INSTRUCTIONS for
DIGIPULSE DUAL
DANA Corporation
F-15-626-E
September, 2000
WIRE FEEDER
P/N 558001536 with PLC Interface
P/N 34849 - Standard Unit
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.
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 Pro-
--
cesses", 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
2
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.
3
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. L 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 incandes-
cent 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 combus-
tibles 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 incandes-
cent 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 ten-
sion 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
4
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. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--
Pour obtenir des informations complémentaires sur les
règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Welding, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:
a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc
Welding “AWS A6. 1.
c. “Safe Practices for Welding and Cutting Containers
That Have Held Combustibles” AWS-A6.0.
d. “Recommended Safe Practices for Plasma Arc Cutting”
AWS-A6. 3.
e. “Recommended Safe Practices for Plasma Arc 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
5
SECTION I INTRODUCTION
I. DESCRIPTION
This manual has been prepared for use by an experienced operator. It provides information to familiarize the
operator with the design, installation and operation of the
Digipulse Dual XR wire feeder designed to Dana Corporation specifications. DO NOT attempt to install or
operate this equipment until you have read and fully
understood these instructions. The information presented
here should be given careful consideration to ensure
optimum performance of this equipment.
II. RECEIVING-HANDLING
Upon receipt, remove all packing material and carefully
inspect for any damage that may have occurred during
shipment. Any claims for loss or damage that may have
occurred in transit must be filed by the purchaser with the
carrier. A copy of the bill of lading and freight bill will be
furnished by the carrier on request.
When requesting information concerning this equipment, it is essential that Item number, Serial number and
Model number of the equipment be supplied.
SPECIFICATIONS
Input Power Required115 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)
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.
Fig. 1 - DANA DIGIPULSE Dual Wire Feeder
6
SECTION I INTRODUCTION
III. FEATURES
Microprocessor accuracy — the microprocessor, the
controlling "brain" of the Digipulse Dual, 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 digital systems that require additional printed circuit
boards and hard wiring whenever a feature or function is
to be added, the Digipulse incorporates electronically
reprogrammable modules; by simply reprogramming
this small plug-in module many existing functions may be
extended or new features maybe added.
Microprocessor reliability — ESAB’s Digipulse Family
of 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.
Patented microprocessor controlled closed loop systems — provides most accurate means of maintaining
wire feed speed (amperage) and welding voltage; the
microprocessor compensates for deviations in ambient
temperature, primary voltage fluctuation and changes in
arc dynamics or wire feed force conditions, to assure that
preset parameters are maintained.
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.
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.
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.
Toggle switch adjustment of weld parameters by
fine increments or rapid coarse adjustment — allows
quick, easy, and accurate adjustments of welding parameters.
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.
Automatic adaptive anti-stick or manual burnback
time feature—a patented adaptive anti-stick circuit au-
tomatically 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 999 cycles in the VOLTS window)
allows you to override the automatic adaptive anti-stick
by setting a specific burnback time.
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.
Circuit protection—resettable circuit breaker for input
power minimizes downtime and maintenance.
EH-10A permanent magnet motors—provide the highest torque, fastest response, and best efficiency of any
mig p.m. motor on the market.
Patented closed loop “J” governor/optical tachometer—provides most accurate means of maintaining
wire feed speed and voltage, regardless of any voltage
drop or drift.
DANA interlock feature insures that all automatic clamps
are engaged before welding can begin.
DANA arc detect circuit reports all welding activity to an
external programmable controller.
7
SECTION 2 INSTALLATION
I. INSTALLATION
To avoid possible lethal shock make sure that all
power to the DANA Digipulse is OFF before making
any welding/control cable and or accessory connections on this unit. Do this by "locking-open" the
input line disconnect switch to the power source.
Do not allow metal-to-metal contact between the
wire feeder chassis and a metal surface connected
in any way to a welding ground. With such contact,
a poor welding ground connection may create a
difference In potential that sends part of the weld
current through the safety ground wiring in the
control cable and wire feeder, resulting in burnout of
that wiring and/or damage to wire feeder circuitry. If
the safety ground burns out, the operator may be
exposed to 115V. shock hazard.
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):
LOCATION INSTRUCTIONS
The wire feeder should be placed close enough to be
easily accessible from the workstation but not so close
that weld spatter could affect the unit. It is critically
important to insure that the base of the wire feeder is
not placed in contact with a grounded metal surface.
A. ELECTRICAL CONNECTIONS
Connect the control cable assembly to the J1
receptacle on the rear panel of the DANA Digipulse
wire feeder. Next, connect the opposite end of the
cable to the J1 receptacle on the rear panel of the
power source as shown in Fig. 3.
Connect the welding cable from the positive output
terminal of the power supply to the power cable
adapter block located on the base of the wire feeder.
A second welding cable should then lead to the
welding torch.
B. HOSES
GAS REGULATION
Install shielding gas supply hoses as shown in Fig. 2.
Regulator/Flowmeters for Argon/C25/Helium/Nitrogen:
R-33-FM-580 P/N 21557
R-36-FM-580 P/N 21505
R-5007, P/N 998124.
