INSTRUCTIONS for
DIGIPULSE DUAL
F-15-496-A
May, 1999
WIRE FEEDER
Bombardier
P/N 33299
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices
for arc welding equipment we urge you to read our booklet Precautions and Safe Practices for Arc Welding, Cutting and Gouging, Form
52-529. Do NOT permit untrained persons to install, operate or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not fully understand these instructions contact your
supplier for further information. Be sure to read the Safety Precautions on page 2 before installing or operating this equipment.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels
and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts
that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or
replacement become necessary, the manufacturer recommends that a telephone or written request for service advice
be made to the Authorized Distributor from whom purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user
of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty
maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.
TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH
SAFETY PRECAUTIONS .......................................................................................................................... 3
SECTION 1 DESCRIPTION ................................................................................................. 7
SECTION 2 INSTALLATION ................................................................................................ 12
SECTION 3 OPERATION ..................................................................................................... 16
SECTION 4 MAINTENANCE ................................................................................................ 19
SECTION 5 REPLACEMENT PARTS .................................................................................. 22
2
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if movement is confined, or if there is danger of
falling.
1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area,
cables, torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields
(EMF). Welding and cutting current creates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
from your body as possible.
10/98
3
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe
fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
5. WARNING: This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety Code
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylinder, valve, or relief device can injure or
kill. Therefore:
1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
§25249.5 et seq.)
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for electric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert!
Your safety is involved.
Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.
Means potential hazards which could
result in personal injury or loss of life.
Means hazards which could result in
minor personal injury.
4
SP98-10
PRÉCAUTIONS DE SÉCURITÉ
AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.
1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles résultant
d’une exposition prolongée au soleil. Aussi convient-il
d’observer les précautions suivantes:
a. Portez un écran facial adéquat muni des plaques
protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez l’exécution.
AVERTISSEZ les personnes se trouvant à proximité
de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.
b. Portez des gants ignifugés à crispins, une tunique
épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.
c. Les étincelles ou les projections de métal incandescent
risquent de se loger dans des manches retroussées,
des bords relevés de pantalons ou dans des poches.
Aussi convient-il de garder boutonnés le col et les
manches et de porter des vêtements sans poches à
l’avant.
d. Protégez des étincelles et du rayonnement de l’arc
électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.
e. Ne jamais omettre de porter des lunettes de sécurité
lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.
f. Le gougeage à l’arc et le soudage à l’arc au plasma
produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.
2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:
a. Éloigner suffisamment tous les matériaux combustibles
du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la sciure,
l’essence, le kérosène, les peintures, les solvants, le
gaz naturel, l’acétylène, le propane et autres substances combustibles semblables.
b. Les étincelles ou les projections de métal incandescent
peuvent tomber dans des fissures du plancher ou dans
des ouvertures des murs et y déclencher une ignition
lente cachée. Veiller à protéger ces ouvertures des
étincelles et des projections de métal.
c. N’exécutez pas de soudures, de coupes, d’opérations
de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.
d. En vue d’assurer la prévention des incendies, il
convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.
e. Une fois le travail à l’arc terminé, inspectez le secteur
de façon à vous assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer
ultérieurement un feu.
3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous tension
venir au contact direct de la peau ou de vêtements
humides. Veillez à porter des gants bien secs.
b. Si vous devez effectuer un travail sur une surface
métallique ou dans un secteur humide, veillez à assurer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.
c. Mettez toujours à la terre le poste de soudage/coupage
en le reliant par un câble à une bonne prise de terre.
d. N’utilisez jamais de câbles usés ou endommagés. Ne
surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.
e. Mettez l’équipement hors tension lorsqu’il n’est pas en
service. une mise à la masse accidentelle peut en effet
provoquer une surchauffe de l’équipement et un danger d’incendie. Ne pas enrouler ou passer le câble
autour d’une partie quelconque du corps.
f. Vérifiez si le câble de masse est bien relié à la pièce en
un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de
passage d’un courant de sortie par des chaînes de
9/97
5
levage, des câbles de grue ou divers chemins
électriques.
g. Empêchez l’apparition de toute humidité, notamment
sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.
