ESAB Digimig Wire Feeders Troubleshooting instruction

INSTRUCTIONS for
DIGIMIG 2 Roll Drive pictured above.
Input Power Required .............. 115 volts, 50/60 hz, 7 amp., 1 ph.
Wire Feed Speed Range ............ 20-999 in./min. (.5-25.2 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 ............................................................... 18.5-in. (470 mm)
Width ................................................................... 13-in. (330 mm)
Height ............................................................... 16.5-in. (419 mm)
Weight (less wire) ................................................. 46 lbs. (21 kg)
INTRODUCTION
The ultimate in semiautomatic mig welding and control is DIGIMIG wire feeders. These microprocessor de­signed controls are the most technologically advanced and functionally complete wire feeders offered in the welding marketplace.
A. FEATURES/BENEFITS
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microprocessor accuracy — the microprocessor, the control-
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ling “brain” of the Digimig operates exclusively on drift free digital logic, unlike competitive systems. The digital logic delivers extraordinarily precise computer-accurate weld pa­rameter control, and weld consistency.
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microprocessor flexibility — in contrast with competitive digi-
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tal systems that require additional printed circuit boards and hard wiring whenever a feature or function is to be added, the DIGIMIG incorporates electronically reprogrammable mod-
F-14-481-B
ules; by simply reprogramming this small plug-in module, many existing functions may be extended or new features may be added.
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microprocessor reliability — Digimig Wire Feeders have proven
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to be rugged and reliable in test after test for absolute minimum downtime.
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presettable wire feed speed (ipm) and voltage (volts) —
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provides ability to easily and accurately preset the exact welding parameters desired, before the welding sequence begins.
F-14-481-B
April, 1995
DIGIMIG
WIRE FEEDERS
DIGIMIG 2-ROLL DRIVE, P/N 30784 DIGIMIG 4-ROLL DRIVE, P/N 30785 (See Suppl. 12-821)
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.
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patented microprocessor controlled closed loop system -
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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.
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sure start interlock — to assure troublefree starts, the Digimig
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individual digital LED meters provide large 1/2-in. readout of
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voltage and wire feed speed — continuous display of preset and then actual welding voltage and wire feed speed for accurate observation.
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dual schedule capability — enables operator to have two
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different sets of weld parameters at his fingertips; Digimig’s microprocessor allows operator to change schedules with a simple “click-click” squeeze of a standard torch trigger switch.
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“lock-in” key - allows preset welding parameters to be “locked-
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automatic “shut down” — assures welding is done at the
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preset parameter; 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.
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arc hours readout — this unique feature provides direct
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measure of “productivity’ by accumulating and displaying, upon command, actual welding arc hours.
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automatic adaptive anti-stick or manual burnback time feature
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— 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 “burnback time” 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 anti­stick by setting a specific burnback time.
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adjustable “hot start” characteristic.
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spot weld timer - because the spot weld timer is adjustable up
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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.
Be sure this information reaches the operator. You can get extra copies through you supplier.
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gas pre and postflow and cold wire inch capability - gas pre and
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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 down time.
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circuit protection - resettable circuit breaker for input power
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minimizes downtime and maintenance.
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EH-10A permanent magnet motor - provides the highest torque,
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fastest response, and best efficiency of any mig p.m. motor on the market.
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patented closed loop “J” governor/optical tachometer - pro-
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vides most accurate means of maintaining wire feed speed and voltage, regardless of any voltage drop or drift.
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dc straight or reverse polarity capability - because the Digimig
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is factory-wire for use with either dcrp or dcsp without making control wiring changes, the process flexibility of the Digimig is further extended.
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trigger lock-in - allows the operator to release the torch switch
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lever during long welding cycles for easier torch manipulation and less operator fatigue.
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“Cold” servo adjustment allows setting controller for optimum
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Hot start characteristic.
B. DESCRIPTION
The digimig is a microprocessor controlled digital wire feeder designed for mig short arc and spray arc, and flux cored welding applications. It 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.
The Digimig offers many features not available in con­ventional wire feeders. It allows the customer to preset both welding parameters, lock-them-in and be assured that each setting will be precisely held regardless of changes in line voltage, arc or load conditions. If more than one setup is required to complete the welding operation, the Digimig also allows you to preprogram two different sets of welding conditions — two wire speed settings and two arc voltage settings. Alternate switching between (RUN Pos.) schedule I and II is controlled by operating a standard torch switch - press (and hold) the torch lever once and you’re in Schedule I; release and repress the torch lever within two-tenths of a second, and you're in Schedule II. For additional
information regarding settings, adjustments and se­quencing of the welding modes and controls, refer to Section V, VI and VII of this booklet.
Two digital readout windows continuously display (1/2­in. high) the preset welding parameters (speed and voltage) as determined by the schedule mode switch. After the arc is struck, they automatically display the actual wire speed and arc voltage conditions for the selected schedule. The readouts can also provide selectable displays of other welding parameters such as inching speed, spot time in cycles, manual burnback time in cycles, gas pre-and postflow times.
The Digimig uses a heavy duty EH-10A wire drive motor designed to feed hard or soft wire from .023-in. to 1/8­in. 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.
All interconnecting cable, hose and auxiliary equipment connection are quickly detachable to provide easy setup and maximum portability of the wire feeder as shown in Figs. 2 & 3. A water kit may be purchased, as an optional accessory, for use with the water cooled torch operation.