Shielding Gas Hoses:
Std Duty, P/N 40V77 (12.5-ft.) or P/N 34V38 (25-ft.)
Hvy Duty, P/N 19416 (12.5-ft.) or P/N 19415 (25-ft.)
TORCH COOLANT
If you are using a water-cooled torch, install coolant
supply and drain hoses as shown in Fig. 2.
Coolant Supply and Drain hoses:
Std Duty, P/N 40V76 (12.5-ft.) or P/N 406196 (25-ft.).
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.
C. WATER KITS (Optional see Fig. 13)
Mount bulkhead adapter (58V75) behind opening
provided in rear vertical support plate, below gas
connections, and secure with screws (No. 8 - 32 x 3/8in.) and lockwashers provided. Attach coupling or
solenoid valve (depending on the type of water kit) and
adapter (11N16) to the bulkhead adapter. Mount torch
cable adapter (45V11) on welding power stud.
Connect water drain hose to this adapter, and water
inlet hose to adapter 11N16. Wire the solenoid valve
(if used) in parallel with the gas solenoid valve (see
wiring diagram).
D. TORCH CONNECTIONS
Attach torch gas hose to outlet of gas solenoid. Plug in
torch switch cables and lock by twisting. Attach water
hose (if used) to wire feeder. Connect torch power
cables to power source, or to power cable adapter
block (with a second cable from that stud to the power
source).
E. INSTALLING FEED ROLL
To install the desired feed roll kit (optional selection)
proceed as shown in Fig. 11:
1. Position the feed rolls over the four gear assembly
hubs aligning the feed roll holes with the gear
assembly holes.
2. Secure the feed rolls to the gear assemblies using
the No. 8-32 x 5/8-in. screws and lockwashers
supplied.
CENTER WIRE GUIDE
To install the proper center wire guide (optional
selection) proceed as follows:
1. Remove the two No. 8-32 x 5/8-in. panhead
screws which attach the Center Guide Clamping
8
SECTION 2 INSTALLATION
Plate (P/N 2075495) to the Center Guide Block
(P/N 2075496). Remove the plate.
2. Insert the center wire guide (optional selection) in
the groove of the guide block.
3. Replace the clamping plate, using the screws
removed in step 1 above.
F. 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 through it were a spool
(see 1 and 3 above). Remove thumbnuts and cover
plate from reel. Remove coil from its package, but do
not remove its binding wires. Slide coil onto reel so that
wire will be drawn from bottom of coil (starting end for
a coil is always the outer end). Replace reel cover
plate and thumbnuts. Cut off coil tie wires and any
kinked wire. Then adjust brakescrew and thread wire
to torch as covered in 4 and 5 above.
G. ADJUSTING THE ACCESSORY SUPPORT ASSEM-
BLY (See Fig. 8).
4. Engage the clapper making sure the wire is held in the
feed roll groove.
5. Tighten the pressure adjusting knob until the wire is
firmly against the feed roll - do not overtighten. The
spring pressure applied should be the minimum required to provide positive, nonslip wire feed. Too little
pressure will result in wire slippage while excessive
pressure will scar and deform the wire. Further adjustment can be made after the wire feed is put into
operation. Note that a light silver-colored spring
(182W55) is installed on the accessory support for
use with soft and small diameter hard wire. For large
diameter hard wire, replace this spring with the optional heavy blue- colored spring (182W54).
II. REQUIRED EQUIPMENT
A. CONSTANT VOLTAGE POWER SOURCE
The DANA Digipulse Dual is specifically designed for use
with the Digipulse power supply.
B. CABLE ASSEMBLIES
A multi-conductor control cable assembly is required to
connect the DANA Digipulse to the power source. (See
Fig. 3).
115 Volt/Contactor/Remote Control J1 Cable, 19-conductor with Amphenol to Amphenol plugs; order one of
the following:
6-foot. 19-cond., P/N 30686.
30-foot, 19-cond., P/N 30780.
60-foot, 19-cond., P/N 30781.
C. WELDING TORCH
Mig welding torches, with contact tip, wire conduit and
outlet guide for wire size/type to be employed, will be
required. Suitable air (Gunmaster 400) or water-cooled
( ST-16) torches may be used with the DANA 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. DRIVE ROLLS, See Table 1 and F-12-821.
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.
III. OPTIONAL ACCESSORIES
A. Water Kit without Solenoid Valve (P/N 994466).
Permits the convenient connection of water-cooled
torches and continuous water supply to the wire
feeder.
A kit is required for each torch and consists of a
coupling, two adaptors and a fitting. A dependable
9
SECTION 2 INSTALLATION
cooling water supply, delivery and return water hoses
(P/N 40V76, 2 required) will also be required. Note
that Fig. 2 illustrates the use of power cable adaptor
P/N 674156, in addition to the kit. If adaptor (674156)
is not used, adaptor (45V11 supplied with kit) can be
connected to the output terminal of the power source.
Install the kit in accordance with Fig. 13 . Connect the
water-cooled torch as shown in Fig. 2.
