ESAB Digimig Dual Wire Feeder Instruction manual

INSTRUCTION MANUAL

DIGIMIG DUAL WIRE FEEDER

F-14-489-C

Sept., 2003

This manual provides installation and operating instructions for the following wire feeder(s):

ESAB Part No. 30912 — 115V, 1-Phase, 50/60 Hertz. (Starting with Serial No. #####) L-TEC Part No. ????? — 115V, 1-Phase, 50/60 Hertz. (Starting with Serial No. #####)

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. Defective 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 TITLE PAGE

PARAGRAPH

SECTION 1 DESCRIPTION ...................................................................................................................... 5

1.1 General ................................................................................................................................. 5

1.2 Scope ....................................................................................................................................5

1.3 Specifications ........................................................................................................................ 5

1.4 Required Equipment ............................................................................................................. 5

1.5 Optional Accessories ............................................................................................................ 8

SECTION 2 INSTALLATION ..................................................................................................................... 9

2.1 General ................................................................................................................................. 9

2.2 Connections .......................................................................................................................... 9

SECTION 3 OPERATION ......................................................................................................................... 11

3.1 General ................................................................................................................................. 11

3.2 Description/Function of Control Features ............................................................................. 11

3.3 Gas/Wire Adjustments .......................................................................................................... 14

3.4 Setting Up Torch Program Parameters ................................................................................. 15

3.5 Welding Operation ................................................................................................................ 16

SECTION 4 TROUBLESHOOTING .......................................................................................................... 18

4.1 Troubleshooting General ......................................................................................................18

4.2 Troubleshooting Guide .......................................................................................................... 18

SECTION 5 MAINTENANCE .................................................................................................................... 23

5.1 General ................................................................................................................................. 23

5.2 Inspection and Cleaning ....................................................................................................... 23

SECTION 6 REPLACEMENT PARTS....................................................................................................... 23

6.1 General ................................................................................................................................. 23

6.2 Ordering ................................................................................................................................23

SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for

your protection. They summarize precautionary information from the references listed in Addi-

tional 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:

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:

als well away from the work area or cover the materials

1. Remove all combustible materi-

with a protective non-flammable 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.

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.

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

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.

§25249.5 et seq.)

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.

SECTION 1 DESCRIPTION

1.1 GENERAL

This Digimig wire feeder is designed as a “dual” torch welder with each torch capable of furnishing two completely different sets of welding parameters—in other words, four (4) completely different welding schedules can be preset to meet the requirements of high production shops. The standard Dual control features include power source, slope, wire type, wire diameter selections, and presettable wire feed speed (ipm), voltage, pre and postflow gas shielding, cold wire inching, gas purging, adaptive or manual burnback and spot welding time functions.

The Digimig Dual torch welder is a microprocessor controlled digital wire feeder designed for mig short arc and spray arc, and flux core 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 Digimig Dual allows the customer to preset both welding parameters (for each torch), lockthem-in, 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 (1/2-in. 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 power source and slope, and wire type and diameter used, and other welding parameters such as inching speed, gas pre- and postflow times, spot time in seconds and manual burnback time in cycles.

The Dual Digimig uses a pair of heavy duty EH-10A wire drive motors designed to feed hard or soft wires from .030in. to 1/16-in. in diameter and flux-cored wires from .035in to 5/64-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 1-1. The front panel contains the torch switch receptacles which use low voltage, d.c., for operator safety. The rear panel contains the on-off power switch, the run/set switch, trigger lock switch, a 7ampere reset circuit breaker for overload protection, a 19pin receptacle (J1) provides 115vac and 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. 2-1 & 2-2. A water kit may be purchased, as an optional accessory, for use with water-cooled torch operation.

1.2 SCOPE

The purpose of this manual is to provide the operator with all information required to install and operate the Dual Digimig wire feeder. Technical information and reference material is also provided to assist in troubleshooting.

1.3 SPECIFICATIONS

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

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

Wire Sizes Accommodated:

Hard/Soft — ......................................... .030 thru 1/16-in. (.8 thru 1.6 mm)

Flux Cored — .................................. .035 thru 5/64-in. (0.9 thru 2.0 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)

1.4 REQUIRED EQUIPMENT

A. CONSTANT VOLTAGE POWER SOURCE

One of the following power sources must be used: SVI-300i cv/cc, P/N 34835. VI-450, P/N 33322. SVI-450i, P/N 31950 V-650 cv/cc, P/N 33324.

B. Cable Assemblies

115 Volt/Contactor/Remote Control J1 Cable, 19-con-

SECTION 1 DESCRIPTION

LEFT DIGITAL READOUT IPM

6-POS. ROTARY SELECTOR SW.

TORCH ACCY. LEFT

SUPPORT ASSY.

& EH-10 MOTOR-GEAR-

TACH UNIT

LEFT INC./DEC. SW.

LEFT TORCH RECPT.

RIGHT DIGITAL READOUT VOLTS

INCH-PURGE (RESET) SW.

SPINDLE

RIGHT INC./DEC. SW.

RIGHT TORCH RECPT.

TORCH ACCY. RIGHT SUPPORT ASSY. & EH-10 MOTOR-GEARTACH UNIT

RIGHT

TORCH GAS SOL CONNEC-

TION

POWER ONOFF SW.

RUN-SET KEY SW.

RESET CIRCUIT BREAKER

TRIGGER LOCK

J1 CONTROL RECPT.

