l’emplacement de travail, des câbles, du porte-électrode et du poste de soudage/coupage. Réparez immédiatement toute fuite d’eau.

4. VENTILATION-- La respiration prolongée des fumées résultant des opérations de soudage/coupage, à l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels. Aussi convient-il d’observer les précautions suivantes: a. Assurez en permanence une aération adéquate de l’emplacement de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécaniques.

N’effectuez jamais de travaux de soudage ou de coupage sur des matériaux de zinc, de plomb, de beryllium ou de cadmium en l’absence de moyens mécaniques de ventilation capables d’empêcher l’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou de coupage à proximité de vapeurs d’hydrocarbure chloré résultant d’opérations voisines de dégraissage ou de pulvérisation. La chaleur dégagée ou le rayonnement de l’arc peut déclencher la formation de phosgène -- gaz particulièrement toxique -- et d’autres gaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de la gorge constatée au cours de l’utilisation de l’équipement dénote un défaut de ventilation. Arrêtezvous de travailler afin de prendre les mesures nécessaires à l’amélioration de la ventilation. Ne poursuivez pas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisations où circule de l’hydrogène. L’armoire de commande est munie d’un ventilateur destiné à empêcher la formation de poches d’hydrogène, lesquelles présentent un danger d’explosion; ce ventilateur ne fonctionne que si l’interrupteur correspondant du panneau avant se trouve placé en position ON (Marche). Veillez à manœuvrer cette commande en vérifiant si le couvercle est bien en place, de façon à assurer l’efficacité de la ventilation ainsi réalisée. Ne jamais débrancher le ventilateur.

e. Les fumées produites par l’opération de soudage ou de coupage peuvent s’avérer toxiques. Aussi est-il nécessaire de disposer en permanence d’un dispositif adéquat de ventilation de type aspirant, afin d’éliminer du voisinage de l’opérateur tout dégagement de fumée visible.

f. Consultez les recommandations particulières en matière de ventilation indiquées à l’alinéa 6 de la norme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement entretenu de façon défectueuse ou inadéquate risque non seulement de réaliser un travail de mauvaise qualité mais, chose plus grave encore, d’entraîner des dommages corporels graves, voire mortels en déclenchant des incendies ou des chocs électriques.

Observez par conséquent les précautions suivantes: a. Efforcez-vous de toujours confier à un personnel qualifié l’installation, le dépannage et l’entretien du poste de soudage et de coupage. N’effectuez aucune réparation électrique sur l’équipement à moins d’être qua-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretien quelconque à l’intérieur du poste de soudage/ coupage, avant d’avoir débranché l’alimentation

électrique.

c. Maintenez en bon état de fonctionnement les câbles, le câble de masse, les branchements, le cordon d’alimentation et le poste de soudage/coupage.

N’utilisez jamais le poste ou l’équipement s’il présente une défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage et des

équipements accessoires. Gardez-les à l’écart des sources de charleur, notamment des fours, de l’humidité, des flaques d’eau maintenez-les à l’abri des traces d’huile ou de graisse, des atmosphères corrosives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tous les panneaux de l’armoire de commande en veillant à les garder en bon état.

f. Utilisez le poste de soudage/coupage conformément à son usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVES À

LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur les règles de sécurité à observer pour le montage et l’utilisation d’équipements de soudage et de coupage

électriques et sur les méthodes de travail recommandées, demandez un exemplaire du livret N°

52529 “Precautions and Safe Practices for Arc Welding, Cutting and Gouging” publié par ESAB. Nous conseillons également de consulter les publications sui-vantes, tenues à votre disposition par l’American

Welding Society, 550 N.W. LeJuene Road, Miami, FL

32126: a. “Safety in Welding and Cutting” AWS Z49.1

b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.

c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.

d. “Recommended Safe Practices for Plasma Arc Cutting”

AWS-A6. 3.

e. “Recommended Safe Practices for Plasma Arc Welding” AWS-C5. 1.

f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.

g. “Code For Safety in Welding and Cutting”

CSA-Standard W117. 2.

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6

SECTION I

SPECIFICATIONS

Input Power Required ....................... 115 volts 50/60 Hz single phase Wire

Feed Speed Range ................................... 20-999 in./min. (.5-26.4 m/min.)

Wire Sizes Accommodated:

Hard/Soft — ............................................. .023 thru 1/8-in. (.6 thru 3.2 mm)

Flux Cored — ......................................... .035 thru 1/8-in. (0.9 thru 3.2 mm)

Length ................................................................................ 24-in. (610 mm)

Width ............................................................................ 22-1/2-in. (572 mm)

Height ................................................................................. 15-in. (381 mm)

Weight (less wire) .................................................................. 80-lbs. (36 kg)

DESCRIPTION

INTRODUCTION

This Digipulse Dual wire feeder is designed as a “dual” torch welder with each torch capable of furnishing eight completely different sets of welding parameters—in other words, sixteen (16) completely different welding schedules can be preset to meet the requirements of high production shops. The standard Dual control features include presettable wire feed speed (ipm), voltage, pre and postflow gas shielding, cold wire inching, gas purging, adaptive or manual burnback, spot welding timer and crater fill functions.

LEFT DIGITAL READOUT (IPM)

LEFT INC-DEC TOGGLE

INCH/GAS PURGE

RESET SELECTOR

CRATER SELECTOR SW.

LEFT TORCH ACCY.

SUPPORT ASSY.

& EH-10 MOTOR

GEAR TACH UNIT

SPINDLE ASSY.

RIGHT DIGITAL READOUT (VOLT)

RIGHT INC-DEC TOGGLE

SPOT/BACK-SELECT SWITCH

RIGHT TORCH RECPT.

TORCH ACCY. RIGHT

SUPPORT ASSY.

& EH-10 MOTOR-GEAR-TACH UNIT

LEFT TORCH RECEPT.

RESET CIRCUIT BREAKER

POWER ON-OFF SW.

RUN-SET KEY SW.

J1 CONTROL RECPT.

LEFT TORCH GAS SOL

CONNECTION

RIGHT TORCH GAS

SOL CONNECTION

LOCATION FOR OPT.

WATER CONNECTIONS

POWER CABLE

ADAPTOR BLOCK

Fig. 1 - Digipulse Dual Feeder

7

SECTION I

A. STANDARD FEATURES/BENEFITS

n microprocessor accuracy — the microprocessor, the controlling "brain" of the Digipulse Dual, operates exclusively on drift free digital logic. The digital logic delivers extraordinarily precise computer-accurate weld parameter control and weld consistency.

n microprocessor flexibility — the Digipulse incorporates electronically reprogrammable modules; by simply reprogramming this small plug-in module many existing functions may be extended or new features maybe added.

n microprocessor reliability — ESAB’s Digipulse Dual

Wire Feeders have proven to be rugged and reliable in test after test for absolute minimum downtime.

n presettable wire feed speed (Ipm) and voltage (volts)

— provides ability to easily and accurately preset the exact welding parameters desired before the welding sequence begins.

n patented microprocessor controlled closed loop systems — provides most accurate means of maintaining wire feed speed (amperage) and welding voltage; the microprocessor compensates for deviations in ambient temperature primary voltage fluctuation and changes in arc dynamics or wire feed force conditions, to assure that preset parameters are maintained.

n sure start interlock — to assure trouble free starts the

Digipulse Dual has an interlock circuit which will not allow wire feed to initiate when the torch trigger Is pulled unless the power supply contactor is closed and voltage is present; the cold wire INCH, however, will be operative at all times.

n individual digital LED meters provide large 1/2-in.

readout of voltage and wire feed speed — continuous display of preset and then actual welding voltage and wire feed speed for accurate observation.

n automatic "shut down" — assures welding is done at the preset parameters; unit automatically shuts down, if for any reason either the volts or ipm cannot be maintained for a preprogrammed time period; simultaneously, cause is indicated by flashing digital display.

