ESAB Digipulse Dual Wire Feeder Dana Corporation Troubleshooting instruction

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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.

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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.

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

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

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

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.

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

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

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.

SECTION 2 INSTALLATION

REGULATOR/ FLOWMETER

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

n WATER KIT (BELOW)

2075760

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)

SECTION 2 INSTALLATION

P4, PLC CONNECTOR

† ESAB will not honor the warranty on Digipulse 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 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

SECTION 3 OPERATION

I. CONTROL FUNCTIONS

BACK PANEL CONTROL

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

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

2. Run Set Key. This "key-operated” switch must be in the SET position to preset, vary and weld-test the welding parameters programmed into the control (e.g.: Sched. I, Sched. II for each torch, Spot). After the desired results are achieved, the program(s) can be “locked-in” by turning the key to the RUN position. The only parameter which can be altered by the operator in the RUN position is the cold wire INCH speed.

3. Reset Circuit Breaker. A seven (7) ampere circuit

— cold wire INCH speed in IPM from 50 to 999

inches per minute in one inch increments.

— wire type

NOTE: With the power turned “on”, but not welding, the

IPM window will continuously read Preset wire speed. 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 toggle selector actuated, this window can also display the following: — shielding gas POSTFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments.

— manual BURNBACK time. Manually adjustable

burnback time period which when preset will override the automatic adaptive anti-stick feature. This time period will be set In one-cycle (60 cycle = 1 sec.) Increments. When set to “zero”, the Automatic Anti-stick feature will be operational.

— wire diameter

P4, PLC Connector

Fig. 4 - Rear Panel Control

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.

FRONT PANEL CONTROL

4. Digital Readout Windows. Two individual three-digit

windows are provided to display preset or actual welding parameters as follows: a. IPM Digital Readout. This window is primarily

used to display wire feed speed in IPM from 20 to 999 inch per minute in one inch increments. However, with the appropriate function selector actuated, this window can also display the following: — shielding gas PREFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments.

— SPOT welding time for each Torch, from 1 to 999

cycles in 1 cycle increments.

NOTE: With the power turned “on”, but not welding, the

VOLTS window will continuously read Preset voltage. When the arc is struck, the VOLTS window will then continuously read Actual welding voltage.

Fig. 4A - Front Panel Controls

SECTION 3 OPERATION

SPINDLE ASSY.

RIGHT TORCH ACCY.

SUPPORT ASSY.

& EH-10 MOTOR-GEAR-TACH UNIT

RIGHT TORCH TRIGGER

SWITCH RECPT.

SPOT/BACK-SELECT SWITCH

RIGHT INC-DEC TOGGLE

RIGHT DIGITAL READOUT (VOLT)

LEFT DIGITAL READOUT (IPM)

LEFT INC-DEC TOGGLE

INCH-/GAS PURGE

RESET SELECTOR

MODE SELECTOR SW.

LEFT TORCH ACCY.

SUPPORT ASSY.

LEFT TORCH TRIGGER

SWITCH RECEPT.

& EH-10 MOTOR

Fig. 5 - DANA Digipulse Dual Feeder (Front View)

GEAR TACH UNIT

SECTION 3 OPERATION

POWER CABLE ADAPTOR

BLOCK - 674156

1/2-IN.-13 STL. NUT

1/2-IN. LOCKWASHER

(2) 1/2-IN. FLATWASHER

LEFT SHIELDING GAS SOLENOID

CONNECTION

PLC CONNECTOR

POWER CABLE

ADAPTOR BLOCK

RIGHT SHIELDING GAS

SOLENOID CONNECTION

VOLTAGE REGULATOR

J1 CONTROL RECPT.

RESET CIRCUIT BREAKER

POWER ON-OFF SW.

Fig. 5A - DANA Digipulse Dual Feeder (Rear View)

RUN-SET KEY SW.

LOCATION FOR OPT.

WATER CONNECTIONS

SECTION 3 OPERATION

5. LED Light. This LED only lights to indicate that the

torch on the left side is in use.

NOTE: All of the following controls are spring-loaded,

center-return toggle switches which must be operated to actuate their indicated function(s).

6. Inc.-Dec. Toggle Switches. Two control toggles are provided to preset the individual welding parameters required for the selected welding mode 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; Preflow, Spot for both torches, Inch, and wire type selection. With appropriate function selector actuated, each parameter setting will be displayed in the digital window directly above this toggle.

b. “VOLTS” Increase/Decrease Control. This toggle

switch is primarily used to set and/or vary the arc Volts, along with all its other functions: Postflow, Burnback, and wire diameter selection. With the appropriate function selector actuated, each parameter setting will be displayed in the digital window directly above this toggle.