LEFT TORCH GAS SOL CONNECTION

LOCATION FOR OPT. WATER CONNECTIONS

POWER CABLE ADAPTOR BLOCK

Fig. 1-1 - Digimig Dual Feeder

SECTION 1 DESCRIPTION

ductor 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 (MT450W, ST-16) torches may be used with the Digimig. 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 (see Section 1.5).

D. Gas Regulation

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

Table 1 - Digimig Feed Rolls

Regulator/Flowmeters:

R-5007 Argon/Helium/Nitrogen, P/N 998124. R-5008 C0

, P/N 998125.

Gas Hoses:

Standard Duty, 40V77 (12-1/2-ft.) or P/N 34V38 (25-ft.) Heavy Duty, P/N 19416 (12-1/2-ft.) or P/N 19415 (25-ft.).

 Must be used for C0

E. Feed Rolls

The Digimig 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. To convert the 2-Roll to 4-Roll Drive, order optional 4-roll Drive Accessory Support, P/N 600216 and the appropriate kit listed in Table 1.

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. 2-1.

Wire Type/ Two Roll Drive Four Roll Drive Outlet Size In. (mm) Feed Roll Feed Roll Kit* Guide

Soft

.030 (.8) 2075304 (U) 999320 29N13** .035 (.9) 2075304 (U) 999321 (U) 29N13** 3/64 (1.2) 2075301 (U)

† 999322 (U) 29N13**

1/16 (1.6) 2075298 (U)†† 999322 (U) 29N13**

Hard

.023 (.6) 17998 (V) — 999745 (c) .030 (.8) 2075300 (V) 999325 (V) 993860 (a) .035 (.9) 2075303 (V) 999326 (V) 993860 (a) .045 (1.2) 2075302 (V) 999327 (V) 39N15 (b) .052 (1.4) 2075330 (V) 999328 (V) 39N15 (b) 1/16 (1.6) 2075299 (V) 999329 (V) 39N15 (b)

Cored

.035 (.9) 19761 (Serr.) — 993860 (a) .045 (1.2) 19761 (Serr.) 999330 (Serr.) 39N15 (b) .052 (1.4) 2075261 (Serr.) 999331 (Serr.) 39N15 (b) .063, 1/16 (1.6) 2075261 (Serr.) 999332 (Serr.) 39N15 (b) 5/64 (2.0) 2075261 (Serr.) 999333 (Serr.) 62N17 (d)

U=U-groove, V=V-groove, Serr. = serrated ** 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) Requires guide bushing (17997). (d) Requires replaceable sleeve (995693)

SECTION 1 DESCRIPTION

1.5 OPTIONAL ACCESSORIES

A. Water Kit (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. 2-1 illustrates the use of power cable adaptor P/ N 634693, in addition to the kit. If adaptor (634693) is not used, adaptor (45V11 supplied with kit) can be connected to the output terminal of the power source. Install the kit in accordance with Fig. 6-7 and Sec. 2.2F. Connect the water-cooled torch as shown in Fig. 2-

B. Spool Enclosure Kit (P/N 600240). Provides protec-

tion for spool of wire against dust and dirt. For installation instructions refer to Form 12-824.

C. Standard Wire Reel Assembly (P/N 995570). Reel

slips over spindle to allow use of coiled wire, see Fig. 6-6.

D. 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.

E. 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.

Either of two additional accessories are required to complete the installation on the wire inlet side of the straightener: a. Wire Inlet Guide, P/N 11N53, or b. Wire Wiper Holder, P/N 598763.

F. Wire Spool Spacer (P/N 948378). Enables the use of

a 8-in. diameter spool of welding wire with spindle assembly on the Digimig wire feeder.

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, 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 or 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 (see F-12-

984).

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 F-12-821 or Table 1.

SECTION 2 INSTALLATION

REGULATOR/ FLOWMETER

GAS HOSE 40V77 (12-1/2 FT.) 34V38 (25 FT.)

 WATER KIT - 994466

 WATER "DRAIN" HOSE - 40V76 (12-1/2 FT.)

 ADAPTOR - 45V11

LEFT TORCH

MOTOR/ACC. SUPPORT

TORCH CONDUIT

TORCH POWER CABLE

 TORCH WATER HOSE

TORCH GAS HOSE

TORCH SWITCH

 WATER "IN" HOSE - 40V76

(12 1/2 FT.)

REGULATOR/ FLOWMETER

GAS HOSE 40V77 (12-1/2 FT.) 34V38 (25 FT.)

PLAN VIEW DUAL FDR.

GAS SOLENOIDS

REF. CONTROL'S REAR SUPPORT FRAME

RIGHT TORCH

MOTOR/ACC. SUPPORT

TORCH CONDUIT

TORCH SWITCH

TORCH POWER CABLE

TORCH GAS HOSE

LEFT TORCH

(WATER COOLED)

 Parts required when

using a Water Kit & Water Cooled Torch.

Fig. 2-1 - Torch and Service Interconnection diagram

2.1 GENERAL

Proper installation can contribute materially to the satisfactory and trouble-free operation of the wire feeder. It is suggested that each step in this section be carefully studied and followed as closely as possible.

After checking to be sure you have all required components and accessories (see Section 1), proceed as follows (with reference to Figs. 2-1 & 2-2, Interconnection Diagrams):

FRONT VIEW CONTROL

To avoid possible lethal shock make sure that all power to the Digimig 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.

2.2 CONNECTIONS

A. Hose And Electrical Connections

Connect shielding gas and water (if used) supply hoses as shown in Fig. 2-1. Connect the control cable assembly (J1) from the Digimig’s rear panel to the power source as shown in Fig. 2-2.