B. Water Kit with Solenoid Valve (P/N 2075760).
Same as kit P/N 994466 listed above except a solenoid valve is required for each torch and is supplied in
place of the coupling. The solenoid valve can be used
in areas where you wish to conserve water or the
water temperature is below the dew point causing
sweating of torch parts, resulting in poor welds. Install
kit in accordance with Fig. 13. Do NOT use with
coolant circulators.
C. Spool Enclosure Kit (P/N 600240). Provides protec-
tion for spool of wire against dust and dirt.
D. Standard Wire Reel Assembly (P/N 34323). Reel
slips over spindle to allow use of coiled wire, see Fig.
12.
E. Heavy Duty Wire Reel Assembly (P/N 19V89).
Spoke-type wire reel includes a four spoke aluminum
alloy casting mounted on a lightweight support shaft
of steel tubing. The reel will handle all wire coils from
2 to 4-5/8-in. wide. The finger design permits quick
and easy accommodation of different coil widths by
simply rotating from one finger position to the other.
F. Wire Straightener P/N 34V74). Reduces wire cast to
improve feedability and increase service life of torch
liners and contact tips. Mounts to the accessory
support inlet guide.
Wire inlet Guide P/N 11N53 is required to complete
the installation on the wire inlet side of the straightener.
G. WC-9 Coolant Circulator, P/N 33540, is used for
water cooled torch operation and is designed to be
"free standing" in a convenient location near the torch.
A four-gallon capacity tank provides 1.0 gal/min @ 50
psi, using 115 volts, 50/60 Hertz, 1 phase input. Since
the cooler is designed to run continuously during a
welding operation, never connect it to a power source
or wire feeder that uses a solenoid controlled water
supply that opens and closes with each operation of
the welding contactor - the cooling efficiency of the
unit will be hampered and the starting winding in the
pump motor may burn out.
H. WC-8C Coolant Circulator, P/N 33739, is used for
water cooled torch operation and is designed to fit in
a cylinder rack of a power supply truck. A 1.5 gallon
capacity tank provides 1.0 gal/min @ 50 psi, 115 volts,
50/60 Hertz, 1 phase input. Since the cooler is designed to run continuously during a welding operation,
never connect it to a power source or wire feeder that
uses a solenoid controlled water supply that opens
and closes with each operation of the welding contactor
- the cooling efficiency of the unit will be hampered and
the starting winding in the pump motor may burn out.
I. Wire Feeder Turntable P/N 678940, allows rotation
of wire feeder as operator changes work positions.
This reduces strain and bending of torch cables.
J. Four Roll Drive Accessory Support Assembly,
P/N 600216. This assembly (shown in booklet F-12-
821) utilizes 4 feed rolls to provide positive nonslip
wire feed. It is designed for feeding .030 thru 1/8--in.
diameter wire. For feed roll/outlet guide accessories
refer to Table 1.
K. PLC Interface Retrofit Kit, P/N 0558001518. This kit
(shown in booklet F-15-608) inhibits the unit from
welding until an external 'enable' signal is received. It
also puts out a signal to DANA's PLC indicating when
the unit is welding. This is a standard part of
0558001536, but an optional component for 34849.
Table 1
Feed Roll Center Upper Lower
Wire Size Kit * Wire Guide Feed Roll + Feed Roll +
.045 999327 2075561 2075545 2075537
.052 999328 2075562 2075546 2075538
.062 999329 2075563 2075547 2075539
+ (2) Upper and (2) Lower feed Rolls are required as a complete set.
* Feed Roll Kit includes Center Wire Guide, (2) Upper and (2) Lower Feed Rolls
For a complete listing of available feed rolls, see F-12-821.
10
SECTION 2 INSTALLATION
REGULATOR/
FLOWMETER
GAS HOSE
40V77 (12-1/2 FT.)
34V38 (25 FT.)
n WATER KIT (BELOW)
2075760
OR
n WATER KIT
994466
n WATER "DRAIN" HOSE - 40V76 (12-1/2 FT.)
n ADAPTOR - 45V11
LEFT MOTOR/ACCY. SUPPORT
TORCH CONNECTION
n WATER "IN" HOSE - 40V76
(12 1/2 FT.)
GAS HOSE
40V77 (12-1/2 FT.)
34V38 (25 FT.)
PLAN VIEW DUAL FEEDER
GAS SOLENOIDS ABOVE
OPT. WATER SOL. BELOW
REF. CONTROL'S REAR
SUPPORT FRAME
RIGHT MOTOR/ACCY. SUPPORT
TORCH CONNECTION
TORCH CONDUIT
REGULATOR/
FLOWMETER
TORCH CONDUIT
TORCH POWER CABLE
LEFT TORCH
(WATER COOLED)
TORCH SWITCH
TORCH GAS HOSE
n TORCH WATER HOSE
FRONT
VIEW
CONTROL
n Parts required when
using a Water Kit & Water
Fig. 2 - Interconnection diagram
TORCH POWER CABLE
TORCH GAS HOSE
TORCH SWITCH
RIGHT TORCH
(AIR COOLED)
11
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