7. Inch/Purge/Reset Switch. This two position (mo-

mentary) switch allows the following operation. a. Inch Function. The INCH selection permits cold-

wire inching without energizing the welding circuit. To preset cold inching speed, operate the inch switch and while the motor is running using the INC/ DEC toggle below the IPM window; set the desired speed. This setting (is independent of the “hot” wire feed) will be displayed in the IPM window.

b. The Gas PURGE (Abort Reset) position provides

the following when actuated: (1) During initial programming, it permits preset-

ting of gas PREFLOW and POSTFLOW “time requirements” which are simultaneously displayed in the IPM and VOLTS windows respectively.

(2) 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.

(3) 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.

8. Spot/Burnback. This two- position (momentary con-

tacts) switch allows the following operations:

a. Spot Time Setting: operate the Spot/Burnback

switch and observe that both the IPM and volts displays will change. The Spot time can be pro-

grammed into the IPM window by holding the Spot/ Burnback switch in the "up" position and the time can be incremented or decremented by the INC// DEC switch under the IPM window.

Note:To get out of Spot welding mode, the Spot time

has to be decremented to 0.

b. Burnback Time Setting:

The Burnback time can be set into the voltage window in a similar fashion, to increment or decrement the burnback time, the INC/DEC switch under the volts window is used. Both the Spot and Burnback times are set in cycles (1 cycle - 1/60th of a second).

9. Mode Selector Toggle Switch. This three-position switch allows you to select the welding process mode you wish to use - non-pulsed mig "Short Arc", mig "Spray Arc" or "Pulsed" mig spray arc.

In all process modes, the operator simply codes the control (wire diameter and material) for any one of the preprogrammed welding conditions, sets the desired wire feed speed (ipm) and the control automatically provides the proper welding parameters to produce the necessary output for the process selected.

II. GENERAL

This dual torch pulsed mig welding system has been designed and manufactured to specifications provided by DANA. The software is modified to provide 3 presettable process schedules. These are short arc, spray arc and pulsed spray arc. When one set of these parameters is entered into the feeder on one side, the other side will automatically be set to the same parameters.

III. GETTING STARTED

Start Up

When primary power is applied, the windows on the feeder will display the Product Code (in the IPM window) and Software Version # (VOLTS window) for one second. This information indicates the type of software installed in the control and the latest version number. To insure all your units have the same software, the Product Code and Software Version numbers shown on start up should all be identical. After one second, the windows will then revert to display the last welding parameters (IPM and Voltage) set by the operator and the unit is ready to weld.

The following DANA Digipulse control functions must be set to feed wire through the torch conduit and to adjust the shielding gas flow rate.

SECTION 3 OPERATION

1. Place the Power switch on the rear panel to the “on” position to energize the control.

2. Place key-operated Run / Set switch (also on the rear panel) in the Set position.

3. With torch connections made as shown in Fig. 2, and wire engaged in accessory support, feed wire through torch conduit and into torch as follows: a. Actuate and immediately release the torch

trigger switch of the left torch. This action (through the control’s switching relay circuitry) sets-up the control to receive the parameter programming for the left torch.

b. Remove the gas nozzle and contact tip from

torch.

c. Hold Inch-Purge toggle (front panel) in the

INCH position until “cold” wire feeds through the torch front end.

d. Slide the contact tip over the end of the wire

and secure it to the torch. Replace the torch nozzle.

e. Operate the 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 with minimum pressure.

f. The parameters for the right side torch will

automatically duplicate the setting of the left torch. No separate programming is required for this torch since it is used as a backup in the DANA system.

4. With shielding gas supply and torch gas hose connections assembled as shown in Fig. 2, set gas flow rate as follows: a. Hold Inch-Purge toggle in PURGE position.

Open the gas regulator-flowmeter control valve and set the required shielding gas flow rate.

b. Continue to hold the Purge position for

approximately 15 seconds to insure adequate purging of each gas hose and torch.

A. PROGRAMMING THE WIRE FEEDER

1. Gas Preflow and Postflow

a. Preset the shield gas preflow time by holding

down the purge key and using the Inc/Dec key under the IPM window to set a time in 1/10 seconds.

b. Repeat the above for postflow using the key

below the VOLTS window.

2. Cold Inch

a. The cold inching feature has a two step speed

control. When the Inch key is operated, the wire will feed at a non-adjustable rate of 100 inches per minute for a period of 2.5 seconds. This speed is displayed in the IPM window

and is designed to “bump” the wire slowly for fine adjustment of wire stick out.

b. Set the cold inching speed by holding the Inch

key adjust IPM using the Inc/Dec key to any speed desired between 50 and 999 inches per minute. This function is designed for wire threading.