RIGHT TORCH

(AIR COOLED)

SECTION 2 INSTALLATION

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 as-

sembly (Figure 6-5) 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.

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 assem-

bly as described in E, following.

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 Assembly (See

Fig. 6-5).

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

J1 CABLE †

4/0 WELDING CABLE*

TYPICAL POWER SOURCE HOOKUP

† ESAB will not honor the warranty on Digimigs 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 J1 cables available refer to Section 1.4.

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

TO WORK) operation.

Fig. 2-2. Welding and Control Interconnection Diagram

GSV'S

OPT. WATER ADAPTOR

POWER CABLE ADAPTOR

RECPT.

TO WORK*

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

SECTION 2 INSTALLATION

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.

F. WATER KIT (Optional see Fig. 6-7)

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 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.

SECTION 3 OPERATION

3.1 GENERAL

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 welding 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.

3.2 DESCRIPTION/FUNCTION OF CONTROL FEATURES

1. Power Switch. This two-position toggle switch turns

power “on” or “off’ to the wire feeder control.

NOTE: Immediately after the control has been turned

“on” various numerical code data (e.g.; Program I.D., Power Source and Slope) will appear in the IPM and VOLTS display windows for 4seconds. After this delay, the preset weld parameters for the last torch used will be shown. This is further described in the General Troubleshooting Section.

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.

3a.Trigger -Lock-In Switch. This feature allows the

operator to release the torch switch (trigger lock “on”), of the torch being used, after starting the weld cycle. To stop the welding cycle, you simply depress the torch switch again, and all welding action ceases. When this function is selected (on), it “locks-in” both torches and their selected schedule. It will also automatically override a Spotweld operation (if programmed). An indicator light (LED) on the front panel lights when this feature is engaged. In the “off” position this feature in not functional, and the LED is off.

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.: Sched. I (RUN), 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. No parameter can be altered by the operator in the RUN position.

Fig. 3-1. Rear Panel Control

SECTION 3 OPERATION

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 Rotary function actuated, this window can also display the following: — Power Source selection designated by the nu-

merals “300”, “450” or “650” (see Rotary Switch Item 6)

— a code number that indicates the MATERIAL

selection programmed for various welding wire applications; #1, #2, or #3 (see Rotary Switch Item 6)

— shielding gas PREFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments.

— SPOT welding time for each Torch, from .1 to

99.9 seconds in one tenth of a second increments.

— cold wire INCH speed in IPM from 40 to 999

inches per minute in one inch increments. Please note the initial starting speed jumps to 100 ipm for 2-seconds and then goes to preset value.

NOTE: When power is first turned “on” (but not welding)

the display windows will initially show the Program I.D. numbers for 1 second and then flash the Power Source and Slope selections for 3seconds (to make sure that the correct power source and slope are being used). Then, the IPM window will “continuously” read Preset wire speed if the Rotary switch is in the RUN or SCH. II mode. 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 Rotary function actuated, this window can also display the following: — indicates power source SLOPE selected and

designated by the numeral 1, 3 or 6 (see Rotary Switch Item 6)

— a pair of numbers represent WIRE DIAMETER

sizes which are programmed for selection as follows: #30, #35, #45, #52 or #63 (see Rotary Switch Item 6).

— shielding gas POSTFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments.

— manual BURNBACK time. Manually adjustable

burnback time period which when preset will override the automatic adaptive anti-stick fea-

ture. 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.

NOTE: When power is first turned “on” (but not welding)

the display windows will initially show the Program I.D. numbers for 1 second and then flash the Power Source and Slope selections for 3seconds (to make sure that the correct power source and slope are being used). Then, the VOLTS window will “continuously” read Preset voltage if the Rotary Switch is in the RUN or SCH. II mode. When the arc is struck, the VOLTS window will then continuously read Actual welding voltage.

5. LED Light. This LED lights to indicate that TriggerLock-In is engaged.

Positions

#2 #3

Pos. #6

Fig. 3-2. Front Panel Controls

IMPORTANT

To setup the torches for programming, simply operate and release the torch switch lever for one torch and preset the desired parameters. Then, repeat this procedure with the remaining torch to preset its welding parameters. Under normal operation, the control’s memory will always “default” to the torch/ parameters last used during the preceding welding operation. When the unit is initially turned “on” or “reset”, the “right” torch is the dominant or “default” torch.

6. Rotary Switch. This six (6) position switch allows

you to select a “pair” of welding parameters per position as follows:

a. Position 1, Power Source/Slope (Must be set).

This position must match the Power Source used, and its Slope setting. These selections will be

SECTION 3 OPERATION

code “3” is for the 5000 aluminum series of

displayed in the IPM and VOLTS windows respectively and are set as follows: (1) Power source. Four power sources are avail-

able for use with this feeder. The choices are, the SVI-300i cv/cc and this designated by the numeral “300”; and the VI-450, or the SVI450I, and these are designated by the numeral “450”; and/or the V-650 cv/cc and this is designated by the numeral “650”. The Power Source “numeral” designation selection is displayed in the left (IPM) window, and set using the IPM Inc./Dec. toggle switch.

(2) Slope. In order to provide optimum starts with

the many Power Source and Slope combinations, the same slope setting used on the power source must also be preset on the wire feeder control, and are designated as follows: by the numeral “1” for Flat; by numeral “3” for Medium; or by numeral “6” for Steep slope. The slope “numeral” designation selected is displayed in the right (VOLTS) window, and set using the VOLTS Inc./Dec. toggle switch.