DESCRIPTION

n toggle switch adjustment of weld parameters by fine increments or rapid coarse adjustment — allows quick, easy, and accurate adjustments of welding parameters.

n gas pre and postflow and cold wire inch capability— gas pre and postflow provides independent adjustment in tenths of a second for highest weld quality and economy; cold wire inch speed can be independently adjusted from welding wire feed speed to reduce downtime.

n eight schedule capability per torch—enables operator to have two different sets of weld parameters (for each torch) at his fingertips. The microprocessor allows the operator to change schedules with a simple “clickclick” squeeze of the torch trigger switch to be used.

n automatic adaptive anti-stick or manual burnback time feature—a patented adaptive anti-stick circuit automatically adjusts the same amount of wire burnback regardless of wire size, speed or voltage; or, you can manually preset a “BurnbackTime” to specifically suit a specialized application; the manual burnback function (programmed up to 30 cycles in the VOLTS window) allows you to override the automatic adaptive anti-stick by setting a specific burnback time.

n spot weld timer—because the spot weld timer is adjustable up to 999 cycles (16.5 sec.) in the IPM window, it is more than a conventional “spot” feature; it is also a weld timer extending its use for “Increment’’ or “Stitch” welding.

n the Crater Fill feature allows the operator to preset a special welding wire feed speed (IPM), arc length

(VOLTS) and time (TIMES) to control the shape and size of the weld crater upon termination of the welding process.

n circuit protection—resettable circuit breaker for input power minimizes downtime and maintenance.

n EH-10A permanent magnet motors—provide the highest torque, fastest response, and best efficiency of any mig p.m. motor on the market.

n patented closed loop “J” governor/optical tachometer—provides most accurate means of maintaining wire feed speed and voltage, regardless of any voltage drop or drift.

8

SECTION I DESCRIPTION

I. DESCRIPTION

The Digipulse Dual torch welder is a microprocessor controlled digital wire feeder designed for mig short arc/ spray and pulse arc welding applications. Its electronic brain — the microprocessor — not only controls, it also remembers and automatically coordinates the program sequencing (that “you” preset) which results in the most accurate wire feed speed and voltage control possible.

By virtue of its microprocessor controlled wire speed and arc voltage design, the Digipulse Dual allows the customer to preset 8 welding parameters (for each torch), and be assured that each setting will be precisely held regardless of changes in line voltage, arc or load conditions.

Two digital readout windows continuously display (1/2in. high) the preset welding parameters (speed and voltage). After the arc is struck, they automatically display the actual wire speed and arc voltage conditions for the selected schedule. The read-outs can also provide selectable displays of other welding parameters such as inching speed, gas pre- and postflow times, spot time in cycles, manual burnback time in cycles, schedule selection, crater times and conditions.

The Dual Digipulse uses a pair of heavy duty EH-10A wire drive motors designed to feed hard or soft wires from

.023-in. to 1/8-in. in diameter and flux-cored wires from

.035-in to 1/8-in. in diameter. Rate of wire feed (20-999 ipm) is precisely controlled by using a closed-loop “J” governor digital feedback circuit that employs an optical tachometer to monitor the motor speed. Arc voltage regulation is also controlled by a closed-loop digital feedback circuit that monitors the arc voltage and automatically adjusts the power source output voltage to maintain the preset voltage.

For identification and location of all functional controls and connections refer to Figure 1. The front panel contains the torch switch receptacles which use low voltage (5 v.d.c.) for operator safety. The rear panel contains the on-off power switch, the run/set switch, a 7ampere reset circuit breaker for overload protection, a

19-pin receptacle (J1) provides 115vac, contactor control, arc monitoring and control signals from the power source.

All interconnecting cable, hose and auxiliary equipment connections are quickly detachable to provide easy setup and maximum portability of the wire feeder as shown in Figs. 2 & 3. A water kit with or without solenoid may be purchased, as an optional accessory, for use with water-cooled torch operation.

II. REQUIRED EQUIPMENT

A. CONSTANT VOLTAGE POWER SOURCE

The Digipulse Dual is specifically designed for use with constant voltage (C.V.) power sources utilizing “electronically controlled voltage regulation” such as:*

SVI-450i, P/N 34055

* The power sources provides three (3) “Slope” outputs

— Flat, Medium and Steep.

B. CABLE ASSEMBLIES

A multi-conductor control cable assembly is required to connect the Digipulse to a power source with electronic voltage control (see Fig. 3).

115 Volt/Contactor/Remote Control J1 Cable, 19-conductor with Amphenol to Amphenol plugs; order one of the following:

6-foot. 19-cond., P/N 30686.

30-foot, 19-cond., P/N 30780.

60-foot, 19-cond., P/N 30781.

C. WELDING TORCH

Mig welding torches, with contact tip, wire conduit and outlet guide for wire size/type to be employed, will be required. Suitable air (MT-400) or water-cooled (MT-

450W, ST-16) torches may be used with the Digipulse.

When using a water-cooled torch it will be necessary to connect the torches water hose to either a continuous water supply or to the wire feeder base by using an optional water kit (with or without a solenoid valve, see

Section III-A and B).

D. GAS REGULATION

Shielding gas regulator/flowmeter and fitted hose to bring gas from flowmeter to wire feeder. Such as:

Regulator/Flowmeters:

R-5007 Argon/Helium/Nitrogen, P/N 998124.

R-5008 C0

2

, P/N 998125.

Gas Hoses:

Standard Duty, P/N 40V77 (12-1/2-ft.) or P/N 34V38

(25-ft.)

Heavy Duty, P/N 19416 (12-1/2-ft.) uor P/N 19415

(25-ft.).u

u Must be used for C0

2

.

9

SECTION I DESCRIPTION

Table 1 - Digipulse Feed Rolls

Wire Type/

Size In. (mm) Feed Roll

Soft

.030 (.8)

.035 (.9)

3/64 (1.2)

1/16 (1.6)

3/32 (2.4)

Outlet

Guide

2075304 (U)

2075304 (U)

29N13u

29N13u

2075301 (U)† 29N13u

2075298 (U)†† 29N13u

2075297 (U) 29N13u

Hard

.023 (.6)

.030 (.8)

.035 (.9)

.045 (1.2)

.052 (1.4)

1/16 (1.6)

Cored

.035 (.9)

.045 (1.2)

.052 (1.4)

1/16 (1.6)

5/64 (2.0)

3/32 (2.4)

7/64 (2.8)

1/8 (3.2)

17998 (V)

2075300 (V)

2075303 (V)

2075302 (V)

2075330 (V)

2075299 (V)

19761 (Serr.)

19761 (Serr.)

2075255 (Serr.)

999745n

993860 (a)

993860 (a)

39N15 (b)

39N15 (b)

39N15 (b)

993860 (a)

39N15 (b)

2075261 (Serr.) 39N15 (b)

2075261 (Serr.) 39N15 (b)

2075261 (Serr.) 62N17 (c)

2075257 (Serr.) 62N17 (c)

2075257 (Serr.) 39N16

39N17

Four Roll Drive

Feed Roll Kit

999320

999321 (U)

999322 (U)

999322 (U)

999325 (V)

999326 (V)

999327 (V)

999328 (V)

999329 (V)

999330 (Serr.)

999331 (Serr.)

999332 (Serr.)

999333 (Serr.) n Requires guide bushing P/N 17997.

u Requires outlet guide insert as follows: For .030, .035 wire use

993902, For 3/64 wire use 05N57, For 1/16 wire use 12N75,

For 3/32 wire use 05N58.

† Recommended U-Groove Pressure Roll 2075346 be used.

†† Recommended U-Groove Pressure Roll 2075348 be used

(a) Includes replaceable sleeve (995651).

(b) Includes replaceable sleeve (995692).

(c) Includes replaceable sleeve (995693).

E. FEED ROLLS

The Digipulse comes equipped with a pressure roll but

NOT a feed roll. Select the proper feed roll and outlet guide from Table 1 for the wire size and type to be used.

F. WATER COOLING

Water supply with fitted hose assemblies are required to bring cooling water from supply to wire feeder, order

Water Hose 12-1/2-ft. P/N 40V76 as shown in Fig. 2.

III. OPTIONAL ACCESSORIES

A. Water Kit without Solenoid Valve (P/N 994466).

Permits the convenient connection of water-cooled torches and continuous water supply to the wire feeder.