3. Burnback Preset

Adjust the wire burnback by holding the Spot/B’back key in the “up” position and setting a burnback number in VOLTS window using the Inc./Dec. key. The number entered relates to line cycles (60=1 sec.). A number between 2 and 6 is the typical range.

4. Spot Weld Preset

a. For normal continuous welding, set this number

to zero (0).

b. If a timed spot weld is required, set the length of

weld time by holding the Spot/B’back key in the “up” position and setting a spot weld time in cycles per second (60 = 1 sec.) in the IPM window.

5. Material/Diameter Preset

Choose the Material/Diameter code (1 through 6) by depressing the Mat’l/Dia key and setting the desired material number (see Material Code Table) in IPM window and wire diameter to be used in the VOLTS window. Most DANA plants run steel on Code #1.

6. Slow Wire “Run In”

a. The slow wire “run in” is set to provide one half

the preset wire feed speed (IPM) until the wire touches the work piece. At that point, the wire feed rate will accelerate to the speed preset in the IPM window. This option, in most cases, improves arc starting characteristics.

b. If full speed “run in” is preferred, the half

speed can be disabled by locating dip switch #2 on the MPU board (see MPU board drawing) and placing rocker switch #1 in the “closed” position.

7. TORCH DEFAULT

The right side torch (Torch #1 - viewed from the front of the feeder) is the default torch. This means that when the feeder is first powered up this torch is ready for use. The software will automatically switch to the torch being used when the torch trigger is depressed. The weld parameter settings, material/dia. code, burnback, spot weld time and cold inching speed, set previously, are ready for use.

8. WELD PROCESS SELECTION

The DANA Digipulse Dual feeder is a synergic welding system in all weld process modes. This means that a specific wire feed speed and arc voltage relationship has been pre-programmed into the control based on the weld process selected the

SECTION 3 OPERATION

Fig. 6 - DANA MPU Board

type of weld wire and the diameter of the wire being used. This information is supplied to the control by selecting the welding process using the “Process Selection” switch on the front panel (short circuit, spray of pulsed spray) and then entering the material/diameter information as described above.

B. ARC STARTING (SERVO) SETTINGS

Most of DANA’s manual welding applications are performed in the “Adaptive” mode. Poor arc starts in the “Adaptive” weld mode are usually caused by an improperly adjusted arc voltage servo. If your arc stumbles upon starting, you should first adjust the voltage servo. The IPM servo should then be adjusted only if setting the voltage servo does not solve the problem. The arc voltage servo is disabled when the control is set up for “Synergic” welding.

1. Arc Voltage Servo Adjustments (Adaptive Mode Only.)

The voltage servo setting can be observed only during welding. While welding, depress the “Purge” key and “Mat’l/Dia.” selection key simultaneously. The VOLTS window will display a number between 0 and 200 with 90 being typical. These numbers will fluctuate and change during welding. Only look for an average of 80 - 100 when the arc voltage is in a steady stable state. Using the “Inc/Dec” key below the VOLTS window, reduce the number shown to give a “hotter” arc start or increase the number for a “colder” arc start. DO NOT make large changes at any one time. Wire burnbacks and other problems can result. Make small adjustments and retest

the arc starting several times in order to optimize starting characteristics. Changes in wire feed speed and/or voltage might necessitate readjusting the voltage servo. This setting will apply to ALL weld process modes.

2. Wire Feed Motor Servo Settings

You can adjust the feed motor response by presetting the motor speed servo. In order to see and adjust the actual speed servo settings, release the pressure roll and pull the torch switch while depressing the “Purge” key and “Mat’l/Dia.” key simultaneously. The IPM window will display a number between 0 and 200 with 110 being typical. Using the “Inc/Dec” key below the IPM window, reduce the number shown by 3 or 4 digits at a time to give a faster acceleration to the wire feed speed or increase the number for a slower acceleration. DO NOT make large changes at any one time.

WELDING PROCESS SELECTION

A. Adaptive Arc Welding

The IPM window will display the wire feed speed in inches per minute and the VOLTS window will display a voltage corresponding the material type and wire diameter you have preset. The arc voltage (arc length) will be automatically maintained by the control at the pre-set values independent of torch manipulation. You can trim the preset values to optimize arc performance and welding characteristic by adjusting the IPM or arc volts using the Inc/Dec keys under each window. If the welding arc length is too long, decrease the

SECTION 3 OPERATION

voltage using the Inc./Dec. key under the VOLTS window which shortens the arc length. If the welding arc is too short, increase the voltage in the VOLTS window. The “adaptive” characteristic is noticeable when pulse spray welding by audible changes in the pulse frequency caused by variations in the wire electrical stick out or torch manipulation. The pulse frequency will automatically be adjusted to maintain the arc voltage you have set in the VOLTS window when welding in the pulse spray process mode.