Remember, that the feeder slope selection must always match the slope output selected at the power source.

In order to help you select the correct Slope setting for the Power Source used, refer to the chart following:

Power Control Slope Codes Source #1 #3 #6

SVI-300i X X X SVI-450i X X X VI-450 X X — V-650 cv/cc X — —

Note, Slope codes indicate the following: #1 = Flat = 1 volt/100 amps. #3 = Medium = 3 volt/100 amps. #6 = Steep = 6 volt/100 amps.

b. Position 2, Material/Wire Diameter (Must be

Set). In this position you set the wire Material type

and Wire Diameter. These selections will be displayed in the IPM and VOLTS windows respectively, and are set as follows: (1) Material. This parameter is set in the left (IPM)

window and displays one of the three available wire material type code numbers that can be used (for each torch), and is set by operating the IPM Inc./Dec. toggle switch. Material code “1” is for Carbon or Stainless Steels, code “2” is for the 4000 aluminum series, and

c. Position 3, Spot Time/Burnback Time (Optional

d. Position 4, Schedule II/Schedule II (Optional

e. Position 5, Preflow/Postflow (Optional Setup).

wires.

(2) Wire Diameter. This parameter is displayed

in the right (VOLTS) window and offers a choice of five (5) wire diameter sizes which can be used (for each torch), and is set by operating the VOLTS Inc./Dec. toggle switch. The wire sizes available are: “30” for .030" dia. “35” for .035" dia., “45” for .045" dia., “52” for .052" dia. and “63” for .063" dia wires.

Setup). This position allows you to preset either or both of these welding features for either or both torches. These parameter times will be displayed in the IPM and VOLTS windows respectively, and are set as follows: (1) Spot time. If a timed weld is desired, a time

from 0.1 to 99.9 seconds can be set in Spotweld timer (IPM window) using its Inc/Dec key. Once set, both Schedules I and II will become “timed” or spot welds. To return to “continuous” welds, the time has to be set to zero (0.0).

When a spot time is programmed for a torch, the “click-click” the torch switch feature for changing schedules cannot be used.

(2) Burnback Time. At the same time, you can

also preset a manual Burnback time. The Burnback time 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. To resume automatic anti-stick operation, the Burnback time must be set back to “zero” (0).

Setup). This position allows you to preset a second welding schedule. The wire speed rate is set using the left Inc./Dec. toggle switch and the setting will appear in the IPM window. The arc voltage is set using the right Inc./Dec. toggle switch and the setting will appear in the VOLTS window.

In this position (5), Gas Preflow (.1 to 99.9 sec.) can be set by the left Inc./Dec. toggle and displayed in the IPM window. Gas Postflow (.1 to 99.9 sec.) is set by the operating the right Inc./Dec. toggle and is displayed in the VOLTS window. These features are adjustable in 0.1 second increments and are shared by both welding schedules.

SECTION 3 OPERATION

f. Position 6, RUN Schedule I (Must be Set). This

position allows you to preset the welding parameters (IPM/VOLTS) for Schedule I (RUN position). The wire speed rate is set using the left Inc./Dec. toggle switch and the setting will appear in the IPM window. The arc voltage requirement is set using the right Inc./Dec. toggle and the setting will appear in the VOLTS window. After all preset parameters have been programmed, the unit is ready to weld.

7. Inc.-Dec. Toggle Switches. Two control toggles are provided to preset the individual welding parameters required for the selected welding Schedules (per torch) as follows:

a. “IPM “ Increase/Decrease Control. This toggle

switch is used to set and/or vary the wire feed speed (IPM), and all of the parameters that appear in the box above the switch, such as; Power Source selection, Material selection, Preflow, Spot for both torches, and Inch. 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 used to set and/or vary the arc Volts, and all of the parameters that appear in the box above the switch, such as; Slope selection, Wire Diameter selection, Postflow, Burnback. With the appropriate function selector actuated, each parameter setting will be displayed in the digital window directly above this toggle.

8. Inch-Purge (Reset) Switch (Optional Setup). This

two position (momentary “on” contact) switch allows the following operation. a. Inch Function. The INCH selection permits cold-

wire inching without energizing the welding circuit. A preset cold wiring inching speed (40 to 999 ipm) can be set and/or changed by operating its Inc./ Dec. toggle switch, and this setting (which is independent of welding wire speed) will appear in the IPM window. Note that the initial starting speed will jump to 100 ipm for 2-seconds and then will go to its preset value. This setting is shared by both torches.

b. the Gas PURGE (Abort Reset) position provides

the following when actuated: (1) 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. It also allows you to look at a pair of numbers that will

have a bearing on the quality of starts as explained in Section 3.4-B-5.

(2) 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.

(3) Actuating the Purge (Reset) key during a

weld, allows you to check the factory-preset numbers that determine the quality of the “arc starts” for each of the four (4) possible weldingconditions. These numbers are displayed in the IPM and VOLTS windows and represent the optimum arc starting (servo) characteristics required for most welding applications. This diagnostic feature is fully explained in the troubleshooting Section 4.2-G.

3.3 GAS/WIRE ADJUSTMENTS

The following Digimig 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 Run-Set switch (rear panel) in Set position.

3. With torch connections made as shown in Fig. 2-1, and wire engaged in accessory support, feed wire through torch conduit and into torch as follows: a. 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. b. Remove nozzle and contact tip from torch. c. Hold Inch-Purge toggle in INCH position 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 pres-

sure adjusting knob until the wire feeds smoothly. f. Now, 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, and you can repeat steps b-e.