A kit is required for each torch and consists of a coupling, two adaptors and a fitting. A dependable cooling water supply, delivery and return water hoses

(P/N 40V76, 2 required) will also be required. Note that

Fig. 2 illustrates the use of power cable adaptor P/N

674156, in addition to the kit. If adaptor (674156) is not

10 used, adaptor (45V11 supplied with kit) can be connected to the output terminal of the power source.

Install the kit in accordance with Fig. 10 and Sec. IV-

F. Connect the water-cooled torch as shown in Fig. 2.

B. Water Kit with Solenoid Valve (P/N 2075760). Same as kit P/N 994466 listed above except a solenoid valve is required for each torch and is supplied in place of the coupling. The solenoid valve can be used in areas where you wish to conserve water or the water temperature is below the dew point causing sweating of torch parts, resulting in poor welds. Install kit in accordance with Fig. 10 and Section IV-F. Do NOT use with coolant circulators.

C. Spool Enclosure Kit (P/N 600240). Provides protection for spool of wire against dust and dirt.

D. Standard Wire Reel Assembly (P/N 34323). Reel slips over spindle to allow use of coiled wire, see Fig.

9.

E. Heavy Duty Wire Reel Assembly (P/N 19V89).

Spoke-type wire reel includes a four spoke aluminum alloy casting mounted on a lightweight support shaft of steel tubing. The reel will handle all wire coils from 2 to 4-5/8-in. wide. The finger design permits quick and easy accommodation of different coil widths by simply rotating from one finger position to the other.

F. Wire Straightener P/N 34V74). Reduces wire cast to improve feedability and increase service life of torch liners and contact tips. Mounts to the accessory support inlet guide.

Wire inlet Guide P/N 11N53 is required to complete the installation on the wire inlet side of the straightener.

G. WC-9 Coolant Circulator, P/N 33540, is used for water cooled torch operation and is designed to be

"free standing" in a convenient location near the torch.

A four-gallon capacity tank provides 1.0 gal/min @ 50 psi, using 115 volts, 50/60 Hertz, 1 phase input. Since the cooler is designed to run continuously during a welding operation, never connect it to a power source or wire feeder that uses a solenoid controlled water supply that opens and closes with each operation of the welding contactor - the cooling efficiency of the unit will be hampered and the starting winding in the pump motor may burn out.

H. WC-8C Coolant Circulator, P/N 33739, is used for water cooled torch operation and is designed to fit in a cylinder rack of a power supply truck. A 1.5 gallon capacity tank provides 1.0 gal/min @ 50 psi, 115 volts,

50/60 Hertz, 1 phase input. Since the cooler is designed to run continuously during a welding operation, never connect it to a power source or wire feeder that uses a solenoid controlled water supply that opens or

SECTION I

REGULATOR/

FLOWMETER

GAS HOSE

40V77 (12-1/2 FT.)

34V38 (25 FT.) n WATER KIT (BELOW)

2075760

OR

n WATER KIT

994466 n WATER "DRAIN" HOSE - 40V76 (12-1/2 FT.) n ADAPTOR - 45V11

LEFT TORCH

MOTOR/ACC. SUPPORT n WATER "IN" HOSE - 40V76

(12 1/2 FT.)

DESCRIPTION

REGULATOR/

FLOWMETER

GAS HOSE

40V77 (12-1/2 FT.)

34V38 (25 FT.)

PLAN VIEW DUAL FDR.

GAS SOLENOIDS ABOVE

OPT. WATER SOL. BELOW

REF. CONTROL'S REAR

SUPPORT FRAME

RIGHT TORCH

MOTOR/ACC. SUPPORT

TORCH CONDUIT

TORCH POWER CABLE

FRONT

VIEW

CONTROL

LEFT TORCH

(WATER COOLED)

TORCH SWITCH

TORCH GAS HOSE n TORCH WATER HOSE n Parts required when using a Water Kit & Water

TORCH CONDUIT

TORCH POWER CABLE

RIGHT TORCH

(AIR COOLED)

TORCH GAS HOSE

TORCH SWITCH

Fig. 2 - Torch and Service Interconnection diagram

closes with each operation of the welding contactor the cooling efficiency of the unit will be hampered and the starting winding in the pump motor may burn out.

I. Wire Feeder Turntable P/N 678940, allows rotation of wire feeder as operator changes work positions.

This reduces strain and bending of torch cables.

J. Four Roll Drive Accessory Support Assembly, P/

N 600216. This assembly (shown in booklet F-12-

821) utilizes 4 feed rolls to provide positive nonslip wire feed. It is designed for feeding .030 thru 1/8-in.

diameter wire. Feed rates for the 4-roll drive are virtually the same as with the 2-roll drive. For feed roll/ outlet guide accessories refer to Table 1.

11

SECTION 2

IV. INSTALLATION

To avoid possible lethal shock make sure that all power to the Digipulse is OFF before making any welding/control cable and or accessory connections on this unit. Do this by "locking-open" the input line disconnect switch to the power source.

After checking to be sure you have all required components and accessories (see Section II), proceed as follows (with reference to Figs. 2 & 3, Interconnection

Diagrams):

A. HOSE AND ELECTRICAL CONNECTIONS

Connect shielding gas and water (if used) supply hoses as shown in Fig. 2. Connect the control cable assembly

(J1) from the Digipulse’s rear panel to the power source as shown in Fig. 3.

B. TORCH CONNECTIONS

Attach torch gas hose to gas connections. Plug in torch switch cables and lock by twisting. After inserting conduit liner (if used) and attaching wire outlet guide of correct size, connect wire feed conduit to welding head clamp and lock in place. Attach water hose (if used) to wire feeder. Connect torch power cables to power source, or to power cable adaptor block (with a second cable from that stud to the power source).

C. INSTALLING FEED ROLL

1. Release the clapper on the accessory support assembly (Figure 8) by disengaging the retainer from the clapper fork.

2. Remove thumbscrew, belleville washer, and flat washer from the feed roll shaft.

3. Slip the feed roll on the shaft, engaging the key. Be sure to observe this “THIS SIDE OUT” marking on the feedroll.

4. Reassemble flatwasher, belleville washer, and thumb screw, tightening screw sufficiently to eliminate all end play from the feed roll.

D. INSTALLING SPOOL OF WIRE

CAUTION: Make sure safety glasses are worn when clipping wire off at the spool or at the end of the torch - serious eye injury can result due to the springiness of the wire which quickly unravels, or a cut wire end which may shoot across the room.

1. Remove “hairpin” clip from spindle.

INSTALLATION

2. Position the spool of wire so that when it is placed on the spindle, wire will be drawn to the feed roll from the bottom of the spool. The spool should be held so that the index hole on the back will engage the lug on the spindle.

3. Slide the spool onto the spindle until it engages the lug.

Lock in place with the hairpin clip.

4. Loosen the brake screw in the center of the spindle hub, then tighten it just enough to prevent coasting of the spool when wire is drawn from it. Too much pressure will load the wire feed motor unnecessarily.

Too little pressure will permit the spool to over-run, causing the wire to kink and tangle.

5. Thread the wire on to the accessory support assembly as described in Section E.

6. When wire coils are to be used instead of spools, mount wire reel on spindle as through it were a spool

(see 1 and 3 above). Remove thumbnuts and cover plate from reel. Remove coil from its package, but do not remove its binding wires. Slide coil onto reel so that wire will be drawn from bottom of coil (starting end for a coil is always the outer end). Replace reel cover plate and thumbnuts. Cut off coil tie wires and any kinked wire. Then adjust brakescrew and thread wire to torch as covered in 4 and 5 above.

E. ADJUSTING THE ACCESSORY SUPPORT ASSEM-

BLY (See Fig. 8).

When a new wire size or type is to be used, set the pressure roll adjustment as follows:

1. Round off the free end of the welding wire with a file.

2. Release the clapper and unscrew the pressure adjusting knob until the pressure spring is free.

3. Thread the wire through the inlet and outlet guides of the accessory support, and 3 or 4 inches into the torch conduit.

4. Engage the clapper making sure the wire is held in the feed roll groove.

5. Tighten the pressure adjusting knob until the wire is firmly against the feed roll - do not overtighten. The spring pressure applied should be the minimum required to provide positive, nonslip wire feed. Too little pressure will result in wire slippage while excessive pressure will scar and deform the wire. Further adjustment can be made after the wire feed is put into operation. Note that a light silver-colored spring

(182W55) is installed on the accessory support for use with soft and small diameter hard wire. For large diameter hard wire, replace this spring with a heavy blue- colored spring (182W54) supplied with the unit.