II. REQUIRED EQUIPMENT
A. CONSTANT VOLTAGE POWER SOURCE
The Digimig is specifically designed for use with con­stant voltage (C.V.) power sources utilizing “electroni­cally controlled voltage regulation”. One of the appropri­ate Power Sources (following) and its slope require­ment must be matched to Position 1 (IPM and VOLTS window displays respectively) of the six-position Rotary
SPINDLE ASSY.
LEFT DIGITAL READOUT IPM
6-POS. ROTARY SELECTOR SW
LEFT INC./DEC. SW.
ACCY. SUPPORT ASSY.
EH-10A MOTOR GEAR UNIT w/TACHOMETER
RIGHT DIGITAL READOUT VOLT
INCH-PURGE (RESET) SW.
RIGHT INC/DEC SW
TORCH SW. RECPT.
LOCATION FOR OPT WATER CONNECTIONS
POWER ON-OFF SW
GAS SOLENOID CONNECTION
POWER CABLE ADAPTOR BLOCK
Fig. 1 - DIGIMIG Wire Feeder (front and rear view)
2
TRIGGER-LOCK SW
RESET CKT. BRK.
J1 CONTROL RECPT.
RUN-SET KEY SW.
selector switch on the control’s front panel (refer to Section V-A-8 for further details on this switch).
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
A multi-conductor control cable assembly is required to connect the Digimig to a power source with electronic voltage control (see Fig. 3).
1. 115 Volt/Contactor/Remote Control J1 Cable, 19­conductor with Amphenol plugs; order one of the following:
a. 6-foot, 19-cond., P/N 30686. b. 30-foot, 19-cond., P/N 30780. c. 60-foot, 19-cond., P/N 30781.
C. WELDING TORCH
A mig welding torch, with contact tip, wire conduit and outlet guide for wire size/type to be employed, will be required. A suitable air (MT-400) or water-cooled (MT­450W, ST-16) torch may be used with the Digimig.
When using a water-cooled torch it will be necessary to connect the torch water hose to either a continuous water supply or to the wire feeder base by using an optional water kit (see Section III).
Table 1
Wire Type- Two Roll Drive Four Roll Drive Outlet Size in./mm Feed Roll Feed Roll Kit* Guide
Soft .030 (0.8) 2075304 (U) 999320 (U) 29N13** .035 (0.9) 2075304 (U) 999321 (U) 29N13** 3/64 (1.2) 2075301 (U)† 999322 (U) 29N13** 1/16 (1.6) 2075298 (U)†† 999323 (U) 29N13** 3/32 (2.4) 2075297 (U) 999324 (U) 29N13**
Hard .023 (0.6) 17998 (V) 999745 .030 (0.8) 2075300 (V) 999325 (V) 993860(a) .035 (0.9) 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 (0.9) 19761 (Serr.) 993860(a) .045 (1.2) 19761 (Serr.) 999330 (Serr.) 39N15(b) .052 (1.4) 2075261 (Serr.) 999331 (Serr.) 39N15(b) 1/16 (1.6) 2075261 (Serr.) 999332 (Serr.) 39N15(b) 5/64 (2.0) 2075261 (Serr.) 999333 (Serr.) 62N17(c) 3/32 (2.4) 2075257 (Serr.) 999334 (Serr.) 62N17(c) 7/64 (2.8) 2075257 (Serr.) 999335 (Serr.) 39N16 1/8 (3.2) 2075255 (Serr.) 999336 (Serr.) 39N17
Require guide bushing P/N 17997 * Includes a center wire guide and 2 upper and 2 lower fed rolls. ** Requires outlet guide insert as follows: For .030 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) Include replaceable sleeve (995651). (b) Includes replaceable sleeve (995692). (c) Includes replaceable sleeve (995693).
D. GAS REGULATION
Shielding gas regulator/flowmeter and fitted hose to bring gas from flowmeter to wire feeder. Such as:
R-5007 Argon/Helium/Nitrogen, P/N 998124. R-5008 CO
, P/N 998125.
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Gas Hoses:
Standard Duty, 40V77 (12-1/2-ft.) or P/N 34V38 (25­ft) Heavy Duty, P/N 19416 (12-1/2-ft)* or P/N 19415 (25-ft.)*.
* Must be used for CO
2.
E. FEED ROLLS
The Digimig comes equipped with a pressure roll but NOT a feed roll. Select the proper feed roll from Table 1 for the wire size and type to be used.
III. OPTIONAL ACCESSORIES
A. Water Kit (P/N 994466). Permits the convenient
connection of a water-cooled torch and continuous water supply or water cooler to the wire feeder.
The kit 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 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. 10 and Sec. IV-F. Connect the
water-cooled torch as shown in Fig. 2.
B. Lifting Bracket (P/N 634287). Mounts on the wire
feeder spool support between the support and the
spindle assembly. Enables you to mount the wire
feeder overhead on a boom. C. Spool Enclosure Kit (P/N 600240). Provides pro-
tection of spool of wire against dust and dirt. For
installation instructions refer to Form 12-824. D. Standard Wire Reel Assembly (P/N 995570). 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 alumi-
num 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
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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.
Either of two additional accessories are required to complete the installation of the wire inlet side of the straightener: a. Wire Inlet Guide, P/N 11N53, or ­b. Wire Wiper Holder, P/N 598763.