4. With shielding gas cylinder and torch gas hose connection assembled as shown in Fig. 2-1, 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.

SECTION 3 OPERATION

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.

3.4 SETTING UP WELDING PARAMETERS

A. INITIAL SETUP PARAMETERS

1. Set POWER switch (on rear panel) to ON position to energize Digimig control.

2. Place RUN-SET keylock switch (on rear panel) to SET position to program welding parameters for the torch. After the desired program (following) has been preset, the operator or supervisor is free to weld and make any changes is in the SET position. The RUN position locks-in all parameters.

NOTE

The following parameters (#3, #4, and #5) are shared between the two torches and cannot be setup independently.

Positions

Pos. #6

is reached. To feed the cold wire preset, you must actuate the INCH position of the Inch-Purge (Reset) switch, with the accessory support closed.

4. Set the Rotary switch to Position #1 (Must be set)

to select the Power Source and Slope used for your welding application as follows:

Remember that this must be correctly set to match the Power Source being used and its slope selection.

a. Power Source: operate the left Inc./Dec. switch

until the numeral “300”, “450” or “650” appears in the IPM window. One of these numbers should match the power source being used: “300” designates an SVI-300i cv/cc; “450” would designate a VI-450 or SVI-450i and “650” would designate a V650 cv/cc. (see section 3.2-6-a.)

b. Slope: operate the right Inc./Dec. switch to set the

appropriate slope characteristic set on your power source. One of three slope designations will appear in the VOLTS window; #1 for Flat, #3 for Medium, or #6 for Steep Slope. Make sure the

feeder slope number matches the slope selected at the power source. (see section 3.2-6a)

5. You can also select (optional) Trigger Lock-In

(see Section 3.2-3A); however, remember when

added (“on”), both torches are locked in.

B. PROGRAM FIRST (e.g. RIGHT) TORCH

3. To set a “cold wire inch speed” parameter (optional), open the accessory support (so as not to feed

wire) and then raise and hold the toggle of the INCHPURGE switch. (The IPM display window will immediately show a speed setting of 100 ipm for 2-seconds, and then the preset rate following). Now, also raise and hold the toggle of the "left" Inc/Dec switch in its INC position until the desired inch speed setting (e.g.: 75 ipm) appears in the IPM window. Note that the cold inch setting starts at 40 ipm and rapidly increments (1 ipm at a time) until the desired setting

After the initial setup has been completed, you can program the welding parameters for the Right torch as follows:

1. To set-up the “Right” torch program circuitry,

actuate and immediately release its trigger switch lever.

2. Set the Rotary Switch to Position #2 (Must be set)

to select the wire Material and Wire Diameter used for your welding application as follows:

Remember, this must be set correctly to match the wire material and diameter being used.

a. Material: operate the left Inc./Dec. switch to set

the wire Material you intend to use. One of three Material designations will appear in the IPM window; #1 for carbon or stainless steel, #2 for 4000 series, aluminum, or #3 for 5000 series aluminum.

SECTION 3 OPERATION

Match the Material number to the wire type being used. (see 3.2-6-b)

b. Wire Diameter: operate the right Inc./Dec. switch

to select the Wire Diameter you intend to use. One of five diameter designations will appear in the VOLTS window; #30 for .030" dia., #35 for .035" dia., #45" for .045" dia., #52 for .052" dia., or #63 for .063" dia. Match the Diameter number to the wire diameter being used. (see 3.2-6-b)

3. Set the Rotary switch to the RUN (Sch. I) Position #6 (Must be set), and then program the following: a. To set the Wire Feed Speed parameter, raise

and hold the toggle of the "left" Inc/Dec switch in its INC position until the desired hot wire speed (e.g.: 185 ipm) appears in the IPM window. Notice that this parameter will start at zero and immediately jump to 20 and then will rapidly increment (ipm at a time) until the planned wire speed setting is reached.

b. To set the Arc Voltage parameter, raise and hold

the toggle of the “right” Inc/Dec switch in its INC position until the desired arc voltage (e.g.: 17.9 volts) appears in the VOLTS window. Notice that this parameter will start at zero and immediately jump to 12 and then will rapidly increment (1/10 volt at a time) until the desired arc voltage setting is reached.

4. The following parameters are “optional” functions which can also be added to the torch setup: a. A Second Schedule (II). Set the rotary switch to

Position #4, and program another set of conditions as described in B-3 above and in Section 3.2-6d.

b. Preflow/Postflow function. Set the rotary switch

to Position #5, and program as described in Section 3.2-6e.

c. Spotweld/Burnback function. Set the rotary

switch to Position #3, and program as described in Section 3.2-6c.

5. Using the torch switch, the parameters for Schedules I and II (of the selected torch) can be weldtested and if necessary readjusted to provide stable

start and welding conditions.

crease the initial arc striking voltage to optimize starting. The following procedure (5-A) allows you to make this correction.

5A. Setting Controller For Optimum Starts.

1. Increase Starting Voltage;

a. Prior to striking the arc, depress the Purge key on

the right side of the feeder. This can be done in either the RUN (Sch. I) or Sch. II mode of the Rotary switch.

b. Initially, the display in both windows will show the

number 100. This number has an adjustment range of 0 to 200, so that 100 is right in the middle of the range.

c. To increase the starting voltage by 1-volt, the

number in the right (VOLTS) window must be increased to 105 using its Inc./Dec. key.

d. To see if this adjustment is adequate, start a new

weld and observe the start. If it is still not “hot” enough, increase the adjusted number until the starts are optimized.

e. The number in the left (IPM) window controls initial

motor speed and, in most cases, the number 100 will work well for the whole speed range.