B. Synergic (Non-Adaptive) Arc Welding

If the “Adaptive” mode is not desired, the feeder can be switched to “non-adaptive” operation. This is still a synergic relationship but the arc voltage is not automatically maintained by the control. This means the arc length will vary with torch manipulation. When pulse spray welding, the pulse frequency will not automatically change with variations in wire electrical stick out. The pulse frequency will remain constant at any given voltage setting. To enter “non-adaptive” pulse operation proceed as follows:

1. Disconnect all input power to power supply.

2. Remove the sheet metal cover on the wire feeder control box by removing the five sheet metal screws.

3. Remove the “J” governor P/C board (small P/ C board in front). Locate the MPU board which is the large P/C board facing you when you remove the “J” governor board. Find dip switch #1 and open rocker switch #1 (as shown in Fig. 6).

4. Replace the “J” governor P/C board.

5. Replace the sheet metal control cover and five screws.

6. Reconnect input power to power supply.

The IPM window will now display the wire feed speed in inches per minute and the VOLTS window will show a number between 0 and 200 with 100 being the default value. This is NOT an arc voltage value! The number is a reference integer used by the digital circuitry and corresponds to the synergic relationship programmed into the control. The number 100 relates to the nominal arc voltage required for the wire feed speed selected in the IPM window. This number will affect the arc length. You can trim the preset values to optimize arc performance and welding characteristic by adjusting the IPM or arc volts using the Inc/Dec keys under each window.

If the welding arc length is too long the number can be decreased which shortens the arc length. If the welding arc is too short, increase the number in the VOLTS window. The ACTUAL arc voltage will be displayed during welding.

The following will detail the installation and operation of this unique welding system. The feeder control circuitry stores weld parameters for the short circuiting, spray and pulse spray welding processes but only one set of welding parameters is used at any one time. Independent control of weld parameters on each torch is NOT supported in this specialized DANA model. It should also be noted that this is a one operator welding system and both torches CANNOT be used at the same time. The operator can choose either Torch #1 or Torch #2, depending on

requirements.

RECOMMENDED MATERIAL AND SHIELD GAS TABLE

WIRE MATERIAL WELD PROCESSES

Code # Material Type Short Arc Spray Arc Pulse Arc

1CO

Carbon Steel Argon-25% CO

2 Alternate Steel C-25 Argon-8%CO2-2%O

Ar-8% CO2-2% O

3 4043 Aluminum Argon Argon 4 5356 Aluminum Argon Argon 5 308 Stainless Steel A-1025 Argon 1%-2% O

6 Silicon Bronze Argon Argon 7* 8* 9*

10*

*These codes are reserved for custom synergic weld parameters.

Argon-5% CO

Argon 2-5% O

Argon-8% CO

Argon-5%CO

Argon 2-5% O

Argon-8%CO2-2% O

Argon-8% CO

Argon-2% CO2-1% H

SECTION 3 OPERATION

DANA DIGIPULSE XR DUAL PROGRAM CHART

PULSE PARAMETERS

With Arc

Standard Detect

DANA Digipulse Dual Feeder 34849 0558001536

PROGRAM #

Carbon Steel

C-5/Stargon

or O-5 Gas

Not in Use

New Data

MATERIAL

TYPE &

C-5 O-5

Gas

Alternate

SHIELD GAS

VARIABLES

.030"

5.8 6.5 6.8 7.0 8.0

25 30 30 40 50

1.8 2.0 2.2 2.3 2.4

5.4 5.8 6.0 6.5

60 60 60 60

2.2 2.5 2.6 3.8

EPROM P/N 18095 18168

Product Code 261 261

Software Code 17.2 17.3

WIRE DIAMETER

.035" .045" .052" 1/16"

SECTION 4 MAINTENANCE

V . TROUBLESHOOTING

Be sure that all primary power to the machine has been externally disconnected. Open wall disconnect switch or circuit breaker before attempting inspection or work inside of the power source.

A. DANA DIGIPULSE 450 POWER SOURCE

If power source is operating improperly, refer to the troubleshooting information located in F-15-014.

B. DIGIPULSE DUAL WIRE FEEDER for DANA CORP.

(Refer to Schematic Diagram D-0558001734)

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 (and program number, as described in step 1-c. following) as well as the serial number of the wire feeder. Do not attempt to repair the PC board yourself. Warranty on a PC board will be null and void if repaired by customer or an unauthorized repair shop.