12

SECTION 2

J1 CABLE

INSTALLATION

J1

4/0 WELDING CABLE*

RECPT.

POWER CABLE

ADAPTOR

TYPICAL POWER

SUPPLY HOOKUP

TO WORK*

† ESAB will not honor the warranty on Digipulse that are used with non-ESAB manufactured interconnect cables and sustain damage that in ESAB’s opinion is caused by these cables.

For a listing of the proper cables available refer to Section II-B.

* 4/0 welding cables (customer supplied) are set-up for DCRP (NEG. TO WORK) operation.

Fig. 3 - Welding and Control Interconnection Diagram

F. WATER KITS (Optional see Fig. 10)

Mount bulkhead adaptor (58V75) behind opening provided in rear vertical support plate, below gas connections, and secure with screws (No. 8 - 32 x 3/8-in.) and lockwashers provided. Attach coupling or solenoid valve

(depending on the type of water kit) and adaptor (11N16) to the bulkhead adaptor. Mount torch cable adaptor

(45V11) on welding power stud. Connect water drain hose to this adaptor, and water inlet hose to adaptor

11N16. Wire the solenoid valve (if used) in parallel with the gas solenoid valve (see wiring diagram).

V. ADJUSTMENTS

Do not allow metal-to-metal contact between the wire feeder chassis and a metal surface connected in any way to a welding ground. With such contact, a poor welding ground connection may create a difference In potential that sends part of the weld current through the safety ground wiring in the control cable and wire feeder, resulting in burnout of that wiring and/or damage to wire feeder circuitry. If the safety ground burns out, the operator may be exposed to 115V. shock hazard.

Fig. 4 - Rear Panel Control

A. CONTROL FUNCTIONS

For location of rear panel control features, refer to Fig. 4.

13

1. Power Switch. This two-position toggle switch turns power “on” or “off’ to the wire feeder control.

2. Run Set Key. This "key-operated” switch must be in the SET position to preset, vary and weld-test the welding parameters programmed into the control (e.g.:

SECTION 2 INSTALLATION

Sched. I, Sched. II for each torch, Spot). After the desired results are achieved, the program(s) can be

“locked-in” by turning the key to the RUN position. The only parameter which can be altered by the operator in the RUN position is the cold wire INCH speed.

3. Reset Circuit Breaker. A seven (7) ampere circuit breaker provides protection to the 115-volt control circuit and the wire feed motor. If an overload occurs, the breaker will trip and suspend all operation. To restore service, depress the breaker button to reset the circuit.

4. Digital Readout Windows. Two individual three-digit windows are provided to display preset or actual welding parameters as follows:

a. IPM Digital Readout. This window is primarily used to display wire feed speed in IPM from 20 to

999 inch per minute in one inch increments. However, with the appropriate function selector actuated, this window can also display the following:

— shielding gas PREFLOW from .1 to 99.9 seconds in one tenth of a second increments.

— SPOT welding time for each Torch, from 1 to 999 cycles in 1 cycle increments.

— cold wire INCH speed in IPM from 50 to 999 inches per minute in one inch increments.

— Schedule select-Left Torch

— Crater time - Left Torch

NOTE: With the power turned “on”, but not welding, the

IPM window will “continuously” read Preset wire speed. When the arc is struck, the IPM window will then continuously read Actual welding wire speed.

b. Volts Digital Readout. This window is primarily used to display arc voltage in VOLTS from 12 to 50 vdc in one tenth volt increments. However, with the appropriate toggle selector actuated, this window can also display the following:

— shielding gas POSTFLOW from .1 to 99.9 seconds in one tenth of a second increments.

— accumulative welding ARC HOUR usage record in one tenth of an hour increments.

— manual BURNBACK time. Manually adjustable burnback time period which when preset will override the automatic adaptive anti-stick feature. This time period will be set In one-cycle (60 cycle = 1 sec.) Increments. When set to “zero”, the Automatic Anti-stick feature will be operational.

— Schedule select - Right Torch

— Crater time - Right Torch

NOTE: With the power turned “on”, but not welding, the

VOLTS window will “continuously” read Preset voltage. When the arc is struck, the VOLTS

14

window will then continuously read Actual welding voltage.

5. LED Light. This LED lights to indicate that the torch on the left side is in use.

NOTE: All of the following controls are spring-loaded, center-return toggle switches which must be operated to actuate their indicated function(s).

Item No. 6 describes the adjustment setting toggle used to preset the program- function selectors. Except as noted above and following, regulation for selected function(s) can only be made if Item No. 2 is in the SET position.

4A

6A

7

9

Fig. 4A - Front Panel Controls

5

4B

8

6B

6. Inc.-Dec. Toggle Switches. Two control toggles are provided to preset the individual welding parameters required for the selected welding mode as follows:

a. “IPM “ Increase/Decrease Control. This toggle switch is primarily used to set and/or vary the wire feed speed (IPM), along with its other functions;

Preflow, Spot for both torches, Inch, Crater time and Left Side schedule. With appropriate function selector actuated, each parameter setting will be displayed in the digital window directly above this toggle.

b. “VOLTS” Increase/Decrease Control. This toggle switch is primarily used to set and/or vary the arc

Volts, along with all its other functions: Postflow,

Burnback, Right Side schedule and Crater time.

With the appropriate function selector actuated, each parameter setting will be displayed in the digital window directly above this toggle.

7. Inch-Gas Purge/Abort Reset Selector. This two position (momentary “on” contact) switch allows the following operation.

a. Inch Function. The INCH selection permits coldwire inching without energizing the welding circuit through the torch switch. The preset cold wiring inching speed (set in Item 9) can also be indepen-

SECTION 2 INSTALLATION

dently changed by operating its associated Inc./

Dec. toggle switch, and this setting (which is independent of “hot” wire feed) will appear in the IPM window.

b. The Gas PURGE (Abort Reset) position provides the following when actuated:

(1) During initial programming, it permits presetting of gas PREFLOW and POSTFLOW “time requirements” which are simultaneously displayed in the IPM and VOLTS windows respectively.

(2) Prior to actual torch triggering, it permits you to actuate the gas solenoid and PURGE the shielding gas line of the torch. At the same time, it also lets you adjust the gas regulator without energizing the welding circuit.

(3) After starting the welding sequence, if an

“abort-shutdown” condition occurs (indicated by a flashing digital display). The RESET position can be actuated and the control automatically “resets” for a new start.

8. Spot/Burnback. This two- position (momentary contacts) switch allows the following operations:

Spot Weld/Manual Burnback times. Actuating this position allows you to preset either or both of these features for either or both torches.

The SPOT time mode can be programmed into either schedule (I or II) for each torch — and the torch selected for operation is chosen by simply squeezing and releasing the torch switch lever for the particular torch desired. These preset

“timed-arc” periods (up to 999 cycles, in one cycle increments) are programmed in the IPM window using its Inc/Dec toggle switch. When

the Spotwelding feature has been preset into one of the schedules for a particular torch, all “continuous" welding applications for

that torch are temporarily disabled. To resume normal program operation in Schedules I and II for either or both torches, you must deactivate the Spotweld mode by keying its timing parameter back to “zero”.

When a spotweld time is programmed for a torch, the "click-click" torch switch feature for changing schedules cannot be used as it was for

“continuous-type” welding operations. To change schedules for spotwelding, you must manually reposition the Schedule toggle switch selector to the desired schedule for that torch—the torch switch is only used to start the arc, and the spot time cuts it off (unless the torch switch is prematurely released).

At the same time, you can also preset a

manual BURNBACK time mode into any schedule for each torch—and the torch selected for

15 programming is chosen by simply squeezing and releasing the torch switch lever for the particular torch desired. The manual Burnback time(s) is adjustable in one cycle increments

(60 cycles/sec.) and is programmed in the

VOLTS window using its Inc/Dec toggle switch.