2. Decrease Starting Voltage.

a. Follow the same procedures outlined above (in 1),

but instead of increasing the numbers decrease them until the starts are optimized.

Please note that if either schedule for either torch required a voltage adjustment to the present condition, you will more than likely require additional adjustments when a different condition is used.

C. PROGRAM REMAINING (e.g. LEFT) TORCH

If you wish to program a different set of conditions for the remainng (or left) torch, simply “click” its trigger switch lever and then repeat the procedures outlined in the preceding section B-2 through B-5.

3.5. WELDING OPERATION

NOTE: The control is designed to provide excellent

starting characteristics with the latest ESAB inverter power sources. However, arc starting

can be affected by many external factors such as cable length, type of torch used (water versus gas cooled), shielding gas, condition of weldment, type of welding wire, etc. To minimize the effect of these variables, a simple adjustment will allow you to increase or de-

After the desired welding modes have been weld-tested (with control to SET position) and satisfactory results achieved, the program parameters can be "lock-in" by placing the key switch in the RUN (Lock-In) position. In the Lock-In position, and the key removed, none of the preset parameters can be changed.

CAUTION: Power source contactor becomes ener-

gized the moment the torch trigger is de-

SECTION 3 OPERATION

shutdown if preset wire speed or arc voltage parameters cannot be maintained due to an abnormal condition. If

Pos. #6

Positions

this occurs, the parameter causing the system shutdown will be signaled by a flashing digital display window. To clear the shutdown/abort, activate the RESET position of the Inch-Purge (Reset) switch on the front panel.

To stop welding if the Trigger-Lock-In feature is actuated (on), simply repress the torch switch lever

again and all welding action will cease.

Whenever you wish to change torches for a different set of welding conditions, simply stop welding with one torch and energize the torch switch lever of the other torch to actuate its programmed circuitry.

pressed. Arcing can occur if the wire touches a ground. Keep torch away from metal ground until welding is to begin.

A. WELDING

Assuming that both Schedules (I and II) for each torch have been preset per section 3.4, the operator simply places the ROTARY switch to the schedule (I or II) he chooses to use first.

To start welding, select either of the two torches and close its torch switch lever to utilize the previously selected welding Schedule (I or II)—please remember that if gas preflow time is programmed, the arc will not establish until the preflow has timed-out. If during the “selected” schedule welding, the torch switch lever is released and reactivated within 2/10 of a second, the microprocessor will automatically switch the control to the "remaining" schedule parameters for the selected torch. Using this simple “click-click” (off-on) cycling action, the operator can easily shift back and forth between Schedules I and II by sequencing the torch lever within the 2/10 second time frame.

B. SPOTWELDING

Remember, if a spotwelding operation is desired, the Spot-weld-time can be programmed into either Schedule (I or II) for either or both torches; and that when programmed, the ”click-click” 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 Rotary switch selector to the desired Schedule (I or II) for that torch.

To start a spotweld operation; close the torch switch to energize gas flow, weld contactor, wire feed motor and start spot timing cycle. The torch switch must be depressed during the entire weld period. After the spot timing cycle is completed; all welding action, except auto-antistick or burnback and postflow will stop when the torch lever is released.

To resume normal (continuous) welding operation in Schedule I and II for either or both torches, you must deactivate the Spot mode by resetting each “timed-arc” parameter back to zero (000).

Remember, if Trigger-Lock-In is actuated, it automatically overrides the alternate Schedule and/or Spotweld function if programmed (see 3.2-3a).

To stop welding, (w/o Trigger-Lock-In), simply release the torch switch lever and do not reactivate (all services will shutdown except auto-antistick or manual burnback and postflow). After welding has been stopped, the control will always recycle back to the “selected” schedule welding parameters. The system will also

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 welding current through the safety ground wiring, resulting in burnout of that wiring and/or damage to the feeder circuitry. If the safety ground burns out, the operator may be exposed to 115-volt shock hazard.

SECTION 4 TROUBLESHOOTING

4.1 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 trade-in 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.

4.2 TROUBLESHOOTING GUIDE

A. General

1. Check interconnection between digimig 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 will appear in the IPM and VOLTS 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 EProm 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. Then, the Power Source and Slope settings will flash for 3 seconds.

4. After the four (4) 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 110-volt power with the other hand.

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 T118 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 Digimig’s I/0 Board, and then release the clapper arm (pressure roll) on the Accessory Support Assembly.

a.Operate the Digimig 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.

SECTION 4 TROUBLESHOOTING

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 Digimig — 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.

TP2 TP1

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 strobe pickup 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 oper-

ated.

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. 4-1). 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 digimig.

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.

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 speed and voltage conditions (servos) need to be checked for each of the four (4) possible schedules and, if necessary, readjusted as follows:

1. This symptom can of occur as a result of either or all of the following; the factory-set Speed and Voltage (servo) adjustments are incorrect and the conditions

Fig. 4-1 - Input/Output (110) P.C. Board

“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

Digimig is connected to suitable ESAB power source in order to obtain the necessary o.c.v. (open circuit voltage); otherwise, the motor will not run.

2. The factory-set Speed and Voltage (servos) adjustments in this control are simultaneously checked and displayed by actuating and holding the front-panel Purge (Reset) key 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 pro-

vide 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), actuate the Purge (Reset) switch position and close the torch switch lever. Check the number in the IPM window — it may appear unsteady but readable and should be about 110.