1. General

a. Check interconnection between control and power

source. b. Energize the power source and the control. c. Immediately after the control is turned “on”, a

number (e.g.:3) will appear in the IPM readout

window and an additional number of numbers in the

volts window. They will only be displayed for 1-

second. These numbers identify the current pro-

gram (E-PROM) used in your control. When a

Program is changed, the new E-PROMS will auto-

matically 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. d. After the one (l) second delay; the preset “Weld”

parameters will be displayed in the IPM and VOLTS

windows. e. If the control is not functioning properly (as de-

scribed above); for example, the numbers that

appear in one or both of the display windows are

meaningless (all zeros, eights, decimals, etc.), or

are completely incorrect in relation to your settings,

— the memory must be cleared. This condition might occur after lightning storm, extremely bad power line surges, etc. To clear the memory, do the following: (1) Place the Run-Set key switch in its SET posi-

tion. (2) Turn “off” the unit’s 110-volt Power switch. (3) Using one hand, hold both of the Inc/Dec

toggle switches in their INC position while

reapplying 110-volt power with the other hand. (4) Almost immediately after the Power has been

turned “On”, release the Inc/Dec toggle switches

to the neutral (spring-return center) position

and the IPM window should display 0 or de-

pending on how quickly the INC/DEC switch

were released if might be a number higher than

20, but in any case it will have changed from the

original displayed info, indicating that a suc-

cessful reset or clearing has take place.

f. You can now enter the desired information as

described in this booklet.

2. No preset displays appear in windows.

a. Make sure the LED Display board harness/plug is

plugged into the P5 receptacle on the MPU board.

b. Check that 110 vac is available across terminals

T1-18 and T1- 19, if present;

c. Check for plus (+) 5 volts between terminals T1-8

and T1-9; if voltage is present, replace the MPU board. If voltage is not present, check the voltage regulator (VR) The voltage regulator is located on the rear panel of the control box.

d. Check the input and output voltage of the regulator

“VR”.

(1) The input should be approximately 10 volts

between terminals T1-9 and VR-1. If voltage is

not present, replace I/O board.

3. Preset display is provided, but cannot be varied.

a. Check normal setup procedures described in Sec-

tion V, then;

b. 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.

c. If neither of the above resolve the problem, replace

the MPU board.

4. Motor does not run.

a. Check to make sure all required (and/or optional)

accessories are correctly assembled as described in SECTION II.

b. Make sure that power source is connected, plug P2

is securely connected to receptacle P2 on the DANA Digipulse I/0 Board, and then release the clapper arm (pressure roll) on the Accessory Support Assembly.

SECTION 4 MAINTENANCE

(1) Operate the control 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.

(2) 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 control. If o.c.v. is not being supplied, motor will not run. Check the power source for trouble.

(3) Also check that the +/- 12 vdc are provided

from the power source on T1-7 and T1-5 respectively.

(4) If power source if O.K., replace the I/O and

MPU boards respectively.

5. Motor runs, but not at right speed.

a. Check tachometer assembly mounted on the end

of the EH-10 wire feed motor.

b. Make sure the tach disc is securely fastened to the

motor shaft. Check that the disc is properly centered in the strobe pickup on the p.c. board.

c. If all items in step b. are in order, and motor speed

is still incorrect, check the bios supply to the tachboard. If the bios supply +5 volt DC and the common are present at the Tach board on the Red and Green wires respectively, test the tach board as follows:

(1) Remove power. (2) Remove (unplug the "J" governor, and resup-

ply 115 power. Connect a DC voltmeter between T1-3 and the chassis of the control cabinet on the feeder. Positive input on T1-3, negative - chassis. Read the potential. It should be either 0 volts or 4.5 - 4.8 volts. Slowly turn the motor armature using the exposed mounting screw at the end of the motor armature. The voltmeter should fluctuate between 0 and then 4.8 volts. If no change occurs, replace the Tach board. If the Tach board is OK., but the motor still runs at the wrong sped, replace the MPU board.

TP2 TP1

Fig. 7 - Input/Output (I/O) P. C. Board, P/N 674994

If power source (P.S.) is not energized, work on contactor - check troubleshooting F-15-014. If P.S. is energized, correct wiring until O.C.V. is obtained between TP1 and TP2 on I/O board. Only after that, go to part "d" if necessary.

d. If its known that the p.c. is energized, proceed as

follows: remove the J-Gov power source board to gain access to the P3 plug (harness) on the MPU p.c. board. Disconnect the P3 plug from its MPU board socket and, using a meter check for +/- 12 volt power supply output between plug pins P3-1 and P3-2 (for +12 v), and between plug pins P3-4 and P3-2 (for - 12 v) respectively. If voltage is present, replace MPU board.