When preset, the Burnback time will override the automatic adaptive anti-stick feature in either schedule for that particular torch. If automatic anti-stick operation is desired, the

Burnback time must be keyed back to “zero”.

Schedule Select. When the switch is in the schedule select position, any schedule from 1 through 8 can be selected for the torch in use.

Schedules 1 - 4 are provided for pulse welding and schedules 5 - 8 for short arc welding.

9. "Crater" Times/Conditions. This toggle switch allows the operator to preset a special welding wire feed speed (IPM), arc length (VOLTS) and time

(TIMES) to control the shape and size of the weld crater .

Each weld schedule can be preset with a unique crater fill IPM, VOLTAGE and crater time.

B. GAS/WIRE ADJUSTMENTS

The following Digipulse control functions must be set to feed wire through the torch conduit and to adjust the shielding gas flow rate.

1. Place Power switch (rear panel) to “on” position to energize the control.

2. Place key-operated Lock-In Set switch (rear panel) in

Set position.

3. With torch connections made as shown in Fig. 2, and wire engaged in accessory support (Sect. IV-E), feed wire through torch conduit and into torch as follows: a. Actuate and immediately release the torch switch lever for the Left Torch/Motor. This action (thru the control’s switching relay circuitry) sets-up the control to receive the parameter programming for the

Left Torch.

b. Remove nozzle and contact tip from torch.

c. Hold Inch-Purge toggle in INCH position (Sect. V-

A-8) until “cold” wire protrudes from the torch front end.

d. Slide the contact tip over the end of the wire and secure it to the torch. Replace the torch nozzle.

e. Reoperate Inch-Purge toggle in INCH position and check for wire feed slippage on the accessory support assembly. Tighten (or loosen) the pressure adjusting knob until the wire feeds smoothly.

f. Now, actuate and immediately release the torch switch lever for the Right Torch/Motor. This action

(thru the control’s switching relay circuitry) sets-up the control to receive the parameter programming for the Right Torch, and you can repeat steps b-e.

SECTION 3

4. With shielding gas cylinder and torch gas hose connection assembled as shown in Fig. 2, set gas flow rate as follows: a. Hold Inch-Purge toggle in PURGE position and open the gas regulator-flowmeter control valve and set the shielding gas flow rate.

b. Continue to hold the Purge position for approx. 15 seconds to insure adequate purging of each gas hose and torch.

5. Place control’s Power switch to “off’ position.

VI GENERAL

This dual pulse Mig welding system has been designed and manufactured to specifications provided by Bombardier, Inc.. The software is modified to provide eight separate schedules for each torch. The first four schedules (1-4) on each torch are dedicated to pulse welding of stainless steel in the synergic mode. The second four schedules (5-8) are dedicated to short or spray arc welding and have no synergic relationships. This means that IPM and VOLTS are entered separately depending if a short arc or spray arc weld condition is required. The following will detail the set-up and operation of this unique welding system.

Start Up

Assembly of the power source, feeder and interconnect cable is the same as specified in the general operating instruction manuals provided with the SVI-450i Power Source and Digipulse Dual wire feeder. After power up of the SVI-450i (460 Vac) and the feeder, the windows on the feeder will display

IPM=51 and VOLTS=45 for a brief period. This indicates that the stainless steel program (same as a standard Digipulse) is running and the synergic curve is for .045-inch (1.2 mm) diameter wire. These parameters CANNOT be changed. The windows will then display the last welding parameters set by the operator. Place the “Remote/Panel” switch on the

SVI-450i power source in the “Remote” position and follow the instructions below.

Selecting System Presets

System parameters are those that affect BOTH torches and ALL schedules. These parameters are always active and should be set first. They are:

Gas preflow preset

Gas postflow preset

Cold inch preset

Trigger selection (dual schedule operation)

Half speed run-in

OPERATING INSTRUCTIONS

Set the shield gas preflow parameters by holding down the “Purge” key and using the “Inc/Dec” key under the IPM window to set a preflow time in 1/10 seconds. Repeat the above for postflow using the key below the VOLTS window.

The cold inching feature is a two speed design. When placing the “Inch” key in the “up” position, the feed motor will operate at 50 ipm for a period of 2-1/2 seconds. This is for “bumping” the wire to adjust the wire stick-out from the contact tip. After 2-1/2 seconds the wire feed speed will transfer to the cold inching speed shown in the IPM window. The wire feed speed can be further adjusted using the “Inc/Dec” key under the IPM window. This function is designed for wire threading.

The “Trigger Selection” option allows dual schedule operation. This means that two welding schedules are available to the operator on each torch. This option is disabled when Rocker Switch #4 on Dip Switch #2 is in the “closed” position. Dip switch #2 is located on the MPU board inside the feeder control box. Place this switch in the “open” position for “Trigger” selection

(dual schedule operation). Welding will always begin using the current weld schedule selected. “Double clicking” the torch trigger switch changes the welding parameters to the next highest schedule number. See diagram below.

Example:

If pulse arc welding is being used in schedule #4,

“double click” the torch trigger to switch to the short/ spray arc parameters resident in schedule #5.

“Double click” the torch trigger a second time causes the weld parameters to switch back to the pulse weld parameters in schedule #4. Releasing the torch trigger stops welding.

16

SECTION 3

The Trigger Selection function (dual schedule operation) is automatically disabled when a spot weld time is preset or its crater conditions are set for the schedules in use on that torch. See “Torch Parameter

Presets” below.

Half speed run-in is always “on” when using the pulse arc schedules (1 to 4). Half speed run-in will also be

“on” in the short/spray arc schedules (5 to 8) when the arc voltage is 26 volts or higher. Below 26 volts will result in full speed run-in of the welding wire. This option is enabled when Rocker Switch #1 on Dip

Switch #2 is in the “open” position. Dip switch #2 is located on the MPU board inside the feeder control box . Place this switch in the “closed” position for full speed run-in for all welding schedules 1 to 8. This function is triggered off the high open circuit voltage

(OCV) of the SVI-450i power source. Half speed runin cannot be enabled using power sources having a low OCV.

Torch Parameter Presets

Each torch can have the following parameters or variables preset:

Schedule number preset

Wire burnback preset

Spot weld time

Crater time

Crater conditions

The software will automatically switch to the torch being used when the torch trigger is depressed. Each torch may have two welding schedules assigned at a time when using the Trigger Selection mode

(described above). The right side torch (viewed from the front of the feeder) is the default torch setting.

This means that when the feeder is first powered up this torch and its parameters will be displayed. If a red light between the IPM and VOLTS display windows is illuminated, the left side torch parameters are being displayed.

Choose the schedule number (1- 8) for each torch by depressing the “Schedule Selection” key and setting the desired schedule number in IPM window for the left torch and the VOLTS window for the right torch.

Preset the desired burnback by “depressing” the torch trigger switch to be preset. This action displays the current welding parameters for that torch. Hold

“Burnback/Spot” key in the “up” position and set a burnback number in VOLTS window. Repeat this procedure for the other torch.

OPERATING INSTRUCTIONS

Attach the desired gas mixture to the appropriate torch for the type of welding to be completed.

Some shielding gases will not pulse arc and short arc equally well. Therefore, the optimization of both pulse arc and short/spray arc parameters will be dependent on the shielding gas and its ability to support both processes.

If spot welding is desired, “depress” the torch trigger switch to be preset. This action displays the current welding parameters for that torch. Hold the

“Burnback/Spot’” key in the “up” position and set a spot time in seconds in the IPM window. Repeat this procedure for the other torch if desired. Entering a spot weld time automatically disables the “Trigger

Selection” mode and dual schedule operation is not possible.

Weld Schedule Parameter Presets

Pulse Arc Welding

Schedules 1 through 4 are dedicated pulse arc welding schedules for stainless steel using .045" (1.2

mm) diameter wire. The synergic relationship is the same on each torch and for each schedule. When entering a schedule number 1 to 4, the feeder control and power source is automatically set for pulse welding with .045" stainless steel wire.

Note: The SVI-450i power source slope switch should be set to the STEEP slope position. The

INDUCTANCE & VOLTAGE knob on the SVI-

450i is deactivated.