If it is higher or lower, use the Inc/Dec toggle (below the IPM window) to adjust the number to 110 - while “holding” the Purge (Reset) toggle as mentioned above and while the wire feed motor is running.

SECTION 4 TROUBLESHOOTING

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 need to be replaced 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, actuate the Purge (Reset) switch 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 Digimig 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 Digimig control.

e. Check the control wires in the interconnecting

voltage control cable for continuity between the appropriate terminals in the power source and digimig 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 Detec-

tion — 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.

SECTION 4 TROUBLESHOOTING

Fig. 4-1. Schematic Diagram - Dual Digimig

30914-L

SECTION 4 TROUBLESHOOTING

30915-N

Fig. 4-2. Wiring Diagram - Dual Digimig

SECTION 5 MAINTENANCE

5.1 GENERAL

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.

5.2 INSPECTION AND CLEANING

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 cable 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 Digimig’s MPU board contains an integral 4-rocker “dip” switch (SW1) that is factory-set to the following positions: Rocker #1, #2, 3, 4 are all OPEN. The microprocessor technology utilized by the Digimig 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.

SECTION 6 REPLACEMENT PARTS

6.1 GENERAL

Replacement Parts are illustrated on the following figures. When ordering replacements parts, order by part number and part name, as illustrated on the figure. DO NOT ORDER BY PART NUMBER ALONE.

Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.

6.2 ORDERING

To assure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB distributor or from:

ESAB Welding & Cutting Products Attn: Customer Service Dept. PO Box 100545, Ebenezer Road Florence, SC, 29501-0545

Be sure to indicate any special shipping instructions when ordering replacement parts.

To order parts by phone, contact ESAB at 1-803-6645540 or 4460. Orders may also be faxed to 1-800-634-

6548. Be sure to indicate any special shipping instruc-

tions when ordering replacement parts.

Refer to the Communication Guide located on the last page of this manual for a list of customer service phone numbers.

SECTION 6 REPLACEMENT PARTS

(2) ACCESSARY SUPPORT ASSY.

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

LEFT TORCH (J4) RECEPTACLE -

6-POS. ROTARY SW. - 679914

CONTROL ASSY.

30913 (see Fig. 7)

C16 CAPACITOR

182W64

672348

COVER - 30170*

WARNING DECAL - 2091514*

FRONT CONTROL SUPPORT - 30917

WARNING DECAL - 995204*

RIGHT TORCH (J3) RECEPTACLE

182W64

(C10, 11) CAPACITOR

672348

(2) EH-10A DIGITAL MOTOR-GEAR

UNIT ASSY. 679777 (See Fig. 6)

BASE - 678806

Fig. 6-1. DigiMig Dual Wire Feeder, P/N 30912 (Front View)

LIFTING BRACKET - 30916

(SW1, 3, 5) SWITCH - 950087 

SECTION 6 REPLACEMENT PARTS

(VR) VOLTAGE REGULATOR includes:

VOLTAGE REGULATOR - 950159

TRANSISTOR SOCKET - 950158

(C4) CAPACITOR - 995544

(2) REEL SUPPORT - 634288

(2) SPINDLE ASSY.

948259 (See Fig. 9)

POWER CABLE ADAPTOR BLOCK -

674156

1/2-IN.-13 STL. NUT

1/2-IN. LOCKWASHER

(2) 1/2-IN. FLATWASHER

(J1) RECEPTACLE - 950762 (19-pin)

C20 CAPACITOR - .1uf, 500 V

(SW) TRIGGER-LOCK - 950492

634517 

(MSL) POWER ON-OFF SW

(CB) CIRCUIT BREAKER -

950874 

RUN-SET SW - 950956

(2) GAS SOLENOID VALVE - 2062305 

(2) GAS INLET CONNECTION - 74S76

(2) GAS BULKHEAD ADAPTOR - 58V58

STRAIN RELIEF - 96W76

KNOCKOUT OPTIONAL

Fig. 6-1. DigiMig Dual Wire Feeder, P/N 30912

WATER CONNECTIONS (See Fig. 10)

REAR CONTROL SUPPORT

Not Illustrated — Accy. Support

INSULATOR RING - 60N90

Key - 28N33

678802

THUMBSCREW - 61351087

FLATWASHER - 64309431

BELLEVILLE WASHER - 950783

worn or lost when replacing panel(s)

* Replace decal if it becomes excessively

Replacement key for Run-Set SW - 32778

 Recommended Spare Parts

SECTION 6 REPLACEMENT PARTS

TACH. P.C.B.D. 675429 (2) Screw-61324746

TACH DISK 950313

MOTOR END HOUSING

TACH COVER - 18787 (2) Screws 61324974

Gear Case Lubricated with Texac Multifak Grease

(Ref.) 54" LG

11.6

VENT PLUG

3.25

2.875

.020 REF

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

Fig. 6-2. EH-10A Digital Motor-Gear Unit Assembly (40:1) P/N 679777

11 BRUSH END BELL - 19732

GEAR ASSY. "B" - 20293

(Includes TWO BRUSH HOLDER ASSYS.)

