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
microprocessor accuracy — the microprocessor, the control-
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.
microprocessor flexibility — in contrast with competitive digi-
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.
microprocessor reliability — Digimig Wire Feeders have proven
to be rugged and reliable in test after test for absolute
minimum downtime.
presettable wire feed speed (ipm) and voltage (volts) —
provides ability to easily and accurately preset the exact
welding parameters desired, before the welding sequence
begins.
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.
patented microprocessor controlled closed loop system -
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.
sure start interlock — to assure troublefree starts, the Digimig
has an interlock circuit which will not allow wire feed to initiate
when the torch trigger is pulled, unless the power supply
contractor is closed and voltage is present; the cold wire INCH,
however, will be operative at all times.
individual digital LED meters provide large 1/2-in. readout of
voltage and wire feed speed — continuous display of preset
and then actual welding voltage and wire feed speed for
accurate observation.
dual schedule capability — enables operator to have two
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.
“lock-in” key - allows preset welding parameters to be “locked-
in” for positive supervisory control of weld quality; with key
turned to “set” position, all parameters may be reset to new
values at any time.
automatic “shut down” — assures welding is done at the
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.
arc hours readout — this unique feature provides direct
measure of “productivity’ by accumulating and displaying,
upon command, actual welding arc hours.
automatic adaptive anti-stick or manual burnback time feature
— a patented adaptive anti-stick circuit automatically adjusts
the same amount of wire burnback regardless of wire size,
speed or voltage; or, you can manually preset a “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.
adjustable “hot start” characteristic.
spot weld timer - because the spot weld timer is adjustable up
to 999 cycles (16.5 sec.) in the ipm window, it is more than a
conventional “spot” feature; it is also a weld timer extending
its use for “increment” or “stitch” welding.
Be sure this information reaches the operator.
You can get extra copies through you supplier.
gas pre and postflow and cold wire inch capability - gas pre and
postflow provides independent adjustment in tenths of a
second for highest weld quality and economy; cold wire inch
speed can be independently adjusted from welding wire feed
speed to reduce down time.
circuit protection - resettable circuit breaker for input power
minimizes downtime and maintenance.
EH-10A permanent magnet motor - provides the highest torque,
fastest response, and best efficiency of any mig p.m. motor on
the market.
patented closed loop “J” governor/optical tachometer - pro-
vides most accurate means of maintaining wire feed speed and
voltage, regardless of any voltage drop or drift.
dc straight or reverse polarity capability - because the Digimig
is factory-wire for use with either dcrp or dcsp without making
control wiring changes, the process flexibility of the Digimig is
further extended.
trigger lock-in - allows the operator to release the torch switch
lever during long welding cycles for easier torch manipulation
and less operator fatigue.
“Cold” servo adjustment allows setting controller for optimum
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.
2
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
3
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
4
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
5
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
6
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.
14
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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