G. Wire Spool Spacer (P/N 548378). Enables the use
of a 8-in. diameter spool of welding wire with spindle assembly on the Digimig wire feeder.
H. Four Roll Drive Accessory Support Assembly (P/
N 600216). This assembly (illustrated in booklet F-
12-821) utilizes four feed rolls to provide the back-up force necessary for positive nonslip wire feed. It is designed for feeding .030 through 1/8-in. diameter wire(s). Feed rates using the four roll drive assembly are virtually the same as with the two roll assembly. For feed roll/outlet guide accessories refer to F-12­821 or Table 1.
I. 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 115/230 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 contractor
- the cooling efficiency of the unit will be hampered and the starting winding in the pump motor may burn out.
J. 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 or a trim­power cart. A 1.5 gallon capacity tank provides 1.0 gal/min @ 50 psi, using 115/230 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 contractor - the cooling efficiency of the unit will be hampered and the starting winding in the pump motor may burn out.
K. Wire Feeder Mobile Undercarriage Kit, P/N 680005.
This kit includes a mounting plate and caster type wheels to provide a complete mobility of the wire feeder (see F-14-322).
L. 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).
IV. INSTALLATION
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.
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 Digimig’s rear panel to the power source as shown in Fig. 3.
B. TORCH CONNECTIONS
Attach torch gas hose to gas connection. Plug in torch switch cable and lock by twisting. After inserting
TORCH CONDUIT
TORCH SWITCH
TORCH GAS HOSE
WATER “DRAIN” HOSE - 40V76 (12-1/2 Ft.)*
WATER “IN” HOSE - 40V76 (12-1/2 Ft.)*
FRONT VIEW
TORCH POWER CABLE
WATER KIT 994466*
ADAPTOR ­45V11*
Power Cable Adaptor Assy ­634693
REAR VIEW
STRAIN RELIEF
GAS HOSE ­40V77 (12-1/2 Ft.) 34V38 (25 Ft.) See Sect. II-D
J1
Fig. 2 - Torch and Service Interconnection Diagram
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REGULATOR/ FLOWMETER
* Parts required when using a Water Kit & Water Cooled Torch.
REAR VIEW DIGIMIG
J1 CABLE†
J1
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 II-B.
* 4/0 welding cables (customer supplied) are set-up for DCRP, (NEG. TO WORK) operation.
Fig. 3 - Welding and Control Interconnection Diagram
POWER CABLE ADAPTOR BLOCK
4 0 WELDING CABLE*
RECPT.
TO WORK*
conduit liner (if used) and attaching wire outlet guide of correct size, connect wire feed conduit to welding head clamp and lock in place. Connect torch power cable to power source, or to power cable adaptor block (with a second cable from that block 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, bell washer, and flat washer from the feed roll shaft.
3. Slip the feed roll on the shaft, engaging the key. Be sure to observe the “THIS SIDE OUT” marking on the feed roll.
4. Replace flat washer, bell washer, and thumbscrew, 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 assem­bly as described in Section E.
6. When wire coils are to be used instead of spools, mount wire reel on spindle as though 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 brake screw and thread wire to torch as covered in 4 and 5 above.
E. ADJUSTING THE ACCESSORY SUPPORT AS-
SEMBLY (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 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 spring (182W54) supplied with the unit.
F. WATER KIT (Optional see Fig. 10)
Mount bulkhead adaptor (58V75) behind opening pro­vided in vertical base plate, above gas connection, and secure with screws (No. 8 — 32 X 3/8 in.) and lockwash­ers provided. Attach coupling and adaptor (11N16) behind 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.
V. ADJUSTMENTS
Do not allow metal-to-metal contact between the wire feeder chassis and a metal surface connected in any
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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.
A. CONTROL FUNCTIONS For location of rear panel control features, refer to Fig. 4.
1. Power Switch - this two-position toggle switch turns
power “on” or “off” to the wire feeder control.
2. Lock-In 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, Spot). After the desired results are achieved, the program(s) can be “locked-in” by turning the key to the RUN position. No parameters can be altered by the operator in the RUN position.
3. Trigger Lock-In Switch. This allows the operator to release the torch switch (trigger-lock “on”) after start­ing the welding cycle in Schedule of your choice (I or II). To stop the welding cycle, you simply depress the torch switch again and all welding action ceases. When this function is ON it automatically overrides the ALTERNATE (or second) schedule and/or a Spotweld operation if programmed. An indicator light (LED) on the front panel will indicate that the Trigger Lock-In feature has been engaged. In the OFF position, this feature is not functional, and the LED is off.
Fig. 4 - Rear Panel Controls
4. 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.
For location of the following front control features, refer to Fig. 4A.
5. 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 inches per minute in one inch increments. However, with the appropriate Rotary switch func­tion actuated, this window can also display the following: — Power Source selected and designated by the
numerals “300” or “450” (see Rotary Switch, Item 8).
— A code number indicates a type of MATERIAL
programmed for various welding wire applica­tions; #1, #2, or #3 (see Rotary Switch, Item 8).
— shielding gas PREFLOW from .1 to 99.9 sec-
onds in one tenth of a second increments
— SPOT welding time from 1 to 999 cycles in one
cycle increments.
— cold wire INCH speed in IPM from 20 to 999
inches per minute in one-inch increments
NOTE: With the power turned “on” but not welding, 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 switch 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 8).