The IPM window will display the wire feed speed in inches per minute and the VOLTS window will show a number between 0 and 200 with 100 being the default value. These numbers relate to the synergic relationship programmed into the software and correspond to a pulse frequency. The number 100 is the nominal pulse frequency required for the wire feed speed selected in the IPM window. This number will also affect the arc length. If the welding arc length is too long the number can be decreased which shortens the arc length. If the welding arc is too short, increase the number in the VOLTS window. Each count in the window changes the pulse frequency by one pulse per second.

17

SECTION 3

Short/Spray Arc Welding

When setting a schedule number 5 to 8, the feeder control and power source is automatically set for short/spray welding. The operator has full control over the slope and inductance of the power source. The

IPM window will display the preset wire feed speed in inches per minute. The VOLTS window will display arc voltage and can be adjusted to any arc voltage needed for a good welding condition by using the “Inc/

Dec” key under the VOLTS window. The feeder control will automatically adjust the power source to maintain the arc voltage set in the VOLTS window.

There is no synergic relationship present in the short/ spray arc schedules.

Crater Fill

The Crater Fill feature allows the operator to preset a special welding wire feed speed (IPM), arc length

(VOLTS) and time (TIMES) to control the shape and size of the weld crater upon termination of the welding process.

Each weld schedule can be preset with a unique crater fill IPM, VOLTAGE and crater time. The feeder thus offers 16 sets of crater conditions.

Note

When a crater TIME is programmed, the “double click” method of changing torch schedules by using the welding torch trigger is automatically disabled for that torch.

Programming a Crater Condition

1. Momentarily depress the trigger of the torch to be programmed. Be sure the desired schedule number is assigned to that torch. Schedules 1 - 4 are

Pulse arc welding schedules and schedules 5 - 8 are Short Circuiting/Spray arc welding schedules.

2. Hold the Crater toggle switch in the TIMES position.

The window corresponding to the torch being used will illuminate. Enter the desired crater time (in seconds) using the INC/DEC switch under the illuminated window. A zero (0) will disable the crater fill feature.

3. Hold the Crater toggle switch in the CONDITIONS position and enter the crater IPM and VOLTS settings desired using the INC/DEC toggle switches beneath their respective window.

4. During welding the crater fill schedule will be enabled when the operator releases the torch trigger.

The crater timer will start and the arc will extinguish automatically when the preset crater time has timed out.

OPERATING INSTRUCTIONS

5. The preset crater time can be terminated also by reoperating the torch switch during the crater condition.

6. For a legitimate crater condition, both crater speed and crater time needs to be set.

Arc Start (Servo) Settings - For short or spray arc welding only, not applicable to pulse welding.

Each schedule on each torch can have its own starting characteristic for any given weld parameter. The arc start level must be set during welding. Choose desired schedule number and set a good welding condition. If the arc starting is less than desirable it can be adjusted as follows:

Depress the “Purge” and “Schedule Select” key simultaneously while making a weld (two man operation). The VOLTS window will display a number between 0 and 200 (95 is the typical setting). Using the “Inc/Dec” key below the VOLTS window, reduce the number shown to give a “hotter” arc start or increase the number for a “colder” arc start. Your setting will be saved to that schedule and will be recalled when you select that schedule again.

Changes in wire feed speed and/or voltage might necessitate readjusting the voltage servo to optimize starting characteristics. Repeat this procedure for other welding schedules being used.

Note: The set number 80 - 95 will only effect the starts, it will not change the preset arc voltage.

Motor Servo Setting

You can adjust the feed motor response by presetting the motor speed servo. Release the pressure roll and pull the torch switch while depressing the “Purge” and

“Schedule Select” key simultaneously. Change the number (110 is standard) in the IPM window using the

“Inc/Dec” key to a lower value if a faster motor acceleration is needed or a higher number for a slower motor acceleration.

The motor response adjustment will be in effect for ALL schedules and BOTH torches. The servo number set in the IPM window can be set exactly for the schedule being used and wire feed speed preset but switching to a different schedule having a different wire feed speed setting will cause the servo number in the IPM window to vary slightly. This is normal and should have little affect on welding performance.

18

SECTION 4

Vll. TROUBLESHOOTING

Listed below are a number of trouble symptoms each followed by the checks or action suggested to determine the cause. Listing of checks and/or actions is in “most probable” order but is not necessarily 100% exhaustive. Always follow this general rule: Do not replace a printed circuit (PC) board until you have made all the preceding checks. Always put the Power switch in off position before removing or installing a PC board. Take great care not to grasp or pull on components when removing a PC board.

Always place p. c. boards on a “static-free” surface.

If a printed circuit (PC) board is determined to be the problem check with your ESAB supplier for a tradein on a new PC board. Supply the distributor with the part number of the PC board as well as the serial number of the wire feeder. Do not attempt to repair the PC board or any other component yourself.

Warranty on a PC board or control will be null and void if repaired by customer or an unauthorized repair shop.

A. General

1. Check interconnection between digipulse control and power source. Make sure that the contactor and voltage control switches are placed in the Remote position.

2. Energize the power source and the control.

3. Immediately after the control is turned “on”, a number

(e.g.: 3) will appear in the IPM readout window and will only be displayed for 1-second. This number identifies the current program (E-Prom) used in your control.

When a Program is changed, the new E-Prom will automatically identify the new program number being used. If a revision is made to an existing program a number .1, .2, .3, etc. indicating the numerical revision will also appear in the VOLTS readout window simultaneously.

4. After the one (1) second delay; the preset “Weld” parameters for the “Right-Side” Torch will be displayed in the IPM and VOLTS windows.

5. If the control is not functioning properly (or as described above); for example, the numbers that appear in one or both of the display windows are meaningless

(all zeroes, eights, decimals, etc.), or are completely incorrect in relation to your settings,—the memory must be cleared. This condition might occur after a bad lightning storm, extremely bad power line surge, etc. To clear the memory, do the following: a. Place the Run-Set key switch in its SET position.

b. Turn “off” the unit’s 115-volt Power switch.

c. Using one hand, hold both of the Inc/Dec toggle switches in their INC position while reapplying 115volt power with the other hand.

MAINTENANCE

d. Almost immediately after the Power has been turned “On”, release the Inc/Dec toggle switches to the neutral (spring-return center) position and each of the windows should display one zero, indicating a successful reset or clearing has taken place.

6. You can now enter the desired information as described in this booklet.

B. No preset displays appear in windows.

1. Make sure the LED Display board harness/plug is plugged into the P5 receptacle on the MPU board.

2. Check that 110 vac is available across terminals T1-

18 and T1-19, if present;

3. Check for plus (+) 5 volts between terminals T1-8 and

T1-9; if voltage is present, replace the MPU board. If voltage is not present, check the voltage regulator

(VR). The voltage regulator is located on the rear panel of the control box.

4. Check the input and output voltage of the regulator

“VR”.

a. The input should be approx. 11 volts between VR-

1 and T1-9. If voltage is not present, replace I/O board.

b. The output should be + 5 volts between terminals

T1-8 and T1-9. If voltage is not present, replace VR, voltage regulator.

C. Preset display is provided, but cannot be varied.

1. Check normal setup procedures described in Section

VI, then;

2. Make sure the Inc/Dec key harness plug is properly connected to receptacle P6 on the MPU board and the lock-in key switch is placed in its SET position.

3. If neither of the above resolve the problem, replace the

MPU board.

D. Motor does not run.

1. Check to make sure all required accessories are correctly assembled as described in Section IV.

2. Make sure that power source is connected, plug P2 is securely connected to receptacle P2 on the Digipulse’s

I/0 Board, and then release the clapper arm (pressure roll) on the Accessory Support Assembly.

a.Operate the Digipulse INCH switch. If motor does not run; replace the “J” governor board, and if it still does not run, replace I/O and MPU boards respectively.

b.If the motor inches, but does not run when the torch switch is operated (energized), check the torch switch circuit components—switch, plug, receptacle, etc. If motor still does not run, check if power source is providing open-circuit voltage to the

19

SECTION 4 MAINTENANCE

Digipulse — if o.c.v. is not being supplied, motor will not run. Check the power source for trouble.

c.Also check that +/- 12 volts d.c. are provided from the power source on T1-7 and T1-5 respectively.

d.If power source is O.K., replace the I/0 and MPU boards respectively.