7. Control Shut-Down — either preset VOLTS or IPM displays will flash. The control will flash the parameter VOLTS or IPM that cannot be maintained.

These symptoms can occur if the preset conditions, IPM or VOLTS, cannot be maintained by the control. The speed (IPM) and voltage (VOLTS) conditions are used to enhance arc starting in the “adaptive mode” of operation. In the “synergic mode”, the voltage condition window will always display the number 100 and cannot be adjusted; the speed condition, however, can be checked and adjusted as described following. To help determine which logic mode (adaptive or synergic) the control is set to operate in, or how to change it, please review Section 3.

6. Arc VOLTS display reads zero after TS is operated.

a. Check that the 5-pin plug is securely connected to

the P3 receptacle on the MPU board.

b. If no reading is displayed, check for arc voltage

feedback between terminals TP1 and TP2 test points on the l/O p.c. board (see Fig. 7). This voltage signal should correspond to that shown on the power source voltmeter.

c. If voltage still reads zero, trace the voltage pickup

wiring from the power source to digipulse and verify that the power source indeed provides O.C.V. If not, ascertain that the power source is energized.

a. IPM (speed) abort and possible causes:

(1) Initial “hot start” parameters incorrectly set. For

proper adjustment, refer to Section 3-B-1 and

2. (2) Defective J-governor board. (3) Defective Motor tachometer board. (4) Defective l/O board. (5) Defective MPU board.

Contact ESAB Engineering Services for further assistance. (803- 664-4416).

SECTION 4 MAINTENANCE

b. VOLTS (voltage) abort and possible causes:

This problem may be located in the wire feeder or the power source. To determine this, check the wire feeder as follows. (1) Set the wire feeder for synergic operation in the

Pulse welding mode.

(2) Strike an arc and while welding, measure the

potential between T1-4 and T1-6 Note that as the arc voltage setting is increased, the potential between T1-4 and T1-6 also increases, and will range from 0 to 8 vdc. If it does not, replace the l/O and/or MPU board. If the potential is

present and responding to the voltage change setting, continue with step (3) follow-

ing.

(3) Now measure the control voltage, for the back-

ground current, between T1-6 and pin J1-J of the amphenol connector. This measurement can be taken without striking an arc. The potential will the be in a range from 1 to 2.5 volts.

If it is not, replace the I/O and/or MPU board. If the background potential is present, con-

tinue with step (4) following.

(4) If both of the preceding conditions (steps 2 and

3) are okay, but the arc is still unsatisfactory, the problem is either in the interconnecting cable, the welding setup, or in the power source. If possible, substitute a cable or power source (known to be good) to check out the possible problem; if these are not available, continue with the wire feeder “calibration test” in step 8 following.

8. Erratic arc especially evident in the Pulse mode. This could be caused by insufficient pulse height. To check this, make the following “calibration test” of the I/O board and power source.

To set up the control in the diagnostic mode, simultaneously depress the Wire Dia/Mat’l. key and hold the IPM Inc/Dec key in its down position for 2.5 seconds until a zero (0) appears in the IPM window. (The 2.5 seconds will prevent accidental zeroing of the Material code.)

Now release both keys. The display windows will change to show a BACKGROUND current value (from 0 to 100) in the IPM window, and a PULSE HEIGHT value (from 0.1 to 10) in the VOLTS window. These numbers can be changed by their respective INC/DEC switches.

To check the calibration of the l/O board, connect a voltmeter from T1-6 (negative) to T1-4 (positive). Energize the torch switch, and check the measured voltage against the number displayed in the VOLTS

window — they should both be the same (for example: for a setting of 8.0, the measured potential should be 8 vdc.). If the measured potential is different, the l/O board should either be recalibrated (by a qualified technician) or the board should be replaced.

Next, check the potential from T1-6 (-) to pin J1- J of the amphenol connector for a display of 40 in the IPM window. The measured reading should be 2 vdc. If it is not, replace the I/O board. If all of the readings are correct, check the power source by using the “calibration procedure” described in Inverter Control Board (lCB) Troubleshooting in the Power Source manual F-15-014.

9. Torch Switch does not activate the machine.

A. Check function and continuity of trigger switch. B. Check for 'enable' signal from PLC through P4

connector. For diagnostic purposes, this signal can be supplied by setting Dip Switch SW2-3 to the closed position (See Fig. 6).

VI. MAINTENANCE

If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts.

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 MOTOR-GEAR UNIT

The EH-10A motor-gear 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.