— a pair of numbers represent WIRE DIAMETER
sizes which are programmed for slelection as follows: #23, #30, #35, #45, or #63 (see Rotary Switch, Item 8).
— shielding gas POSTFLOW from .1 to 99.9 sec-
onds in one tenth of a second increments
— Manual BURNBACK time. Manually adjust-
able 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 Adaptive Anti-stick fea­ture will be operational.
NOTE: With the power turned “on”, but not welding, the
VOLTS window will “continuously” read Preset
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Fig. 4A - Front Panel Controls
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.
6. LED light. This LED lights to indicate that Trigger Lock-In, is engaged.
7. Inc/Dec. Toggle Switches. Two control toggles are provided to preset the individual welding parameters required for the selected welding mode Schedule I (RUN), Alt. Sched. II or Spot/B.Back, 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; Power Source selection, Material selection, Preflow, Spot (cycles) and Inch. With the 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: Slope selection, Wire Diameter selection, Postflow and Burnback (Cyc). With the appropriate function selector actuated, each parameter setting (or record) will be displayed in the digital window directly above this toggle.
8. Rotary Parameter Switch. This six (6) position switch allows you to select a “pair” of welding parameters“ per position” as follows:
(1) Power Source. Four power sources as avail-
able for use with this feeder. The choices are, the SVI-300i cv/cc and this is designated by the numeral “300”; and the VI-450, or the SVI­450i, or the V-650 cv/ccc and these are desig­nated by the numeral “450”. The Power Source “numeral” designation selection is displayed in the left (IPM) window, and set using the IPM INC/DEC toggle switch.
(2) SLOPE. This feeder is designed to provide the
correct output to the selected power source using any of three slope characteristics: 1­volt/100 amperes, designated by numeral “1” for FLAT; 3-volts/100 amperes, designated by numeral “3” for MEDIUM; or 6-volts/100 am­peres, designated 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. Please note that the feeder slope
selection must always match the slope out­put selected at the power source. To select
the appropriate slope for the available power sources, use the following: SVI-300i cv/cc, use slope 1, 3 or 6; for V-450, use slope 1 or 3; for SVI-450i, use slope 1, 3 or 6; and for V­650 cv/cc, use slope 1.
b. Position 2, Material/Wire Diameter. This posi-
tion sets the wire Material type and wire Diameter size which are preprogramed in the feeder for a wide variety of welding combinations. 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 “numerals” that can be used, and is set by operating the IPM INC/DEC toggle switch. Material numeral “1” is for Carbon or Stainless Steels, numeral “2” is for the 4000 aluminum series, and numeral “3” if for the 5000 aluminum series of 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 use, and is set by operating the VOLTS INC/DEC toggle switch. The wire size selec­tion designations available are: “23” for .023" dia., “30” for .030" dia., “35” for .035" dia., “45” for .045" dia. and “63” for .063" dia wires.
a. Position 1, Power Source/Slope. This position
sets the designated Power Source selected for use, and its operating Slope requirements. These selections will be displayed in the IPM and VOLTS windows respectively and are set as follows:
c. Position 3, SPOT TIME/BURNBACK TIME. This
position allows you to preset either or both of these welding features in a weld condition. If pro­grammed, these parameter times will be dis­played in the IPM and VOLTS windows respec­tively, and are set as follows:
7
(1) SPOT TIME. The spotweld time mode is al-
ways programmed into the Schedule I (RUN position) welding parameters. These preset “time-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 is programmed into the control, all “continuous” welding programs are temporarily disabled. To resume normal program operation in the first or alternate Schedules you must deactivate the spotweld mode by keying its “timing¨ parameter back to zero (000).
(2) BURNBACK TIME. At the same time, you can
also preset a manual Burnback time mode into the VOLT window using its Inc./Dec. toggle switch. The Burnback time is adjust­able in one cycle increments (60 cycles/sec.); and when preset, the Burnback time will over­ride the automatic adaptive anti-stick feature in either welding schedule. To resume auto­matic anti-stick operation, the Burnback time must be set back to “zero” (000).
d. Position 4, SCHEDULE II/SCHEDULE II. This
position allows you to preset the parameters for 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 requirement is set using the right INC./ DEC. toggle switch and the setting will appear in the VOLTS window. Operation of the SCH. I (RUN Pos.) or SCH. II welding mode is controlled by the double-click operation of the torch switch.
e. Position 5, PREFLOW/POSTFLOW. In this posi-
tion, 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 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.
f. Position 6, RUN (Schedule I). This position al-
lows you to preset the welding parameters 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 appear in the VOLTS win­dow. After all preset parameters have been pro­grammed, the unit is ready to weld. Note that the feeder will only inch wire in the Run position. If two schedules are being used, the operator can choose to start in Schedule II by placing the rotary switch in Position 4 (Schedule II). Schedule I may be switch over to during welding by using the double­click procedure with the torch switch. This same procedure (double-click) is also available if you
remain in the RUN (Sch. I) position.
9. Inch-Purge (Reset) Selector. Operating this toggle allows the following operations:
a. The INCH selection permits cold-wire inching
without energizing the welding circuit through the torch switch. Initially, when toggled or bumped, the INCH selector will feed cold wire at 20 ipm for 2-seconds and will then begin feeding wire at a preset wire inching speed. A “preset” inch speed can be set and independently controlled (while INCHING) by operating its Inc./Dec toggle switch, and this setting (which is independent of “hot” wire feed) will appear in the IPM window.
b. The PURGE (RESET) position provides the fol-
lowing 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.