E. Motor runs, but not at right speed.

1. Check tachometer assembly mounted on the end of

EH-10A wire feed motor.

2. Make sure the tach disc is securely fastened to the motorshaft and that the strobe markings are not scratched. Check that the disc is properly centered in the optical switch on the p.c. board.

3. If all items in step 2 are in order, and motor speed is still incorrect, replace MPU board.

F. Arc VOLTS display reads zero after TS Is operated.

1. Check that the 5-pin plug is securely connected to the

P3 receptacle on the MPU board

2. If no reading is displayed, check for arc voltage feedback between terminals TP1 and TP2 test points on the I/0 board (see Fig. 4B). This voltage signal should correspond to that shown on the power source voltmeter.

3. If voltage still reads zero, trace the voltage pickup wiring from the power source to digipulse.

4. Remove the J-Gov. p.c. board to gain access to the P3 plug (harness) on the MPU p.c. board. Disconnect the

P3 plug from its MPU board socket and, using a meter check for +/-12 volt power supply output between plug pins P3-1 and P3-2 (for +12 v.) and between plug pins

P3-4 and P3-2 (for -12 v.) respectively. If voltage is present, replace the MPU board.

Fig. 4B - Input/Output (110) P.C. Board

G. Control Shut Down — either preset VOLTS or IPM displays will flash. The control will flash the parameter,

VOLTS or IPM, that cannot be maintained.

If this condition occurs, the respective servos need to be checked and, if necessary, readjusted.

1. This symptom can of occur as a result of either or all of the following; the Speed and Voltage servo) adjustments are incorrect and the conditions “set” may not be maintainable. To check and, if necessary, readjust the servos — proceed as follows:

NOTE: Prior to checking the servos, make sure the

Digipulse is connected to SVI-450i power source in order to obtain the necessary o.c.v. (open circuit voltage); otherwise, the motor will not run.

2. The Speed and Voltage servos in this control are simultaneously checked and displayed by depressing and holding the front-panel Schedule Select switch in its "down" position during an actual weld with the wirefeed motor running. The speed servo number is displayed in left (IPM) window and should be about

110, and the right (VOLTS) window will display the voltage servo number. This number will be between

90 and 100* for the actual welding condition.

* Voltage servo setting below 95 will normally provide hot arc starts; whereas, setting over 100 will not.

3. If a Speed abort had occurred (IPM window flashing), check and/or adjust the speed (servo) as follows:

Open the pressure roll clapper (so as not to feed wire), toggle-down the Schedule Select switch position, and either close the torch switch lever or toggle-up the

INCH position of the Inch-Purge switch. Check the number in the IPM window — it may appear unsteady but readable and should be about 110.

TP2

TP1

If it is higher or lower, use the Inc/Dec toggle (below the IPM window) to adjust the number to 110 - while

“holding” the A.H./INCH Preset and Purge/Reset toggle as mentioned above and while the wire feed motor

is running.

If the speed servo cannot be adjusted at all, the problem may be in the J-Governor, and/or I/O, and/or

MPU p.c. boards which needs to be as required.

4. If a Voltage abort had occurred (VOLTS window flashing), check and/or adjust the voltage (servo) as follows:

This is a two man operation. Set a welding condition which closely corresponds to your welding application and the proper speed (ipm) for a given wire size and then — close the torch switch and strike a welding arc.

While welding, toggle-down the Schedule Select switch

20

SECTION 4

position and read the number displayed in the VOLTS window, it may appear unsteady but readable and should be 95.

If the number is not in the 90-100 range, use the Inc/

Dec toggle (below the VOLTS window) to adjust the number to 95 — while “holding” the toggle positions mentioned above and while welding.

5. If the voltage servo cannot be adjusted, check for proper operation of the power source as follows: a. Set the Digipulse voltage display to zero (this setting will override the servo).

b. Place the Panel/Remote switch on the power source in PANEL position.

c. Make a weld by controlling the arc voltage directly from the power source potentiometer.

d. If a weld can be made with good control over power source voltage; a problem exists either in the interconnecting voltage control cable, or in the Digipulse control.

e. Check the control wires in the interconnecting voltage control cable for continuity between the appropriate terminals in the power source and digipulse using the schematic diagrams.

f. If continuity is correct, replace the I/O board and/or the MPU board.

H. Control Shut-Down Due to Ground Fault Detection — both IPM and VOLTS displays will flash.

The purpose of this circuit is to make sure that welding current is not present in the wire feeder frame/base, control box, or the equipment safety ground. If this should occur, the ground fault detector will temporarily energize and immediately terminate the weld. This abort is indicated by both visual displays flashing simultaneously. — Before attempting to make a new weld, make sure that the Work Ground cable and its connections are properly and securely made to the workpiece.

VIII. MAINTENANCE

If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts.

MAINTENANCE

A. GENERAL MAINTENANCE

Little maintenance is required to keep the wire feeder in top operating condition. It is important, however, that moving parts such as feed and pressure rolls, wire feed motor, etc., be kept clean and free of dust or dirt.

Cleaning is best accomplished by regularly blowing off these parts with dry compressed air. This should be done once for every eight hours of operating time, more often if necessary.

B. LUBRICATION OF DIGITAL MOTOR-GEAR UNIT

The EH-10A motor-gear digital unit is lubricated with a heavy duty grease when assembled at the factory and should not require further lubrication unless disassembled.

If disassembled relubricate with Texaco Multifak grease.

C. CHECK OR REPLACEMENT OF MOTOR BRUSHES

Motor brushes should be checked periodically. If a brush is broken, or worn down to less than 3/8-in. length, it must be replaced. Brushes can be inspected by unscrewing the brush-holder plug and withdrawing the brush assembly. Never remove a brush without matchmarking it and its holder, so that it can be replaced in the same holder in its original position.

D. REMOVAL OF EH-10A DIGITAL WELDING HEAD

1. Unplug the control cables from the rear panel of the wirefeeder control.

2. Remove the accessory support assembly from the motor-gear unit by loosening the cap screw at the bottom of the assembly.

3. Disconnect the motor and tachometer cables from terminal board (T1) inside the control assembly as shown on the wiring diagram.

4. Remove the four screws which secure the digital motor-gear unit to the base and remove the digital unit.

E. ADDITIONAL DIGIMIG PROGRAM FEATURES

The Digipulse’s MPU board contains an integral 4-rocker

“dip” switch (SW1) that is factory-set to the following positions: Rocker #1 is CLOSED, and Rockers #2, 3, 4 are OPEN. The microprocessor technology utilized by the Digipulse control is extremely versatile and can be modified for specific purpose by ESAB’s engineering services group. To add specific features or programs to your unit, consult your ESAB representative. If additional optional features are provided, the SW1 rocker positions may need to be repositioned — and this information will be conveyed in the appropriate instruction booklets provided with the option kits.

21

SECTION 5 REPLACEMENT PARTS

1. All replacement parts are keyed on the illustrations which follow. Order replacement parts by part number and part name, shown on illustrations. DO NOT ORDER BY PART NUMBER ALONE.

2. Always state the series or serial number of the machine on which the parts are to be used. The serial number is stamped on the unit nameplate.

COVER - 30170YL

WARNING DECAL - 2091514*

CONTROL ASSY.

33387 (see Fig. 7)

(SW1, 3, 5, 7) SWITCH - 950087 n

WARNING DECAL - 995204*

RIGHT TORCH (J3) RECEPTACLE

- 182W64

(C10, 11) CAPACITOR

- 672348

(2) EH-10A DIGITAL MOTOR-GEAR

UNIT ASSY. 679777 (See Fig. 6)

(2) ACCESSARY SUPPORT ASSY.