4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:
a. Assurez en permanence une aération adéquate de
l’emplacement de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.
b. N’effectuez jamais de travaux de soudage ou de
coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et d’autres
gaz irritants, à partir des vapeurs de solvant.
c. Une irritation momentanée des yeux, du nez ou de la
gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtezvous de travailler afin de prendre les mesures nécessaires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.
d. Certaines commandes comportent des canalisations
où circule de l’hydrogène. L’armoire de commande est
munie d’un ventilateur destiné à empêcher la formation de poches d’hydrogène, lesquelles présentent un
danger d’explosion; ce ventilateur ne fonctionne que si
l’interrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manœuvrer cette commande en vérifiant si le
couvercle est bien en place, de façon à assurer
l’efficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.
e. Les fumées produites par l’opération de soudage ou
de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’éliminer du voisinage de l’opérateur tout dégagement de
fumée visible.
f. Consultez les recommandations particulières en
matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.
5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner des
dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:
a. Efforcez-vous de toujours confier à un personnel qua-
lifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.
b. Ne procédez jamais à une tâche d’entretien
quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.
c. Maintenez en bon état de fonctionnement les câbles,
le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage et des
équipements accessoires. Gardez-les à l’écart des
sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri des
traces d’huile ou de graisse, des atmosphères corrosives et des intempéries.
e. Laissez en place tous les dispositifs de sécurité et tous
les panneaux de l’armoire de commande en veillant à
les garder en bon état.
f. Utilisez le poste de soudage/coupage conformément à
son usage prévu et n’effectuez aucune modification.
6. INFORMA TIONS COMPLÉMENT AIRES RELATIVES À
LA SÉCURITÉ--
Pour obtenir des informations complémentaires sur les
règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Welding, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:
a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc
Welding “AWS A6. 1.
c. “Safe Practices for Welding and Cutting Containers
That Have Held Combustibles” AWS-A6.0.
d. “Recommended Safe Practices for Plasma Arc Cutting”
AWS-A6. 3.
e. “Recommended Safe Practices for Plasma Arc Weld-
ing” AWS-C5. 1.
f. “Recommended Safe Practices for Air Carbon Arc
Gouging and Cutting” AWS-C5. 3.
g. “Code For Safety in Welding and Cutting”
CSA-Standard W117. 2.
9/97
6
SECTION I DESCRIPTION
SPECIFICATIONS
Input Power Required....................... 115 volts 50/60 Hz single phase Wire
Feed Speed Range ................................... 20-999 in./min. (.5-26.4 m/min.)
Wire Sizes Accommodated:
Hard/Soft ............................................. .023 thru 1/8-in. (.6 thru 3.2 mm)
Flux Cored ......................................... .035 thru 1/8-in. (0.9 thru 3.2 mm)
Length ................................................................................ 24-in. (610 mm)
Width ............................................................................ 22-1/2-in. (572 mm)
Height ................................................................................. 15-in. (381 mm)
Weight (less wire) .................................................................. 80-lbs. (36 kg)
LEFT DIGITAL READOUT (IPM)
LEFT INC-DEC TOGGLE
INCH/GAS PURGE
RESET SELECTOR
CRATER SELECTOR SW.
INTRODUCTION
This Digipulse Dual wire feeder is designed as a dual
torch welder with each torch capable of furnishing eight
completely different sets of welding parametersin
other words, sixteen (16) completely different welding
schedules can be preset to meet the requirements of
high production shops. The standard Dual control features include presettable wire feed speed (ipm), voltage, pre and postflow gas shielding, cold wire inching,
gas purging, adaptive or manual burnback, spot welding timer and crater fill functions.
SPINDLE ASSY.
RIGHT DIGITAL READOUT (VOLT)
RIGHT INC-DEC TOGGLE
SPOT/BACK-SELECT SWITCH
RIGHT TORCH RECPT.
LEFT TORCH ACCY.
SUPPORT ASSY.