(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 two (2) possible weld­ing-condition schedules pre-programmed by the weldor. These factory-preset 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 a “Note” following.
NOTE: This is a diagnostic tool available to the expe-
rienced operator or serviceman and need not be activated during a normal operation un­less you are experiencing weld starting prob­lems, or weld condition (speed and/or volt­age) aborting problems. The factory-set “arc
starting” condition is represented by numbers that are displayed, on command (by simulta­neously actuating the Arc Hrs./Inch Preset and Purge Reset keys during a weld), in the digital IPM and VOLTS windows. Since this welder may have up to two (2) different welding pro­grams scheduled, it may be necessary to check the arc-starting conditions for each program if you have problems. For good welds and starts, these numbers should be in a range from 105 to 115 (with 110 being the norm) in the IPM window, and from 90 to 100 (with 95 being the norm) in the VOLTS window. If your weld starts are not acceptable, please refer to Section VI-
8
B-6 for a simple adjustment procedure that will enhance good starting. If you are experiencing frequent speed and/or voltage aborts, please refer to Section VIII-G (Troubleshooting) for checking and resetting condition (servo) func­tions.
B. 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 (on rear panel) to “on” position to energize the control.
2. Place key-operated Run-Set switch in Set position.
3. With torch connection 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. Remove nozzle and contact tip from torch. b. Hold (or bump) Inch-Purge toggle in INCH position
(Sect. V-A-9) until “cold” wire protrudes from the torch front end.
c. Slide the contact tip over the end of the wire and
secure it to the torch. Replace the torch nozzle.
d. 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.
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 gas hose and torch.
5. Place control’s Power switch to “off” position.
VI. SETTING UP PROGRAM PARAMETERS
A. Two sets of welding parameters can be preset in your
control, one in Schedule I (RUN pos.), and one in the alternate Schedule II (if provided). In the following example, we will use typical parameters for an actual welding condition for Schedule I. Note that the setup procedure for the alternate Schedule II Condition is similar to Schedule I, although the parameter set­tings will be different.
Typical Welding Conditions:
Cold Wire Inch Speed ................................. 75 IPM*
Wire Feed Speed ....................................... 185 IPM
Arc Voltage ..............................................17.9 Volts
Spot Weld Time ....................................... 45 Cycles
Preflow Time ...................................... 1.2 Seconds*
Postflow Time ..................................... 3.1 Seconds*
Burnback Time ..........................................7 Cycles*
* These parameters are shared between Schedule I and the
alternate Schedule II (if provided).
1. Set Power Switch (on the rear panel) to “on” position to energize Digimig Control.
2. Place key switch in SET position to program welding parameters for Schedule I, Alternate or Spot/Burn­back welding operation(s). After the desired pro­grams (following) have been preset, the operator or supervisor is free to weld and make any changes while this switch is in the SET position.
3. To set a Cold Wire Inch parameter of 75 ipm, raise and hold the toggle of the Inch-Purge (Reset) switch in its “up” position. Simultaneously, raise and hold the toggle of the left Inc./Dec switch in its INCREASE position until 75 appears in the IPM windows. Note that the cold inch setting starts at 20 ipm and rapidly increments (1 ipm at a time) until the 75 ipm setting is reached. If you overshoot the planned setting, simply “bump” the DECREASE position of the Inc/ Dec toggle to obtain the exact IPM setting. When preset, this parameter will automatically be pro­grammed or shared with the Alternate Schedule program parameters (if provided).
4. Set the Rotary Switch to Position 1 to select the Power Source and Slope used for your welding application as follows: a. Power Source: operate the left Inc/Dec switch
until the numeral “300” or “450” appears in the IPM window. One of these numbers should match the power source being used: “300” designates as SVI-300i cv/cc; whereas “450” would designate a VI-450 or SVI-450i or a V-650 cv/cc. (see section V-A-8-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 V-A-8­a)
5. Set the Rotary Switch to Position 2 to select the Wire Material and Wire Diameter used for your welding application as follows: 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 steels, #2 for 4000 series aluminum, or #3 for 5000 series aluminum.
Match the material number to the wire type being used. (see V-A-8-b)
b. Wire Diameter: operate the right Inc/Dec switch to
select the wire diameter you intend to use. One of five diameters designations will appear in the VOLTS window; #23 for .023" dia., #30 for .030 dia., #35 for .035" dia., #45 for .045" dia., or #63 for
9
.063" dia. Match the diameter number to the
wire diameter being used. (see V-A-8-b)
B. PROGRAM SCHEDULE I (RUN pos.) PARAM-
ETERS
1. To set a Wire Feed Speed parameter of 185 ipm,
set the Rotary Switch to RUN position and then raise and hold the toggle of the left Inc/Dec switch in its INCREASE position until 185 appears in the IPM window. Notice that this parameter setting will start at zero and immediately jump to 20 and then will rapidly increment (1 imp at a time) until the 185 ipm setting is reached. If you overshoot the planned setting, simply “bump” the DECREASE position of the left Inc/Dec toggle to obtain the exact IPM setting.