2 ROLL DRIVE (See Fig. 8) - 49V51

LEFT TORCH (J4) RECEPTACLE -

182W64

C16 CAPACITOR

672348

FRONT VIEW

FRONT CONTROL SUPPORT - 35742

(CB) CIRCUIT BREAKER - 950874 n

(MSL) POWER ON-OFF SW

634517 n uRUN-SET SW - 950956

STRAIN RELIEF - 96W76

(2) GAS SOLENOID VALVE - 2062305 n

(2) GAS INLET CONNECTION - 74S76

(2) GAS BULKHEAD ADAPTOR - 58V58

KNOCKOUT OPTIONAL

WATER CONNECTIONS (See Fig. 10)

REAR CONTROL SUPPORT

36278

Not Illustrated — Accy. Support

INSULATOR RING

60N90

Key - 28N33

THUMBSCREW

61351087

FLATWASHER - 64309431

BELLEVILLE WASHER - 950783

(J1) RECEPTACLE - 950762 (19-pin)

C20 CAPACITOR - .1uf, 500 V

(2) SPINDLE ASSY.

948259 (See Fig. 9)

(VR) VOLTAGE REGULATOR includes:

VOLTAGE REGULATOR - 950159

TRANSISTOR SOCKET - 950158

(C4) CAPACITOR - 995544

BASE w/SUPPOFT - 36279

REAR VIEW

u Replacement key for Run-

Set SW - 32778

POWER CABLE ADAPTOR BLOCK - 674156

1/2-IN.-13 STL. NUT

1/2-IN. LOCKWASHER

(2) 1/2-IN. FLATWASHER

* Replace decal if it becomes excessively worn or lost when replacing panel(s) n Recommended Spare Parts n Recommended Spare Parts

Fig. 5 - DIGIPULSE Dual Wire Feeder, P/N 33299

22

TACH. P.C.B.D.

675429

(2) Screw-61324746

TACH DISK

950313

MOTOR END

HOUSING

(Ref.) 54" LG

TACH COVER - 18787

(2) Screws 61324974

Gear Case Lubricated with

Texac Multifak Grease

11.6

VENT PLUG

.020

REF

2.875

10

2.370

.93

.6251

50

DP

MIN.

33 LOCATING COLLAR

(REF.)

TACH HOUSING - 18786

(2) 8-32 X 3/8" Screw

END VIEW w/COVER REMOVED

MTR.

LEAD

4.010 SQ.

2.25

2.000

1.375

1.375

.25

5.16 18 UNC 2B

.25

2.86

63 MIN. DEPTH

FOR MOTOR REPLACEMENT

PARTS (See Fig. 6A)

Fig. 6 - EH-10A Digital Motor-Gear Unit Assembly (40:1) P/N 679777

WARNING DECAL - 995164*

DISPLAY P/C BOARD

ASSY. - 675236

(I/O) P/C BOARD ASSY. - 674994

(I/O P4 to MPU P2) CABLE ASSY. - 677938

(MPU) P/C BD. ASSY. - 18155

(RLY) RELAY - 951089

C21, C22 - CAPACITOR - .1uf, 500V

BR-RECTIFIER - 2 Amp., 400v - 63515

(R1) RESISTOR -

17240001

(25W, 3 ohm)

(MOV) METAL OXIDE

VARISTOR - 995104

(FN1) FILTER

NETWORK - 679874,

Includes

C1, C2 CAPACITOR -

950702

C3 CAPACITOR -

993716

“J” GOV. P/C BOARD

ASSY. - 994236 (See Note)

MTG. Bracket - 995297

(P1) Receptacle - 636608

(T1) 20 PT. Terminal

Strip - 950182

NOTE: The heat sinks of the “J” gov. board are electrically hot. Do Not touch or ground while unit is energized.

(GRF) SENSOR - 950448

(Mtd. on Cabinet Base)

Fig. 7 - DIGIPULSE Dual Control Assembly P/N 33387

(CTR1,CTR2) CONTROL TRANSFORMERS

CTR1 - 950088

CTR2 - 994303

BRACKET - 35477

* Replace decal if it becomes excessively worn or lost.

Recommended Spare Parts

CLAPPER - 60N98

SHAFT - 60N65

ROLL PIN 1/4" X 1-3/4" LG

INLET

KNOB - 60N68

LIGHT SPRING 182W55 (FOR

SOFT & SMALL DIA. HARD WIRE)

RETAINER 58N24

FORK - 49V43

WIRE OUTLET GUIDE INSERT

*

CONDUIT

INLET WIRE GUIDE

29N13

INLET GUIDE INSERT

05N58

OUTLET

WIPER HOLDER

*

598764

SET SCREW # 6-32 X 1/4" LG

61330849

(

2) LOCKING HANDLE ASSEM - 49V44

INCLUDES:

BOLT 1/4" x 1-5/8"

LG

SPACER - 60N79

PRESSURE ROLL

28V52

SUPPLIED

HEAVY SPRING - 182W54 (FOR LARGE DIA. HARD WIRE)

WIRE OUTLET GUIDE

*

(See Table 1)

ROLL PIN 3/16" X 1-3/4" LG

SCREW 5/16" -18 X 2" LG

CLAMP - 61N02

NUT 5/16"-18

*

Outlet guide And Wiper Holder Not Included in Assembly Part No. 49V51.

Fig. 8 - Accessory Support Assembly, P/N 49V51

WIRE REEL - 995570

Includes:

REEL - 995568

COVER - 995569

(4) WING NUT, 1/2" - 13

63398183

WATER

CONNECTION

58V75

(OUTLET)

WATER SOLENOID

VALVE - 2062355

ADAPTOR - 11N16

(INLET)

(Ref. Hair Pin Clip)

REEL

(4) .359" DIA. HOLE ON 3" DIA. D.C.

SPINDLE - 948258

"D" TYPE

WASHER - 948254

SCREW -

5/16" -18 x 2"

HAIR PIN

CLIP - 634347

5/8 -18 Lh

1/4 N.P.T.

WATER

CONNECTION

58V75

(OUTLET)

WITH SOLENOID VALVE

COUPLING - 68121075

ADAPTOR - 11N16

(INLET)

5/8 -18 Lh

WASHER -

948256

SPRING - 948253

(2) BRAKE PAD - 948255

SUPPORT -

948257

SPINDLE

Fig. 9 - Spindle Assembly, P/N 948259,

Optional Wire Reel, P/N 995570

5/8 -18 Lh

1/4 N.P.T.

5/8 -18 Lh

25

WITHOUT SOLENOID VALVE

Fig. 10 - Water Kit with Solenoid Valve, P/N 2075760

Water Kit without Solenoid Valve, P/N 994466

*

Do not use with Coolant Recirculator

*

Digipulse Dual Control Revision History

Rev. A

Added label P/N 954232 (Schedule Select) to front panel.

Rev. B

Removed the 6 pin (P/N 634772) and 8 pin (P/N 2062106) box receptacles and added a 19 pin (P/N 950762) box receptacle P/N 950762. (Ref. Schematic Diagram Rev.A and Wiring

Diagram Rev. A).

Rev. C

Modified note 7 of the assembly drawing and added the accessory support leads 1&2 to

T1-20 of the wiring diagram. (Ref. Schematic Diagram Rev.A and Wiring Diagram Rev. B).

Rev. D

Changed from a green/light green cabinet with L-Tec decals to a gray/yellow cabinet with

ESAB decals, changed CTR1 and CTR2 from a welded assembly ,added mounting bracket

P/N 35477, and changed the signal lead assembly from P/N 30685 to P/N 36644. Title

Digmig Dual was changed to Digipulse Dual. (Ref. Schematic Diagram Rev.B and Wiring

Diagram Rev. C).

Rev. E

Added Craterfill as a factory installed option.

Digipulse Dual Wire Feeder Revision History

Rev. A

Re-designed the base and reel support , changed the color from L-Tec green to ESAB gray/yellow.

26

27

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATIONS GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS: Telephone (843) 664-5540/Fax: (800) 634-7548

Order Entry Product Availability Pricing Hours: 8:30 AM to 5:00 PM EST

Order Changes

Shipping Information

Saleable Goods Returns Delivery

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST

Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST

Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5501 / Fax: (843) 664-5548

Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4469 / Fax: (843) 664-5557

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

Telephone: (843)664-4428 / Fax: (843) 664-4476

Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 / Fax: (843) 664-4454

H. TECHNICAL ASST. CONSUMABLES:

Telephone: (800) 933-7070

Hours: 7:30 AM to 4:00 PM EST

Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/Web: http://www.esab.com

Hours: 7:30 AM to 5:00 PM EST

F-15-496-A 5/99 Printed in U.S.A.

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