& EH-10 MOTOR
GEAR TACH UNIT
RESET CIRCUIT BREAKER
POWER ON-OFF SW.
RUN-SET KEY SW.
LEFT TORCH RECEPT.
TORCH ACCY. RIGHT
SUPPORT ASSY.
& EH-10 MOTOR-GEAR-TACH UNIT
J1 CONTROL RECPT.
LEFT TORCH GAS SOL
CONNECTION
RIGHT TORCH GAS
SOL CONNECTION
LOCATION FOR OPT.
WATER CONNECTIONS
Fig. 1 - Digipulse Dual Feeder
POWER CABLE
ADAPTOR BLOCK
7
SECTION I DESCRIPTION
A. STANDARD FEATURES/BENEFITS
n microprocessor accuracy the microprocessor, the
controlling "brain" of the Digipulse Dual, operates
exclusively on drift free digital logic. The digital logic
delivers extraordinarily precise computer-accurate
weld parameter control and weld consistency.
n microprocessor flexibility the Digipulse incorpo-
rates electronically reprogrammable modules; by simply reprogramming this small plug-in module many
existing functions may be extended or new features
maybe added.
n microprocessor reliability ESABs Digipulse Dual
Wire Feeders have proven to be rugged and reliable
in test after test for absolute minimum downtime.
n presettable wire feed speed (Ipm) and voltage (volts)
provides ability to easily and accurately preset the
exact welding parameters desired before the welding
sequence begins.
n patented microprocessor controlled closed loop sys-
tems provides most accurate means of maintaining
wire feed speed (amperage) and welding voltage; the
microprocessor compensates for deviations in ambient temperature primary voltage fluctuation and
changes in arc dynamics or wire feed force conditions,
to assure that preset parameters are maintained.
n sure start interlock to assure trouble free starts the
Digipulse Dual has an interlock circuit which will not
allow wire feed to initiate when the torch trigger Is
pulled unless the power supply contactor is closed
and voltage is present; the cold wire INCH, however,
will be operative at all times.
n individual digital LED meters provide large 1/2-in.
readout of voltage and wire feed speed continuous
display of preset and then actual welding voltage and
wire feed speed for accurate observation.
n automatic "shut down" assures welding is done at
the preset parameters; unit automatically shuts down,
if for any reason either the volts or ipm cannot be
maintained for a preprogrammed time period; simultaneously, cause is indicated by flashing digital display.
n toggle switch adjustment of weld parameters by fine
increments or rapid coarse adjustment allows
quick, easy, and accurate adjustments of welding
parameters.
n gas pre and postflow and cold wire inch capability
gas pre and postflow provides independent adjustment in tenths of a second for highest weld quality and
economy; cold wire inch speed can be independently
adjusted from welding wire feed speed to reduce
downtime.
n eight schedule capability per torchenables operator
to have two different sets of weld parameters (for each
torch) at his fingertips. The microprocessor allows the
operator to change schedules with a simple clickclick squeeze of the torch trigger switch to be used.
n automatic adaptive anti-stick or manual burnback
time featurea patented adaptive anti-stick circuit
automatically adjusts the same amount of wire
burnback regardless of wire size, speed or voltage; or,
you can manually preset a BurnbackTime to specifically suit a specialized application; the manual burnback
function (programmed up to 30 cycles in the VOLTS
window) allows you to override the automatic adaptive
anti-stick by setting a specific burnback time.
n spot weld timerbecause the spot weld timer is
adjustable up to 999 cycles (16.5 sec.) in the IPM
window, it is more than a conventional spot feature;
it is also a weld timer extending its use for Increment
or Stitch welding.
n the Crater Fill feature allows the operator to preset a
special welding wire feed speed (IPM), arc length
(VOLTS) and time (TIMES) to control the shape and
size of the weld crater upon termination of the welding process.
n circuit protectionresettable circuit breaker for input
power minimizes downtime and maintenance.
n EH-10A permanent magnet motorsprovide the high-
est torque, fastest response, and best efficiency of
any mig p.m. motor on the market.
n patented closed loop J governor/optical tachom-
eterprovides most accurate means of maintaining
wire feed speed and voltage, regardless of any voltage drop or drift.