2. To set an Arc Voltage parameter of 17.9 volts, set the Rotary Switch to RUN position and then raise and hold the toggle of the right Inc/Dec switch in its INCREASE position until 17.9 appears in the VOLTS window. Notice that this parameter setting will start at zero and immediately jump to 12 and then will rapidly increment (1/10 volt at a time) until the 17.9 volt setting is reached. If you overshoot the planned setting, simply “bump” the DECREASE position of the right Inc/Dec toggle to obtain the exact VOLT setting.
This parameter setting will start a zero and rapidly increment (1 cycle at a time) until the 45 cycle time is achieved. If you overshoot the planned setting, simply “bump” the DECREASE position of the left Inc/ Dec toggle to obtain the desired Spot cycle setting.
4. To set shielding gas Preflow and Postflow time parameters of 1.2 seconds and 3.1 seconds re­spectively, turn the Rotary Switch to the Preflow/
Postflow position and then raise and hold the toggle of the “left” Inc/dec switch in its INCREASE position until 1.2 seconds of Preflow time appears in the IPM window and then; repeat this procedure using the “right” Inc/Dec switch until 3.1 seconds of Postflow time appears in the VOLTS window. Both of these parameter settings will start at zero and rapidly increment (1/10 second at a time) until the desired time is achieved. If you overshoot the planned settings, simply “bump” the DECREASE position of the respective Inc/Dec toggles to obtain the desired Preflow and Postflow time settings.
5. The set a manual Burnback time (if provided) parameter of 7 cycles, turn the Rotary Switch to the
Spot Time/Burnback position and then, raise and hold the toggle of the “right” Inc/Dec switch in its INCREASE position until 7 cycles appears in the VOLTS window. This parameter setting will start at zero and rapidly increment (1 cycle at a time) until planned setting, simply “bump” the DECREASE po­sition of the right Inc/Dec toggle to obtain the desired Burnback cycle setting.
NOTE: The remaining parameters can also be pro-
grammed into the Schedule I mode of opera­tion; however, when preset, these parameters will automatically be programmed or shared with an Alternate Schedule set of conditions (if provided).
3. To set a Spotweld time (if provided) parameter of
45 cycles, turn the Rotary Switch to the Spot Time/
Burnback Time position and then raise and hold the toggle of the “left” Inc/Dec switch in its INCREASE position until 45 cycles appears in the IPM window.
Remember — if a manual Burnback function is programmed, it will override the standard “automatic adaptive anti-stick” feature in either welding sched­ule.
6. Using the torch switch, the Schedule I parameters can be weld-tested and if necessary readjusted to provide a stable welding condition.
As mentioned earlier in the “NOTE” following Section V­A-9, 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 decrease the initial arc striking voltage to optimize starting. The following procedure allows you to make this correction.
SETTING CONTROLLER FOR OPTIMUM STARTS. A. Increase Starting Voltage:
1. 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.
10
2. 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.
3. 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.
4. 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.
5. 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.
B. Decrease Starting Voltage.
Follow the same procedures outlined above (in A), but instead of increasing the numbers, decrease them until the starts are optimized.
Please note that if either schedule required a voltage adjustment to the present condition, you will more than likely require additional adjustments when a different condition is used.
IMPORTANT: If Trigger Lock-In is selected (“on” posi-
tion) it allows the operator to release the torch switch after starting or testing the schedule I welding parameters only. In the ON position, it automatically over­rides the Alternate (or Second) schedule and/or Spotweld operation if provided and programmed. To stop the Schedule I welding cycle, simply depress the torch switch again and welding action will stop. In the OFF position, the Trigger Lock-In is not functional.
7. If a second schedule of welding parameters are
desired, refer to “C” following.
C. PROGRAM SCHEDULE II PARAMETERS (If de-
sired)
To preset a second welding schedule (II) which can alternately be used with Schedule I (RUN pos.), do the following:
1. Set the Rotary Switch to its SCHEDULE II position.
2. Using the left-side Inc/Dec toggle switch, set the wire speed rate (IPM). The desired setting will appear in the IPM digital window.
3. Using the right-side Inc/Dec toggle switch, set the arc voltage requirements (VOLTS). The desired setting will appear in the VOLTS digital window.
NOTE: If a 2nd schedule is not desired, set param-
eters in steps 2 and 3 to zero.
4. With both Schedule I and II parameters preset, the programs are ready to be weld-tested and, if neces­sary, readjusted (in SET position). Both schedules are available by simply sequencing the torch switch lever on and off. Also, see Section VI-B-6 for
quality starts adjustment.
VII. OPERATION
After the desired welding modes have been weld-tested (with control to SET position) and satisfactory results achieved, the program parameters can be “locked-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 de­pressed. Arcing can occur if the wire touches a ground. Keep torch away from metal ground until welding is to begin.
A. WELDING, SCHEDULES I AND II
When the torch switch lever is first activated, the Sched­ule I (RUN pos.) welding parameters will be utilized. If during the first schedule welding, the torch switch lever is released and reactivated within two tenths of a second (2/10 sec.) the Digimig microprocessor will automati­cally switch the control to the Schedule II welding parameters. Using this simple “off-on” cycle action, the operator can easily shift back and forth between Sched. I and II as frequently as desired by sequencing the torch lever within the required time frame (2/10 sec.)
Remember, if Trigger Lock-In is actuated, it auto­matically overrides the alternate Schedule II and/or Spotweld functions if provided and programmed.