SECTION 4 MAINTENANCE

D. REMOVAL OF EH-10A DIGITAL WELDING HEAD

1. Unplug the control cables from the rear panel of the wirefeeder control.

2. Remove the accessory support assembly from the motor-gear unit by loosening the cap screw at the bottom of the assembly.

3. Disconnect the motor and tachometer cables from terminal board (T1) inside the control assembly as shown on the wiring diagram.

4. Remove the four screws which secure the digital motor-gear unit to the base and remove the digital unit.

E. ADDITIONAL DIGIPULSE PROGRAM FEATURES (See DANA MPU Board - Fig. 6)

The MPU Board (Fig. 6) contains two integral 4-rocker 'DIP' switches. For DANA Digipulse Dual Feeders Part

Number 0558001536 with the PLC interface, these should be positioned as:

SW-1 SW-2

1 CLOSED 1 OPEN 2 OPEN 2 OPEN 3 OPEN 3 OPEN 4 OPEN 4 OPEN

For the DANA Digipulse Dual P/N 37879, SW2-3 should be in the closed position.

F. DANA Interface Board

The DANA interface board 0558001143 sends a signal to the external Programmable Logic Control through the P4 connector whenever the unit is actively welding. The board also looks for input from the PLC indicating that all clamps are energized. It can be disabled by setting dipswitch SW2-3 to the closed position.

SECTION 5 REPLACEMENT PARTS

5.0 PARTS

5.1 GENERAL

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

Replacement parts may be ordered from your ESAB distributor. For a list of Authorized Distributors in your area, contact ESAB at 1-800-ESAB-123.

5.2 ORDERING

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

For your convenience an ESAB Communication Guide listing important contact phone numbers has been printed on the rear cover of this book.

SECTION 5 REPLACEMENT PARTS

BASE - 678806

nRecommended Spare Parts

Replace decal if it becomes

excessively worn or lost when

WARNING DECAL - 995204

replacing panel(s)

(2) EH-10A DIGITAL

MOTOR-GEAR - TACH

UNIT ASSY. 679777

MODE SEL. (GUARD)SWITCH - 680088 n

Replace decal if it becomes

excessively worn or lost when

COVER - 30170*

replacing panel(s)

WARNING DECAL - 2091514*

CONTROL ASSY. - 32337 (see Fig. 10)

FRONT VIEW

Fig. 8 - DANA DIGIPULSE Dual Wire Feeder, P/N 30912

(SW1, 3, 5, 7) SWITCH - 950087 n

LEFT AND RIGHT TORCH

SWITCH (J3, J4)

RECEPTACLES - 182W64

C16 CAPACITOR - 672348

DO NOT ORDER BY PART NUMBER ALONE.

1. All replacement parts are keyed on the illustrations which follow. Order replacement parts by part number and part name, shown on illustrations.

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.

FRONT CONTROL SUPPORT - 30917

(2) ACCESSORY SUPPORT ASSY.

4 ROLL DRIVE (See Fig. 11) - 600216

SECTION 5 REPLACEMENT PARTS

(2) SPINDLE ASSY.

948259

POWER CABLE ADAPTOR

BLOCK - 674156

1/2-IN.-13 STL. NUT

1/2-IN. LOCKWASHER

(2) 1/2-IN. FLATWASHER

(2) REEL SUPPORT

- 634288

(VR) VOLTAGE REGULATOR includes:

VOLTAGE REGULATOR - 950159

TRANSISTOR SOCKET - 950158

(J1) RECEPTACLE - 950762 (19-pin)

C20 CAPACITOR - .1uf, 500 V

634517 n

(C4) CAPACITOR - 995544

(CB) CIRCUIT BREAKER - 950874 n

(MSL) POWER ON-OFF SW

P4 PLC CONNECTOR - 0558001738

REAR VIEW

Fig. 9 - DANA DIGIPULSE Dual Wire Feeder, P/N 32337

STRAIN RELIEF - 96W76

uRUN-SET SW - 950956

(2) GAS SOLENOID VALVE

- 2062305 n

(2) GAS INLET CONNECTION -

74S76

(2) GAS BULKHEAD ADAPTOR -

58V58

KNOCKOUT OPTIONAL

WATER CONNECTIONS (See Fig. 13)

REAR CONTROL SUPPORT - 678802

nRecommended Spare Parts

uReplacement key for Run-Set SW - 32778

SECTION 5 REPLACEMENT PARTS

Interface Board -

0558001443

(R1) RESISTOR - 17240005 n

(RLY) RELAY - 951089 n

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

BR-RECTIFIER - 2 Amp., 400 V - 63515

(25W, 5 Ohm)