4.010 SQ.

2.25

2.000

MTR. LEAD

FOR MOTOR REPLACEMENT PARTS (See Fig. 6-3)

1.375 1.375

.25

5.16 18 UNC 2B

63 MIN. DEPTH

2.86

.25

OUTPUT SHAFT ASSY. (Part of 19734

- OUTPUT GEAR CASE

OUTPUT GEAR CASE 19734 (Includes Output Shaft Assy. Shown Above)

GEAR ASSY. "A" 20292

MAGNET ASSY. 19730

ARMATURE SHAFT SEALz

OUTPUT GEAR CASE GASKET

ARMATURE & BEARINGS 19726

Includes: ARMATURE BEARINGS 20288

OUTPUT SHAFT SEALz

Fig. 6-3. EH-10A Motor-Gear Unit Parts Breakdown

MOTOR CORD LEAD - 19731

BRUSH HOLDERzz

BRUSH

CAP

(2) CARBON BRUSH REPLACEMENT KIT - 679784 Includes: (2) BRUSH CAP (2) CARBON BRUSH

zGASKET/SEAL KIT - 20542 (Includes those items market with)

SECTION 6 REPLACEMENT PARTS

"J" GOV P/C BOARD

ASSY. - 994236 (See Note)

MTG Bracket 995297

* Replace decal if it becomes

 Recommended Spare Parts

excessively worn or lost.

NOT touch or ground while unit is energized.

NOTE: The heat sinks of the "J" gov. board are electrically hot. Do

(T1) 20 PT. Terminal

Strip - 950182

(P1) Receptacle 636608

DISPLAY P/C BOARD 

ASSY. - 675269

WARNING DECAL -

995164*

For Replacement Battery (on I/O Board), order P/N 951733

(I/0) P/C BOARD ASSY. - 674956

(I/0 P4 To MPU P2 CABLE ASSY. 677938

(GRF) SENSOR - 950448

(Mtd. on Cabinet Base)

- 994303 

(CTR1) BOT. CONT. TRANSFORMER

- 950088

(CTR2) TOP CONT. TRANSFORMER

(FN1) FILTER NETWORK - 996918

(R1) RESISTOR - 17240003 

(25W, 3 Ohm)

(MPU) P/C BD. ASSY. - 18163 

(RLY) RELAY - 951089 

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

BR-RECTIFIER - 2 Amp., 400 V - 635152

Fig. 6-4 DigiMig Dual Control Assembly, P/N 30913

SECTION 6 REPLACEMENT PARTS

CLAPPER - 60N98

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

INLET

INLET WIRE GUIDE

29N13

INLET GUIDE INSERT

05N58

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

SUPPLIED

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

28V52

NUT 5/16"-18

SHAFT - 60N65

KNOB - 60N68

LIGHT SPRING 182W55 (FOR

SOFT & SMALL DIA. HARD WIRE)

RETAINER 58N24

FORK - 49V43

WIRE OUTLET GUIDE INSERT*

CONDUIT

OUTLET

WIRE OUTLET GUIDE* (See Table 1)

CLAMP - 61N02

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

SCREW 5/16" -18 X 2" LG

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

WIRE REEL - 995570 Includes: REEL - 995568 COVER - 995569 (4) WING NUT, 1/2" - 13 63398183

(Ref. Hair Pin Clip)

REEL

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

SPINDLE - 948258

"D" TYPE WASHER - 948254

SPRING - 948253

SUPPORT 948257

(2) BRAKE PAD - 948255

SPINDLE

Fig. 6-5. Accessory Support Assembly, P/N 49V51

WATER CONNECTION

SCREW 5/16" -18 x 2"

58V75 (OUTLET)

HAIR PIN CLIP - 634347

WASHER -

5/8 -18 Lh

948256

WITHOUT SOLENOID VALVE

COUPLING - 68121075

ADAPTOR - 11N16 (INLET)

5/8 -18 Lh

1/4 N.P.T.

Fig. 6-6. Spindle Assembly, P/N 948259,

Optional Wire Reel, P/N 995570

Fig. 6-7. Water Kit, P/N 994466

NOTES

INSTRUCTIONS for

REMOTE CONTROL KIT

For V 452, V 582, V 652cvcc and V 782cvcc Power Sources

Item No. 36010

F-15-286

December,

1995

This kit, when installed, permits the use of the HC-3B Remote Pendant Control (I/N 33838) with the power source.

To Install, proceed as follows:

Before installing this kit, make sure all primary input power to the power source is disconnected and/or lock out procedures are in place.

1. Remove the left side panel of the power source.

2. Remove the plastic cover from the REMOTE CONTROL location on the front panel of the power source.

3. Remove the two screws from the upper corners of the control panel on the power source and open the control panel.

4. Install the 14-pin receptacle into the front panel from the inside and secure with the four screws provided with the kit.

5. Locate the control leads access grommet to the control panel. Insert the connector from the 14pin receptacle through this grommet. Route the leads along with the other control leads and secure with tie-wraps provided with the kit.

6. Connect the connector from the 14-pin receptacle to the J4 header on the control PC board (see Fig. 1). Make sure the connector is firmly connected.

7. Reinstall left side panel and the upper control panel. The power source is now ready to operate with the HC-3B Remote Pendant Control.

J4 Header

Fig. 1. Control Board Assembly (located behind Control Panel)

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST

Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:

Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST

Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:

Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST

Part Numbers Technical Applications Specifications Equipment Recommendations

D. LITERATURE REQUESTS:

Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST

Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING

Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST

Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070 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

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

visit us on the web at http://www.esabna.com

The ESAB web site offers

Comprehensive Product Information

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F-14-489-C 09/2003 Printed in U.S.A.

ESAB Digimig Dual Wire Feeder Instruction manual

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User Manual