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 burnback and post-
11
flow). The system will also shutdown if the preset wire speed on arc voltage parameters cannot be maintained due to an abnormal condition. If this occurs, the parameter causing the system shutdown will be sig­naled by a flashing digital display. When welding has been stopped, the Digimig control will always recycle to the Schedule set on the Rotary selector switch.
To stop welding if the Trigger Lock-In feature is actuated, simply repress the torch switch lever again and all welding action will cease.
B. SPOT WELDING
As mentioned earlier, this feature is programmed in the Schedule I welding mode and its operational sequence follows.
Close the torch switch to energize gas flow, weld contractor, wire feed motor and start spot timing cycle. The torch switch must be depressed during the entire weld period. After the spotweld timing cycle is com­pleted; all welding action, except auto-antistick or burn­back and postflow gas will stop when torch lever is released.
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.
VIII. 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 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.
A. General
1. Check interconnection between digimig control and power source. Make sure that the contractor 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-Proms) used in your control. When a Program is changed, the new E-Proms 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 will be displayed in the IPM and VOLTS windows.
5. If the control is not functioning properly (or as de­scribed above); for example, the number that appear in one or both of the display windows are meaning­less (all zones, 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 surges, 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 110-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 T1-11 and T1-12; 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”:
12
a. The input should be approx. 11 volts between VR-
1 and T1-12. If voltage is not present, replace I/O board.
b. The output should be 5 volts between terminals
T1-11 and T1-12. 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 Selec­tion VI, then;
2. Make sure the key wiring 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 (and/or optional) 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/O Board, and then release 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.
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 the +/-12 vdc are provided from the
power source on T1-10 and T1-8 respectively, T1­9 is common.
d. If power source is OK, replace the I/O and MPU
boards respectively.
TP-2
TP-1
Fig. 4B - Input/Output (I/O) P.C. Board
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 +12v.), and between plug pins P3-4 and P3-2 (for -12v.) 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 schedule and, if necessary, readjusted as follows:
1. This symptom can occur as a result of the either or all of the following; the factory-set Speed and Voltage (servo) adjustments are incorrect and the conditions “set” may not be maintainable. To check and, if necessary, readjust the servo—proceed as follows.
E. Motor runs, but not at right speed.
1. Check tachometer assembly mounted on the end of EH-10 wire feed motor.
2. Make sure the tach disc is securely fastened to the motor shaft and that the strobe markings are not scratched. Check that the disc is properly centered n 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/O p.c. board (see Fig. 4B). This voltage
NOTE: Prior to checking the servos, make sure the
Digimig is connected to a suitable power supply 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) adjust­ment 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 wire feed 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.
13
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) key 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 must 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 supply 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.
IX. MAINTENANCE
If the 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.
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 wire feeder control.
2. Remove the accessory support assembly from the motorgear unit by loosening the capscrew at the bottom of the assembly.
3. Disconnect the motor an tachometer cables from terminal board (T1) inside the control assembly as shown on the wiring diagram Fig. 12.
4. Remove the four screws which secure the digital motorgear 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 purposes 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.
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X. REPLACEMENT PARTS DATA
1. All replacement parts are keyed on the illustrations which follow. Order replacement parts by part number and part name, as 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.
(SW-6) TRIGGER LOCK-IN - 950492
(VR) VOLTAGE REGULATOR Includes: VOLTAGE REGULATOR - 950159 TRANSISTOR SOCKET - 950158 (C4) CAPACITOR - 995544
SPINDLE ASSY. 948259 (See Fig. 9)
CONTROL ASSY. (See Fig. 7) 30786
RECEPTACLE - 950762 (19 PIN)
STRAIN RELIEF ­96W76
(GSV) GAS SOLENOID VALVE -2062305
GAS INLET CONNECTION 74S76
(Ref.) OPENING FOR POWER SUPPLY LIFTING RING
POWER CABLE ADAPTOR BLOCK - 674156 1/2-IN. - 13 STL. NUT 1/2-IN. LOCKWASHER (2) 1/2-IN. FLATWASHER
Recommended Spare Parts
* Replace decal if it becomes
excessively worn or lost.
BASE FRAME ­ 2075554
(MSS) 6-Pos. Rotary SW.­679914 & Knob - 950282
Not illustrated INSULATOR RING 60N90 KEY - 28N33 THUMBSCREW 61351087 FLATWASHER - 64309431 BELLWASHER - 950783
COVER - 30170*
EH-10 DIGITAL MOTOR-GEAR UNIT ASSY. - 679777 (See Fig. 6)
ACCESSORY SUPPORT ASSYS: 2 ROLL DRIVE (Shown, See Fig. 8) - 49V51 4 ROLL DRIVE (Not Shown, See Suppl. L-12-821) - 600216
KEYLOCK - 950956 REPLACEMENT KEY ­32778
WARNING DECAL ­2091514*
(SW1, 3, 5) SWITCH ­950087
WARNING DECAL - 995204
(J3) RECEPTACLE 182W64 (C10, 11) CAPACITOR 672348
GAS OUTLET CONNECTION 58V58 (Front of Mtg. Plate)
FRONT VIEW
(MLS) POWER SWITCH - 634517
(CB) CIRCUIT BREAKER - 950874
(2) SKID - 999629
REAR VIEW
TACH, P.C. BD. 675429 (2) SCREW­61324746
A
TACH DISK 950313
A
(ref) 54" lg
TACH COVER - 18787 (2) SCREWS #61324974
Fig. 5 - DIGIMIG Wire Feeder w/2-Roll Drive, P/N 30784
DIGIMIG Wire Feeder w/4-Roll Drive (Not illustrated), P/N 30785
3.25 Ø
11.6
VENT PLUG
2.875
.020 REF.