(MOV) METAL OXIDE

VARISTOR - 995104

(FN1) FILTER NETWORK -

679874, Includes:

C1, C2 CAPACITOR - 950702

C3 CAPACITOR - 993716

(CTR1, CTR2) CONTROL

nRecommended Spare Parts

TRANSFORMER ASSY. - 30684 n

(I/0) P/C BOARD ASSY. - 674994

For Replacement Battery (on I/O Board),

order P/N 951733

WARNING DECAL - 995164

(MPU) DANA P/C BD. ASSY. - 18169 n

(MPU) STANDARD P/C BD. ASSY. - 18134 n

(I/0 P4 To MPU P2

CABLE ASSY. 677938

Replace decal if it becomes

excessively worn or lost.

(GRF) SENSOR - 950448

(Mtd. on Cabinet Base)

(T1) 20 PT. Terminal Strip - 950182

Fig. 10 - DANA DIGIPULSE Dual Control - P/N 32337

"J" GOV P/C BOARDn ASSY. - 994236 (See Note)

MTG Bracket 995297 (P1) Receptacle 636608

DISPLAY P/C BOARD n

ASSY. - 675269

NOTE!

The heat sinks of the "J" gov. board

are electrically hot. Do NOT touch

or ground while unit is energized.

SECTION 5 REPLACEMENT PARTS

INLET GUIDE

(See torch instruction booklet)

(2) LOCKING HANDLE (49V44)

OUTLET GUIDE

(See torch instruction booklet)

ROLLPIN - 2075523

CLAMPING PLATE - 2075495

CAPSCREW - 5/15" - 18 X 1 3/4" (61340166) NUT - 5/16" - 18 (63350121)

(4) FLATWASHER 2075524

CLAPPER ASSY. 2075500

(4) GEAR ASSY. (2075492)

(4) FEED ROLL

( Optional Selections - see Table 1)

Feed Roll Mounting Hardware:

(17) SCREW - No. 8-32 x 5/8" (61307881) (17) LOCKWASHER - No. 8 (63402887)

KNOB - 60N68

SPRING - 182W54

RETAINER - 58N24

FORK - 49V43

GEAR & INSULATOR ASSY. - 999179

SCREW - 1/4 X 20 X 1/2" (61307087) BELL WASHER - 1/4" (950783) FLATWASHER - 1/4" (64309431)

Fig. 11 Four Roll Drive “Uniform Pressure” Accessory Support Assembly - P/N 600216

ROLLPIN - 62350066

(3/16 X 1-3/4")

SECTION 5 REPLACEMENT PARTS

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

(Ref. Hair Pin Clip)

REEL

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

SPINDLE - 948258

"D" TYPE WASHER - 948254

SPRING - 948253

SUPPORT 948257

(2) BRAKE PAD - 948255

SPINDLE

SCREW 5/16" -18 x 2"

HAIR PIN CLIP - 634347

WASHER 948256

WATER CONNECTION 58V75 (OUTLET)

5/8 -18 Lh

WATER CONNECTION 58V75 (OUTLET)

5/8 -18 Lh

WITHOUT SOLENOID VALVE

WATER SOLENOID VALVE - 2062355

1/4 N.P.T.

WITH SOLENOID VALVE

COUPLING - 68121075

ADAPTOR - 11N16 (INLET)

5/8 -18 Lh

1/4 N.P.T.

ADAPTOR - 11N16 (INLET)

5/8 -18 Lh

Fig. 12 - Spindle Assembly, P/N 948259,

Optional Wire Reel, P/N 995570

Fig. 13 - Water Kit with Solenoid Valve, P/N 2075760*

Water Kit without Solenoid Valve, P/N 994466

*Do not use with Coolant Recirculator

D-0558001734-A

DANA Digipulse Dual Wire Feeder - Schematic Diagram

D-0558001735

DANA Digipulse Dual Wire Feeder - Wiring Diagram

NOTES

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

Order Entry Product Availability Pricing Delivery Order Changes Saleable Goods Returns Shipping Information

Telephone: (800)362-7080 / Fax: (800) 634-7548

Telephone: (800)783-5360 / Fax: (800) 783-5362

Telephone: (800) 235-4012/ Fax: (888) 586-4670

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

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

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 / Fax: (843) 664-4454 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

Eastern Distribution Center

Central Distribution Center

Western Distribution Center

Hours: 7:30 AM to 4:00 PM EST

F-15-626-E 9/2000

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com

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

ESAB Digipulse Dual Wire Feeder Dana Corporation Troubleshooting instruction

Specifications and Main Features

Frequently Asked Questions

User Manual