8
SECTION I DESCRIPTION
I. DESCRIPTION
II. REQUIRED EQUIPMENT
The Digipulse Dual torch welder is a microprocessor
controlled digital wire feeder designed for mig short arc/
spray and pulse arc welding applications. Its electronic
brain the microprocessor not only controls, it also
remembers and automatically coordinates the program
sequencing (that you preset) which results in the most
accurate wire feed speed and voltage control possible.
By virtue of its microprocessor controlled wire speed and
arc voltage design, the Digipulse Dual allows the customer to preset 8 welding parameters (for each torch),
and be assured that each setting will be precisely held
regardless of changes in line voltage, arc or load conditions.
A. CONSTANT VOLTAGE POWER SOURCE
The Digipulse Dual is specifically designed for use with
constant voltage (C.V.) power sources utilizing electronically controlled voltage regulation such as:*
SVI-450i, P/N 34055
* The power sources provides three (3) Slope outputs
Flat, Medium and Steep.
B. CABLE ASSEMBLIES
A multi-conductor control cable assembly is required to
connect the Digipulse to a power source with electronic
voltage control (see Fig. 3).
Two digital readout windows continuously display (1/2in. high) the preset welding parameters (speed and
voltage). After the arc is struck, they automatically display the actual wire speed and arc voltage conditions for
the selected schedule. The read-outs can also provide
selectable displays of other welding parameters such as
inching speed, gas pre- and postflow times, spot time in
cycles, manual burnback time in cycles, schedule selection, crater times and conditions.
The Dual Digipulse uses a pair of heavy duty EH-10A
wire drive motors designed to feed hard or soft wires from
.023-in. to 1/8-in. in diameter and flux-cored wires from
.035-in to 1/8-in. in diameter. Rate of wire feed (20-999
ipm) is precisely controlled by using a closed-loop J
governor digital feedback circuit that employs an optical
tachometer to monitor the motor speed. Arc voltage
regulation is also controlled by a closed-loop digital
feedback circuit that monitors the arc voltage and automatically adjusts the power source output voltage to
maintain the preset voltage.
For identification and location of all functional controls
and connections refer to Figure 1. The front panel
contains the torch switch receptacles which use low
voltage (5 v.d.c.) for operator safety. The rear panel
contains the on-off power switch, the run/set switch, a 7ampere reset circuit breaker for overload protection, a
19-pin receptacle (J1) provides 115vac, contactor control, arc monitoring and control signals from the power
source.
All interconnecting cable, hose and auxiliary equipment
connections are quickly detachable to provide easy
setup and maximum portability of the wire feeder as
shown in Figs. 2 & 3. A water kit with or without solenoid
may be purchased, as an optional accessory, for use with
water-cooled torch operation.
115 Volt/Contactor/Remote Control J1 Cable, 19-conductor with Amphenol to Amphenol plugs; order one of
the following:
6-foot. 19-cond., P/N 30686.
30-foot, 19-cond., P/N 30780.
60-foot, 19-cond., P/N 30781.
C. WELDING TORCH
Mig welding torches, with contact tip, wire conduit and
outlet guide for wire size/type to be employed, will be
required. Suitable air (MT-400) or water-cooled (MT450W, ST-16) torches may be used with the Digipulse.
When using a water-cooled torch it will be necessary to
connect the torches water hose to either a continuous
water supply or to the wire feeder base by using an
optional water kit (with or without a solenoid valve, see
Section III-A and B).
D. GAS REGULATION
Shielding gas regulator/flowmeter and fitted hose to
bring gas from flowmeter to wire feeder. Such as:
Regulator/Flowmeters:
R-5007 Argon/Helium/Nitrogen, P/N 998124.
R-5008 C02, P/N 998125.
Gas Hoses:
Standard Duty, P/N 40V77 (12-1/2-ft.) or P/N 34V38
(25-ft.)
Heavy Duty, P/N 19416 (12-1/2-ft.) uor P/N 19415
(25-ft.).u
u Must be used for C02.
9
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