2.370
.93
.6251Ø
50 D.P. MIN.
1.0
33 LOCATING COLLAR
(REF)
View “AA”
END VIEW
W/COVER REMOVED
FOR MOTOR REPLACEMENT PARTS (Not illustrated) - See Fig. 10A
Gear Case Lubricated with Texaco Multifak Grease
h
h
Fig. 6 - Digital Motor-Gear Unit Assembly (40:1), P/N 679777
15
TACH HOUSING - 18786 (2) #8 — 32 x 3/8" SCREW
j
4.010 SQ.
2.25Ø
2.000
1.375
1.375
.25
5/16 - 18UNC 2B
63 MIN DEPTH (11 full threads)
2.86
.25
For 4.5 volt. Type 531 Replacement Battery (on I/O Bd.). Order P/N 951733
I/O-P4 To MPU-P2 CABLE ASSY. - 677938
WARNING DECAL - 995164
DISPLAY P/C BOARD ASSY. 675269
NOTE: The heat sinks on the “J” gov. board are electrically hot. Do NOT touch or ground while unit is energized
MPU P.C. BD. ASSY. - 18162
“J” GOV. P.C. BOARD ASSY. - 994236 (See Note) MTG. BRACKET - 995297 P.C. BOARD RECEPTACLE (P1) ­636608
(T1) 20 PT. TERMINAL STRIP - 950182
(I/O) P.C. BOARD ASSY. - 674956
Fig. 7 - DIGIMIG Control Assembly, P/N 30786
(R1) RESISTOR - 17240003 (25W, 3 Ohm)
(FN1) FILTER NETWORK 996918
(CTR2) TOP CONT. TRANSF. - 994303 (CTR1) BOT. CONT. TRANSF. 950088
Recommended Spare Parts * Replace decal if it becomes
excessively worn or lost.
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
CLAPPER - 60N98
SHAFT - 60N65
KNOB - 60N68
LIGHT SPRING - 182W55 (FOR
SOFT 8 SMALL DIA. HARD WIRE)
RETAINER - 58N24
FORK - 49V43
ROLLPIN - 3/16" x 1-3/4" LG.
SCREW - 5/16" - 18 x 2" LG.
WIRE OUTLET GUIDE INSERT*
CONDUIT
OUTLET
WIRE OUTLET*
GUIDE
CLAMP -- 61N02
PRESSURE ROLL
28V52
SUPPLIED
HEAVY SPRING - 182W54 (FOR LARGE DIA. HARD WIRE)
Fig. 8 - Accessory Support Assembly, P/N 49V51
NUT - 5/16" - 18
* Outlet Guide And Wiper Holder Not Included In
Assembly Part No. 49V51
16
WIRE REEL - 995570 Includes: REEL - 995568 COVER - 995569 (4) WING NUT, 1/2" — 13 63398183
COUPLING - 68121075
REEL
(4) .359" DIA. HOLE ON 3" DIA. D.C.
SPINDLE - 948258
“D” TYPE WASHER 948254
SCREW ­5/16" — 18 X 2"
SPRING - 948253
SUPPORT ­948257
(2) BRAKE PAD - 948255
SPINDLE
Fig. 9 - Spindle Assembly, P/N 948259
Optional Wire Reel, P/N 995580
(Ref. Hair Pin Clip)
HAIR PIN CLIP ­634347
WASHER ­948256
WATER
CONNECTION
58V75
(OUTLET)
5/8-18 Lh
ADAPTOR - 11N16 (INLET)
1/4 N.P.T.
Fig. 10 - Water Kit, P/N 994466
5/8-18 Lh
OUTPUT SHAFT ASSY. (Part of 19734 - OUTPUT GEAR CASE)
OUTPUT GEAR CASE 19734 (Includes Output Shaft Assy. Shown above)
GEAR ASSY. “B” - 20293
OUTPUT SHAFT SEAL•
Fig. 10A, EH-10A Motor-Gear Unit Parts Breakdown
GEAR ASSY. “A” - 20292
MAGNET ASSY. - 19730
ARMATURE SHAFT SEAL•
OUTPUT GEAR CASE GASKET•
•GASKET/SEAL KIT - 20542 (Includes those items marked with •)
••BRUSH END BELL - 19732 (Includes TWO-BRUSH HOLDER ASSYS.)
ARMATURE & BEARINGS ­19726 Includes: ARMATURE BEARING - 20288
MOTOR CORD LEAD - 19731
BRUSH HOLDER••
BRUSH
CAP
(2) CARBON BRUSH REPLACEMENT KIT - 679784 Includes: (2) BRUSH CAP (2) CARBON BRUSH
17
D-30787
Fig. 11 - Schematic Diagram - DIGIMIG Wire Feeder
18
D-30788
Fig. 12 - Wiring Diagram - DIGIMIG Wire Feeder
19
F-14-481-B 4/95 1.5M Printed in the U.S.A.
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